84 Interstate Fork Rebuild - Opinions Wanted


Information and questions on GL1200 Goldwings (1984-1987)
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racetteb
Posts: 4
Joined: Tue Sep 14, 2010 8:22 am
Location: Montrose, British Columbia
Motorcycle: 1984 GL1200 Interstate

84 Interstate Fork Rebuild - Opinions Wanted

Postby racetteb » Thu May 19, 2011 10:47 pm



Hey there,

Have my old 1200 Interstate, left fork seal is completely toast and have had enough of dealing with the sloppy front end. So I've ordered up a pair of new fork and dust seals, additionally ordering a set of progressive springs for the front end while I'm endeavoring to take this thing this far apart. Was wondering if anyone has any experience with doing this? I've heard several different opinions, some say remove the fairing, some day can work without, have read quite a few different interpretations on how to go about this, but no real solid thought from anyone as to how the whole deal can be approached in a smart fashion. I've got some copies of some of the guides from this site, and also will be getting my hands on a Honda shop manual for the bike sometime this week. Any additional info would be great.

Thanks



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virgilmobile
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Motorcycle: 1988 GL1500 I
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Re: 84 Interstate Fork Rebuild - Opinions Wanted

Postby virgilmobile » Fri May 20, 2011 7:55 am

I'm dealing with the same problems.Bad stiction(front end bouncing down the road)..anti-dive does not work.I pulled mine off the bike without removing the faring.Left the fork pipes on the bike for now.I'm having trouble with the teflon bushings.It seems to bind when I set the top one back in the slider.Acts like the bushing is a little to big..Doesn't make sense.I would have thought if they were worn out they would get loose not tight.I'm looking into a improper previous rebuild.

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thrasherg
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Re: 84 Interstate Fork Rebuild - Opinions Wanted

Postby thrasherg » Fri May 20, 2011 10:04 am

Are you sure the stanchions are not bent? If they are then the forks get stiffer as they slide up and down?

Gary

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virgilmobile
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Location: Denham Springs,La.
Motorcycle: 1988 GL1500 I
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81 GL1100
82 GL1100 I
83 GL1100 I
83 GL1100 standard
84 GL 1200 I

Re: 84 Interstate Fork Rebuild - Opinions Wanted

Postby virgilmobile » Fri May 20, 2011 10:12 am

The fork tubes on both bikes are clean and straight.re-assembled by the book.
Oil replaced.forks move with bumps at slow driving,but are stuck when driving down the road.Front end bouncing,shocks don't move(float on the springs).The slider bushing is very hard to get back in and seems to bind to the fork pipe.Almost like it's too large.It's not new but may have been replaced by the PO.Do the bushings have to be trimmed to fit?Should the slider move full stroke without binding?My 1100 isn't much better.With no springs in it,It slides up and down easy but it still sticks while driving.It takes quite an effort (or rodent) :lol: to get them to move.

I also pushed the front end down then let it settle back up,marked the fork...lifted the front up and let it settle back down.I read it's suppose to be about a 1/2 inch.I get 3 inches.It just seems to jam up with the bikes weight.

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thrasherg
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Re: 84 Interstate Fork Rebuild - Opinions Wanted

Postby thrasherg » Fri May 20, 2011 10:14 am

I don't know what else to suggest, as you state, something definitely is not right.. It sounds like a complete dismantle and careful examination is required..

Gary

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virgilmobile
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Motorcycle: 1988 GL1500 I
Previously owned
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82 GL1100 I
83 GL1100 I
83 GL1100 standard
84 GL 1200 I

Re: 84 Interstate Fork Rebuild - Opinions Wanted

Postby virgilmobile » Fri May 20, 2011 10:39 am

I got the feeling that the teflon bushings are bad.They don't have any brass showing but they are very very smooth surfaced(microscope viewed).The teflon surface seems to be flattened down.Theres no texture to the surface. I think that It's not allowing oil to mingle in the surface and letting the entire bushing to rub on the pipe squeezing out the oil and binding it.My 1100 will slide smooth until I put weight to it,then it binds.The 1200 seems to have the same problem

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virgilmobile
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78 GL1000
81 GL1100
82 GL1100 I
83 GL1100 I
83 GL1100 standard
84 GL 1200 I

Re: 84 Interstate Fork Rebuild - Opinions Wanted

Postby virgilmobile » Fri May 20, 2011 11:46 am

To test my theory,I'm going to modify the teflon slides(I have to replace them anyways) by knurling the surface of the teflon(very small detentes).This may reduce the contact area and allow oil to be retained on the surface of the slide thus reducing friction contact.It' one of those " in theory " ideas :roll:

racetteb
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Motorcycle: 1984 GL1200 Interstate

Re: 84 Interstate Fork Rebuild - Opinions Wanted

Postby racetteb » Tue May 31, 2011 7:22 pm

Well all finished with the fork rebuild as of about 2 hours ago. Now just time for the weather to break again so I can go for my test ride. Ended up not having too tough of a time with the removal of the forks, was able to drop them out without having to remove the fairing or anything. Was able to use a floor jack to get the bike up an extra 6" or so, then used a set of jack stands underneath the crash bars to support the bike, and from there was easy peasy. Thanks for all the info.

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virgilmobile
Posts: 7663
Joined: Sun Sep 19, 2010 5:39 pm
Location: Denham Springs,La.
Motorcycle: 1988 GL1500 I
Previously owned
78 GL1000
81 GL1100
82 GL1100 I
83 GL1100 I
83 GL1100 standard
84 GL 1200 I

Re: 84 Interstate Fork Rebuild - Opinions Wanted

Postby virgilmobile » Fri Jun 03, 2011 11:10 pm

End results of rebuilding the front end of my 1200.
I purchased a set of guides($5 each) .The info says the forks on the 1200 are 41mm.So I got a set of slides made for Showa forks,41mm upper and lower.Harley parts.
Can't find the micrometer anywhere so I test fitted the upper slide,It was just a little loose,same as what came out of it.Wouldn't fit in the slide(too big)it was driven in hard.
I tried it in a 41mm slide from a Harley(showa)slide,It fit.
The lower bushing seemed to be just a little sloppy.Poor size?or worn slide.Don't know.
Apparently the 1200 fork is a different size than the Harley,even though the books say they are.
I had to increase the end gap .010" and sand off a few thousands of the back side to get the upper slide to fit snug without jamming it.
Mechanic before me lied.He didn't pull the forks and check for a bent fork.
I pulled them both.One was straight as a arrow,the other had a .032"total runout.Book says limit is .0038"
WOW . I didn't have a press with me,soooo I farmer browned it.2@ 4x4 notched blocks,20' of 2" pipe and the back end of a fork lift.
Well I got it to less than .003 total runout.
Re-assembled and it floats on a cloud.
This all took me 5 hours.Lesson learned...Don't believe anything,check everything.
It turned out OK cost wise but the aggravation,I can do without.




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