1978 GL1000 Resto Mod

[rcmatt007]

if the bike was stored inside, I would not be too concerned about 5 year old tires. Stored outside and I would change them out. My Ltd which I got running again had 12 year tires. They went to the dump

[GalDemSuga]

if the bike was stored inside, I would not be too concerned about 5 year old tires. Stored outside and I would change them out. My Ltd which I got running again had 12 year tires. They went to the dump

Yes, it was stored in an air conditioned warehouse. They hold air and I did ride the bike for 3 miles on them without issue. Of course I will have to balance them later. I will begin today with semi-tear down.

[GalDemSuga]

I began the disassembly today. I found three oil leaks, one at the starter, one just behind the thermostat housing and the last one is the gear selector shaft seal. There is an actual hole in the engine case. I also removed the Windjammer wire harness from the main harness, so I will have to repair some wires. Also found what looks to be the neutral switch wire grounding against the engine. I removed the carburetors and they’re in bad shape. Someone went in there before and they did some damage as almost all of the float bowl screws have been replaced with self tapping screws. It leaks all over. In order to remove the carbs from the frame, I had to remove a housing for a diaphragm. I posted pictures below. There is a picture with two relays, I assume they have something to do with the coils. Also, the bike still has points and they seemed as if they were recently replaced.

[GalDemSuga]

More pictures

[pidjones]

"Diaphragm" is the anti-afterburn valve that has to be removed (did you read any instructions for carb removal?) Stripped screws are pretty common. I had one that even had sheetrock screws in it. You can get Helicoil kits on Amazon. Make sure you use a JIS screwdriver on all of those cross-point screws. The hole is a tell-tale between the water pump and oil pump to let you know when the seal fails.

You really should obtain a Honda service manual (there are pdfs online).

[GalDemSuga]

"Diaphragm" is the anti-afterburn valve that has to be removed (did you read any instructions for carb removal?) Stripped screws are pretty common. I had one that even had sheetrock screws in it. You can get Helicoil kits on Amazon. Make sure you use a JIS screwdriver on all of those cross-point screws. The hole is a tell-tale between the water pump and oil pump to let you know when the seal fails.

You really should obtain a Honda service manual (there are pdfs online).

This is great info. I do have the Haynes Manual and I will use it. I assumed pulling carbs would be straightforward but lesson learned. Now I know that there is a failed seal and I have to go deeper. Peeking at the intake valves didn’t reveal any oil buildup from leaking valve seals.

[rcmatt007]

somewhere there is a diagram of the water pump and all the ways it can leak (either coolant or oil). Looks like time to replace the pump (and O rings and crush gaskets on the three bolts that hold the pump

[GalDemSuga]

somewhere there is a diagram of the water pump and all the ways it can leak (either coolant or oil). Looks like time to replace the pump (and O rings and crush gaskets on the three bolts that hold the pump

I have to find all of the parts numbers. Also, is there a cooler than 180F thermostat for this engine?

[rcmatt007]

you do not need a cooler thermostat. There are "kits" which have all the O-rings and gaskets needed to take off the "transmission" cover and replace the water pump.

[pidjones]

"Diaphragm" is the anti-afterburn valve that has to be removed (did you read any instructions for carb removal?) Stripped screws are pretty common. I had one that even had sheetrock screws in it. You can get Helicoil kits on Amazon. Make sure you use a JIS screwdriver on all of those cross-point screws. The hole is a tell-tale between the water pump and oil pump to let you know when the seal fails.

You really should obtain a Honda service manual (there are pdfs online).

This is great info. I do have the Haynes Manual and I will use it. I assumed pulling carbs would be straightforward but lesson learned. Now I know that there is a failed seal and I have to go deeper. Peeking at the intake valves didn’t reveal any oil buildup from leaking valve seals.

Please BURN the Haynes manual and get a Honda manual!

[GalDemSuga]

"Diaphragm" is the anti-afterburn valve that has to be removed (did you read any instructions for carb removal?) Stripped screws are pretty common. I had one that even had sheetrock screws in it. You can get Helicoil kits on Amazon. Make sure you use a JIS screwdriver on all of those cross-point screws. The hole is a tell-tale between the water pump and oil pump to let you know when the seal fails.

You really should obtain a Honda service manual (there are pdfs online).

This is great info. I do have the Haynes Manual and I will use it. I assumed pulling carbs would be straightforward but lesson learned. Now I know that there is a failed seal and I have to go deeper. Peeking at the intake valves didn’t reveal any oil buildup from leaking valve seals.

Please BURN the Haynes manual and get a Honda manual!

Its brand new and still in plastic I have an old Clymer manual as well. I found that in the water logged trunk and I dried it out and slapped some ducktape over it.

[GalDemSuga]

you do not need a cooler thermostat. There are "kits" which have all the O-rings and gaskets needed to take off the "transmission" cover and replace the water pump.

I will search for that, thank you.

I found this one @ Z1 Enterprise

[rcmatt007]

yes that will work. be advised you will have left over O-rings. The Clymer and Haynes are so-so as long as you realize they do not tell you everything, and occasionally are wrong. But that is what NGW is for

[GalDemSuga]

yes that will work. be advised you will have left over O-rings. The Clymer and Haynes are so-so as long as you realize they do not tell you everything, and occasionally are wrong. But that is what NGW is for

I agree this Forum is priceless and it's members can't be thanked enough for their contributions .

[rcmatt007]

most of us learned all this the hard way