86 GL1200 Refresh and Mod project

[dan filipi]

The one 1200 I have experience with had pretty clear arrows.
It was an 84.

 

[slabghost]

I believe those little dimples are the correct marks. They do vary from one set of pullies to another.

 

[backlander]

Your right slab, I just read Steve Saunders write up on goldwingfacts and his pics show the dots and referenced them so all is good. Had me wondering what I was dealing with though.

 

[joedrum]

just plain crazy how they did the pulley marks all over the place...glad you got it line out ....dang job has enough risks in it...without the marks everywhere to throw in the mix

 

[backlander]

Here's some progress pics of the project.

IMG00999-20120526-1509 (8)

• backlander
• Oct 22, 2012
• 2

Before the tear down began

IMG01136-20120723-1237

• backlander
• Oct 22, 2012

Removing the body

IMG01168-20120723-1702

• backlander
• Oct 22, 2012

Removing the bars

IMG01174-20120724-1337

• backlander
• Oct 22, 2012

Fairing is gone

IMG01205-20120801-1238

• backlander
• Oct 22, 2012

Drained oil and coolant, removed timing covers, thermostat, radiator, hoses and found bad water...

IMG01287-20120810-1747

• backlander
• Oct 22, 2012

Things get nasty down there.

IMG01476-20121018-1324

• backlander
• Oct 22, 2012

Cleaned and painted for reinstallation

IMG01477-20121018-1324

• backlander
• Oct 22, 2012

Everything painted and Clear coated with Dupli color engine paint, cast coat Aluminum.

IMG01479-20121020-1443

• backlander
• Oct 22, 2012

Drilling timing covers for crankshaft pulley for external alternator modification.

IMG01480-20121020-1503

• backlander
• Oct 22, 2012

Showing fit of pulley in timing covers

IMG01482-20121021-1330

• backlander
• Oct 22, 2012

Rebuilt water pump and front trans cover installed.

 

[backlander]

:builder: Work is proceeding on Suzy-Q. New timing belts and spark plugs were installed today. All timing marks are on the money and there is no interference on six rounds of rotation of the crankshaft. Belt tensioners are in great shape. I happen to glance at the front axle today while working with the belts and noticed that someone had installed the axle holders backwards with the arrows pointing to the rear. Also there was about an 1/8 in gap at the front of the cap. HMMMMMMM> What's going on here? :headscratch:

 

[Denver]

The water pumps you are working with are NOT originals. They have brown ceramic like impellers, not bent metal ones. Replaced pumps in two 81's, 84,& 87' none had metal impellers.

 

[backlander]

Got the new ignition switch, timing belt covers, thermostat and housing, radiator, new hoses, new SS hose clamps, antifreeze, oil and battery installed today. Removed the case guards for modification and was going to crank her up to work the air out of the cooling system and hit the starter button. Zilch, nothing, big fat zero. It ran after I stripped it down cause I checked it. Then I remembered the neutral switch is disconnected. I think when I fix that tomorrow it will fire up.

 

[backlander]

Finished soldering in the neutral switch connector this morning and fired this baby up. So far no leaks and she fired up pretty smooth. Here's a short vid: https://www.youtube.com/watch?v=mfMDtBax ... e=youtu.be

 

[joedrum]

:yahoo: nothing like the scary moments of testing ...glad this morning start went well :yahoo: :mrgreen:

 

[backlander]

yep it makes you a little nervous on that first crank up, not even wanting to hear that "ka thunk" noise when Mr. Valve introduces itself to Mr. Piston. :shock: :headscratch: Thanks Joe. :mrgreen:

 

[dan filipi]

Love it when it all comes together.
Bike sounds real good.

 

[backlander]

Thanks Dan, and thanks to everyone for all the great info I received on this site. :thanks: Now that it's running again, it's time to head to the back of the bus and work on the final drive and rear brakes. :builder: :heat: Ain't no rest for the weary. :Egyptian:

 

[backlander]

After getting this gal running Saturday I noticed a small amount of antifreeze laying in the front bottom of the radiator :shock: , didn't think to much about it, figured it was from when I spilled a little filling it and working the air out of it. I wiped it dry and went about my business, working on the rear drive Sunday afternoon. Tuesday I noticed a small amount of antifreeze in same place :headscratch: . Wiped it dry, told myself it was from all the bubbling of air working out. Today, it was there again. then I saw it, a track of antifreeze leaking from the top front of my freshened radiator :head bang: :head bang: . I remembered it had been bumped there while it was with all the other parts that had been waiting to go back on the bike, had about ten bent fins but I straightened those with coil comb and didn't see anything that looked major but I guess it cracked a tube :doh: :doh: . So.... today I started striping down the blue 85 for it's radiator and a few more parts. I hate doing things twice. :Awe: :head bang:

 

[joedrum]

oh well mike these radiators are priceless you know ....careful big guy ...i hate when i take something out

 

[dan filipi]

I had a tiny leak in the fins on mine...4 years ago.
I put the silver powder stop leak in, 1/2 a tube. No problem since.

Oh it's called alumaseal.

 

[backlander]

Ok, I will check that out. It sure is aggravating to spend money having one cleaned and tested, then for this to happen. But, life goes on.

 

[dan filipi]

I've used Alumaseal through the years on various cooling systems, aluminum, copper. Never had a problem and I wouldn't hesitate to use it again.
Interesting too, after putting it in that one time way back, I have flushed and changed coolant quite a few times and not added any Alumaseal and no leak has ever come back.

 

[backlander]

It sounds like good stuff. I'm going to put this 85 radiator on my 86, the future long distance bike, since it has no damage, not leaking and is clean, it was just redone before I bought the bike. I will then put the damaged 86 radiator on the 84 and add the Alumaseal since it will be a solo local bike.

 

[backlander]

Finally getting back on track health wise and felt pretty good today so it was time to jump back on this project. Got all setup and put Suzy on the HF lift I haven't used yet and it sure made a difference on my body working on this bike. Sitting on my stool the carbs are about neck high. Don't feel like I'm standing on my head now. :smilie_happy: I cranked her up and let her run a bit then ran the carbs dry because I still have a leak somewhere on the backside of #4. Figured I might as well yank the rack off and spruce them up while I'm at it. While removing them I found some split vacuum lines which the ICM uses to adjust the timing once you hit fourth and fifth gear, not good, so now all rubber lines will be replaced, after all their old like me. Now I got the rack in the house and will go thru them, don't think they will need any parts, someone has already done some work in that area, the cables were run outside the frame rail already. Whoever it was, thanks for saving me some frustration. :Egyptian: :smilie_happy: :smilie_happy: