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Discussion Starter #61
I decided to put in a 1200 spring chain tensioner. Ordered one from eBay. So now I am waiting for the oil pump studs and the spring chain tensioner. I know that I need to modify the chain shroud, any suggestions would be great


While I am waiting for the parts, I decided to clean and paint something else. I picked the front cover, oil filter and water pump. Inspecting the water pump, I realize that it takes two hands to turn the pump. Wow. So earlier I discussed that I thought the bike had cooling issues. One head gasket had been replaced, there was no thermostat, it really seems that the PO was struggling with overheating issues. I find a serious issue in the water pump. Try to free up the water pump, the vanes crumble, No problem, I will buy another. WOW those are a little pricey! But the water pump is a pretty important part. If I get the cooling under control it will be worthwhile.
 

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Discussion Starter #63
did you see the 'note' about NOT using moly on those bolts?

that is a real no no...
Yes. I heard it. As it is said, education is expensive! I really appreciate that you guys keep the cost to a minimum.



Won't do that again, but YES on the moly for the head bolts?
 

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Junior Grue
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This time with my torque wrench set to 150 inch pounds. What? Ok. Time to back away and figure out what is going on. My 40 year old torque wrench is failing me. I took it all apart, hardened grease and sticky parts, cleaned it and compared it to my foot pound wrench, They both read the same at 10 and 20 foot pounds. Tried it on the pump again and it felt MUCH better.
Most manufacturers recommend checking the calibration of their click type torque wrenches yearly.

For home mechanics (Shade Tree) I would recommend a beam type torque wrench.
 

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Discussion Starter #65
I needed a success, and I saw the timing hole cover and said, "I can polish that ". Well that felt good, instant gratification polishing aluminum!
 

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Discussion Starter #67
Waiting for parts so I took some time to. --- clean , paint, assemble!

Finished the front cover. Quite a PIA. Lots of nooks and crannies. As i was cleaning it I realized that the existing paint was flaking off. I had to take all the paint off from all those nooks and crannies But it is done, waiting for the new water pump
 

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Average Goldwing Rider
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Wajulia, nice work. I will be going down the same path with my 1100. One thing I have learned, you cannot just pretty up a few parts. Once you start you have to do them all.
Do you have any comments on splitting the case halfs? How did you break the seal? Did you remove the alternator rotor and clutch? THX- JimP
 

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Just Winging It
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You have or will need to clean each of those bolt holes so the moly is out.

Right!



In the beginning I would have said soak the cylinders.........

What you are doing is better you needed new rings.

Them water pumps only last 60,000 miles. So replace the pump anytime your unsure.
 

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Discussion Starter #71
I got the gl1200 chain tensioner and put it in today. Modified the chain guide so it all fits. I hate cutting up original parts, but I talked myself into it. I was waiting for all that to come in so I could see what it was all about and I was going to commit to cutting up the chain guide. So know I can move on
 

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Discussion Starter #72
The crank, chain and the rest of the transmission went in. Starting to look like an engine again. Time for the Pistons, but my rings haven't arrived yet. USPS says they are somewhere between Washington state and Maryland. That narrows it down!
 

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Discussion Starter #73
Wajulia, nice work. I will be going down the same path with my 1100. One thing I have learned, you cannot just pretty up a few parts. Once you start you have to do them all.
Do you have any comments on splitting the case halfs? How did you break the seal? Did you remove the alternator rotor and clutch? THX- JimP
I just kept knocking it gently with a block of wood and a hammer and it eventually started to split. Be very careful, resist sticking a screwdriver in the space, there are a lot of thin parts and passages that you can't see from the outside. I was afraid that thin aluminum would break

I removed everything including clutch and alternator. The clutch needs a special tool that I made from a socket ( I wonder why they couldn't use a hex nut there). A couple of days after I made the tool a friend of mine who had done that a few years ago found the tool. Well at least putting it back together will be easier. ( can you tell which one I made?)
 

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Discussion Starter #74
The rings came today. I should be able to get the Pistons in tomorrow.

I will be ready to join the halves next weekend. Question, what sealer do you suggest to seal the halves?
 

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The rings came today. I should be able to get the Pistons in tomorrow.

I will be ready to join the halves next weekend. Question, what sealer do you suggest to seal the halves?
Don't forget the neutral switch :surprise:,
Three bond case sealant liquid gasket works fine.
You're doing a great job
 

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Discussion Starter #76
I always find great people in this hobby. I was putting the rings on the Pistons and one of the new ones snapped as I was putting it on. I didn't do anything unusual or different than all the others but "boing:crying2:" it went flying across the room

I sent a message to the guy who sold them to me " can I buy just one more set?" His response, "I'll put one The mail tomorrow, no charge".

There seems to be a great respect among the people that like to preserve the past. I am all warm inside. :)
 

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Average Goldwing Rider
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I just kept knocking it gently with a block of wood and a hammer and it eventually started to split. Be very careful, resist sticking a screwdriver in the space, there are a lot of thin parts and passages that you can't see from the outside. I was afraid that thin aluminum would break

I removed everything including clutch and alternator. The clutch needs a special tool that I made from a socket ( I wonder why they couldn't use a hex nut there). A couple of days after I made the tool a friend of mine who had done that a few years ago found the tool. Well at least putting it back together will be easier. ( can you tell which one I made?)
It looks like pulling the clutch and alternator are the next steps for me. I have the tool you are pointing out. Yours looks nice. I bought mine on ebay. I made one from 1 1/2 inch hex steel to fit the swing arm and headstock. The alternator looks straight forward. I need to figure out how to hold the inner clutch drum to break the nut loose. On my 450 the HondaTwins.net gurus recommend a copper penny in the clutch drive gear. This doesn't look like an option on the GL1100.
 

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Discussion Starter #78
It looks like pulling the clutch and alternator are the next steps for me. I have the tool you are pointing out. Yours looks nice. I bought mine on ebay. I made one from 1 1/2 inch hex steel to fit the swing arm and headstock. The alternator looks straight forward. I need to figure out how to hold the inner clutch drum to break the nut loose. On my 450 the HondaTwins.net gurus recommend a copper penny in the clutch drive gear. This doesn't look like an option on the GL1100.
There is a hole bored in the alternator, I used a drill bit that fit the hole wrapped with a rag so it didn't cut my hand. It worked. I guess you could by some round stock at Home Depot to do it.
 

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Discussion Starter #79
The Pistons are in!

I have to wait for the new rings to come in. I was at least lucky enough that the broken one is one of the exposed ones so I could put it on the crankshaft and still change the rings later. The blue things in the picture are the Pistons, I wrapped them in blue tape to protect them. I love blue tape.

I probably won't get back to it again until next weekend. Time to put the Halves together.
 

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Discussion Starter #80
The two halves are together. :grin3:

It went quite well. I forgot to take a pic of the setup before we put the top on, but I used two hose clamps over the rings and two blocks of wood holding up the Pistons. The Pistons were even with each other. We had to do it twice, the first time there was no way to get the blocks out. So we made them smaller, they came right out the second try.

The case sat together nice and easily clamped together as the bolts were tightened.

The new water pump is in, so I will start that next, but I will be traveling for the next two weeks, so until then:wink2:
 

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