How to remove this??? (LTD engine removal job)


Information and questions on GL1200 Goldwings (1984-1987)
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Sander van Bussel
Posts: 12
Joined: Thu Aug 31, 2017 4:07 am
Location: Tilburg, Netherlands
Motorcycle: 1976 GL1000 / 1982 GL1100 Interstate/ 1985 GL1200 Limited Edition

How to remove this??? (LTD engine removal job)

Post by Sander van Bussel » Thu Aug 23, 2018 11:09 am



I have a clutch starter problem. Tried the seafoam trick, didn't help. Now I'm removing the enigine. I did this job on a GL1100 years ago. But a LTD is way more work it seems, and lot's of parts are unknown to me.

I noticed this sensor (right side on top of engine, goes in the engine) that has a wire that is fixed to the sensor and seems I can't remove it from this side. The other side is very much hidden in the spaghetti, and are afraid I cant't get it back when i pull the connector all the way through...

Question: what to do? remove the whole sensor before taking the engine out?





DaveO430
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Re: How to remove this??? (LTD engine removal job)

Post by DaveO430 » Thu Aug 23, 2018 12:00 pm

Unplug the engine harness and take it out all together.

Sander van Bussel
Posts: 12
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Location: Tilburg, Netherlands
Motorcycle: 1976 GL1000 / 1982 GL1100 Interstate/ 1985 GL1200 Limited Edition

Re: How to remove this??? (LTD engine removal job)

Post by Sander van Bussel » Thu Aug 23, 2018 12:48 pm

Is this the oil pressure sensor? and what is the rubber tube doing there?
Just wrench it out of the engine block? And re assemble it with sillicone gasket?

DaveO430
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Re: How to remove this??? (LTD engine removal job)

Post by DaveO430 » Fri Aug 24, 2018 7:31 am

Sander van Bussel wrote:
Thu Aug 23, 2018 12:48 pm
Is this the oil pressure sensor? and what is the rubber tube doing there?
Just wrench it out of the engine block? And re assemble it with sillicone gasket?
Yes it is the oil pressure sensor. Where did you read "wrench it out" in my post. You don't have to remove it at all, just unplug the wire harness and take it all out with the engine.

Sander van Bussel
Posts: 12
Joined: Thu Aug 31, 2017 4:07 am
Location: Tilburg, Netherlands
Motorcycle: 1976 GL1000 / 1982 GL1100 Interstate/ 1985 GL1200 Limited Edition

Re: How to remove this??? (LTD engine removal job)

Post by Sander van Bussel » Fri Aug 24, 2018 9:48 am

Sorry if i misunderstood 'engine harness'. I'm dutch and English is my second language. The wire harness was impossible to get out through the spaghetti of injector and vacuumhoses. Just too little space. Had to wrench the sensor out, no other options left...

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Rednaxs60
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Location: Victoria, British Columbia, Canada
Motorcycle: 1985 GL1200 LTD
1995 GL1500 SE CDN Edition
2008 GL1800 (sold)
Ontario 1985 GL1200 LTD (sold)

Re: How to remove this??? (LTD engine removal job)

Post by Rednaxs60 » Fri Aug 24, 2018 10:08 am

The switch comes out with the engine. As Dave 0430 mentions, follow the braided wire and disconnect up top and remove with the engine. There is also an oil temp switch on the front of the engine, bottom right side that is easy to miss - disconnect. You can tie up the fuel injection manifold out of the way as well. It stays with the bike.

You will of course drain the oil. When I removed my engine to do the stator, I did the starter clutch and new clutch as well. When yo remove the rear case there will still be oil in the case, about 1/4 to 1/2 quart, put an aluminum pan under the case to catch the oil. Makes a mess if you don't, BTDT.

Also found that the right side exhaust studs are long enough that these will hit the frame on removal. Had to shim the engine a bit to raise the right side so the studs would clear.

You may want to consider doing the clutch as well while it is out. The PO of my '85 LTD pulled a trailer and the steel plates were overheated and "blue" around the outside edge.

When you replace the three parts of the starter clutch, there are no holes like the earlier models to hold the parts in place. Put the new ones in and gently place the rotor back on the shaft and rotate the rotor ever so slowly and it will slip onto the shaft. There is a video on the web that shows this procedure instead of doing it like the video on Randack's site for earlier models.

Here are some pics for reference:
Engine out of frame with oil pressure sensor still attached. You can see the braided wire still attached (disregard red arrow):


Engine with rear case removed. When you remove the rear case, the output shaft will come out of the engine with the case if you do not hold it in place:


Rear case showing stator:


Carefull taking the rear case bolts out. Broke two:


I was fortunate, I was able to drill, clean the threads and reuse the same holes and size of bolts.

Hope this helps.

Good luck.
"When you write the story of your life, don't let anyone else hold the pen"

Ernest

Sander van Bussel
Posts: 12
Joined: Thu Aug 31, 2017 4:07 am
Location: Tilburg, Netherlands
Motorcycle: 1976 GL1000 / 1982 GL1100 Interstate/ 1985 GL1200 Limited Edition

Re: How to remove this??? (LTD engine removal job)

Post by Sander van Bussel » Fri Aug 24, 2018 10:37 am

Thanks a lot Ernest. yes, had some trouble with bolts already: 3 out of 4 bolts that hold the Pulse Generator cover...
What is best in your experience: use a rachet and socket or give it a hit with a 'slagschroevendraaier' with a 8mm socket first? (don't know the Einglish word: see picture)
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Rednaxs60
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Motorcycle: 1985 GL1200 LTD
1995 GL1500 SE CDN Edition
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Ontario 1985 GL1200 LTD (sold)

Re: How to remove this??? (LTD engine removal job)

Post by Rednaxs60 » Fri Aug 24, 2018 5:06 pm

Pulse generator cover - you mean the one on the end of the right cylinder head. these are the Gr/Gl sensors for injector timing. The pic is of an impact driver.

Wouldn't hurt to give them a good smack.

Cheers
"When you write the story of your life, don't let anyone else hold the pen"

Ernest

DaveO430
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Re: How to remove this??? (LTD engine removal job)

Post by DaveO430 » Fri Aug 24, 2018 5:14 pm

Tell us why you are removing the PG cover. It doesn't need to come off to do the starter clutch.

Sander van Bussel
Posts: 12
Joined: Thu Aug 31, 2017 4:07 am
Location: Tilburg, Netherlands
Motorcycle: 1976 GL1000 / 1982 GL1100 Interstate/ 1985 GL1200 Limited Edition

Re: How to remove this??? (LTD engine removal job)

Post by Sander van Bussel » Sat Aug 25, 2018 5:28 am

@Rednaxs, yes, the sensor at the back of the right cylinder. Also; easier to remove the unit at the cylinder then to get the wiring out of the spaghetti. My hands are not that small :)
Yes. impact driver. thank you.

I hope all bolts will come out in one go. the stator wires are soldered, which could be indicative of the stator being replaced by PO. Which could mean that the bolts have come out later then 1985.

The picture of the engine out is helpfull, thanks. showed me that some hoses still connected will have to come out with the engine. All pictures and help is helpfull. Am working on the bike every now and then when I find some hours time. Hope to be riding this bike again soon.

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Rednaxs60
Posts: 1804
Joined: Wed Nov 18, 2015 12:44 pm
Location: Victoria, British Columbia, Canada
Motorcycle: 1985 GL1200 LTD
1995 GL1500 SE CDN Edition
2008 GL1800 (sold)
Ontario 1985 GL1200 LTD (sold)

Re: How to remove this??? (LTD engine removal job)

Post by Rednaxs60 » Sat Aug 25, 2018 9:07 am

Take lots of pictures as you go, be helpful when you put the engine back in the frame.

Instead of removing the Gr/Gl sensor unit, disconnect the sensors from the unit and tie these up and out of the way. Will have to gingerly feed them through to the front of the engine to do this.

Understand the hand issue, have it as well.

Cheers


"When you write the story of your life, don't let anyone else hold the pen"

Ernest

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