Project: 1984 Aspencade (GL1200) Revival


Information and questions on GL1200 Goldwings (1984-1987)
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Afraziaaaa
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Location: New Jersey
Motorcycle: 1984 GL1200 Aspencade

Project: 1984 Aspencade (GL1200) Revival

Post by Afraziaaaa » Thu Feb 01, 2018 7:50 pm



I'm Aaron, 34 and live in western NJ. I've owned this GL1200 since 2012 and it ran fair when I bought it. I was able to ride it that summer, but put it up because it needed a lot of work to be the bike I really wanted. Since then i've had a daughter, bought a home and changed jobs a couple times and the bike has been laid up. I did own an HD touring bike during that time as well but sold it...just not a fan of them as tourers (still have another HD though). Things are settling down and I really want to ride this bike again because it's a great bike. I'd like to start a project thread to document and chat about vintage wings with fellow moto-nerds. Hope this is the right place to do so.

I am in the middle of buttoning up another project, but have started this one while I wait for paint to cure and parts to come in.

I have already done:
1. Brake master cylinder rebuilds
2. Clutch bleeding
3. Fuel pump
4. New rear shocks - air shocks were totally blown out.


Here is the current state of the bike:






And here is the laundry list of what I have identified as necessary for it to be road worthy again:

1. Replace front wheel (it is damaged and unbalanced as a result - contributing to death wobble @ 45mph)

2. Rebuild front end - forks are blown out and the oil is gone, will do new neck bearings too. It will get progressive springs in the rebuild

3. Replace timing belts/thermostat and possible waterpump - age unknown and I am a bit concerned about overheating

4. Drop engine to replace stator - One phase is gone and the bike doesn't charge. I bought Randakk's version and have high hopes for it. While I am there I will also replace the pulse generator and check the primary chain because I am worried it is too loose. I have a knock at idle which could be carbs, but better to check the chains while I have the motor out.

5. Rebuild and sync carburetors - Also a kit from Randakk

6. Rebuild Slave Cylinder (if necessary)

7. Install newer subframe, battery box and center stand. These parts are rusted badly.

8. Seat covers

9. Clean exhaust headers out and install new exhaust gaskets in the system - I did a compression test (115-120psi all cylinders) and put a bit of ATF in the cylinders while doing the test. I had the bike idling roughly a couple months ago, but didn't have time to keep moving on the project. Anyway, the bike smokes badly from the residual oil.

As a bonus I might do some metal polishing and trim down my spare windshield, but these are not necessary.



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madmtnmotors
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Location: Saint Cloud, Florida
Motorcycle: 1984 Goldwing

Re: Project: 1984 Aspencade (GL1200) Revival

Post by madmtnmotors » Thu Feb 01, 2018 9:05 pm

Subscribed. I've got two GL1200's here that will be getting similar treatment. 8-)

DaveO430
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Re: Project: 1984 Aspencade (GL1200) Revival

Post by DaveO430 » Thu Feb 01, 2018 9:06 pm

You do know you have to split the engine to get to the primary chain?

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brianinpa
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Location: Lebanon, PA
Motorcycle: 1984 GL1200 Standard
1987 GL1200 Interstate

Re: Project: 1984 Aspencade (GL1200) Revival

Post by brianinpa » Thu Feb 01, 2018 9:14 pm

How many miles are on the bike? The primary chain rarely causes a problem, so I think you are on track with the cause - carbs.
Brian

If you aren't having fun doing it, find something else to do.

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Afraziaaaa
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Location: New Jersey
Motorcycle: 1984 GL1200 Aspencade

Re: Project: 1984 Aspencade (GL1200) Revival

Post by Afraziaaaa » Thu Feb 01, 2018 11:13 pm

Bout 45k on the odometer.

I used a stethoscope on the rear engine cover and the knock is definitely strongest there. That’s why I have a slight concern about the chains. From what I have been reading here though it seems like carb issues cause that type of intermittent knocking pretty frequently.

I looked at an exploded parts diagram and thought that the primary chain tension could be checked just by taking the clutch basket off, but I didn’t really dig into it so that is more of an assumption. I do know that the cases need to be split to replace the chain though.

My hope is that I’ll be able to get some kind of peace of mind about it before I start the bike up again, but not sure I want to split the cases to do so.

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julimike54
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Motorcycle: 1986 GL1200A original owner
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Re: Project: 1984 Aspencade (GL1200) Revival

Post by julimike54 » Fri Feb 02, 2018 12:07 am

As Brian stated it's the carbs, when not in sync they will cause the chain to make an awful racket. Lots of posts about it :)
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Shadowjack
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Re: Project: 1984 Aspencade (GL1200) Revival

Post by Shadowjack » Fri Feb 02, 2018 8:37 am

Always do the cheap stuff first. If those are also the easy ones, so much the better.

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Afraziaaaa
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Location: New Jersey
Motorcycle: 1984 GL1200 Aspencade

Re: Project: 1984 Aspencade (GL1200) Revival

Post by Afraziaaaa » Fri Feb 02, 2018 8:58 am

Ok thanks guys. Keeping that in mind, maybe the best plan is to pull the carbs and rebuild/sync them all before I pull the motor. This way, I can verify that my knocking and stumbling at idle is good to go without having to open anything.

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Rednaxs60
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Location: Victoria, British Columbia, Canada
Motorcycle: 1985 GL1200 LTD (X2), 2008 GL1800 (sold)

Re: Project: 1984 Aspencade (GL1200) Revival

Post by Rednaxs60 » Fri Feb 02, 2018 10:57 am

Pull the engine, then drop the carbs - more room to work.

You mention that you are going to change the stator as well. Be careful when you remove the rear case to get at the stator, there is about a 1/2 quart of oil that will come out - been there, not mentioned in the service manual.

Rebuild of the clutch slave would be good, lots of crud will have accumulated in the clutch slave and the only way to clean is to disassemble the clutch slave. Only a few parts needed and not expensive.

Cheers
"When you write the story of your life, don't let anyone else hold the pen"

Ernest

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Afraziaaaa
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Location: New Jersey
Motorcycle: 1984 GL1200 Aspencade

Re: Project: 1984 Aspencade (GL1200) Revival

Post by Afraziaaaa » Sun Feb 04, 2018 8:15 pm

Removed the seats and panels and started pulling the forks. Found a nut loose on each axle retainer...probably contributing to the front end wobble.

Pretty heavy pitting in the fork tubes, so not sure if I can use them anymore unless you guys have a tip for getting the new seals on without destroying them?













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Rednaxs60
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Re: Project: 1984 Aspencade (GL1200) Revival

Post by Rednaxs60 » Sun Feb 04, 2018 10:28 pm

Just brain storming here - use wax paper between fork tube and seal. What about putting the seal on from the bottom up with the upper fork tube out - would have to put everything on the tube then insert into the lower case? Use some wet/dry sandpaper - 2000 grit, or crocus cloth to smooth out the fork tubes?

Other wise new/used fork tubes? Checked with Frank's Forks regarding new. $349.00 USD plus shipping. eBay for used?

Good luck
"When you write the story of your life, don't let anyone else hold the pen"

Ernest

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Afraziaaaa
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Location: New Jersey
Motorcycle: 1984 GL1200 Aspencade

Re: Project: 1984 Aspencade (GL1200) Revival

Post by Afraziaaaa » Sun Feb 04, 2018 11:02 pm

Thanks. I thought about putting them on from the bottom. I’ve only ever done Harley forks before and those are a real tight slip-fit around the tube that only seal correctly in one direction. Maybe these are different?

I didn’t think about the wax paper at all. That is interesting.

I don’t think sandpaper would do it without removing too much material. The pitting is just too deep.

I’m definitely going to disassemble the forks and see what I see.

DaveO430
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Re: Project: 1984 Aspencade (GL1200) Revival

Post by DaveO430 » Mon Feb 05, 2018 6:38 am

That pitting is on the part of the tube that slides over the seal, they will never work like that for long. What some people have done is sand them off smooth then apply JB weld to the pits and sand it down smooth.

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Afraziaaaa
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Motorcycle: 1984 GL1200 Aspencade

Re: Project: 1984 Aspencade (GL1200) Revival

Post by Afraziaaaa » Mon Feb 05, 2018 7:01 am

I think I am going to try to find a decent used set for replacement, and then fix them if needed.

I think you are right that any fork seal replacement on these won’t last long at all.

Gave them another once over and found this. That is fork oil that leaked out of the top of one of the forks overnight:









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julimike54
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Motorcycle: 1986 GL1200A original owner
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Re: Project: 1984 Aspencade (GL1200) Revival

Post by julimike54 » Mon Feb 05, 2018 4:20 pm

Regarding the oil leaking out....if you have the fork cap on, it might be leaking out the cap 'o' ring, if not then new seals and dust caps. I'm in the process of refurbing mine after 65k miles and one dust/seal change. The dust seals were all cracked/split. Wonder if Honda is selling (at the time) 20 year old stock? Maybe now its 30+ year old stock :roll:
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Rednaxs60
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Location: Victoria, British Columbia, Canada
Motorcycle: 1985 GL1200 LTD (X2), 2008 GL1800 (sold)

Re: Project: 1984 Aspencade (GL1200) Revival

Post by Rednaxs60 » Mon Feb 05, 2018 5:52 pm

Can still get the fork seal kits from Honda, Just did mine in November last.
"When you write the story of your life, don't let anyone else hold the pen"

Ernest

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Afraziaaaa
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Location: New Jersey
Motorcycle: 1984 GL1200 Aspencade

Re: Project: 1984 Aspencade (GL1200) Revival

Post by Afraziaaaa » Mon Feb 05, 2018 6:32 pm

It's definitely coming out of the top, but haven't opened up the tube yet to determine why. O-rings are probably a good guess.

I got my fork seal kit from cyclemax.

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Afraziaaaa
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Motorcycle: 1984 GL1200 Aspencade

Re: Project: 1984 Aspencade (GL1200) Revival

Post by Afraziaaaa » Mon Feb 05, 2018 8:32 pm

Started to go after the triple tree. I’m not quite sure how to get the steering angle sensor out...? Also, is this normal? It kind of seems like a hack job to me.


Can I just delete this thing? I looked at the wiring diagram and it goes straight to the turn signal canceling module. I don't think I need it to make the bike run, and I can just cancel manually. Who needs an angle sensor on the steering neck anyway? I know what the angle is. I’m driving the bike!!

DaveO430
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Re: Project: 1984 Aspencade (GL1200) Revival

Post by DaveO430 » Mon Feb 05, 2018 10:06 pm

Just unplug the wires. It's not needed on the 84 if I remember right. The switch doesn't spring back to center does it?

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Afraziaaaa
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Motorcycle: 1984 GL1200 Aspencade

Re: Project: 1984 Aspencade (GL1200) Revival

Post by Afraziaaaa » Mon Feb 05, 2018 10:17 pm

DaveO430 wrote:
Mon Feb 05, 2018 10:06 pm
Just unplug the wires. It's not needed on the 84 if I remember right. The switch doesn't spring back to center does it?
There is definitely no spring force anywhere on the switch.

I forgot to add that I found that the neck plate reads “1985”. Hahaha. Means my title is incorrect maybe.

Unplug the wires from where? I can’t figure out where/how to unplug it. Usually when I come across something like this it turns out to be pretty simple and I’m just ignorant about it!

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Rednaxs60
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Motorcycle: 1985 GL1200 LTD (X2), 2008 GL1800 (sold)

Re: Project: 1984 Aspencade (GL1200) Revival

Post by Rednaxs60 » Tue Feb 06, 2018 12:22 am

1985 seems correct, the side mirrors on your bike indicate at least an '85. The '84 side mirrors are different.
"When you write the story of your life, don't let anyone else hold the pen"

Ernest

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julimike54
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Re: Project: 1984 Aspencade (GL1200) Revival

Post by julimike54 » Tue Feb 06, 2018 12:30 am

If you look at the last picture you posted, showing wires exiting the tree. Those clear(ish) covers just poking out are the plugs.



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Afraziaaaa
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Motorcycle: 1984 GL1200 Aspencade

Re: Project: 1984 Aspencade (GL1200) Revival

Post by Afraziaaaa » Tue Feb 06, 2018 5:44 am

Thanks, I’ll have a go at them this evening.

Double checked the title this morning and looks like it does say 1985, so oops! At least we are getting reacquainted.

DaveO430
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Re: Project: 1984 Aspencade (GL1200) Revival

Post by DaveO430 » Tue Feb 06, 2018 7:36 am

Afraziaaaa wrote:
Mon Feb 05, 2018 10:17 pm
DaveO430 wrote:
Mon Feb 05, 2018 10:06 pm
Just unplug the wires. It's not needed on the 84 if I remember right. The switch doesn't spring back to center does it?
There is definitely no spring force anywhere on the switch.

I forgot to add that I found that the neck plate reads “1985”. Hahaha. Means my title is incorrect maybe.

Unplug the wires from where? I can’t figure out where/how to unplug it. Usually when I come across something like this it turns out to be pretty simple and I’m just ignorant about it!
If it's an 85 you do need the cancel unit to make the signals work. I was referring to the turn signal switch when I asked about the spring action, that's why the cancel unit (angle sensor) is relevant. The connections are right at the bottom of the stem in your picture.

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Afraziaaaa
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Motorcycle: 1984 GL1200 Aspencade

Re: Project: 1984 Aspencade (GL1200) Revival

Post by Afraziaaaa » Tue Feb 06, 2018 8:31 am

Who needs turn signals anyway?! :lol:

Thanks all. Maybe I just need to get a bit more slack there so I can disconnect the bullet plugs safely.



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