76 GL1000 Issues, Questions, Upgrades


Information and questions on GL1000 Goldwings (1975-1979)
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76GL1000LTD
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76 GL1000 Issues, Questions, Upgrades

Post by 76GL1000LTD »



Hi all,

Figured I will create another thread related to issues that my bike has apart from smoke. As well as any questions or upgrades I can think of.

Here are the issues that I would want to address:
1. Throttle is a bit sticky, doesn't return to neutral position easily. What can be done? Cable replacement, lubrication, etc? On the GS1000 that I had, I replaced throttle tube with later years Yamaha R1 tube to improve response, could this mod work for GL1000 as well?
2. Horn doesn't work. Not sure which part is broken, but when I press the button nothing happens.
3. Rust in the fuel tank. Either clean it out somehow or replace (finding replacement is probably next to impossible?). Looks like the tank has been repainted on the outside, paint is relatively fresh.
4. Noticed a cracked hose on the left hand side underneath fuel tank. What does it do and how important is it? (Will attach picture)
5. Another little issue is tachometer gauge slightly out of place. It seems to come out a bit from the rubber surround, unlike speedometer that is still in place. And in general gauges with the center lights are a bit shifted to the left (minor gripe). I'll try to attach picture of what I'm talking about, don't know if anything can be done or I should just accept that it's an old bike so it won't be perfect.

Question: What is a good repair manual to buy? I found two online, one is Clymer the other one is Haynes, which one is better?
Also, I am thinking of replacing handlebars with something more straight, with not as much pullback (would be better for my wrists). I realized that wiring is actually routed through the original handlebars, so it will need to be pulled out. What is the best way without damaging anything?
And I'm not sure if I will need shorter cables if changing to new handlebars. Any suggestions?

Thank you.
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~ Mykhaylo, aka Mike
1976 Honda GL1000 LTD - current
1994 Honda XR650L (first bike) - sold
1978 Suzuki GS1000 - sold
1982 Suzuki GS400L - wife's, sold
2016 Suzuki V-Strom 1000 - totaled
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Re: 76 GL1000 Issues, Questions, Upgrades

Post by DenverWinger »

Cracked hose is the crankcase vent - it goes up to the air box. Not critical. Wouldn't hurt to replace it some time though.
♫ 99 Little Bugs in the Code, ♪
♪ 99 Bugs in the Code. ♫ :(
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Re: 76 GL1000 Issues, Questions, Upgrades

Post by WingAdmin »

76GL1000LTD wrote: Sun Mar 29, 2020 9:46 pm Question: What is a good repair manual to buy? I found two online, one is Clymer the other one is Haynes, which one is better?
Neither. Get the actual Honda service manual. Too many mistakes and omissions in both the Haynes and Clymer manuals.

http://www.helminc.com/helm/product2.as ... ku=6137102
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Re: 76 GL1000 Issues, Questions, Upgrades

Post by winguyjo »

throttle cable routing and lubrication are both critical. cannot comment re : modification.
to test a horn simply apply 12v+ and ground to the 2 terminals. if the horn works then i would proceed to clean the horn button contacts.
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76GL1000LTD
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Re: 76 GL1000 Issues, Questions, Upgrades

Post by 76GL1000LTD »

Thanks for the answers, I'll try your suggestions. Will have to order proper service manual and crank hose.
~ Mykhaylo, aka Mike
1976 Honda GL1000 LTD - current
1994 Honda XR650L (first bike) - sold
1978 Suzuki GS1000 - sold
1982 Suzuki GS400L - wife's, sold
2016 Suzuki V-Strom 1000 - totaled
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Re: 76 GL1000 Issues, Questions, Upgrades

Post by Rambozo »

Gauges are mounted with rubber grommets. Perhaps you are missing them or have the wrong ones side to side?
Plus one on the Honda factory manual. Well worth the investment. ebay can be your friend for these, too.
The control connectors on the older Hondas are usually bullet plugs so they can be fished through the bars. You can either put the appropriate holes in your new bars, or just cable tie them to the outside. If you do that, you will need to cut a slot in the control pod so the wires have a place to come out. As I recall there is also an anti-rotation pin that goes into a hole in the bars. You can drill the hole or the pin is just a light press fit and can be pulled out. Lubing the throttle cables can make a big difference. As far as cable length, that will depend on your bars and how your controls are positioned.
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Re: 76 GL1000 Issues, Questions, Upgrades

Post by SnoBrdr »

Got to fix that rust issue.

If you don't it can cause major issues.

Start by changing the fuel filter and check it often.

I have a cleanable filter.

The tank issue is a major one to do it properly.

You have to basically remove the whole back part of the bike to get the tank out.

You could try it with it in place but results are mixed at best.

There are many ways to clean and preserve the tank.

Home remedies to commercial ones.

I went the Por-15 route.
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Re: 76 GL1000 Issues, Questions, Upgrades

Post by winguyjo »

re : rusty gas tank ...

i recently had a beat-up little suzuki 2 stroke with a gas tank that was pretty ugly inside. i had watched a few youtube videos on cleaning gas tanks using electrolysis and i had little to lose so i gave it a try ... i was gob-smacked at how well it worked ! you might want to look into it.
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Re: 76 GL1000 Issues, Questions, Upgrades

Post by 76GL1000LTD »

Honda service manual has been ordered.
Next, I'll research suggested methods for fuel tank cleaning and removal, this will be high on my priority list.
Maybe order new handlebars while I'm at it. Gauges will have to wait for now, they seem to be working, other than sitting a bit off.
~ Mykhaylo, aka Mike
1976 Honda GL1000 LTD - current
1994 Honda XR650L (first bike) - sold
1978 Suzuki GS1000 - sold
1982 Suzuki GS400L - wife's, sold
2016 Suzuki V-Strom 1000 - totaled
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Re: 76 GL1000 Issues, Questions, Upgrades

Post by GL1000K1dan »

I changed the handlebars on my 76 GL1000. As the bars were not as tall, I had to replace the clutch and throttle cables, also the upper reservoir brake hose.
Before pulling out the switch wires, tie a piece of strong string around them. This will make it easier to feed the switch wires back through the new bars.
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76GL1000LTD
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Re: 76 GL1000 Issues, Questions, Upgrades

Post by 76GL1000LTD »

GL1000K1dan wrote: Thu Apr 02, 2020 10:28 am I changed the handlebars on my 76 GL1000. As the bars were not as tall, I had to replace the clutch and throttle cables, also the upper reservoir brake hose.
Before pulling out the switch wires, tie a piece of strong string around them. This will make it easier to feed the switch wires back through the new bars.
I am thinking of getting these handlebars: https://fortnine.ca/en/emgo-7-8in-unive ... bar#76=631
Which clutch and throttle cables you used? Do you have part numbers? Also, which reservoir brake hose?
Thanks for the tip about wires, but I will probably just keep them outside of the new bars.
~ Mykhaylo, aka Mike
1976 Honda GL1000 LTD - current
1994 Honda XR650L (first bike) - sold
1978 Suzuki GS1000 - sold
1982 Suzuki GS400L - wife's, sold
2016 Suzuki V-Strom 1000 - totaled
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Re: 76 GL1000 Issues, Questions, Upgrades

Post by GL1000K1dan »

I sourced my cables from David Silvers and the brake hose from SIRIUSCONINC in the US.
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76GL1000LTD
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Re: 76 GL1000 Issues, Questions, Upgrades

Post by 76GL1000LTD »

GL1000K1dan wrote: Fri Apr 03, 2020 1:20 pm I sourced my cables from David Silvers and the brake hose from SIRIUSCONINC in the US.
Alright, thanks for the info. What was the length of the cables that worked for you, and did you have to specify it when ordering?
~ Mykhaylo, aka Mike
1976 Honda GL1000 LTD - current
1994 Honda XR650L (first bike) - sold
1978 Suzuki GS1000 - sold
1982 Suzuki GS400L - wife's, sold
2016 Suzuki V-Strom 1000 - totaled
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76GL1000LTD
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Re: 76 GL1000 Issues, Questions, Upgrades

Post by 76GL1000LTD »

A bit of an update.
- Fuel tank removed, cleaned and lined by a local radiator shop, waiting to be put back in.
- Old handlebars removed.

I figured I'll deal with handlebars and any other things that are easier to access while tank is out. I realized routing the wires from the switches is not as easy.
I don't really want to cut out any holes in the new handlebars for the wires, and would rather zip tie them to the outside. But the problem is the wires are taking up space in the handlebar hole of the switch, and I'm not sure what to do about it. Any suggestions?
~ Mykhaylo, aka Mike
1976 Honda GL1000 LTD - current
1994 Honda XR650L (first bike) - sold
1978 Suzuki GS1000 - sold
1982 Suzuki GS400L - wife's, sold
2016 Suzuki V-Strom 1000 - totaled
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wing2 : 1980 gl1100 interstate; resurrection complete. SOLD.
wing3 : 81gl1100i frame/82gl1100a engine/81cb900 bits. resurrection complete. naked. SOLD.
wing4 : 1977 gl1000 black w/ blue pinstripes; resurrection complete. SOLD
wing5 : 1977 gl1000 black w/gold pinstripes; nearly roadworthy when purchased, NOW RIDING.
wing6 : 1975 gl1000 blue; SOLD

Re: 76 GL1000 Issues, Questions, Upgrades

Post by winguyjo »

i went through this a while ago on my '75. i decided to file out a semi-circle on the bottom half of the switch to allow room for the wires.
this did NOT work. the way the wires are connected inside the switch will never allow it to be tightened down flush to the handlebars ... they sit too high (or low, depending on how you look at it). maybe search ebay for a suitable switch which has the semi-circle in the bottom half to allow for external wiring.
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Re: 76 GL1000 Issues, Questions, Upgrades

Post by 76GL1000LTD »

Thanks for letting me know. I guess that leaves me with only two options:
- Find new switches or
- Cut holes in the bars.
~ Mykhaylo, aka Mike
1976 Honda GL1000 LTD - current
1994 Honda XR650L (first bike) - sold
1978 Suzuki GS1000 - sold
1982 Suzuki GS400L - wife's, sold
2016 Suzuki V-Strom 1000 - totaled
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Re: 76 GL1000 Issues, Questions, Upgrades

Post by 76GL1000LTD »

Finally got around to continue refreshing my bike, this riding season is done, have to get it ready for the next.
New handlebars were drilled, wires run on the inside, looks good.
Since the tank was out it was easy enough to install new throttle and clutch cables. Figured I would grease all of the driveshaft pieces and splines and change final drive oil.
When I tried to drain the final drive oil it looked very dark and didn't flow easily at all, I'm afraid there could be some sludge in there. Drained it best I could, put new oil and drained it again.
Filled it up and probably will have to drain it one more time at least, but probably later when I ride it around first.

After all that I put the tank back, reassembled the rear end and tried to see if everything is ok by putting the fuel in the tank. Guess what, not everything is ok, haha. The fuel started leaking from the petcock area.
I guess it needs a rebuild.
What's a best place to get the rebuilt kit?
I called local dealer to see if they have the O-rings, part #16175-551-950, but they are discontinued. I found another O-ring with a similar dimensions, part #91312-415-000. Is it a suitable substitution?
~ Mykhaylo, aka Mike
1976 Honda GL1000 LTD - current
1994 Honda XR650L (first bike) - sold
1978 Suzuki GS1000 - sold
1982 Suzuki GS400L - wife's, sold
2016 Suzuki V-Strom 1000 - totaled
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76GL1000LTD
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Re: 76 GL1000 Issues, Questions, Upgrades

Post by 76GL1000LTD »

Petcock is now rebuilt, back on the bike, doesn't seem to leak anymore. Replaced fuel lines as well just in case.

New problem: when I try to start the bike, fuel starts leaking from the middle portion of left exhaust. Not sure what can cause it, suspect something with carbs.
Pulled spark plugs out to check, left rear one (cyl 4?) looks wet.
Any ideas?
~ Mykhaylo, aka Mike
1976 Honda GL1000 LTD - current
1994 Honda XR650L (first bike) - sold
1978 Suzuki GS1000 - sold
1982 Suzuki GS400L - wife's, sold
2016 Suzuki V-Strom 1000 - totaled
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Re: 76 GL1000 Issues, Questions, Upgrades

Post by Maz »

No 4 carb is flooding. Float valve sticking (try tapping float bowl with a screwdriver handle to see if it unsticks). Either that or there's crap on the seat of the float valve (quite possible if your tank was rusty). The carbs may need pulling to check, clean and rebuild.
Maz
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76GL1000LTD
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Re: 76 GL1000 Issues, Questions, Upgrades

Post by 76GL1000LTD »

Carbs are out of the bike now, just need to find the time to disassemble them and clean.
Previous owner mentioned that carbs were rebuilt at some point in the last few years (can't verify if true). How often do they need to be rebuild? Will spraying the insides with Carb cleaner be enough?
If not, what is the best rebuild kit? is it Randakks?
Thanks.
~ Mykhaylo, aka Mike
1976 Honda GL1000 LTD - current
1994 Honda XR650L (first bike) - sold
1978 Suzuki GS1000 - sold
1982 Suzuki GS400L - wife's, sold
2016 Suzuki V-Strom 1000 - totaled
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Re: 76 GL1000 Issues, Questions, Upgrades

Post by Maz »

76GL1000LTD wrote: Mon Nov 16, 2020 2:49 pm Carbs are out of the bike now, just need to find the time to disassemble them and clean.
Previous owner mentioned that carbs were rebuilt at some point in the last few years (can't verify if true). How often do they need to be rebuild? Will spraying the insides with Carb cleaner be enough?
If not, what is the best rebuild kit? is it Randakks?
Thanks.
These carbs need to be CLEAN. Spraying carb cleaner won't reach all of the jets and passages. Randakks kit is the best, but I believe some people have had problems getting them, since Randall sold the business.
I rebuilt mine about 3 years ago and so long as you drain them when laying the bike up for long periods and use a decent fuel filter, they will be fine for years.
Maz
Ironically, Common Sense is the LEAST common of all senses!
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76GL1000LTD
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Re: 76 GL1000 Issues, Questions, Upgrades

Post by 76GL1000LTD »

Alright, I'll wait until the kit is back in stock and get it.
When you drain the carbs, how do you catch the fuel or do you just let it drip on the engine and down? Before removing them I tried draining but could not find a good way to catch the fuel, especially from front carbs.
~ Mykhaylo, aka Mike
1976 Honda GL1000 LTD - current
1994 Honda XR650L (first bike) - sold
1978 Suzuki GS1000 - sold
1982 Suzuki GS400L - wife's, sold
2016 Suzuki V-Strom 1000 - totaled
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Maz
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Re: 76 GL1000 Issues, Questions, Upgrades

Post by Maz »

76GL1000LTD wrote: Tue Nov 17, 2020 11:19 am Alright, I'll wait until the kit is back in stock and get it.
When you drain the carbs, how do you catch the fuel or do you just let it drip on the engine and down? Before removing them I tried draining but could not find a good way to catch the fuel, especially from front carbs.
It's easiest to run the engine with the fuel off, until it dies. Other than that, I have used a section cut from a plastic milk carton as a crude 'gutter' to direct the fuel into a jar.
Maz
Ironically, Common Sense is the LEAST common of all senses!
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GL1000K1dan
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Re: 76 GL1000 Issues, Questions, Upgrades

Post by GL1000K1dan »

Just use an absorbent cloth.
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76GL1000LTD
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Re: 76 GL1000 Issues, Questions, Upgrades

Post by 76GL1000LTD »

Alright, thanks, I'll keep that in mind. I do have some empty milk jugs laying around.


~ Mykhaylo, aka Mike
1976 Honda GL1000 LTD - current
1994 Honda XR650L (first bike) - sold
1978 Suzuki GS1000 - sold
1982 Suzuki GS400L - wife's, sold
2016 Suzuki V-Strom 1000 - totaled
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