Clutch removal GL1100


Information and questions on GL1100 Goldwings (1980-1983)
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eklimek
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Motorcycle: 81, 82, 83GL1100 in stasis, CB350f x many, (CB400f x2 -sold cb550 -sold 2012 cbr250 -sold) 2017 cb500x daily driver, 2017 zx6r on the work bench to campaign in the existing 650cc (171 mph) record. (August 2019 157 mph)

Clutch removal GL1100

Post by eklimek » Sat Jul 09, 2016 3:34 pm



(Not sure if here, or GL110, or "How to" is best place. Admin move as you think best)

clutch slipping ... time for refurb.

Honda has proprietary tools to remove clutch (Photo in Manual page 9-6.) I am sure there are other ways to do this. Here is one way. Of course this all takes place on the bike after cover is removed. For clarity only, the clutch has been removed from the outer drum.

Remove rear wheel to get to the cover and work between centre stand with 10 mm tools. Don't forget to either drain oil or stand bike on its nose.

clutch removed from drum for clarity
clutch removed from drum for clarity


clutch centre removed, here's the slotted nut that needs to be removed
clutch centre removed, here's the slotted nut that needs to be removed


slotted nut and socket tool
slotted nut and socket tool

Tool made of key stock welded to socket of suitable dimension. (Could also simply cut a larger socket) Unpean lock washer with pointed tool.

measure lifter plate for dimensions and cut out centre for socket tool
measure lifter plate for dimensions and cut out centre for socket tool

If clutch is not slipping one could replace springs and tighten without lifter plate.

use long 10 mm bolts from case
use long 10 mm bolts from case


hold centre and use socket tool
hold centre and use socket tool


may need small extension to lower socket tool
may need small extension to lower socket tool




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eklimek
Posts: 396
Joined: Tue Feb 15, 2011 1:55 pm
Location: St Catharines Ontario Canada
Motorcycle: 81, 82, 83GL1100 in stasis, CB350f x many, (CB400f x2 -sold cb550 -sold 2012 cbr250 -sold) 2017 cb500x daily driver, 2017 zx6r on the work bench to campaign in the existing 650cc (171 mph) record. (August 2019 157 mph)

Re: Clutch removal GL1100

Post by eklimek » Mon Jul 25, 2016 9:41 am

Correction. Rear wheel removal is NOT necessary.

All bolts are 10 mm. A selection of sockets and xtensions and ratchet wrenches will come in handy. The tricky one is the long case bolt at 1 o'clock. Remove and install first. The others are much easier.

Best tip is to clean up the cover and centre stand area as best you can before getting into it. Prepare to be filthy as this will be the first time this area is cleaned.

Much easier with the bike at comfortable working height slightly nose down to reduce oil dripping.

I was not able to find a torque value for cover bolts. I used 7 ft lb.

If you are assembling from donor bikes specific length clutch release rods mate with actuating lever of the clutch cover. If you have the right length the cover slips on and mates easily. If too long the cover can still be installed but the rod will be bent as cover is tighted down. This will jam mechanism.

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eklimek
Posts: 396
Joined: Tue Feb 15, 2011 1:55 pm
Location: St Catharines Ontario Canada
Motorcycle: 81, 82, 83GL1100 in stasis, CB350f x many, (CB400f x2 -sold cb550 -sold 2012 cbr250 -sold) 2017 cb500x daily driver, 2017 zx6r on the work bench to campaign in the existing 650cc (171 mph) record. (August 2019 157 mph)

Re: Clutch removal GL1100

Post by eklimek » Sat Jul 30, 2016 6:32 pm


nose down and easy access
nose down and easy access


ponyroller
Posts: 14
Joined: Sun Jan 13, 2019 5:01 pm
Location: Canada
Motorcycle: 1983 gl1100
2015 versys
2017 xt250

Re: Clutch removal GL1100

Post by ponyroller » Mon Jul 08, 2019 8:26 pm

hello,
I just took apart the clutch on my gl1100 and I didn't see the clutch lifter rod?? I looked online at a parts blow up and all the parts that came out of my clutch are on the picture with nothing extra but in the service manual they show this lifter rod that I don't seem to have. this is the parts list I was looking at.

https://www.cmsnl.com/honda-gl1100-gold ... SPsu2hE00P


I would just like some confirmation that I didn't lose some vital piece

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eklimek
Posts: 396
Joined: Tue Feb 15, 2011 1:55 pm
Location: St Catharines Ontario Canada
Motorcycle: 81, 82, 83GL1100 in stasis, CB350f x many, (CB400f x2 -sold cb550 -sold 2012 cbr250 -sold) 2017 cb500x daily driver, 2017 zx6r on the work bench to campaign in the existing 650cc (171 mph) record. (August 2019 157 mph)

Re: Clutch removal GL1100

Post by eklimek » Tue Jul 09, 2019 8:36 am

Seems to be missing in diagram.

its a rod or pin about 1 1/2 inch x 1/4 diameter rounded at both ends, if I recall correctly, extending from clutch cover #5 on

https://www.bikebandit.com/oem-parts/19 ... 4#sch17825

to guide pin lifter for throughout bearing( #10 on your diagram.)

It is found on this diagram

https://www.bikebandit.com/oem-parts/19 ... 9#sch40574

see item #11

Note there is no part number for this on the page.

I interchanged the 1983 and 1981 and found they are different lengths.

ponyroller
Posts: 14
Joined: Sun Jan 13, 2019 5:01 pm
Location: Canada
Motorcycle: 1983 gl1100
2015 versys
2017 xt250

Re: Clutch removal GL1100

Post by ponyroller » Tue Jul 09, 2019 1:17 pm

thank you for your reply. there is a picture of the pin in the service manual, but I can honestly say that never came out of my clutch! how important is this piece?
can I make my own?
how long should it be?

thanks for your help

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eklimek
Posts: 396
Joined: Tue Feb 15, 2011 1:55 pm
Location: St Catharines Ontario Canada
Motorcycle: 81, 82, 83GL1100 in stasis, CB350f x many, (CB400f x2 -sold cb550 -sold 2012 cbr250 -sold) 2017 cb500x daily driver, 2017 zx6r on the work bench to campaign in the existing 650cc (171 mph) record. (August 2019 157 mph)

Re: Clutch removal GL1100

Post by eklimek » Tue Jul 09, 2019 3:15 pm

The pin is there somewhere.

If It is really, truly and sincerely lost, not merely lost, I will endeavour to find the one I took out and measure and photograph it.

ponyroller
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Location: Canada
Motorcycle: 1983 gl1100
2015 versys
2017 xt250

Re: Clutch removal GL1100

Post by ponyroller » Tue Jul 09, 2019 3:21 pm

thanks, that would be greatly appreciated! I bought this bike it was mostly in pieces. when I took the clutch out I never saw the pin. It isn't just that I misplaced it, I don't believe it was in there.

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eklimek
Posts: 396
Joined: Tue Feb 15, 2011 1:55 pm
Location: St Catharines Ontario Canada
Motorcycle: 81, 82, 83GL1100 in stasis, CB350f x many, (CB400f x2 -sold cb550 -sold 2012 cbr250 -sold) 2017 cb500x daily driver, 2017 zx6r on the work bench to campaign in the existing 650cc (171 mph) record. (August 2019 157 mph)

Re: Clutch removal GL1100

Post by eklimek » Tue Jul 09, 2019 4:40 pm

I looked through the parts box and the bent pin has been tossed.

You will need an exact measurement to fabricate it but there is not much to it as it physically fills the space. Rounding both ends of a 1/4 or 5/16 rod should work.

Likely some one on the forum has the piece and contribute the dimensions. As above, length seems specific for the year.

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eklimek
Posts: 396
Joined: Tue Feb 15, 2011 1:55 pm
Location: St Catharines Ontario Canada
Motorcycle: 81, 82, 83GL1100 in stasis, CB350f x many, (CB400f x2 -sold cb550 -sold 2012 cbr250 -sold) 2017 cb500x daily driver, 2017 zx6r on the work bench to campaign in the existing 650cc (171 mph) record. (August 2019 157 mph)

Re: Clutch removal GL1100

Post by eklimek » Tue Jul 09, 2019 4:45 pm

I cant find a GL1100 photo but it looks like this.



ponyroller
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Motorcycle: 1983 gl1100
2015 versys
2017 xt250

Re: Clutch removal GL1100

Post by ponyroller » Wed Jul 10, 2019 8:43 pm

never seen one, looked on ebay doesn't come with any of the clutches that are for sale. thanks for the info. I will have to make one after a little more research

ponyroller
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Motorcycle: 1983 gl1100
2015 versys
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Re: Clutch removal GL1100

Post by ponyroller » Wed Jul 10, 2019 9:10 pm

what year is your gl1100? mine is a 1983. would that make a difference?

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eklimek
Posts: 396
Joined: Tue Feb 15, 2011 1:55 pm
Location: St Catharines Ontario Canada
Motorcycle: 81, 82, 83GL1100 in stasis, CB350f x many, (CB400f x2 -sold cb550 -sold 2012 cbr250 -sold) 2017 cb500x daily driver, 2017 zx6r on the work bench to campaign in the existing 650cc (171 mph) record. (August 2019 157 mph)

Re: Clutch removal GL1100

Post by eklimek » Thu Jul 11, 2019 6:30 am

I interchanged 83 and 81 covers because I thought they were identical. It was easier, so I thought, to clean the cover of the 81 replacement before removing the 83 to replace the slipping discs. I did not observe the difference in covers and rod initially. When I bolted it back together it was jammed and bent.

ponyroller
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Location: Canada
Motorcycle: 1983 gl1100
2015 versys
2017 xt250

Re: Clutch removal GL1100

Post by ponyroller » Thu Jul 11, 2019 7:20 am

since reading about the lifter pin and commenting here I've watched some YouTube videos. one of the videos shows a guy taking his clutch cover off, no pin was taken out or mentioned. is it possible that in 83 they made a small change to the clutch making the pin obsolete?

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eklimek
Posts: 396
Joined: Tue Feb 15, 2011 1:55 pm
Location: St Catharines Ontario Canada
Motorcycle: 81, 82, 83GL1100 in stasis, CB350f x many, (CB400f x2 -sold cb550 -sold 2012 cbr250 -sold) 2017 cb500x daily driver, 2017 zx6r on the work bench to campaign in the existing 650cc (171 mph) record. (August 2019 157 mph)

Re: Clutch removal GL1100

Post by eklimek » Thu Jul 11, 2019 8:48 am

Sure its possible.

How does the clutch linkage work without it?

The two items in the diagrams above would need to physically transmit pressure without the intervening pin.


ROD,CLUTCH LIFTER
product number: 22850463000

https://www.cmsnl.com/honda-gl1100-gold ... Sc98OhKiUk

User avatar
eklimek
Posts: 396
Joined: Tue Feb 15, 2011 1:55 pm
Location: St Catharines Ontario Canada
Motorcycle: 81, 82, 83GL1100 in stasis, CB350f x many, (CB400f x2 -sold cb550 -sold 2012 cbr250 -sold) 2017 cb500x daily driver, 2017 zx6r on the work bench to campaign in the existing 650cc (171 mph) record. (August 2019 157 mph)

Re: Clutch removal GL1100

Post by eklimek » Thu Jul 11, 2019 9:12 am

here is close up

no dimensions given
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ponyroller
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Motorcycle: 1983 gl1100
2015 versys
2017 xt250

Re: Clutch removal GL1100

Post by ponyroller » Sat Jul 13, 2019 1:02 am

to be totally honest I have no idea how this whole thing works, I am not even very mechanically inclined. I am rebuilding this motorcycle with the help of YouTube, goldwingdocs, and unlimited wifi. I am getting pretty good at removing broken bolts. I have accidentally broken two clutch pressure plates, once because I thought I could take the clutch out without buying the special tool and the other because I put the wrong bolts in the wrong holes. I don't know what I'm doing, all I know is that no pin came with either clutch I ordered and none came out the first time I took it apart.

User avatar
eklimek
Posts: 396
Joined: Tue Feb 15, 2011 1:55 pm
Location: St Catharines Ontario Canada
Motorcycle: 81, 82, 83GL1100 in stasis, CB350f x many, (CB400f x2 -sold cb550 -sold 2012 cbr250 -sold) 2017 cb500x daily driver, 2017 zx6r on the work bench to campaign in the existing 650cc (171 mph) record. (August 2019 157 mph)

Re: Clutch removal GL1100

Post by eklimek » Sat Jul 13, 2019 6:23 am

No harm in diving in. Its not beyond the average ability.

Briefly the clutch serves to separate spinning friction discs allowing the gears to disengage. The separation is accomplished by overcoming the spring pressure compress the spinning discs against each other. If the discs are worn too thin they will spin since the springs are inadequate to maintain the pressure. Think of the discs as shims that wear out.

To accomplish this the springs are compressed by the bearing. To move the bearing mechanical action from the clutch cover lever is conveyed by the rod (or pin) under discussion. The pin serves merely to transmit this action.

ponyroller
Posts: 14
Joined: Sun Jan 13, 2019 5:01 pm
Location: Canada
Motorcycle: 1983 gl1100
2015 versys
2017 xt250

Re: Clutch removal GL1100

Post by ponyroller » Sun Jul 14, 2019 7:39 pm

ok, so I took it apart again. fiddled with the clutch and cover. the lever on the cover pushes out a flat, round metal piece. this metal piece is the same size as the lifter guide pin (#10). when I reassembled everything I turned the lever o the clutch cover and it definitely makes contact and pushes against the springs. I can feel the pressure increase and decrease as I'm turning it.

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eklimek
Posts: 396
Joined: Tue Feb 15, 2011 1:55 pm
Location: St Catharines Ontario Canada
Motorcycle: 81, 82, 83GL1100 in stasis, CB350f x many, (CB400f x2 -sold cb550 -sold 2012 cbr250 -sold) 2017 cb500x daily driver, 2017 zx6r on the work bench to campaign in the existing 650cc (171 mph) record. (August 2019 157 mph)

Re: Clutch removal GL1100

Post by eklimek » Sun Jul 14, 2019 7:47 pm

Super.

Hard to argue with success.

You know we like pictures?

ponyroller
Posts: 14
Joined: Sun Jan 13, 2019 5:01 pm
Location: Canada
Motorcycle: 1983 gl1100
2015 versys
2017 xt250

Re: Clutch removal GL1100

Post by ponyroller » Sun Jul 14, 2019 8:05 pm

this is the power plant out on the table! everything else is apart and on shelves in the garage. she doesn't look like much now, but given enough time she will look and sound like a dream!
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