Secondary air injection removal question


Information and questions on GL1200 Goldwings (1984-1987)
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froche
Posts: 275
Joined: Wed Mar 12, 2014 1:56 pm
Location: Vista, ca
Motorcycle: 1985 Goldwing Aspencade (GL1200A)
2002 GL1800

Former bikes;
2000 R1100RT
2005 Suzuki Bandit
1979 Yamaha XS1100
1978 Yamaha XS1100 Special
1990 Yamaha XV250
1980 Yamaha XV750
1979 Honda CB750
1968 Triumph Bonneville T120
1973 Honda CB450
1968 Harley Davidson Sportster
1974 Honda CB750
1968 Honda CL72

Secondary air injection removal question

Post by froche »



Took of carbs to replace choke cable, and decided to plug the secondary air injection system. Took measurements and trying to find a lathe I can turn the plugs on, but those of you that have done this, what have you used?

Is there a part used on non California 1200's that was used? Or is it on all?
If you made you part what material did you use? And do you have dimensions (to compare to mine)?
Did you find another material that worked fine without making the plugs?

Any other ideas, or cautions?



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twocams
Posts: 677
Joined: Tue Sep 29, 2015 11:25 am
Location: Grants Pass, Oregon
Motorcycle: 1985 GL1200 Aspencade ( sold in Canada), 2003 K1200GT BMW, 1969 R69S BMW,92 R100 RT BMW
Sold : 84 V65 Magna, 82 Moto Guzzi, XS 1100 Yamaha,84 Wing Int., 80 650 Special, Only new bike 82 XV750 Virago (Guam),Honda 250,84 R100RT BMW,87 K100 LT BMW,93 K1100 LT BMW, 91 535 Virago, Honda 50

Re: Secondary air injection removal question

Post by twocams »

Why go through all that trouble I asked myself. I just cut the pipes off, file down a bit. Whipped up some 2 part epoxy. let it dry over night,put a new "O" ring on it. Turn that cut off bit in, so can't be seen and you're done. Im sure they are cheaper to get off ebay than to get something machined if you ever want to replace them.

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spiralout
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Re: Secondary air injection removal question

Post by spiralout »

I don't own a 1200 nor have I ever even touched one but I remember reading somewhere about a Dorman freeze plug that fits those holes. If I didn't have the means to make them, I'd take the hose/pipes to an auto parts store and have them find a plug that will work.

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twocams
Posts: 677
Joined: Tue Sep 29, 2015 11:25 am
Location: Grants Pass, Oregon
Motorcycle: 1985 GL1200 Aspencade ( sold in Canada), 2003 K1200GT BMW, 1969 R69S BMW,92 R100 RT BMW
Sold : 84 V65 Magna, 82 Moto Guzzi, XS 1100 Yamaha,84 Wing Int., 80 650 Special, Only new bike 82 XV750 Virago (Guam),Honda 250,84 R100RT BMW,87 K100 LT BMW,93 K1100 LT BMW, 91 535 Virago, Honda 50

Re: Secondary air injection removal question

Post by twocams »

Plugging the hole is only half. There will be a 1/2"-3/4" gap between the "intake" & head without something to take up that space.
The chrome pipe end does that well. :shock:

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froche
Posts: 275
Joined: Wed Mar 12, 2014 1:56 pm
Location: Vista, ca
Motorcycle: 1985 Goldwing Aspencade (GL1200A)
2002 GL1800

Former bikes;
2000 R1100RT
2005 Suzuki Bandit
1979 Yamaha XS1100
1978 Yamaha XS1100 Special
1990 Yamaha XV250
1980 Yamaha XV750
1979 Honda CB750
1968 Triumph Bonneville T120
1973 Honda CB450
1968 Harley Davidson Sportster
1974 Honda CB750
1968 Honda CL72

Re: Secondary air injection removal question

Post by froche »

Actually there is a .589 gap between the surface of the intake horn and the surface of the head. I suppose that one could find the freeze plug that fits and drive it down and then put the "cutoff" plugs back in since there is a bit extra but...

I am having plugs made by a friend that should be exactly the same, and even use the original o rings (ordered), and fit in place of the original plugs with the tubes.

Already figured on plugging the hole feeding the secondary air valve with a 5/16 bolt, and RTV. The hole is tapered and a tap should fit well enough to make threads, so RTV or epoxy to fill the hole and grip the lower threads.

User avatar
twocams
Posts: 677
Joined: Tue Sep 29, 2015 11:25 am
Location: Grants Pass, Oregon
Motorcycle: 1985 GL1200 Aspencade ( sold in Canada), 2003 K1200GT BMW, 1969 R69S BMW,92 R100 RT BMW
Sold : 84 V65 Magna, 82 Moto Guzzi, XS 1100 Yamaha,84 Wing Int., 80 650 Special, Only new bike 82 XV750 Virago (Guam),Honda 250,84 R100RT BMW,87 K100 LT BMW,93 K1100 LT BMW, 91 535 Virago, Honda 50

Re: Secondary air injection removal question

Post by twocams »

Are U sure about that .589 gap? :roll: Just kidding I have never measured :lol:

twocams

froche
Posts: 275
Joined: Wed Mar 12, 2014 1:56 pm
Location: Vista, ca
Motorcycle: 1985 Goldwing Aspencade (GL1200A)
2002 GL1800

Former bikes;
2000 R1100RT
2005 Suzuki Bandit
1979 Yamaha XS1100
1978 Yamaha XS1100 Special
1990 Yamaha XV250
1980 Yamaha XV750
1979 Honda CB750
1968 Triumph Bonneville T120
1973 Honda CB450
1968 Harley Davidson Sportster
1974 Honda CB750
1968 Honda CL72

Re: Secondary air injection removal question

Post by froche »

I would guess that it's probably 15 mm cause 15 mm = .5905512in so it is easily measured .589



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