1976 GL1000 restoration


Information and questions on GL1000 Goldwings (1975-1979)
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suha
Posts: 16
Joined: Tue Sep 10, 2024 3:57 am
Location: Halleforsnas, Sodermanland, Sweden
Motorcycle: 1976 GL1000
1982 VF750C

1976 GL1000 restoration

Post by suha »



Hello,

I'm new here and a bit nervous about posting, but I hope it's OK that I share the story (and maybe some pictures) of my ongoing restoration.

First, the background story: In 2022, I had been looking for a GL1000 for almost a year, when a friend told me there was one for sale in a closed group on a social media site. I joined the group, contacted the seller asking if he could hold on to the bike for one more week to give me time to travel to him, and to my surprise he replied that I was the first person to actually say I was interested in buying the bike. He was sick of people calling to tell him it was too expensive, or people looking for someone to just chat with.

The day arrived and my husband and I went to see the bike. It looked just like in the seller's pictures - well preserved. Of course, it had some issues. Not really surprising, as it's been sitting in a garage since 1987 along with a cardboard box containing various parts. The seller didn't have any info from the previous owner, who was the son of the first owner (the first owner had passed some years ago). The seller had intended to get the bike running again, but after two years he realized he didn't have time to fix it, and here we were. I was in love. My husband and I rented a trailer and with some effort, the seller, my husband and I pushed the bike up the ramp. When we got back home I had to call a friend to help unloading the bike and get it into my garage.

Time went by, and I wanted to get started, but I was also hesitant to do so, because I'm not a mechanic and I've never really done anything like this. I bought a battery, installed it and noticed the left hand turn signals didn't flash, they were always lit when turning them on. That's how I left it for two more years. Then, finally, this summer I ordered new cambelts and tensioners and the project took off.

As I mentioned above, I didn't really get much info from the seller. Here are the known issues when I bought the bike:
  • Sitting since 1987
  • Wrong handlebar
  • Throttle stuck
  • Wheels difficult to turn/Malfunctioning brakes
  • Cracks in seat cover
  • No battery
  • Dusty
Before the new cambelts and tensioners arrived, I drained the coolant (which actually didn't look too bad), pulled out the radiator and then I removed the old cambelts. It wasn't a pretty sight, and the tensioners made a hissing sound when i spun them. I would guess they had never been changed, and the same goes for the air filter which was nasty looking.

Speaking of the air filter, the compartment that goes on top of the air filter housing was missing from the bike, but when I started rummaging through the cardboard box I found it. I also found the pouch with almost all of the original tools, and a filthy ziplock bag containing the Owner's manual (thank goodness it wasn't filthy on the inside!). There were nuts, bolts, things like that. Three ignition coils with cut wires. One new OEM front brake piston in its box. A pair of rear shocks. A rusty handlebar. A pair of used grips. Bits and pieces left for me to try to figure out where they should go.

As I said, I'm not a mechanic and replacing the cambelts was intimidating. While working up courage to get it done, I tried to figure out how to get the throttle unstuck. I applied lubricant as best I could to the wires and to the moving parts outside the carburetors (sorry, I don't know what they're called :oops: ), and slowly the throttle gave way. Well, that's one thing I could cross off the list :)

A few days later, encouraged by the success with the throttle, I finally got the left cambelt and tensioner in place. Happy with the result, I went on to do the right side as well. Nope. Couldn't get the pulley to stay in the correct position. While pondering this road bump, I started looking at the front brake master cylinder. It was a mess. Stuck. I removed the lever (and noticed that the rubber thingy that the lever rests on was worn out), and then I removed the whole master cylinder. Might as well, as I was going to replace the handlebar. Not knowing how to remove the stuck parts from the master cylinder, I let it sit on the workbench while I went on to have a look at the malfunctioning high beam. It wasn't just the high beam that was malfunctioning, the bulb was ruined. No wonder the light was so dim when it only came from the pilot bulb. Oh, and the horn didn't work either. I got a new bulb and put it in and I will replace the horn later.

I turned my attention back to the right side cambelt and finally managed to get everything lined up. Oh the joy! :D

At some point during all of this, I realized the brake light didn't come on from the brake pedal. Upon closer investigation, I found out that the switch was broken. Easy enough to replace, but now I noticed another problem. The pilot bulb and tail light had stopped working. I studied the wiring diagram, traced wires on the bike, saw nothing wrong. Then it occured to me there are fuses. Yep, one fuse was blown. Ok, well, good thing the spare fuses were still there in the fuse box.

With that out of the way I decided to see if the starter engine works. The result was inconclusive, as the starter relay did nothing. I wriggled it out but at this point I needed a break, so my husband went on to try to persuade the relay to function again. Somehow, he did. Before putting the relay back, I peeled off the insulation from the relay's battery lead and replaced it, as it was badly cracked, and then I tested again if the starter engine works. This time, it started spinning like it should. What a wonderful sound it was! I tried it again, just to get in on film. Then I put the relay back.

Next issue: Both ignition coils had been dismounted from their brackets and left laying inside the dummy tank frame. This was quite the challenge for me. First I had to locate the brackets. Luckily, they were in that cardboard box. Then I had to figure out how to put everyting together. This was the truly tricky part, as I didn't see how they looked before being dismounted. I checked drawings on parts sites, googled pictures, got an idea of how it should be and proceeded to digging out screws, nuts, washers and cable clips from the cardboard box. I think I got the left coil correctly installed on my fifth attempt. It's surprising how many ways it can be done wrong :oops:

And, well, that's the current status of this project. I might have forgotten to mention some details, but the overall description is there.


User avatar
winguyjo
Posts: 639
Joined: Sat Aug 11, 2018 9:26 pm
Location: b.c. Canada
Motorcycle: wing 8 : 1982 gl1100 standard.

Re: 1976 GL1000 restoration

Post by winguyjo »

i went through that same thing the first time i had to mount coils ... amazing how such a simple task can be so confusing. it sounds like you are enjoying the challenge of reviving this bike and have the required patience to do so. good luck and have fun !
RobbyMoto
Posts: 87
Joined: Thu Feb 16, 2023 10:36 am
Location: Cleveland, Oh.
Motorcycle: 1975 GL1000, 1976 GL1000, 2005 Yamaha V-star 1100 (XVS1100), 2003 Honda Rebel 250 (CMX250C)

Re: 1976 GL1000 restoration

Post by RobbyMoto »

Yes good luck with it. The good thing is even though it is old, seems to me these bikes were designed to be serviced. Welcome to the forum. Please keep us posted. :D
suha
Posts: 16
Joined: Tue Sep 10, 2024 3:57 am
Location: Halleforsnas, Sodermanland, Sweden
Motorcycle: 1976 GL1000
1982 VF750C

Re: 1976 GL1000 restoration

Post by suha »

Thank you winguyjo and RobbyMoto! I am having fun, yes. Today, I have been making some progress with the front brake master cylinder - the circlip was rusted in place but now it can be rotated in its grove. I'm not sure the master cylinder can be saved but I hope it looks ok inside when I get the moving parts out. I've also located a missing cable clip for the ingition coil assembly. It had been left hanging on to one of the coils in the cardboard box. My intention was to get the second coil in place tonight, but wires and cables have become entwined so I'll need to sort them first and I'm not up to that after a long day at work. Instead, I'll post a link to the film where I test the starter engine after my husband got the relay to work. I'll get back to posting pictures when I know where to put them.



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suha
Posts: 16
Joined: Tue Sep 10, 2024 3:57 am
Location: Halleforsnas, Sodermanland, Sweden
Motorcycle: 1976 GL1000
1982 VF750C

Re: 1976 GL1000 restoration

Post by suha »

I said earlier that I was going to post pictures. Let's see if I can do it.

First, some pictures I took at the seller's place. Besides the wrong handlebar and grips, isn't she just beautiful?







Ready to go home
Ready to go home

suha
Posts: 16
Joined: Tue Sep 10, 2024 3:57 am
Location: Halleforsnas, Sodermanland, Sweden
Motorcycle: 1976 GL1000
1982 VF750C

Re: 1976 GL1000 restoration

Post by suha »

Fast forward to mid-July and through the rest of July 2024:

Radiator and spark plugs removed
Radiator and spark plugs removed


The old cam belts and tensioners were not a pretty sight
The old cam belts and tensioners were not a pretty sight


Neither was the old air filter
Neither was the old air filter


Guess which one I'd begun polishing
Guess which one I'd begun polishing

suha
Posts: 16
Joined: Tue Sep 10, 2024 3:57 am
Location: Halleforsnas, Sodermanland, Sweden
Motorcycle: 1976 GL1000
1982 VF750C

Re: 1976 GL1000 restoration

Post by suha »

August 2024:

Before cleaning off rust from the pulleys
Before cleaning off rust from the pulleys


New cam belt and tensioner in place on left side
New cam belt and tensioner in place on left side


Right side not as cooperative
Right side not as cooperative


Front brake lever with some hardened stuff on it
Front brake lever with some hardened stuff on it


Messy and stuck front brake master cylinder
Messy and stuck front brake master cylinder


Broken headlight bulb
Broken headlight bulb

suha
Posts: 16
Joined: Tue Sep 10, 2024 3:57 am
Location: Halleforsnas, Sodermanland, Sweden
Motorcycle: 1976 GL1000
1982 VF750C

Re: 1976 GL1000 restoration

Post by suha »

September 2024:

Finally, cam belt and tensioner in place on right side
Finally, cam belt and tensioner in place on right side



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Notice how the tail light isn't on in the above video. That's because of this culprit:

Blown fuse
Blown fuse



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New handlebar in place:


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Sorry about the shaky videos.
RobbyMoto
Posts: 87
Joined: Thu Feb 16, 2023 10:36 am
Location: Cleveland, Oh.
Motorcycle: 1975 GL1000, 1976 GL1000, 2005 Yamaha V-star 1100 (XVS1100), 2003 Honda Rebel 250 (CMX250C)

Re: 1976 GL1000 restoration

Post by RobbyMoto »

Great looking bike! I have a 1975 gl1000 that I did a lot of work to. Basically the same as yours. Even the same color.


I am no expert but I’ve worked on almost every part of this bike. This forum is a great place to get help with it. Let me know if you need any advice.

One thing I learned, all of the rubber parts are 49 years old and are suspect. Just assume you will have to replace those parts. For example the brake calipers and master cylinder. If you are taking anything like that apart, order the full rebuild kit and plan on replacing all of the ancient rubber in there.
suha
Posts: 16
Joined: Tue Sep 10, 2024 3:57 am
Location: Halleforsnas, Sodermanland, Sweden
Motorcycle: 1976 GL1000
1982 VF750C

Re: 1976 GL1000 restoration

Post by suha »

Trust me, I'm somewhat familiar with old rubber. When I bought my VF750C the hydraulic clutch didn't work, so I had to fix it. Fixing it included rebuilding the rusted slave cylinder as well as the leaky master cylinder. So when I began to check what's wrong with the front brakes on the GL1000, I assumed from the start I would need a rebuild kit and sure enough the rubber boot split in two when i pulled on it. Then of course there's the rusty circlip - can't reuse that.

On the positive side, today I borrowed a horn from a friend who has a 1975 GL1000. He got it very cheap in 2001 because its right side had been damaged in a fire. One of the damaged parts was the horn (not an original part). It still works, but the plastic has gone a bit bubbly on the surface that faced the fire. It doesn't matter to me, though, as I only wanted to confirm that the horn button and wiring is working, and it is.
suha
Posts: 16
Joined: Tue Sep 10, 2024 3:57 am
Location: Halleforsnas, Sodermanland, Sweden
Motorcycle: 1976 GL1000
1982 VF750C

Re: 1976 GL1000 restoration

Post by suha »

Today has been a day of disappointments. When I got home from work, I made another attempt to get the circlip out of the front brake master cylinder but the pliers were slightly too short. Then I detangled the ignition coil wires and cables, mounted the right coil on the brackets and attached the assembly to the frame. Did I get sparks from the spark plugs? No. That's when I left the garage and had dinner instead.
suha
Posts: 16
Joined: Tue Sep 10, 2024 3:57 am
Location: Halleforsnas, Sodermanland, Sweden
Motorcycle: 1976 GL1000
1982 VF750C

Re: 1976 GL1000 restoration

Post by suha »

It's been a few days since I did anything to the bike, but this morning I decided to test the spark plugs again. This time there were bright and clear sparks from 3 and 4, so I guess none of the ignition coils are completely dead. I was so excited that I didn't think to change the plugs around to see if I could get sparks from 1 and 2 also. I'll get to it later. But for now, yay! Sparks! :D

I need to ask, though. Is it possible that the electrical wiring is incomplete somewhere and causing spark plugs 1 and 2 to not have spark? It seems too symmetrical to me to be a coincidence.

(Also, sorry if my English gets incomprehensive. It's not my first language.)
User avatar
winguyjo
Posts: 639
Joined: Sat Aug 11, 2018 9:26 pm
Location: b.c. Canada
Motorcycle: wing 8 : 1982 gl1100 standard.

Re: 1976 GL1000 restoration

Post by winguyjo »

1 and 2 run off the same coil so it's not unusual to see loss of spark on both at the same time. i always remove them and clean up the grounds. actually, i clean up any ground i can find when i am resurrecting one of these 45 - 49 year-olds.
suha
Posts: 16
Joined: Tue Sep 10, 2024 3:57 am
Location: Halleforsnas, Sodermanland, Sweden
Motorcycle: 1976 GL1000
1982 VF750C

Re: 1976 GL1000 restoration

Post by suha »

I remembered wrong. I was sure it was 1 and 3 from one coil, and 2 and 4 from the other. Hence my assumption both coils kind of work, but with 1 and 2 from one, and 3 and 4 from the other, then obviously it makes more sense how 3 and 4 gets spark but not 1 and 2. Glad I got that cleared up. I do wonder, however... There are three used coils in the cardboard box. They are all the 1 and 2 coil. And as I wrote before, the ignition coil assembly had been taken apart. Had the 1 and 2 coil been acting up and been replaced several times, or was someone in the process of replacing it for the first time (with used parts) at some point in the bike's history? All these questions that will never get answered...
suha
Posts: 16
Joined: Tue Sep 10, 2024 3:57 am
Location: Halleforsnas, Sodermanland, Sweden
Motorcycle: 1976 GL1000
1982 VF750C

Re: 1976 GL1000 restoration

Post by suha »

Finally! Progress on the front brake master cylinder!




You can't really tell from these pictures but the inside of the cylinder was perfectly fine after cleaning it out. I was concerned it might need replacement but now I can just order a rebuild kit.

I have a question regarding the oil in the final drive housing. I read in the workshop manual that I should use a hypoid gear oil conforming to GL-5 specification, and that it should be SAE 90 due to me having no plans whatsoever to go driving in cold weather. I'm feeling very unsure how to translate this into the oils that are being produced nowadays. Which ones are safe to use?
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Rambozo
Posts: 3981
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Location: Disneyland
Motorcycle: 1992 GL1500 Aspencade
Ducati Monster

Re: 1976 GL1000 restoration

Post by Rambozo »

GL-5 80W-90 will do the job.
suha
Posts: 16
Joined: Tue Sep 10, 2024 3:57 am
Location: Halleforsnas, Sodermanland, Sweden
Motorcycle: 1976 GL1000
1982 VF750C

Re: 1976 GL1000 restoration

Post by suha »

Another day of frustration. The rebuild kit I ordered for the front brake master cylinder hasn't showed up, even though I've been notified it arrived in Sweden yesterday and supposedly was on its way to me. To keep myself busy, I've de-mounted the ignition coil assembly and measured resistances on both coils. The primary circuits are good in both, but the secondary circuits don't even have continuity. All four caps seem to be good, though (yes, I measured them, too). Guess I'll have to order new coils, and I don't even know where to buy them. By the way, does anyone here know anything about old Piranha electronic ignition? I have one of those instead of the original ignition, but there are no instructions. Do I need special coils to work with the Piranha ignition?
RobbyMoto
Posts: 87
Joined: Thu Feb 16, 2023 10:36 am
Location: Cleveland, Oh.
Motorcycle: 1975 GL1000, 1976 GL1000, 2005 Yamaha V-star 1100 (XVS1100), 2003 Honda Rebel 250 (CMX250C)

Re: 1976 GL1000 restoration

Post by RobbyMoto »

Hi suha. I replaced my coils with these...

https://www.ebay.com/itm/333910263062

Wires...

https://www.ebay.com/itm/140887097250

and ignition...

https://www.ebay.com/itm/325655913509

The coils and ignition are Chinese knockoffs of the Dynatek system sold for this bike. I've been running them a couple months with no issues so far.

There is a good set of instructions here...
viewtopic.php?f=13&t=66926
suha
Posts: 16
Joined: Tue Sep 10, 2024 3:57 am
Location: Halleforsnas, Sodermanland, Sweden
Motorcycle: 1976 GL1000
1982 VF750C

Re: 1976 GL1000 restoration

Post by suha »

So it's best to just ditch the old Piranha?

With nothing better to do (yeah right) while waiting for the front brake cylinder rebuild kit, I polished the main fuse stay. It was blackened from who knows what, but now it's all shiny again. Then I rinsed the wire guards for the radiator hoses. They look cleaner now, but only on the outside. I don't know how to clean them on the inside.
guidoverrier
Posts: 1
Joined: Fri Jun 30, 2023 12:18 pm
Location: Coimbra, Portugal
Motorcycle: 1976 GL1000 KZ

Re: 1976 GL1000 restoration

Post by guidoverrier »

https://www.ebay.com/itm/223166677570 Did buy from this seller good quality and service a high handlebar. (21cm) There is also a lower one (18cm) that is aparently original for the 76 series but I prefer the higher one from the 78 series. If you want the lower one I can sell it to you for a good price.
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77Goldwing
Posts: 57
Joined: Wed Aug 19, 2020 6:57 pm
Location: Holland MI
Motorcycle: 1977 GL1000

Re: 1976 GL1000 restoration

Post by 77Goldwing »

I cannot tell you how impressed I am that you are doing this yourself. Other than basic maintenance, I had to take mine to a shop (took a couple tries to find one willing to work on a '77) to go through everything. I have owned since 1978 but it sat for about 10 years when my kids were busy with sports in high school (university) and I wanted the belts, brakes, and all fluids replaced. I paid the shop almost as much as I paid for the bike in 1978. This was in 2018 and all I do is change oil annually and clean the plugs as needed, and she just keeps running.

I have a repair book for the 1975-78 Goldwing (not a shop manual, but the kind an owner could buy from the dealer). If there is something specific you need (e.g., a parts explosion or torque settings) I can scan and email if it is available. Me: jjaiven@gmail.com

PS - It might be worth changing the conventional headlamp to a LED. Swap ins from cars are available and they draw a lot less power from an aged alternator. It took me two tries to find one but I have a vetter housing (even though the original headlight housing sits behind the fairing).

Good luck and please continue the story.
1977 Goldwing GL1000
Vetter SS fairing/lowers; custom saddle seat
Purchased 6/30/1978, 1585 miles

1973 CB450/K6 (sold) (1976-Schenectady NY to Guadalajara MX and back)
1972 CB100 (sold)
suha
Posts: 16
Joined: Tue Sep 10, 2024 3:57 am
Location: Halleforsnas, Sodermanland, Sweden
Motorcycle: 1976 GL1000
1982 VF750C

Re: 1976 GL1000 restoration

Post by suha »

The rebuild kit for the front brake master cylinder finally arrived yesterday, but I was at work from 7 AM to 6:15 PM so I pretty much went straight to sleep after I ate dinner. Today wasn't much better. I really want to put it together but I don't trust myself to do it right when I'm tired. It feels good though, knowing the kit is waiting for me in the garage.


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