27 Year Service; your wise council please.


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Sadanorakman
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27 Year Service; your wise council please.

Post by Sadanorakman » Tue Jan 01, 2019 5:02 pm



Happy New Year to you all.

I managed to ship my 'new-to-me' 1991 SE home to the UK from Tenerife in October, a full year after buying her. Now that Christmas is out of the way, it's time to start seriously planning the work required to restore her to her former glory.

I'd appreciate your wise council on my following plan please, as I've not tackled a Goldwing before. So far I've priced the parts I'll need for the below work at about £1200 without anything 'unexpected', and will be doing it all myself with the aid of WingAdmin's wonderful how-to's, and a shop-manual.

She has been looked after very well for most of her life, but has not been ridden or serviced for the last two years. She has a fuel leak out of an overflow, but hoping this is just a stuck float needle. So far all I have done is extract the stale fuel and refilled with fresh and marine stabil to protect the tank from rusting in this cold weather whilst she is laid-up. Her cam belts are 10 years old, as are the tires. She has stiff (dry) throttle cables, sticking handlebar switches, and no pressure in the rear brake. I've pretty-much decided on a deep work regime rather than just the bare minimum to get her running, as I want to end up with a nice reliable bike. She has only 33,000 Miles from new, but I figure 27 years of age justifies some major 'planned maintenance'.

I'm trying to plan stuff logically, so that I don't drown in a sea of partially completed tasks. This way I'll get a sense of achievement as tasks get ticked off of the list. I'm intending to start tackling her from the front and systematically work my way backward throughout the old-gal, stripping the bodywork as necessary:

1. Lower front-end: fork bushings, seals, measure springs (only replace if necessary), fork oil. rebuild brake calipers, new pads (check disks), stainless brake hoses, check wheel bearings, new tire (avon cobra or dunlop elite 4), balance beads, lubricate speedo drive.

2. Upper front-end: Rebuild brake and clutch master cylinders, strip, clean and lubricate switches, clean and lube throttle cables, check steering head bearings and re-torque. Check levers for play and replace lever pins if necessary (available?)

3. Engine/Fuel/Ignition: Replace Cam belts, oil and filter, spark plugs, flush and replace coolant. Remove carbs and check every vacuum pipe for damage/wear. New carb boots. I'm not intending to strip carbs unless it turns out to be absolutely necessary, as I feel I might do more harm than good (opinions please?). Petcock rebuild and new fuel filter. Air filter, sub filter, and cruise filter. There's no rust in the tank. check coils/ht leads.

4. Electrics: Inspect and clean where necessary. New AGM battery (old one is completely FUBAR) and battery maintainer. Will probably add an accessory fuse panel and replace all main lamps with LED's whilst the tupperware is off (including fitting power resistors to correct indicator load). Not sure whether I'll go as far as replacing all dash bulbs and illuminated grip switch lamps with LEDs just yet though. Not sure if the starter and alternator brushes are easily checked too?

5. Transmission/rear end: fit shifter brace, and if necessary new shifter shaft seal. Overhaul clutch slave cylinder with new seals, check, clean, and lubricate UJ and drive shaft splines. change final drive oil, check cush-drive rubbers, replace rear tire (avon cobra or dunlop elite 4), balance beads. Check shocks and rubbers, replace shock oil. check swing arm bearings. Rebuild rear brake master cylinder and calipers, and again stainless hoses.

6. Sundries: dry-out the compressor desiccant, new screen (existing one crazed), install volt meter, new Horns (old ones shot), new speakers.

7. Recommission her: balance carbs, check fans kick in, adjust cruise-control. check her all over before taking for road-worthiness test (MOT), and register on to new UK plates:G14 WNG.

8... ride the hell out of her for the next decade!!!!

What have I missed please folks?

I'm hoping I don't have to replace anything too costly right now which would bust my budget (brake disks, mufflers, rear shocks). The thought of a nice pair of new Progressive 416's and matching front springs along with a fork brace appear very enticing indeed, but it's an extra £600-£700 I cannot justify this year, so I think these will have to wait. At least this way I'll get to see what a difference they make to the handling, as I'll have experience of before and after.

What would you do differently or in addition please?

Kindest regards Craig


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keithg64
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Re: 27 Year Service; your wise council please.

Post by keithg64 » Tue Jan 01, 2019 7:57 pm

You are on a great quest, I love doing these things. Somethings will just be checked but a lot of your list you are on the right path. Keep us posted.
It's not what you buy, it's what you build.

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brettchallenger
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Re: 27 Year Service; your wise council please.

Post by brettchallenger » Wed Jan 02, 2019 8:54 am

Have a good look at the swing arm as they can tend to rust badly there. I know Tenerife is a nice hot climate but its also an island subject to some big Atlantic seas and the bike might have been subject to some fair degree of salt spray over the years.
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Sadanorakman
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Re: 27 Year Service; your wise council please.

Post by Sadanorakman » Wed Jan 02, 2019 11:23 am

brettchallenger wrote:
Wed Jan 02, 2019 8:54 am
Have a good look at the swing arm as they can tend to rust badly there. I know Tenerife is a nice hot climate but its also an island subject to some big Atlantic seas and the bike might have been subject to some fair degree of salt spray over the years.
Thanks Brettchallenger. The previous owner was a family member. It was kept garaged in the UK for over half of it's life, and really looked after; not ridden in the rain, and laid up during each winter to avoid the road-salt. He moved to Tenerife about ten years ago taking the bike with him. I'm hoping therefore that there is little to no corrosion on the swing arm when I get into the bike that far, and I'm intending to clean and seal the groove that runs around its inner with copious quantities of hammerite or similar to prevent corrosion. There is some surface oxidization to the alloy wheels due to the salt in the air, but I'm hoping they will clean up well.

I did happen across a swing arm on ebay a couple of months ago for only £50 that was basically brand new, as it had been taken off for a trike conversion when the bike was new... I passed on it, because I figured mine should be just fine when I get that far into the bike. Don't you just know that sod's law will dictate that I should have grabbed that bargain with both hands! Hindsight eh?

regards
Last edited by Sadanorakman on Wed Jan 02, 2019 11:30 am, edited 1 time in total.
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Sadanorakman
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Re: 27 Year Service; your wise council please.

Post by Sadanorakman » Wed Jan 02, 2019 11:28 am

keithg64 wrote:
Tue Jan 01, 2019 7:57 pm
You are on a great quest, I love doing these things. Somethings will just be checked but a lot of your list you are on the right path. Keep us posted.
Thanks Keithg64. Are you hinting that I should really be looking to replace the bits I've said I only intend checking, e.g. wheel bearings and steering-head bearings? Should I really be stripping the carbs as a matter of course seeing as I will be removing them from the bike anyway?

regards
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Rednaxs60
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Re: 27 Year Service; your wise council please.

Post by Rednaxs60 » Wed Jan 02, 2019 2:13 pm

Good looking bike and excellent work/maintenance list.

I would replace the wheel and steering stem bearings, now or in the near future will have to be done. These I submit are a safety item.

Suspension should be a consideration even if the original spec out when not installed. Difference when installed to when out. Rear shocks as well. I'd plan on this in the near future, say 2020. It will make a difference in ride quality and performance. The bike is 27 years old.

Timing belts - yes

Check clutch lever bushing when doing clutch. Flush brake and clutch systems first before doing a rebuild of the MCs. May not need to be done upfront. Would spend money on replacing clutch and brake lines with SS first. Agree with clutch slave rebuild, most crud will accumulate there. Rebuild front/rear calipers - yes.

Get engine running then make assessment of carb condition. May not need to be done up front, and can wait for 2020.

Fuel system - fuel filter replace, get engine running then decide on whether to do the petcock. Air filters all round, yes.

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

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RockportDave
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1981 GL1100 Interstate
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1988 GL1500

Re: 27 Year Service; your wise council please.

Post by RockportDave » Wed Jan 02, 2019 8:55 pm

“ I’m not intending to strip carbs unless it turns out to be absolutely necessary, as I feel I might do more harm than good (opinions please?).”

If you are going to remove the carbs, I would definitely rebuild them. If it has been sitting a while, the small passages are probably stopped up. After taking my carbs off 4 times, I finally soaked them in Berrymans carb cleaner and added new jets, orings, air needles and accelerator pump. I also cut grooves in the air adjustment screws for a flat head screwdriver.
Here is a good how to on carbs
http://www.jmartino.me/carb/
Is a nice looking bike.
Dave
1999 GL1500SE 5th Goldwing through the years

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keithg64
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Re: 27 Year Service; your wise council please.

Post by keithg64 » Wed Jan 02, 2019 9:14 pm

Sadanorakman wrote:
Wed Jan 02, 2019 11:28 am
keithg64 wrote:
Tue Jan 01, 2019 7:57 pm
You are on a great quest, I love doing these things. Somethings will just be checked but a lot of your list you are on the right path. Keep us posted.
Thanks Keithg64. Are you hinting that I should really be looking to replace the bits I've said I only intend checking, e.g. wheel bearings and steering-head bearings? Should I really be stripping the carbs as a matter of course seeing as I will be removing them from the bike anyway?

regards
Check the things you need to check and replace the things that others have mentioned. Wheel bearings, head bearings, cam belts, fork oil, brake and clutch fluid all definitely. Plugs also.
It's not what you buy, it's what you build.

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Sadanorakman
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Re: 27 Year Service; your wise council please.

Post by Sadanorakman » Thu Jan 03, 2019 4:59 am

Now THIS is why I posted! Thank you all for your very valuable input.

Words of wisdom like 'the clutch slave cylinder is where all the crud gathers' ...I wouldn't have thought about that until it was brought to my attention, and yet it is simple logic! Every day's a school day! Makes sense too that the master cylinders are going to likely be in better condition than the callipers/slaves.

I wasn't considering replacing steering-head and wheel bearings, but seems at least two of you good folk have pointed the error of my ways! OK, I'll get them done at the same time, it's only a few pounds more on the budget.

* Regarding the above, should I be looking to replace the swing-arm bearings at the same time?

Thanks also to RockportDave. I was just in denial really over stripping the carbs Dave... I know it makes total sense, and I knew it made total sense; I was just burying my head in the sand! I wasn't sure if I'd be opening a can of worms and end up breaking something. Yes the carbs I'm sure could do with a good cleaning out from varnish and sticky ethanol residue. Thank you also for the URL! Maybe I should sort the front and back ends first (wheels, brakes, tires, clutch, final drive, suspension etc), and then culminate in the carb-rebuild as the last part of the refurbishment... hmmm food for thought.

* When stripping the carbs, should I be replacing jets, O-rings, and float needles as a matter of course, or just strip, clean, set float heights, and rebuild?

This is me arriving home with her last October 13th:
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bellboy40
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Re: 27 Year Service; your wise council please.

Post by bellboy40 » Thu Jan 03, 2019 10:00 am

I think it is some good advice to go ahead and take the carbs apart and do a good cleaning on them. Replace the o-rings, float bowl gaskets, etc. You definitely do not want to have to remove those carbs again! While you have the carbs out, be SURE to take that rubber mat under the carbs off and inspect/replace those vacuum lines. The one with the 90° bend in it especially. It is pointed out in the link that Dave posted. I used Jim Martino's write up when I had mine out fixing a float bowl leak a couple years ago. Those pictures helped a lot.

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RockportDave
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Re: 27 Year Service; your wise council please.

Post by RockportDave » Thu Jan 03, 2019 7:18 pm

I originally replaced the orings and bowl gaskets on mine, but ended up pulling the carbs a fourth time and decided to soak them in carb cleaner and put new Honda parts in them and set the floats correctly.
When setting the floats I cut a piece of cardboard 8mm and made a gauge.




The needles have a spring loaded end and you want to roll the carb over slowly until the float just touches the needle without pushing the spring in. Bend the tab on the float to get the 8mm as seen in the photos.
Also, as bellboy mentioned, be sure to pull the rubber heat mat and check every vacuum line. You don’t want to have to go back into the carbs or replace a vacuum line. My heat mat was in bad shape so I bought a new one.


I printed a large view of the vacuum routing and highlighted them as I checked them.
The “NO 1 (ORN) TUBE” line at bottom of diagram is the one mine had a hole in. I cut a piece of vacuum line and routed it with a longer curve to make the bend. The others were in pretty good shape.


Dave
1999 GL1500SE 5th Goldwing through the years

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RockportDave
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1981 GL1100 Interstate
1985 GL1200 LTD
1988 GL1500
1988 GL1500

Re: 27 Year Service; your wise council please.

Post by RockportDave » Thu Jan 03, 2019 7:45 pm

Be sure to check the diaphragms in the carbs for cracks or holes. Mine were ok so I cleaned them and reused them.
Here is what I replaced in the carbs with Honda parts. New orings and carb gaskets including needle seat gasket for both carbs. I reused the needles and seats. Low speed jets, main jets, jet holders, air adjustment screws with the spring, washer and oring, sub filter, cruise filter, rubber heat shield, carb insulators (boots). I cut slots in the air adjustment screws before I installed them so I could use a flat screwdriver to adjust them. I also rebuilt the accelerator pump on the side of the carbs.
My jets were corroded and one broke apart when I tried to remove it, so I decided to bite the bullet and get all new. I didn’t want to have to go back into the carbs. It is well worth the time and money spent as it idles smooth and runs great.
There are very small passages in the carbs so I used Berrymans chem dip to soak them, rinsed them with water and sprayed them with Berrymans spray to get the moisture out.
Dave
1999 GL1500SE 5th Goldwing through the years

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Sadanorakman
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Re: 27 Year Service; your wise council please.

Post by Sadanorakman » Fri Jan 04, 2019 8:45 am

RockportDave wrote:
Thu Jan 03, 2019 7:18 pm
My heat mat was in bad shape so I bought a new one.
Winner of the understatement of the week Dave! You mean you couldn't get away with re-using that mat? :D :D :D Hand me the Duck Tape!!! :D :D :D
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Sadanorakman
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Re: 27 Year Service; your wise council please.

Post by Sadanorakman » Fri Jan 04, 2019 8:49 am

But More seriously, thank you RockportDave for the thorough info re your carb rebuild; it's greatly appreciated.
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Re: 27 Year Service; your wise council please.

Post by RBGERSON » Sat Jan 05, 2019 9:14 am

Small detail; the two subfilters are likely toast..replacement them
HAD LOTS OF GOLDWING 75-83
NOW INTO 1500'S..RIDING A 1998 SE

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Sadanorakman
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Re: 27 Year Service; your wise council please.

Post by Sadanorakman » Sun Jan 06, 2019 2:33 pm

RBGERSON wrote:
Sat Jan 05, 2019 9:14 am
Small detail; the two subfilters are likely toast..replacement them
Thank you RBGERSON. I fully intend to, but struggling to source these in the UK. I can only find main air filter.
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Re: 27 Year Service; your wise council please.

Post by Happytrails » Mon Jan 07, 2019 7:05 am

Good looking bike. My fixit list was about as long as yours. Well worth the effort. Some stuff needs replacing, others just checking. Hope your project goes well. :)
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Rednaxs60
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Re: 27 Year Service; your wise council please.

Post by Rednaxs60 » Mon Jan 07, 2019 10:24 am

Sadanorakman wrote:
Sun Jan 06, 2019 2:33 pm
RBGERSON wrote:
Sat Jan 05, 2019 9:14 am
Small detail; the two subfilters are likely toast..replacement them
Thank you RBGERSON. I fully intend to, but struggling to source these in the UK. I can only find main air filter.
These are just a foam product. Pick some foam up at a local shop and cut to fit.
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Re: 27 Year Service; your wise council please.

Post by DenverWinger » Tue Jan 08, 2019 6:59 am

Might check with Cyclemax.com, I understand they ship pretty much worldwide. Don't know about shipping costs or tariffs, but doesn't hurt to ask....
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Sadanorakman
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Re: 27 Year Service; your wise council please.

Post by Sadanorakman » Tue Jan 08, 2019 7:37 am

DenverWinger wrote:
Tue Jan 08, 2019 6:59 am
Might check with Cyclemax.com, I understand they ship pretty much worldwide. Don't know about shipping costs or tariffs, but doesn't hurt to ask....
Thank you, and I will certainly look to use cyclemax for anything important, but I can't justify paying to ship a small square of foam across the pond, when I could just cut up a washing-up sponge.

Thanks again.
Every day's a school day....What have you learned today?

DarthJ
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Re: 27 Year Service; your wise council please.

Post by DarthJ » Wed Jan 09, 2019 11:24 am

Sadanorakman wrote:
Tue Jan 08, 2019 7:37 am
DenverWinger wrote:
Tue Jan 08, 2019 6:59 am
Might check with Cyclemax.com, I understand they ship pretty much worldwide. Don't know about shipping costs or tariffs, but doesn't hurt to ask....
Thank you, and I will certainly look to use cyclemax for anything important, but I can't justify paying to ship a small square of foam across the pond, when I could just cut up a washing-up sponge.

Thanks again.
I wouldn't use a sponge, if you can source from your local hardware store a foam filter for a lawnmower or other piece of equipment, you may be able to cut what you need out of that.


You ain't lost, you're just somewhere you ain't been before.

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