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GL1200LTD restoration - rear brakes question

Posted: Sat Jan 15, 2022 11:39 am
by EmelioLizardo
Last year I acquired my deceased friend's 1985 GL1200LTD, and I will be getting it on the road after several (8?) years in climate controlled-"ish" storage. Thanks to the fine advice and information found here (special thanks to Rednaxs60!), I have a plan, and the parts, mostly. I put the project off, mainly because the fuel tank needs to be replaced. I'll try to post more about that under a different topic in the future (possibly under the heading, "It came from the fuel tank").

Yes, I know what I'm in for with the fuel tank. I have read the warnings, and that it's probably not worth it. Since they built the thing around the fuel tank, I figured I'll refurb or at least clean everything from the tank back, since it has to be removed anyway. It definitely needs a rear brake rotor, and since the fellow that worked on it passed away before my friend (the prior owner), all I have is a vague memory of "something wrong with the rear brakes."

When I actuate the rear brakes by hand, I can't feel the brake caliper moving. So that make me think "master cylinder needs rebuild or replacement," which I would do as part of the project anyway. The battery is disconnected. I know this model has a fancy brake distribution system, but I don't know much about it. My questions to the forum are:

1) is there any typical problem I should be looking for with the rear brakes, other than the master cylinder? Part of that distribution system perhaps?
2) is there a current aftermarket replacement known for the rear master cylinder, hoses, or other parts?
3) any recommendation for sourcing a rebuild kit for the master cylinder and the rear caliper/slave cylinder?

I have experience rebuilding brakes, engines, etc., and have a small machine shop.

Thanks!

Re: GL1200LTD restoration - rear brakes question

Posted: Sat Jan 15, 2022 1:36 pm
by Rednaxs60
Fuel tank removal/replacement isn't that bad. Be patient and take your time. May find a good interior cleaning is all that is required.

The brakes on this bike are linked, meaning that the front left brake caliper is actuated by the front handlebar brake lever, and the right front brake and rear brake are controlled by the rear brake pedal. The front left brake caliper and rear brake caliper use the same size parts. The front right brake caliper has smaller parts because it aids in rear braking.

I would rebuild all the brake calipers then try the brakes. I have yet to rebuild the rear brake MC. A good brake fluid flush would be a good idea.

When you have the fuel tank out, do the clutch slave cylinder, probably a lot of crud build up.

Take the centre stand off when you do the fuel tank. A good clean and lube will have it working well. A lot of crud builds up.

Good luck

Re: GL1200LTD restoration - rear brakes question

Posted: Sun Jan 16, 2022 10:50 am
by EmelioLizardo
Thanks! So it sounds like there's no magical devices in the brakes to watch for, which is a relief. I had intended to rebuild the hydraulics anyway. I do have the shop manuals and the LTD supplement, but it still feels like an alien autopsy sometimes. A lot of "What the...?" and "Where's the...?" moments.

Thanks also for the encouragement on the tank. When I opened the fuel tank the first time, the smell made my heart sink, you probably know what I mean. It also knocked a friend of mine on his backside for a scary 15 minutes. After picking, pulling, probing, and a lot more "What the...?" I figured out someone had poured a liner into it, but I think there was already rust in the tank before the liner. it looked like fake vomit was peeling off the inside of the tank. The tank can probably be made usable again once it's off, but the fuel gauge sender was mostly disintegrated. I was pretty chuffed to find a reasonably priced replacement tank with an intact sender. I'll let you know how it goes.

Re: GL1200LTD restoration - rear brakes question

Posted: Sun Jan 16, 2022 11:12 am
by Rednaxs60
The fuel tank on my '85 Limited Edition was a bit rusty on the inside as well when I bought it. Used good steel back then. Think I used vapo-rust to clean the tank, and was able to get at a lot of the sides and bottom with a stiff bristle brush as well through the sending unit hole. If you can't get the liner off completely, and have a new-to-you tank to put in that does not have a liner, I'd opt for the latter. Nothing worse than a fuel blockage when you are out and about. It would also be the last thing you might think is wrong.

Nothing magical about the brake system. When you bleed the rear brake system, the front is bled first then the rear. The left front, believe this is the single front caliper, is straight forward.

You can also consider replacing the old brake and clutch lines with new SS braided lines - teflon tube. The teflon tube is on the inside, the SS braid protects this tube.

The older brake lines may look good on the outside but be deteriorating on the inside causing the hose to swell when pressure is applied. Reduces the pressure going to the caliper. If you have a hydraulic shop nearby, take the old line(s) in and have a set made. Would recommend doing this work with the front fairing off, gives more work space.

Re: GL1200LTD restoration - rear brakes question

Posted: Sun Jan 16, 2022 11:19 am
by julimike54
I just finished rebuilding all the brake cylinders on my '86. Check for the service limits on the bores, if ok no need for new unless somethings broke.

All the brake rebuild parts I got from the following....
https://newmotorcycleparts.net/

They provided factory type parts from K&L, which I think was the factory vendor. I had good luck with them. The only hitch I found was the left front caliper part that was listed, wound up on 'factory back order'. Contacted K&L and they advised that the 1177 number was replaced with a 1159. That fixed the back order.

Good luck with your project!

Re: GL1200LTD restoration - rear brakes question

Posted: Mon Jan 17, 2022 9:06 am
by EmelioLizardo
I had not found them yet - I'll take a look later. Thanks!

Re: GL1200LTD restoration - rear brakes question

Posted: Mon Jan 17, 2022 1:46 pm
by EmelioLizardo
New Teflon/SS braid sounds like the way to go, thanks. I can just see the brake lines turning to balloon animals on the first test ride.

Know of any good online sources? A quick search brought up a set of 4 brake lines from a place called Randakks for $200 US, which could be worth it, but I've never heard of them. Having them made might be less expensive if I can find anyone near here - Maybe NAPA? Heck, I could swage 'em meself if I had the parts and the right dies.

Re: GL1200LTD restoration - rear brakes question

Posted: Tue Feb 01, 2022 8:09 am
by dthorntonministries
Speaking of NAPA, I can't speak to the brake lines, but when you get around to your timing belts, NAPA has them at a highly reduced price from Honda...and they carry the same numbers.
You are a fortunate man to have inherited this Limited model. The biggest thing I miss about the 1200 Aspencade that I had on the 1500 is the cruise control. I'm looking for one to install on mine.
Be blessed, DT

Re: GL1200LTD restoration - rear brakes question

Posted: Tue Feb 01, 2022 10:52 am
by EmelioLizardo
Good advice DT - but I have to say I beat you to it! The NAPA belts are even Gates branded, but much less expensive than several other places. They still have other parts for these things too. I scoured the forum(s) and found people listing a bunch of equivalent parts, like the fuel injectors that fit an 85 Honda Prelude should work as well. Rednaxs60 has provided a wealth of information here in that regard and I can't thank him enough. Especially for the reminder that the timing belts should be changed before starting.

I haven't put the belts on yet because I was trying to clean/refinish the covers first, then I ran out of good weather. Current garage is unheated and it's about 15 degrees F. I also acquired some toothed timing belt pulley holders that someone designed and 3D printed for the job. They seem like cheap insurance that'll make the job a bit less stressful.

I haven't used cruise control on anything with 2 wheels, but so far the parts on mine look ok, so we'll see. I haven't actually ridden the LTD or any GoldWing at all. I'm just a little worried - I have short legs - moving won't be a problem, just stopping. I'm thinking about fabricating some landing gear to put on the trailer hitch. A sidecar is outside my budget.

Thanks again!
Tom

Re: GL1200LTD restoration - rear brakes question

Posted: Wed Feb 02, 2022 9:38 am
by Rednaxs60
There's a lot of seat padding that can be removed to lower your seating position - good 1" to 1 1/2". Carve out a good chunk then install a gel seat pad. Can almost go down to the seat pan doing this. Son-in-law is the same. He rides a 2014 Moto Guzzi California. Took his seat down to the seat pan, installed a gel pad and all is well. He mentions it's still quite comfortable. Leave the passenger seat alone and the passenger will have the theatre seating, looking over you instead of at the back of your helmet.

Re: GL1200LTD restoration - rear brakes question

Posted: Sat Feb 26, 2022 5:23 pm
by EmelioLizardo
Been avoiding the computer for a couple of weeks. Thanks for the seat lowering advice - it'll probably come to that. But the seat is soooo nice - I'm going to be worried about botching it, but if I must, then so be it. I'll try to think of it as a theatre seating upgrade. I also removed the bolts the prior owner installed to raise the seat about an inch so I'll need to sit on it again. Gotta get it running and off the lift first. it's 20F today, but they tell me Spring is coming.

Re: GL1200LTD restoration - rear brakes question

Posted: Sun Feb 27, 2022 4:12 am
by Rambozo
BTW Randakks is a great vendor. Especially well known for their carb kits for GoldWings.

Re: GL1200LTD restoration - rear brakes question

Posted: Sun Feb 27, 2022 8:01 am
by joecoolsuncle
EmelioLizardo wrote: Sat Feb 26, 2022 5:23 pm Been avoiding the computer for a couple of weeks. Thanks for the seat lowering advice - it'll probably come to that. But the seat is soooo nice - I'm going to be worried about botching it, but if I must, then so be it. I'll try to think of it as a theatre seating upgrade. I also removed the bolts the prior owner installed to raise the seat about an inch so I'll need to sit on it again. Gotta get it running and off the lift first. it's 20F today, but they tell me Spring is coming.
hello mr. lizardo! would you mind posting a picture of "bolts the prior owner installed to raise the seat about an inch"? thanks i have redone my seat four times already, as the PO had lowered it. im over 6 ft, so it really cramped my legs while seated. i have it about an inch higher than stock now, maybe another inch would get it right, but the cover is as tight as a guitar srting now.

Re: GL1200LTD restoration - rear brakes question

Posted: Sun Feb 27, 2022 8:17 am
by EmelioLizardo
It was simply two longer bolts in place of the two that hold the seat down, then 3 or 4 oversized nuts were slipped over each shank for spacers. Then nuts to tighten the bolts.

It won't be easy to take a picture because said nuts and bolts would have gotten dispersed and assimilated into the shop. If I find them still intact I'll send a pic.

Both my brothers were over 6 feet. I guess I got good looks instead. It seems that proportionally my femurs are about 3-4 inches too short. I Haven't found any aftermarket extensions.

Re: GL1200LTD restoration - rear brakes question

Posted: Sun Feb 27, 2022 12:20 pm
by joecoolsuncle
EmelioLizardo wrote: Sun Feb 27, 2022 8:17 am It was simply two longer bolts in place of the two that hold the seat down, then 3 or 4 oversized nuts were slipped over each shank for spacers. Then nuts to tighten the bolts.

It won't be easy to take a picture because said nuts and bolts would have gotten dispersed and assimilated into the shop. If I find them still intact I'll send a pic.

Both my brothers were over 6 feet. I guess I got good looks instead. It seems that proportionally my femurs are about 3-4 inches too short. I Haven't found any aftermarket extensions.
thanks, you description of the extensions was very good! i get it! lol thanks for the reply.