Engine Swap


Information and questions on GL1200 Goldwings (1984-1987)
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GoldSmith
Posts: 8
Joined: Sat Aug 08, 2020 9:40 am
Location: Bath Ontario
Motorcycle: 1985 GL1200 LTD

Engine Swap

Post by GoldSmith »



My 85 LTD stator is down and I need a replacement.
Found a 84 engine close by with less miles on it and what is claimed to be a good stator.
There are some basic differences in the engine style, like the Pulse Generator for instance.
Can I swap engines or should I stick with the LTD engine and replace the stator?

Thanks



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Rednaxs60
Posts: 2353
Joined: Wed Nov 18, 2015 12:44 pm
Location: Victoria, British Columbia, Canada
Motorcycle: 1985 GL1200 LTD
1995 GL1500 SE CDN Edition
2012 Suzuki DL1000 VStrom
2008 GL1800 (sold)
Ontario 1985 GL1200 LTD (sold)

Re: Engine Swap

Post by Rednaxs60 »

Stick with the Limited Edition engine, too many differences between the '84 an FI engine. You have to pull the engine to swap anyway. When you do replace the stator, have the engine out, oil drained - there is still a good amount of oil in the rear case that will make a mess when the rear cover is removed. Put a drain pan underneath rear case - BTDT.

Stator is less capacity - 350 watts versus 500 watts. Cannot fit an '85 Limited Edition stator into an '84 engine. You would need to change the heads, specifically the right side for the Gr/Gl sensor. The Ns sensor would have to be installed on the '84 engine. Don't know if the air chamber will fit an '84 engine without modification - width. Water pp cover may be different, the '85 FI engine has a water bypass hose. The '85 engine has an oil temp switch, don't know if the '84 does. Probably missed a few. Good luck either way.
"When you write the story of your life, don't let anyone else hold the pen"

Ernest

GoldSmith
Posts: 8
Joined: Sat Aug 08, 2020 9:40 am
Location: Bath Ontario
Motorcycle: 1985 GL1200 LTD

Re: Engine Swap

Post by GoldSmith »

Thanks my gut was saying all that, but I was hoping to get a lower miles engine, have them both on the ground now and there are many differences to be sure.
New Stator going in as soon as it arrives.

Is there a list of things posted that should be done when the engine is out, may as well do whatever I can when it is out?

Thanks

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Rednaxs60
Posts: 2353
Joined: Wed Nov 18, 2015 12:44 pm
Location: Victoria, British Columbia, Canada
Motorcycle: 1985 GL1200 LTD
1995 GL1500 SE CDN Edition
2012 Suzuki DL1000 VStrom
2008 GL1800 (sold)
Ontario 1985 GL1200 LTD (sold)

Re: Engine Swap

Post by Rednaxs60 »

How many miles on the 1200? I had the same issue when I first got mine. Stator went, was going to replace it but went with the external alt mod. Did the bike tow a trailer - clutch was toast, only 115,000 Kms on the engine, if so replace clutch friction and if require steel plates - I'd do the clutch because the engine is out and rear case off. There is a plate B that is a damper plate, replace at the same time. It's two plates with a spring clamped between the two. Rivets get loose - can self-destruct. Take off the rotor, clean and replace the starter clutch springs, 9 bits required, but inexpensive. Careful taking the rear cover off as you may pull the engine final drive shaft out with it, - not good, watch for this.

Here are some pics with the rear case removed:






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

Ernest

GoldSmith
Posts: 8
Joined: Sat Aug 08, 2020 9:40 am
Location: Bath Ontario
Motorcycle: 1985 GL1200 LTD

Re: Engine Swap

Post by GoldSmith »

Thanks
Great advice. Bike has 104K KMs
Was running fine before Stator issue.
I will have a bike mechanic open the engine, to replace the stator and this other work.
I think my ability is limited to the remove and install engine parts.
I will add the clutch to the list to get done at the same time makes sense.
Timing Belts replace
Clutch Slave rebuild

PS; I was in the navy in Victoria 68-74 and lived there until 91.

Greg

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Rednaxs60
Posts: 2353
Joined: Wed Nov 18, 2015 12:44 pm
Location: Victoria, British Columbia, Canada
Motorcycle: 1985 GL1200 LTD
1995 GL1500 SE CDN Edition
2012 Suzuki DL1000 VStrom
2008 GL1800 (sold)
Ontario 1985 GL1200 LTD (sold)

Re: Engine Swap

Post by Rednaxs60 »

Another sailor :D , I didn't get to Victoria until '76.

You are more than able to do the work. Need a good set of metric wrenches/sockets, primarily 8/10/12/14/17 mm. Need a set of JIS screwdrivers. 1/2 and 3/8 drive torque wrench - Princess Auto on sale. Buy tools that you need. Better to spend a few dollars more and get what is required, then buy a set and only use one or two from the set.

Once the rear case is off, quite easy to get the rotor off, do the starter clutch. May take you longer than a motorcycle mechanic, but these aren't complicated engines, may seem so but not. I was intimidated when I got my first Gold Wing, and soon realized that I was more than capable. Steep learning curve, but once there you ask yourself what was the issue. If the mechanic is a friend, great, if not - paying shop rates is not something I would do. Being from a family of mechanics, and being a pump kicker keeping steamers going, I've used more of my training on my Gold Wings then when I was in the Navy.

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

Ernest

GoldSmith
Posts: 8
Joined: Sat Aug 08, 2020 9:40 am
Location: Bath Ontario
Motorcycle: 1985 GL1200 LTD

Re: Engine Swap

Post by GoldSmith »

Thanks for the encouragement.
Weapons Under remustered to Pay Writer.
But love to tinker.
Not that many garage days left in Ontario, compared to Victoria
Will see how it goes, after hours mechanic is not at shop rates but not free.
Picking away at electrics and polishing parts is a good role for me.

Thanks again
Greg

User avatar
Rednaxs60
Posts: 2353
Joined: Wed Nov 18, 2015 12:44 pm
Location: Victoria, British Columbia, Canada
Motorcycle: 1985 GL1200 LTD
1995 GL1500 SE CDN Edition
2012 Suzuki DL1000 VStrom
2008 GL1800 (sold)
Ontario 1985 GL1200 LTD (sold)

Re: Engine Swap

Post by Rednaxs60 »

The only issue I foresee that is a challenge is rebuilding the clutch if you want to - having the engine out, rear case off might as well. Compressing the clutch diaphragm spring is the challenge without having the OEM tool. Can be done using a couple of good C-clamps, proper diameter ABS pipe and set of snap ring pliers. Lots of possibilities. Will be doing my 1500 clutch soon so a new tool will be in order.

A good strap wrench and the rotor can be removed and installed so you can do the starter clutch.

If you got the engine out, you can do the stator.

Ohara on this site is in your area. You should get in touch with him. He does a lot of wrenching on these old bikes. He doesn't have an FI model, but can be of assistance as well.

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

Ernest

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Ohara
Posts: 100
Joined: Mon Nov 16, 2015 9:05 am
Location: Ontario Canada
Motorcycle: 1986 Interstate
1986 Aspencade

Re: Engine Swap

Post by Ohara »

Thanks for the kind words Ernest, I can offer some support... Hate to see a good wing down........

User avatar
Rednaxs60
Posts: 2353
Joined: Wed Nov 18, 2015 12:44 pm
Location: Victoria, British Columbia, Canada
Motorcycle: 1985 GL1200 LTD
1995 GL1500 SE CDN Edition
2012 Suzuki DL1000 VStrom
2008 GL1800 (sold)
Ontario 1985 GL1200 LTD (sold)

Re: Engine Swap

Post by Rednaxs60 »

He's just around the corner from you. Meet for coffee and PIE! :D

As an aside, rebuilding the engine on my '85 Limited edition. Have had the engine parts/pieces vapour blasted, and just finished spraying with CERAKOTE MC-5100 aluminum clear. Letting the parts/pieces setup for today and start assembly tomorrow. Going to give it a fresh coat of paint in September.

Did a complete paint job on my 1500 this past spring as well, my first C-19 project.

Here are my threads on the 1200:

viewtopic.php?f=5&t=60006
https://www.classicgoldwings.com/forum/ ... 24&t=14067
https://www.classicgoldwings.com/forum/ ... 24&t=14073
https://www.classicgoldwings.com/forum/ ... 25&t=13973

Lots of work but very satisfying when finished. Looking to rebuild the 1500 engine next year.

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

Ernest

GoldSmith
Posts: 8
Joined: Sat Aug 08, 2020 9:40 am
Location: Bath Ontario
Motorcycle: 1985 GL1200 LTD

Re: Engine Swap

Post by GoldSmith »

Need some help identifying the function of this part.
37602-MG9-951 Ignition case
the one are my LTD are empty and one is smashed.
There is a harness going to them but nothing in the end of the wires.
Could it be some kind of light?? if so bulbs are missing

Thanks
Attachments



User avatar
Rednaxs60
Posts: 2353
Joined: Wed Nov 18, 2015 12:44 pm
Location: Victoria, British Columbia, Canada
Motorcycle: 1985 GL1200 LTD
1995 GL1500 SE CDN Edition
2012 Suzuki DL1000 VStrom
2008 GL1800 (sold)
Ontario 1985 GL1200 LTD (sold)

Re: Engine Swap

Post by Rednaxs60 »

I have wondered what these do as well, but since everything has been working, not an issue. I did get into the wiring schematic and with Honda using one wire for an item, I traced the brown/white wire in the schematic and it goes to several places that relate to lights, travel computer, signals, and other places. Checked the supplement and have not found an explanation. It has to be somewhere in the manuals. More reading and looking into these sensors is required. Hope someone else can chime in with an answer.
"When you write the story of your life, don't let anyone else hold the pen"

Ernest

GoldSmith
Posts: 8
Joined: Sat Aug 08, 2020 9:40 am
Location: Bath Ontario
Motorcycle: 1985 GL1200 LTD

Re: Engine Swap

Post by GoldSmith »

Thi was basically a private post, I will open it up to general discussion.
Thanks

User avatar
Rednaxs60
Posts: 2353
Joined: Wed Nov 18, 2015 12:44 pm
Location: Victoria, British Columbia, Canada
Motorcycle: 1985 GL1200 LTD
1995 GL1500 SE CDN Edition
2012 Suzuki DL1000 VStrom
2008 GL1800 (sold)
Ontario 1985 GL1200 LTD (sold)

Re: Engine Swap

Post by Rednaxs60 »

No worries. Read through the manuals again, still can't find info on this sensor. Still looking.


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

Ernest

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