Arghghg GL1500 trunk jammed shut


Information and questions on GL1500 Goldwings (1988-2000)
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WingAdmin
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Arghghg GL1500 trunk jammed shut

Postby WingAdmin » Tue Aug 25, 2015 8:22 am



Some days it doesn't pay to get out of bed...

Yesterday I discovered my universal joint was starting to go.

Today while riding in, I set my cruise control, which worked normally - except I noticed the "Set" light on the dash wasn't lighting up. This is an LED, so I doubt it's burned out. Add it to the "to do" list...

When I got to work, I went to open my trunk up and get my work clothes, lunch, other work stuff out...and the trunk wouldn't open. Pulling the lever, the left side of the trunk unlatches, but the right side remains firmly latched.

So I'm sitting here at work, in riding clothes, about to go back out to the parking lot and see if I can finagle my trunk open.



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WingAdmin
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Re: Arghghg GL1500 trunk jammed shut

Postby WingAdmin » Tue Aug 25, 2015 9:09 am

Well I went out and pulled the trunk under cover off, got a wire up in there and yanked down as hard as I could on the release lever, both on the left and the right side. Each time the left side of the trunk unlocked dutifully, but the right side remains locked solid. I tried bumping, I tried outright force. I'm completely unable to get the trunk unlocked.

I'm thinking that perhaps one of the straps from my bag got on top of the catch before the trunk was closed, and perhaps it has jammed as a result? The only way I can think of getting it to release is to get at it from inside the trunk. Sigh - I guess I know what I'll be doing tonight.

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NVSB4
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Re: Arghghg GL1500 trunk jammed shut

Postby NVSB4 » Tue Aug 25, 2015 10:28 am

I have a similar issue with my right saddlebag.
I was able to get it open and found that one of the screws for the locking mechanism had come loose, allowing it to swing with the latch instead of releasing.
Because it was the right bag, I had to take it off to get to the nuts that had fallen out of reach.

I think I'm going to schedule a maintenance day to go around and tighten every bolt and nut that I can find.
It's never too late to have a happy childhood!

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Chris

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WingAdmin
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Posts: 17046
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Location: Strongsville, OH
Motorcycle: 2000 GL1500 SE
1982 GL1100A Aspencade (sold)
1989 PC800 (wife's!)
1998 XV250 Virago (sold)
2007 Aspen Sentry Trailer

Re: Arghghg GL1500 trunk jammed shut

Postby WingAdmin » Tue Aug 25, 2015 8:36 pm

Alright, I got it open. What an ordeal!

The left side latch was working just fine, the right side was not opening at all. After quite a bit of messing around, here's how I got it open.

I have a "camera on a flexible stick" that also has a light on the end of it. I lifted up the one side of the trunk that would come unlatched as far as I could, and fed the camera into the trunk.

Camera going into trunk
Camera going into trunk

I had a look inside the trunk, I could see nothing obviously broken inside when looking at the right latch.

Image on camera
Image on camera

I removed the seat, which was a challenge, as this normally requires opening the trunk - I had to use a bit of force.

Remove seat
Remove seat

I then drilled a 1/2" hole in the front of the trunk:

Drill hole in seat back
Drill hole in seat back

Here's the location of the hole:

Hole position in seat back
Hole position in seat back

I made up a long screwdriver from a socket extension, a bit holder, and a philips bit:

Long screwdriver
Long screwdriver

I fed the screwdriver into the hole, and watching the latch on the camera, removed the two screws holding the latch to the lid.

Watch screwdriver on camera
Watch screwdriver on camera

Here's what the latch looks like on the inside of the lid normally, so you can get an idea of what I was unscrewing:

The position of the catch on the lid I removed
The position of the catch on the lid I removed

Success! When the two screws were removed, the lid popped open - note I wrapped the end of the screwdriver in duct tape to keep it from accidentally coming apart inside the trunk. You can also see the business end of the camera on the left side of the picture:

Success!
Success!

The lid latch stayed fastened in the catch. Wiggling it around, I was able to pull it free.

Lid latch stays latched in catch
Lid latch stays latched in catch

Watching the catch mechanism, I pulled the release - the catch on the right side did not move, which is obviously why it was not releasing. Something was wrong inside the latch release mechanism.

Removed latch, catch doesn't operate
Removed latch, catch doesn't operate

I started to remove the latch bar cover. However, one screw wouldn't come out:

Remove screws on back, except one
Remove screws on back, except one

The screw anchor was turning inside the plastic of the latch cover:

Screw anchor turning in plastic
Screw anchor turning in plastic

I've fixed this kind of thing before - I got out my soldering gun.

Get out solder gun
Get out solder gun

I put the soldering gun against the anchor, heating it up, and re-melting it into the ABS. Then I let it cool. This re-anchors the anchor in the plastic, and allowed me to remove the last screw.

Heat up screw anchor, let cool
Heat up screw anchor, let cool

I pulled the latch mechanism apart, and found that the latch bar had pulled out of the catch on the right side:

Bar pulled out of catch
Bar pulled out of catch

For whatever reason, the bar had slid too far to the left, causing the bar to pop out of the right hand catch - which caused it to no longer unlatch the right side. The bar had slid all the way through the left catch, and pulled out of the right catch altogether.

My solution to prevent this from happening again was to put a dollop of J-B Weld epoxy on both ends of the bar, just inboard of where the catches slide onto:

J-B Weld on bar
J-B Weld on bar

I put it on both sides of the bar:

J-B Weld on both sides
J-B Weld on both sides

With the J-B Weld in place, the bar is now prevented from sliding too far into the catches:

Bar now prevented from sliding too far into catch
Bar now prevented from sliding too far into catch

I reassembled the catch mechanism:

Reassembling catch mechanism
Reassembling catch mechanism

Greased it up and it was good as new:

Greased up and ready to go
Greased up and ready to go

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Bluewaterhooker0
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Motorcycle: 1997 Goldwing GL 1500 SE

Re: Arghghg GL1500 trunk jammed shut

Postby Bluewaterhooker0 » Tue Aug 25, 2015 10:22 pm

I have to admire your tenacity, when it comes to photos and tutorials. I can assure you that when I am confronted by such an issue, you don't want to hold your breath, waiting for my expose' on how I fixed it. I could post an audio summary of all the colorful 4, 5, and 6 letter words that might pass my lips while working on it. But, that probably won't help anyone on these pages.
:shock:

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NVSB4
Posts: 1127
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1992 GL1500I (sold)
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1993 Yamaha Virago XV1000 (sold)
Too many others to list

Re: Arghghg GL1500 trunk jammed shut

Postby NVSB4 » Wed Aug 26, 2015 6:17 am

I not only admire his tenacity, appreciate the tutorials, but also envy all of his tool goodies.
I can just hear the conversation with my wife, "but I need it, and Scott has one". :D
It's never too late to have a happy childhood!

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Aussie81Interstate
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1981 GL1100 Interstate (sold)
1988 GL1500

Re: Arghghg GL1500 trunk jammed shut

Postby Aussie81Interstate » Wed Aug 26, 2015 7:29 am

Kudos,

Great article - hopefully I will never have to do something like that.

I think my 4lb block hammer would be my tool of choice ( probably not) - but I would not have had your patience.

:D

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WingAdmin
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Motorcycle: 2000 GL1500 SE
1982 GL1100A Aspencade (sold)
1989 PC800 (wife's!)
1998 XV250 Virago (sold)
2007 Aspen Sentry Trailer

Re: Arghghg GL1500 trunk jammed shut

Postby WingAdmin » Wed Aug 26, 2015 8:56 am

NVSB4 wrote:I not only admire his tenacity, appreciate the tutorials, but also envy all of his tool goodies.
I can just hear the conversation with my wife, "but I need it, and Scott has one". :D


The camera I actually bought when I installed an alarm system in my house, to help with pulling wire through various walls. It has saved my bacon more than a few times, and was worth the expense!

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virgilmobile
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Re: Arghghg GL1500 trunk jammed shut

Postby virgilmobile » Wed Aug 26, 2015 9:43 am

Great job too. :ugeek:
Just one more thing to put on my "to check" list.
My my....it's gettin to be a long list too.. :D

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Bluewaterhooker0
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Re: Arghghg GL1500 trunk jammed shut

Postby Bluewaterhooker0 » Wed Aug 26, 2015 11:09 pm

I am a bit of a "tool-aholic" myself. However, I have to say, I don't think I ever bought a tool that didn't pay for itself immediately, or soon after. I have an uncanny knack for buying tools, sometimes that I just happen to like, or think, "someday I might need that sucker". Then shortly after, sure enough, it is a tool that I need for a job or project within about 3-6 months of buying it. Not every time, but more times than I could count. If you read these pages, and work on your own bike, you'll save enough money to justify almost any tools you buy. I got my bike 3 years ago, and have worked on all sorts of projects, repairs, and maintenance, thanks to these pages and tutorials. It hasn't seen a Honda shop yet. And some of those projects are things the Honda dealer wouldn't do, anyway.

PS - The only thing I did pay to have done was a rear tire install. But I removed the bags and brought the wheel to a generic shop for mounting and balancing. While I was in there (rear of bike), I got some much needed maintenance done on the brakes, splines, drive rubbers, air shock, and rubber boot. The $35 for tire mount and balance was well worth it.

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Re: Arghghg GL1500 trunk jammed shut

Postby roadwanderer2 » Thu Aug 27, 2015 7:19 am

nice job you did with your trunk there wingadmin. what year and model bike is that trunk on? ......and not trying to highjack this thread, but hey bluewaterhooker, talking about tools, the few tools i bought from harbor freight have already paid for themselves, like my 1/4" drive air ratchet and my other air tools, but i absolutely love my motorcycle tire bead breaker and the 3 flat tire irons i bought. ive used them to r & r my front and rear tires. very good investment for such cheap tools. im glad i bought the bead breaker before H F decided to discontinue selling it. it came in very handy for when i had to remove my rear tire 4 times to change wheels due to wheel bearing failure.

stuart.

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WingAdmin
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1998 XV250 Virago (sold)
2007 Aspen Sentry Trailer

Re: Arghghg GL1500 trunk jammed shut

Postby WingAdmin » Thu Aug 27, 2015 8:41 am

roadwanderer2 wrote:nice job you did with your trunk there wingadmin. what year and model bike is that trunk on?


That's my 2000 GL1500 you see.

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Motorcycle: 83 GL1100A aspencade, previously owned, 1981 honda GL500i silverwing interstate, 1974 yamaha xs400, 1974 Honda cb450 twin cam, 1983 honda vt30, 1982 honda 700 shadow, 1972 cb750four, and my first bike, a brand new 1982 honda CM400e. and a new to me 1986 GL1200 aspencade SEi
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Re: Arghghg GL1500 trunk jammed shut

Postby roadwanderer2 » Thu Aug 27, 2015 9:14 am

oh, ok, i was wondering what bike that trunk was on.

stuart.




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