El Jefe - Restoration Take 2 - '82 GL1100

[SlyDogJeff77]

Hi Guys.. It's been a while since I've posted. I've been on the NGW Facebook page and keeping busy tweaking and adding to my bike here and there. Nothing really new to report until now. My Engine has seized!!

SOOO.. LET'S GET CAUGHT UP!

I have a 1982 Honda Goldwing GL1100 Interstate I got as a hand me down from my Dad. He let it sit down on Long Island, NY for about 7 years and it rusted pretty bad. I brought it up to Albany and tore it down. Rebuilt the carbs, made it naked, new starter, new bars, new lights, new rear fender, new seat, new tires, new wheel bearings, new battery, new timing belts, changed the oil a few times, etc. etc. everything was going great. I put about 5000 miles on the bike since I got it up here. this summer so far I put 2000 miles on it. Newest addition was a pair of black powder coated timing belt covers and VALVE COVERS... the problem was I reused the valve cover gaskets (seals) and they leaked. Took about 2 weeks but I eventually lost all my oil. The oil light didn't come on which is a seperate issue but that's just pointing fingers. Right now I need to tear this thing down again and get the engine running again. I figure i'll do it right and take the engine out of the frame. Since the clutch slips in 4th, I'll do the clutch plates too. The exhaust is shot and rusty also, so I'll add that to the list. New fork seals, Along with a new digital gauge to replace the gauge cluster, and new progressive shocks... lets just do this right and get the whole thing done the way i really want it!! We are talking about a long winter project.

Ok so how about some pics. I'll try and attach the ORIGINAL of how I got the bike back in 2011.. and how it is now. Along with the work I've done tonight. Tonight I took off the false tank, seat, carbs, radiator, exhaust and while I was getting the Exhaust off, I found the leak at the bottom of the Valve covers.

I knew it was a seized engine because when I drained the oil on Thursday night last week when it happened, I only got about 1/2 a quart out. Tonight, I noticed that I only had about 1/2 a gallon of antifreeze but at least it was still bright green. Again, I think this is another great reason for a good engine gasket set and an engine rebuild. I want to clean this girl up RIGHT this time.

[SlyDogJeff77]

I hate finger pointing but this time it was my own fault. Here is the new valve covers with the gaskets / seals that I RE-USED!!! I FEEL LIKE AN IDIOT!

Ignore the nuts and bots missing on the exhaust. I took the pic after I took them off. Just notice all the oil dripping between the exhaust pipes right under the valve cover.. It was like that on BOTH sides.

[SlyDogJeff77]

OK so.. BOARD MEMBERS.. GURUS.. OH GREAT SWAMMYS OF GOLDWINGS.. AND MASTERS OF THE GL'S..
what do I need to do to free up a seized engine?

I've gone through many of the shop talks..
here are some of my concerns.
I DO NOT have all the tools you guys have!
1) Just to get the engine out I don't have the 90 degree snap ring pliers to disconnect the drive shaft! Not sure what I'm going to do about that yet.
2) Do I have to take apart the cylinder heads or can I get them off intact to inspect and repair what I have to inside the crank case?
3) If I do have to take apart the lifter arms and take out the cams, I don't have the the tool to compress the valve springs!
4) I don't have the measuring tool to see if the valve springs are adequate any more.. or if the cam lobes are warn.
5) I think my torque wrench is shot too! any idea how to test if it's accurate? I'll def need that to be accurate if I'm going to do this.

[SlyDogJeff77]

Also, I think I should start getting a parts list ready.
I know I need some simple stuff, new oil filter (comes with oil filter gaskets small and large)
I took off the lower front water pump housing so i need that new o-ring
I disconnected the carbs for the umteeth time so i want to get the 4 o-rings that sit right on top of the heads where the carb tubs connect to the heads.

ok so, engine GASKET KIT.. what's the most complete kit? WITH VALVE COVER GASKETS! duh..

[pierce]

Do not want to be redundant, but on FB I pointed you in the right direction. It would be cheaper, and more cost effective to buy a new engine.

However, if you decide to go the rebuild route, then read the two threads I sent you. The 1100 is a bored out 1K, so would be nearly identical, with the exception that you should buy the 1100 Vesrah complete gasket set instead, and you will have a different ignition system placed in the rear.

I would also suggest taking things very slow. If you ran out of oil, a great many parts may need to be replaced other than the usual. You may have warped parts, damaged head heads, tappets, in addition to engine damage. You may even have scored your cylinder walls and need to have them machined.

My advice, running out of oil is just about one of the worst things that can happen to an engine. Almost so much so that I would most likely buy another engine rather than rebuild.

Also, I am a bit skeptical on how you lost so much oil. It seems implausible that enough oil could be lost from the valve cover gasket without you noticing. Were talking nearly four quarts of oil - that means lots of smoking from the exhaust, it would be all over your shoes, the street, your sidewalk etc etc. It sounds like something else is at play, and that may just complicate things as well. Reusing those gaskets is just fine.

[Rugis]

I always reuse my valve cover gaskets unless there is visible wear and tear. You would probably have a pool of oil on your garage floor if if was leaking that bad? It does seem plausible that faulty gaskets are to blame though, since it happened now, after you changed the covers..

[Oldewing]

you need snapring pliers to free the driveline, no work around there.


you can pull the heads as a unit. Cams and rockers can stay, heads can stay together, but you should lap the valves and replace the valve stem seals since you are in that far. So put a spring compresser on your short list of tool's after snap ring pliers and beam type(cheap,but fine) torque wrench. I do agree if money is tight, short block rebuild is not the way to go, used motor is.

[SlyDogJeff77]

Don't worry guys.. I want to see what there is to see. It cost's nothing to take it apart right!? So, let me dig in and take it apart. But help me take it apart correctly so that if it's not that bad, I can change the damaged parts and put it back together.

But in the mean time..
http://nwct.craigslist.org/mcy/3938412780.html
I'm keeping my eyes open. This guy wants $200.. I offered him $50 bucks to haul this thing away for him. If it's not running, I eloquently pointed out that's more than what the junk yard will give him. It's about an hour from my house. No idea of what could be wrong with it.

[pierce]

Use Whiskerfish's guide in shoptalk to remove the engine. Once the engine is out, remove the heads, front and rear case, and then split the case by removing all bolts. Use the manual as a guide. I also show in my thread where are the bolts are located. That should take a good days work.

[Roady]

Nothing to add ... but this looks like it might get interesting.

[hoganJr]

You say the engine is siezed and you seem eager to pull it and tear it down. Just curious...will it turn at all now? Could be that you could do some valuable diagnostics before you tear it down.

hoganJr

[SlyDogJeff77]

@hoganJr. Yea I have a mental problem. If I'm not able to ride, all I can think about is the broken bike!! All I want to do is work on this thing and get it back on the road! I start to get stressed out without it! This is my release! My wife knows it.. My kids know it. When I get bugged.. I go turn a wrench. I'm actually a Computer / Systems Administrator for a huge Data Center for a career. I love to take things apart and put them back together. My passion is making computers connect to each other and making the network WORK! I'm responsible for 100's of servers and 1000's of workstations at my company. The only difference between my work and my hobby is that my 9 to 5 doesn't require OIL!! This is relaxing for me!

quick true story. When my wife was about to give birth for the first time, she was going to be induced. The doctor said come into the hospital on Monday morning at 9am.. You're going to have a baby.. On Sunday night at 9pm, I built a computer! This is the same thing. I want to build an engine.. RIGHT NOW! LOL so I come here.. to you guys.. my friends.. for support.. and I'm great for a laugh! I hope my experience can help you guys out as much as you can help me. I'm great with a computer, I take tons of pictures! And at the same time I hope I can give you guys a ton of smiles while doing it!! Cheers!

That being said.. The only thing I can do right now is tear this thing apart because I have no money for a new bike or a new engine. I'm looking to see if I can get that scrap bike I found 100 miles away on Craigslist for spit cheap. Maybe I'll get lucky and the engine in that one is good! Maybe I'll be not lucky but not bad and the engine will just need a little bit of work. Or worst case scenario, I can frankenstein the 2 motors together and save a bundle.. Maybe I'll just need a full gasket set!? Who knows. Right now, this engine isn't turning at all.
I still want to take the engine out. I HAVE to do the clutch anyway! This was just the straw that broke the camels back..

TROUBLESHOOTING!! So how should I try to turn the engine once it's out?
Another thing I'm worried about. I had someone change my timing belts in 2011-2012 for me because I was paranoid about getting them just 1 sprocket off and the whole TDC thing! Now I see there's 10 different ways lock the pullies in place.. sigh.. still kind of worried about that.. I have to go over octain's timing belt how to again. Not that I think I need to change them.. but I just need to take them off to get the heads off, examine the cylinders & split the engine case right?!

[jimmyz3286]

Yes to get heads off timing belt must cone off. Here is a plus if you'd u get the other bike for next to nothing tear this motor down and what ever is good on the inside you could try and eBay the good internal parts.

[SlyDogJeff77]

of course.. sell left over parts to pay for the restoration. I'm used to that. That's how I'm planning on paying for the full gasket kit. That's why I hope to get that junk bike on craigslist.

[pierce]

So you are aware, these are most of the parts you will need, and what was needed for Old Fogeys rebuild.

And yes, that figure does read almost 4K. And yes, you could buy several Wings with the cost of a rebuild. Now of course, you can bring that figure down, but by how much? Also, with engine building being my forte, I can attest that this engine is pretty sophisticated, far more than most motorcycle engines, and unless one has significant experience, I would warn against doing so. Thats not to say it cant be done. Where theres a will theres a way.

Here is your parts list you would need if you choose to re-build: (just make sure to get the parts for the 1100, many cross, but make sure)