Big Bertha, The bike Honda never built
Posted: Fri Nov 12, 2021 9:28 am
Several years ago a friend who knew I worked on old Hondas offered me a 96 GL1500 that had been sitting in his garage long enough his wife was complaining. It had belonged to his father-in-law and had been partially dis-assembled and sitting in his garage for some time as well. Anyway I helped him smooth relations with his wife and haul it away. No one remembered what the original problem was or where all the parts were. The brakes were both frozen and the clutch would not release. A winch and two healthy old-timers managed to scoot it onto the trailer. Then it sat at my place. Over the last three years I have occasionally messed with it a bit. First confirming the engine would turn over, then doing a compression check (all good) and spark at the plugs. Then sitting another year. Gradually assorted components were removed in an effort to get back to the basic motorcycle.
About a year ago I managed to get the carbs out and cleaned. If you are not familiar with this bike the carbs are wrapped inside the frame and covered with spaghetti. Something like 12 vacuum lines, three drain hoses, two water lines to the radiator,an air duct from the left manifold to the air box, two drain lines from the air box, and probably more that I am forgetting. Since I had removed the fairing and assorted tupperware with associated check valves and relays, I just plugged the vacuum lines with quetips. I installed a cheap after market fuel pump and a new battery. Maybe spark plugs, can't remember for sure.
Anyway, to my surprise it started up and sounded great. The clutch was still stuck and the brakes frozen but it was running. There was hope.
We migrated north for the summer so it sat several more months. Upon return, it would not start, the fuel pump quit working and the carbs had to be pulled again. The idle jets on both carbs were clogged and had to be cleaned. This time I bought some vacuum caps at O'Reileys an did away with all the vacuum lines. Left off the cooling lines from the radiator and didn't bother with the cruise control hardware. Another cheap fuel pump was installed. ($40 new vs. 350+ used OEM).
It started. Meanwhile the brakes were redone, the clutch cured itself and the wiring was sorted and modified. A test ride of forty or so miles confirmed it was going to be OK.
About a year ago I managed to get the carbs out and cleaned. If you are not familiar with this bike the carbs are wrapped inside the frame and covered with spaghetti. Something like 12 vacuum lines, three drain hoses, two water lines to the radiator,an air duct from the left manifold to the air box, two drain lines from the air box, and probably more that I am forgetting. Since I had removed the fairing and assorted tupperware with associated check valves and relays, I just plugged the vacuum lines with quetips. I installed a cheap after market fuel pump and a new battery. Maybe spark plugs, can't remember for sure.
Anyway, to my surprise it started up and sounded great. The clutch was still stuck and the brakes frozen but it was running. There was hope.
We migrated north for the summer so it sat several more months. Upon return, it would not start, the fuel pump quit working and the carbs had to be pulled again. The idle jets on both carbs were clogged and had to be cleaned. This time I bought some vacuum caps at O'Reileys an did away with all the vacuum lines. Left off the cooling lines from the radiator and didn't bother with the cruise control hardware. Another cheap fuel pump was installed. ($40 new vs. 350+ used OEM).
It started. Meanwhile the brakes were redone, the clutch cured itself and the wiring was sorted and modified. A test ride of forty or so miles confirmed it was going to be OK.
