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-   -   '85 Interstate refresh (https://www.goldwingfacts.com/forums/2-goldwing-technical-forum/666223-85-interstate-refresh.html)

whodat90 02-04-2019 09:44 AM

'85 Interstate refresh
 
22 Dec 2018

Ok, I have a lot of stuff to post, so I'm just going to copy my posts directly from ADVRider where I usually hang out. All pics posted now so it should make more sense.

So a while back an uncle called me out of the blue telling me that he has a bum foot and will never be able to ride his goldwing again. An acquaintance offered him an insulting amount of money, and he said he'd rather burn it than let that guy have it. Would I like it? Well duh, free bike!
So time passes, and I finally get some free time to zip up to Jersey to pick the bike up. Usual story; pouring rain, flat tires, no air in the suspension, inoperable clutch. Unusually for me, the bike actually ran. Sometimes. Has a single carb conversion instead of honda's insanely complex set, which will occasionally leak down and hydrolock one cylinder. After a night of bullshitting and catching up, the next morning it fired right up and smoked like an old two-stroke, plus had a nasty clatter on one side. On the good side it had a strong fully charged battery so I used that in conjunction with the inoperable clutch to drive the bike up onto the trailer with the starter, and brought it home trouble free. This thread is gonna be long and rambling, and is more as a reminder to myself about all that I did than for y'all. No offense, and don't take that to mean that I don't want to bring you along with me or appreciate your comments.
https://farm5.staticflickr.com/4874/...c6708471_z.jpgBefore by Uncle Grr!, on Flickr

whodat90 02-04-2019 09:44 AM

22 Dec 2018

As soon as I got it home I pulled it off the trailer, took the VFR off the lift and put the gl on once again using the starter. I got about halfway up before I turned it turtle, with all the flat tires and such causing hard parts to hit the lift and flop it to the brake side. I rode it all the way down counterbalancing it like I was on the high side of a hobie cat. No damage other than rebreaking the right side mirror; first part on the list. Flipped it back upright, got it on the lift, and pretty much left it alone for a few days which may be a record for me. When I finally went back out to it, my intentions were to pull apart the rear brake since it was dragging. However, I got distracted by some electrical fvckery I found under one of the side covers. The starter relay had every wire spliced, some with crimp butt connectors, some with posilocks, some with both. I cut all that madness out and redid it with proper, crimp style, adhesive-lined heat shrink shrouded connectors using a good quality crimp tool. Then I found the stator connector burnt to a crisp and repaired that similarly. However I just ordered some much heavier silicone wire and will be taking out my repairs and redoing them as soon as that arrives.
https://farm5.staticflickr.com/4898/...2ab2e861_z.jpgOn the lift by Uncle Grr!, on Flickr
https://farm8.staticflickr.com/7860/...a28c20e9_z.jpgSketchy wiring on starter solenoid by Uncle Grr!, on Flickr

whodat90 02-04-2019 09:45 AM

25 Dec 2018

So a bit more about the bike's situation. It's an '85, and my uncle bought it secondhand in '90. He put lots of miles on it for the area (it has 46k) and swapped to the single carb figuring one carb has to be easier to deal with than 4. Then it got so far out of adjustment it wouldn't run well, so he got another and swapped it in. Then the bike sat in a small plastic shed for pretty much 10 years. Last inspected in '91, last registered I don't know when. He kept the battery charged and started it regularly, which is honestly not the best thing to do to a bike unless you're going to get it fully up to temp.
The tires are ancient and have to be replaced. There's a fine sprinkling of rust on all the chrome. The fork seals are blown, there's quite a bit of electrical fvckery that has to be undone. Someone put an am/fm radio from a Subaru in, holding the speaker grills in with sheetmetal screws. The clutch and brake fluid are a fine opaque purple-brown color. The neutral light usually doesn't work.
https://farm8.staticflickr.com/7850/...3becf0c4_z.jpgUntitled by Uncle Grr!, on Flickr

whodat90 02-04-2019 09:45 AM

25 Dec 2018

This comes at a good time for me. I've spent the past 15ish years going through bikes regularly; buying, selling, trading. Mostly finding bikes in need of love, giving it to them and releasing them back into the wild. However, lately I have three bikes I love, that all run well, and tickle my fancy very well so I've been bored with nothing to do. SWMBO put the law down stating no buying any more bikes. This gl neatly sidestepped that rule by being both free and family. So now I have a nice winter project. Plans for the bike are to put a lot of time and effort and not much money into it, and once it's running right maybe yank the sidecar off my inop Dnepr MT-16 and install it to the wing. I also can't get rid of the single carb fast enough, I honestly don't think some bubba with a welder and an idea can say that putting a carb from an even older car on the bike can outsmart a bunch of Japanese engineers with slide rules and meetings. Granted it runs, and even starts pretty dang fast, but I still want a set of stock carbs on it.

whodat90 02-04-2019 09:45 AM

26 Dec 2018

So finally back to the brakes. I start taking off plastic to get to the rear brake and recall how much I dislike bikes covered in Tupperware. So much delicate crap with so many bolts to take off to get to the hard bits. Taking off the left side bag took two 8mm head bolts, two more that also had 10mm nuts, taking off a reflector that had one 10mm nut plus a wing nut which exposed the #3 Phillips screw. Seriously Honda, wtf? This finally exposed the rear brake, which had a 12mm bolt for the hose, a 13mm bolt and a 14mm bolt. Again, WTF? Take it off and start disassembly. Brand new pads, but the pistons were seized pretty solid. Gave them some degrippant, a bit of c-clamp action and found that one of my air guns would almost thread into the thing so I used a hundred PSI to drive the pistons out into a wooden block. Then I pulled out the seals, realized they wouldn't be reusable and ordered new ones. I sandblasted the caliper and gave it a couple coats of VHT Epoxy paint. I didn't like the finish on that so I ordered some VHT Caliper paint, and swapped the coal slag in my sandblaster for crushed glass.

https://farm5.staticflickr.com/4822/...475c9c7b_z.jpgDisassembling rear brake caliper by Uncle Grr!, on Flickr
https://farm5.staticflickr.com/4869/...702def18_z.jpgFront brake caliper sandblasted by Uncle Grr!, on Flickr
https://farm8.staticflickr.com/7873/...b4f714fa_z.jpgUsing air pressure to pop the brake pistons out by Uncle Grr!, on Flickr

whodat90 02-04-2019 09:45 AM

26 Dec 2018

Figured that since I was waiting on parts I may as well do the fronts as well. This bike has a weird linked brake system where the front lever activates the left front caliper, and the rear pedal activates the rear and the right front. Plus it has the TRAC system, or Torque Reactive Antidive Control. Honda looked at the bike and said "hey, every time someone hits the brakes hard on this 700+ pound bike the front suspension compresses. How about if we make a system that when you hit the front brake, a needle jams into the forks that cuts off the fluid flow and totally disables the front suspension." Or something to that effect. I'm keeping it for the sake of authenticity. Anyway the boots on the TRAC system were torn so they were ordered. The pistons for the brakes are different sizes so not interchangeable, plus they were ugly. They are stainless though so I chucked them gently in the big lathe and polished them back to shiny. There's still some slight pitting but it's all outboard of the seals so I'm going to keep them for now. Worst case scenario if they leak I can buy some stainless and turn my own for scads cheaper than buying them from Honda. Oh yeah I also ran a fine stone brake cylinder hone through each cylinder, still have to clean out the sealing grooves.
https://farm8.staticflickr.com/7808/...95db46d8_z.jpgUntitled by Uncle Grr!, on Flickr
https://farm8.staticflickr.com/7870/...a9c0e237_z.jpgFront calipers cleaned, painted by Uncle Grr!, on Flickr
https://farm8.staticflickr.com/7852/...58c84f6f_z.jpgBrake pistons before polish by Uncle Grr!, on Flickr

whodat90 02-04-2019 09:45 AM

Also the more experienced among you have probably already diagnosed the clatter. I started the bike and ran it for a while to warm up the oil before I drained it. Yes it started, yes it clattered. It has hydraulic valve adjusters. As previously mentioned, it also sometimes leaks gas and hydrolocks. So, long story short there was a gallon or so of gas mixed in with the oil. I consider it an engine flush. I drained all the gas/oil, bored a hole in the drain plug and epoxied in a magnet, then refilled it with just oil to the correct level. Started up right away, ran Honda quiet, and no more white smoke. Inadvertent engine power flush complete.

whodat90 02-04-2019 09:46 AM

28 Dec 2018

Today was originally going to be my day to change the fork seals, but that didn't happen. I started digging a bit more and found more electrical challenges so I figured I'd strip the bike down and find it all. Actually found about what I expected; a bit of cracking in the fairing, lots of wiring done not to my standards (which to be fair are unrealistically high) and a fair amount of surface corrosion. However the caliper paint I ordered came in so I figured I'd give them a spray. Below is as found, then sandblasted, and painted.
https://farm8.staticflickr.com/7906/...da6d58f1_z.jpgStator wiring connector melted solid by Uncle Grr!, on Flickr
https://farm5.staticflickr.com/4826/...b58a81dc_z.jpgSketchy wiring in the tail light by Uncle Grr!, on Flickr

whodat90 02-04-2019 09:46 AM

28 Dec 2018

I found a mouse nest in the fairing, looked comfy. Took it out anyway. Whoever wired this bike used an interesting combination of solder, electrical tape, wire nuts, crimps, scotchlocks, and hope. Some interesting wiring for the Empi carb, which will be going away. No pics of the fairing yet but I'm repairing it using ABS glue, but had to order some more ABS sheet as backer.
https://farm8.staticflickr.com/7888/...32079d5e_z.jpgMouse nest in fairing by Uncle Grr!, on Flickr
https://farm8.staticflickr.com/7882/...45130c51_z.jpgAftermarket carb by Uncle Grr!, on Flickr

whodat90 02-04-2019 09:46 AM

30 Dec 2018

Pulled the rear rack off, pulled the back wheel and removed the tire. Lots of cracks in the tire, long past time to replace it. I also removed a bunch of the rusty bits and put them in a tub of evaporust. Finally I polished up the exhaust pipes a bit. Pics show as found, cleaned with degreaser, rubbed down with some nevr dull, then polished up with a buffing wheel in a cordless drill and brown polish stick. Granted it's not like brand new chrome, but it looks so much better than it did.
https://farm8.staticflickr.com/7872/...39cbe1cf_z.jpgSeverely cracked rear tire by Uncle Grr!, on Flickr
https://farm5.staticflickr.com/4826/...eece096c_z.jpgExhaust as found by Uncle Grr!, on Flickr
https://farm5.staticflickr.com/4906/...36c29b92_z.jpgExhaust after degrease by Uncle Grr!, on Flickr
https://farm5.staticflickr.com/4886/...e730cba9_z.jpgExhaust after final polish by Uncle Grr!, on Flickr


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