Well, I got it out easy... but,

Information and questions on GL1500 Goldwings (1988-2000)
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Location: Northborough, ma
Motorcycle: 1995 GL1500AS Interstate

Well, I got it out easy... but,

Post by tnwebwise »

I got the GL1500 (1996) Interstate engine out - wasn't too bad. But, to replace the starter idle and starter drive gears, I need to remove:

The clutch cover
Take the tabbed nut (see pic with red arrows)
The clutch basket (but appears I do not need to take the clutch apart, take out as whole?)
Take the weird staked star nut off that is behind the clutch
Remove the rear engine cover
Replace the gears, find broken teeth and look for more damage
Replace gaskets and reassemble

Issue is that, I can't find the special honda tools:
Clutch center holder
Clutch outer holder
A lock nut wrench (46mm) - Pretty sure a large hardened socket and breaker bar?

Nor do I understand the "staked" part the books says to use a grinder and stone to remove the staked part and discard to get the nut off.

Is there any other method to take these two nuts out and put them back? Secret poor mans shop method? Something stupid but might work?

See attached files for the gears I am replacing and the excerpt of the docs on the tools. Thx for the help!

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Re: Well, I got it out easy... but,

Post by Rambozo »

A staked nut has a thin ring that is bent into a groove to keep it from coming loose. They are typically used on rotating mechanisms where the torque forces can loosen things up.

Sometimes they can be expanded with a small punch to remove them intact. If they torque to a new index, by changing the assembled thickness, you can sometimes reuse them. However, for all the work of getting to a clutch, just get new ones. If something comes loose, and you catch it before any damage happens you still have to do the whole job over. Just not worth it.

The holding tools can usually be shop made items, for just the one job. Maybe not as easy to use as the factory stuff, but it's not like you're doing this everyday. Either welded up scraps, or I've seen plenty just made out of wood.

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Re: Well, I got it out easy... but,

Post by WingAdmin »

I agree. Keep in mind that these service manuals were written for Honda techs, with the assumption that they would have available all the special Honda tools. For the most part, I've been able to "make do" with tools that I had on hand, or to look at the intention of the special tool, and manufacture/modify a tool to do the same thing.

The exception is the fork spring compressor, for which I bought the expensive Honda tool (and have used it several times). Everything else I've ever made myself or come up with a different way of doing it.
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