How to remove 1500 honda GL 1995 carburetor from engine


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How to remove 1500 honda GL 1995 carburetor from engine

Postby insanelyhappy1 » Thu Mar 22, 2012 12:22 am



Hi I am trying to rebuild my carburetors but I cant figure out how to detach them from the engine mount??? Any suggestions and advice would be greatly appreciated! Iv tried to locate info and manuals to this end but keep coming up empty handed... Pleas if any1 out their has any good info your input would be greatly appreciated! Thanks again! And I look forward to hearing from you


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Re: How to remove 1500 honda GL 1995 carburetor from engine

Postby virgilmobile » Thu Mar 22, 2012 9:11 am

I've had my 88 gl1500 carbs out twice now.
The first time,I never said "you got to be kidding" so many times.
Here's a basic rundown,assuming that you are at least down to the top plate of the carb assembly.
1 Pull all the lower plastic off.Yes ,everything,the vent covers,reverse handle,all the way to the radiator grille.Needed to get to the screws and adjustments.
2.drain the radiator,there's coolant that goes to the bottom of the carbs.
3.from each side,you can get to the clamps that hold the carbs mounted in the rubber coupler.
4.mark or take pictures of the 4 vacuum lines that attach to the carbs on the left side.
5.there are hoses that attach under stuff as you may have seen.It's one of those times when you need a long pair of needle nose.
6.grab the carb assembly and pull back and up.This took quite an effort back and forth to dislodge them from the rubber coupler.
7.lift up the front of the carbs,pull loose the 2 coolant lines and the choke cable.
8 remove the throttle cable and follow the wire from the carb to the plug on the left side and unplug the cruise switch.
Sorry,this is getting long
9.lift the carbs up and pull the drain hose loose,they should lift out.

Now this is basic,so I expect you can handle any different things that pop up.
The first time I pulled my carbs,from start it took a little over 4 hours.
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Re: How to remove 1500 honda GL 1995 carburetor from engine

Postby zamboni920 » Sun Jun 03, 2012 7:37 pm

Good write-up! How about doing a DIY article on this subject? I just got a great deal on a set of used(from a running, same year, GL1500) carbs, so my idea is to rebuild these, then just do a swap. Virgil....your "run-down" is quite helpful. Now I just need to find the post where you "talked" a member through cleaning and rebuilding. I remember reading it at the time, but now can't find it.
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Re: How to remove 1500 honda GL 1995 carburetor from engine

Postby virgilmobile » Mon Jun 04, 2012 9:01 am

I'd love to do a how to.Perhaps if I could get my hands on a 90 or later set of carbs to replace my P.O.S.
setup I'd do it.
I think that the 88-89 was the first attempt to make a bike with carbs that far away from the intake valves and all the junk added to it is an attempt to overcome an inherent design problem.
The way it's made,I don't think it will ever perform like the 1200.
A mod to the accelerator pump has helped a bunch to get over the "off idle hesitation" problem all 88-89 drivers have.
I'm interested to find out what "they" did different in 90 to fix the problem.

Harbor Freight has the 11" needle nose pliers for $5.You'll need them to manipulate the hoses off the carb,
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Re: How to remove 1500 honda GL 1995 carburetor from engine

Postby sprintexec » Mon Mar 10, 2014 7:35 am

Thanks for the information virgilmobile, you have given me the details I needed to be confident enough to face removing my carburettors. Getting them back looks like being a bit of a pig but that will come later after I've delved into the float chambers... :)
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Re: How to remove 1500 honda GL 1995 carburetor from engine

Postby virgilmobile » Mon Mar 10, 2014 9:36 am

sprintexec wrote: Getting them back looks like being a bit of a pig but that will come later after I've delved into the float chambers... :)


Seating the carbs back into the rubber couplers was a chore...Mine were quite hardened...I used a smear of petroleum jelly to help...
It still took all my weight to get them to seat properly,and a 18" Phillips screwdriver to reach the clamps.
Whatever you do on the carbs,do not use any Permatex #2 gasket sealer...the ethanol gas dissolves it and it will plug the slow speed jet....I found out the hard way...That was the 3rd time I had to removed the carbs...
I do bench test the carbs first to test for slide action,fuel leaks and accelerator pump settings...Get it where it squirts as soon as you operate the throttle.
Replace the "O" rings on the riser tube from the accelerator pump too.
Don't forget to sync the carbs when you get done.
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Re: How to remove 1500 honda GL 1995 carburetor from engine

Postby sprintexec » Mon Mar 10, 2014 10:11 am

So, thanks to advice received from contributors in this forum 8-) , the carburettors are out of the bike :P .

I've separated them and I've had a look into the float bowls.

What I found has convinced me that no amount of "tapping" on the outside of the float bowls would ever have "cured" the mess I saw.

I'm feeling happier, a lots less apprehensive than I was at the start. And, for those of you reading this in the future, if I can do this so could you. By the way - I'll be draining my fuel system down at the end of every riding season from now on!
Attachments
This is the bottom of the float bowl of carburretor one. The green substance is soft and waxy, melting when touched!
This is the bottom of the float bowl of carburretor one. The green substance is soft and waxy, melting when touched!
This shot shows more of the build up of deposit on the floats and the jets of carburettor one.
This shot shows more of the build up of deposit on the floats and the jets of carburettor one.
This is the bottom of the float bowl of carburretor two. Much like carburretor one in terms of build up.
This is the bottom of the float bowl of carburretor two. Much like carburretor one in terms of build up.
After viewing this I closed up both carburretors and placed them in plastic bags. Will visit my local mechanic tomorrow as he has offered to clean them out for me.
After viewing this I closed up both carburretors and placed them in plastic bags. Will visit my local mechanic tomorrow as he has offered to clean them out for me.
My improvised workbench - at least I get to work on the carburettors without my back going totally into spasm!
My improvised workbench - at least I get to work on the carburettors without my back going totally into spasm!
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Re: How to remove 1500 honda GL 1995 carburetor from engine

Postby virgilmobile » Mon Mar 10, 2014 10:22 am

Great job.
As always,I still recommend testing them before you put them back on.
Pre-sync,fuel leaks,hose condition,accelerator pump,slide action,etc.
Also,look at the vacuum line under the rubber mat.It usually gets poorly at the 90* bends.
Easier to replace those now while the carbs are out.
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Re: How to remove 1500 honda GL 1995 carburetor from engine

Postby sprintexec » Mon Mar 10, 2014 10:40 am

virgilmobile wrote:Great job.
As always,I still recommend testing them before you put them back on.
Pre-sync,fuel leaks,hose condition,accelerator pump,slide action,etc.
Also,look at the vacuum line under the rubber mat.It usually gets poorly at the 90* bends.
Easier to replace those now while the carbs are out.


I may come back to you on this as getting hold of spare parts is likely to be difficult here in Cyprus. Any recommendations for an on-line parts order? 8-)
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Re: How to remove 1500 honda GL 1995 carburetor from engine

Postby virgilmobile » Mon Mar 10, 2014 10:52 am

My local bike shop had the accelerator diaphragm in stock and I used "O" rings on the riser tube from a Harbor Freight Kit,I got all of them.
Vacuum lines came from a "real" auto parts place.
Check the Vendor database for parts you can't get local.Randakks.com is a good store.They have a $99 kit...I paid over $50 just for the accelerator diaphragm by itself.
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Re: How to remove 1500 honda GL 1995 carburetor from engine

Postby WingAdmin » Mon Mar 10, 2014 11:17 am

virgilmobile wrote:Seating the carbs back into the rubber couplers was a chore...Mine were quite hardened...I used a smear of petroleum jelly to help...
It still took all my weight to get them to seat properly,and a 18" Phillips screwdriver to reach the clamps.


When I did this to my wife's PC800, those rubber couplers were as hard as a rock, and even with the clamps tightened up, they were still loose. I ended up buying a new set of OEM couplers - they weren't at all expensive, were nice and soft, sealed up tight, and made the carbs easy to reinstall. When the time comes to pull the carbs on my GL1500, I'll do the same thing - order a set of couplers in advance.
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Re: How to remove 1500 honda GL 1995 carburetor from engine

Postby virgilmobile » Mon Mar 10, 2014 2:51 pm

Good idea on replacing the couplers...mine also got hard thus the extreme pressure needed to seat them..Next time I'll do that..
Did you determine what the green stuff is or where it came from.???
The fuel filter dissolved perhaps.
I'd be concerned that more of it is in the fuel lines,tank,filter,pump,vacuum cutoff valve,etc.....Just waiting to get back into the carbs and mess with it....
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Re: How to remove 1500 honda GL 1995 carburetor from engine

Postby sprintexec » Mon Mar 10, 2014 5:11 pm

virgilmobile wrote:Did you determine what the green stuff is or where it came from.???
The fuel filter dissolved perhaps.
I'd be concerned that more of it is in the fuel lines,tank,filter,pump,vacuum cutoff valve,etc.....Just waiting to get back into the carbs and mess with it....

I'm fairly confident that the green stuff is a residue left over after the evaporation of fuel. Possibly quite a lot of fuel. That said I am keeping an open mind until I've seen the local mechanic tomorrow. He repairs everything in our village from prestige motor cars to vintage tractors, Theo does the lot. My Greek is a few words at best and Theo only speaks a few words of English but we find a way of communicating!

The fuel filter appears in good order but I will give it a closer view tomorrow. I plan to clean out the fuel tank but have yet to decide on my plan of action. I'm off to do some on-line research to see if anyone else has had a similar experience. I'll keep you informed 8-)
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Re: How to remove 1500 honda GL 1995 carburetor from engine

Postby virgilmobile » Mon Mar 10, 2014 5:20 pm

Keep us posted...Whatever left that stuff in your carbs is of concern to me.
Especially where it came from...It would be something I would want to avoid.
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Re: How to remove 1500 honda GL 1995 carburetor from engine

Postby sprintexec » Tue Mar 18, 2014 1:33 pm

virgilmobile wrote:Keep us posted...Whatever left that stuff in your carbs is of concern to me.
Especially where it came from...It would be something I would want to avoid.

Update: I have the carburettors rebuilt and back in the bike. She starts and runs and doesn't leak fuel BUT she doesn't run well and when I road tested her I found that the foot brake doesn't work!
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Re: How to remove 1500 honda GL 1995 carburetor from engine

Postby virgilmobile » Tue Mar 18, 2014 2:19 pm

The foot brake on mine was dead too.Complete service.clean the calipers and master,flush with new fluid bleeding the front first.
Not running well is ...well ....a bit vague..sorry.
Does it run ok up to a certain rpm or bad all the way.
You can also link to a uploaded u-tube video.
Hearing and seeing how it runs badly helps to diagnose it.
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Re: How to remove 1500 honda GL 1995 carburetor from engine

Postby sprintexec » Tue Mar 18, 2014 3:36 pm

virgilmobile wrote:The foot brake on mine was dead too.Complete service.clean the calipers and master,flush with new fluid bleeding the front first.
Not running well is ...well ....a bit vague..sorry.
Does it run ok up to a certain rpm or bad all the way.
You can also link to a uploaded u-tube video.
Hearing and seeing how it runs badly helps to diagnose it.


virgilmobile I was amazed by the way things have just stopped working on the bike because I hadn't used her. If I had not had it happen to me I would not have believed it!

One other thing that I didn't post about before is that the cruise control also seems to have stopped working.

However back to the brakes. I've downloaded the service manual and printed the pages about the brake system. I have managed to remove both of the luggage boxes and so now have pretty good access to most of the braking components. I'll need to get hold of some new fluid and one of those one-man-bleed hoses. First though a read of the manual pages before bed!

Engine running issues - I've uploaded this short video

however the sound quality is less than good so I will shoot another video tomorrow, in the garage and out of the wind! :idea:
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Re: How to remove 1500 honda GL 1995 carburetor from engine

Postby virgilmobile » Tue Mar 18, 2014 4:46 pm

As far as the cruise...look through this post..viewtopic.php?f=6&t=21022

The engine does appear to be idling a bit low..bump it up and vacuum sync the carbs...You may also need to tweak the slow speed jets...A pain to reach(through and above the radiator) with a 18" flat blade screwdriver....It's called the "idle down adjustment".

The brakes....while your there,you might spend a little more time and clean out all the calipers..you know how oxidizing aluminum builds up under the seals and binds the piston...All 3 of mine eventually bound up...I couldn't even get the bike off the trailer..

I had 3 months of service work I did on mine before I could confidently drive it and it sat in a conditioned garage for a year and a half covered up....I think it was the lack of sunshine and 70 MPH wind that caused it to go bad....

Also don't forget...this is not a crotch rocket...It's more like a truck with a big engine...Quick,yes..super snappy engine..not so much...It will pull like a freight train..strong and hard...I idle down below 1000 RPM in Overdrive (4th)..round a corner at 20 MPH and just slowly twist the throttle...never shift a gear and pulled back up to highway speed.
That's torque..lots of it...and the engine didn't grumble at all.
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Re: How to remove 1500 honda GL 1995 carburetor from engine

Postby CrystalPistol » Wed Mar 19, 2014 8:56 pm

So ..... any updates on what that green stuff was / is ????

:shock:
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Re: How to remove 1500 honda GL 1995 carburetor from engine

Postby sprintexec » Thu Mar 20, 2014 1:26 am

CrystalPistol wrote:So ..... any updates on what that green stuff was / is ????

:shock:


CrystalPistol The green stuff was surprisingly soft to touch. I say this because I was expecting it to be harder. It had the consistency of hot not quite melted butter. With a blast or two of carb cleaner spray it washed out of the float bowls very easily.

My best guess was and still is that this residue is what you get when you park your bike up for months on end without draining the carbs (as I did :( ) Here in Cyprus the fuel has an additive, I'd guess that the additive is ethanol. When I ask at my local garage they just shrug their shoulders in that typically Cypriot "I don't know" way! At my age I am fortunate enough to be able to remember what straight fuel used to smell like and this stuff smells... different!!

Apart from causing the bike to flood out fuel when I went to start her the green stuff does not seem to have dine any other harm (yet). I'd guess that once it built up on the floats, it prevented them from raising up and shutting off as the float bowls filled with fuel which in turn led to the overflow.

I could ask Petrolina, the supplier, what they put in their fuel. Maybe I will once I get my bike up and running again. I say this because I am currently working on getting the rear brake master cylinder seals etc replaced. Then I have a cruise control problem to figure out and I need to set up the slow running etc on the carbs.

As a final note - :idea: Has anyone else experienced this specific type of build up in their carbs?
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Re: How to remove 1500 honda GL 1995 carburetor from engine

Postby TheChief » Sun Mar 30, 2014 8:39 am

sprintexec wrote:So, thanks to advice received from contributors in this forum 8-) , the carburettors are out of the bike :P .

I've separated them and I've had a look into the float bowls.

What I found has convinced me that no amount of "tapping" on the outside of the float bowls would ever have "cured" the mess I saw.

I'm feeling happier, a lots less apprehensive than I was at the start. And, for those of you reading this in the future, if I can do this so could you. By the way - I'll be draining my fuel system down at the end of every riding season from now on!

I've seen that green crap before in carbs that were left sitting with gas in the bowls that was treated with Sta-Bil. This stuff is nasty. It clogs the metering circuits and is a PITA to remove. You need to completely disassemble the carbs and soak them in something like Berryman's Chem Dip. Make sure you do not dip any rubber or plastic parts.... Use sewing needles and/or cutting torch tip cleaners to check/clean passages. Blow low pressure air through EVERY PASSAGE. Do the same thing with the metering jets, atomizer tubes, and float needle seats. Check the float needles for deformation. When in doubt, replace the float needles. Replace the fuel inlet screens. Change the fuel filter. Add Red Line SL-1 Fuel System Cleaner to your first few tanks of gas. Use the 10 gallon mix...
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Re: How to remove 1500 honda GL 1995 carburetor from engine

Postby leakycarb » Sun Apr 20, 2014 2:54 pm

virgilmobile wrote:The foot brake on mine was dead too.Complete service.clean the calipers and master,flush with new fluid bleeding the front first.
Not running well is ...well ....a bit vague..sorry.
Does it run ok up to a certain rpm or bad all the way.
You can also link to a uploaded u-tube video.
Hearing and seeing how it runs badly helps to diagnose it.

my 95 has had a bad foot brake since day one Nobody was able to figure out why....every year I used to bleed the right side brake on the front wheel seemed to help it always gets air in it don't know why or how
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Re: How to remove 1500 honda GL 1995 carburetor from engine

Postby Basschaser » Wed Aug 06, 2014 10:11 am

Mr. Sprintexec I watched your video and noticed your temp gauge was all most straight up and down. On mine If I'm moving it stays about half way between cold and the temp symbol unless I stop then it creeps up to half way and the fans come on. seems to stay about were yours is. until I start moving again is this the norm? The reason I'm asking is I had a coolant leak. It was hard to find never ran hotter then I mentioned and didn't leak less it was running and sometimes didn't leak at all or so I thought. Found a quarter inch line coming off front of carb. I removed the clamp that was there and put a hose clamp. Couldn't find the other end or were the hose went to down and to the right. Maybe to the pump? I'll keep looking has to go some were right. Your post is a few months old so I'm sure you got yours repaired by now. Have fun riding.
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Re: How to remove 1500 honda GL 1995 carburetor from engine

Postby Mh434 » Thu Aug 07, 2014 3:47 pm

For those who need to re-instal their carbs (and have to deal with those stiff intake boots), here's a tip -

Use a heat gun (or a substantial blow drier, if you have to) on the boots, and try to get them evenly HOT (don't burn 'em, though!).

Even old, hardened boots will become soft and pliable again, at least for a few minutes. I would also recommend using a lubricant on them, but I would NOT use petroleum-based lube...IF the boots are, in fact, rubber, petroleum will quickly destroy them.

I used a thin wipe of silicone-based lubricant (non-petroleum "brake grease") on mine (not on my 'Wing, but on my Kawasaki Concourse - had to re/re the carbs several times while chasing down a problem), and with some wiggling & pushing, they just popped into place. Without heat & lube, it simply wasn't possible....


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