My 81 GL1100 Maiden Voyage

[56michael]

Well after replacing the head gaskets, rebuilding the carbs, fuel lines and filter, doing the idle adjustments and carb sync, replacing the front fork seals, airing up the tires and suspension I was anxious to take her out for a spin. The temp was a balmy 45 and sunny here in Minnneapolis so here I go 35 south to Fairbault. About 80 miles round trip. I couldn’t believe how smooth the engine ran and not much wind on me. I had checked brake pads tested and bleed the brakes in the neighborhood before I left an they seemed to work “ok”. When I got back home I felt the front brake rotors and one was cool the other hot. I pulled all three of the calipers apart and what a mess. The pistons would hardly move. Soaked them with penetrating oil and after a couple hours of blowing 150 pounds of air in the pistons finally came out. CAUTION!! keep your fingers out of the way the pistons come out unless you like sore fingers…. I learned the hard way. Ouch!!!!
Nice and clean now, waiting on the rebuild kits. I don’t thing the pistons were releasing the pads all the way I thing they should work right after I rebuild the calipers. I’m sure the master cylinders will need some work too. See attached photo.
I want to thank every again for all your help so far couldn’t of made it this far without all your help,

 

[dan filipi]

That's some nasty stuff right there. Amazing some things still work as bad as they can get.

 

[julimike54]

Yep I put a wadded up towel in there. I just went through the entire brake system and rebuilt it all. Corrected all of the items that were bugging me! Good as new....

 

[56michael]

That's some nasty stuff right there. Amazing some things still work as bad as they can get.

Dan question, when I took apart the 3 calipers only the front 2 had the silver shim with the arrow on it between the piston and the pad, shouldn’t there be a shim in the rear Caliper also? Thanks.
Dick Michael

 

[julimike54]

Are you referring to item #19 in the below?

https://classicgoldwings.com/media/80-82-gl1100-oem-parts-manual-page-097.14225/

 

[56michael]

No sir, mine is a 81 with a single piston, item 10 below.

 

[dan filipi]

Dan question, when I took apart the 3 calipers only the front 2 had the silver shim with the arrow on it between the piston and the pad, shouldn’t there be a shim in the rear Caliper also? Thanks.
Dick Michael

I never had a shim on the rear.

 

[dan filipi]

Actually the Clymer manual shows 1980 forward having a shim on the rear caliper.
Evidently they work fine without them, I don't have any in the front either.
1975-1983ClymerManual Page 259

 

[56michael]

Mine has them on the front but not the rear.
Thanks.

 

[GTC@MSAC]

I believe they are just for pad noise abatement. The only brakes of mine that are noisy are the rear shoes in my 82 GL500i, so shims won't be helping that, lol!
Found my '81 GL1100 in 2016 and had to overhaul all brakes & master cylinders including new pistons, seals & hoses before putting it on the road. The guy I bought it from tried to hide the leaky calipers (pitted pistons) by packing Vaseline around the pistons & seals.

 

[Winger 82]

Well know I know what that shim that fell out last fall while doing a front brake pad change on the "ole" 82 Asppy , pulled the other side off to see where it went but couldn't find one on that side either # 6

 

[56michael]

Im having trouble with my front brakes on my 81 getting the air out of the lines after installing the new seals. Then I found mcgovern61 post on bleeding them with the pistons squeezed with the clamp and holding the caliper with the bleed valve straight up, seemed to do the trick. Now what happened when I took it for a ride I was going slow pumping the front brake and when I let off and the front braked just seemed to slowly start squeezing on the rotor all by itself. I went right back home and the brake lever wouldn’t move at all , put the bike on a lift and couldn't move the front wheel. The front brakes were 100% on. i couldn’t squeeze the lever at all. Opened the bleed valves and some fluid came out of each. Now I can squeeze the lever and spin the wheel but the pads still rub on the rotor. What do I do next?

 

[dan filipi]

There is a tiny return/relief hole in the master cylinder. It sounds like that is getting blocked. A good flushing might take care of it.

 

[56michael]

I’ll give that a try.

 

[56michael]

I have the master apart, the hole is not apparent. Where should I look?

 

[dan filipi]

I have the master apart, the hole is not apparent. Where should I look?

Sorry, can't help you there and the manuals don't help. Someone else have an idea where to look?

 

[dan filipi]

This video at about 11:25 he shows the hole

 

[56michael]

Thanks, I did some searching too and found some info on the hole. It was all clogged up had to use the high E guitar string. See attached. I’ll put it back on the bike tomorrow.