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The NGW Project Bike. Carburetor rebuild

Posted: Tue Jun 27, 2006 3:00 pm
by octane
Just an appetizer:

Carbs have been taken apart.
Pics to follow later


I couldn't find the original picture for this so I put this one in it's place! WF

GoldWing Carbs.jpg sure you wonna' go there?

Posted: Tue Jun 27, 2006 3:50 pm
by thedutchman1975
uhhhhhhhhhhh i would be afraid to. But its a nice puzzle you have there. If i would do it i probably have spare parts left over.... You know the ones that are thrown in the corner in the "I do not need these parts pile" lol

Posted: Thu Jul 27, 2006 2:27 pm
by bandido
Hi Octane,
I've done the same in my "little twin" Kawa, but I know this was just 1/2 of the work... ;) For now, the carbs on my GL works extremely soft, so I expect no to dissasembly them for a loooong time..

Posted: Thu Jul 27, 2006 2:51 pm
by mmstingray
Off in the distance, I can hear Randakk saying "one at a time! One at a time!" ;)

Posted: Thu Jul 27, 2006 4:22 pm
by octane
mmstingray wrote:Off in the distance, I can hear Randakk saying "one at a time! One at a time!" ;) ?....I thought he ment one set at the time.-)

Posted: Thu Jul 27, 2006 4:24 pm
by octane
...reminds me; now that the picture gallery is up and running;
I gotta get them photos posted.

Posted: Wed Aug 02, 2006 5:16 am
by mtbwana
Actually, it looks like you have impeccable "shop practices". I like the corrugated trays and the little plastic bins.

Now just don't trip and turn over the workbench. :shock: OR, my personal favorite, leave the project for a week, and then have to struggle to remember all the sequence in reverse.

Posted: Wed Aug 02, 2006 6:19 am
by bandido
Hi, after a look to your carbs album, I've decided to rebuild mines when I'm getting older or in pension!! It's such a lot of work but must be funny and you must feel proud of yourself if all works fine after that mess :-D
BTW, thanks for teaching us...

Posted: Fri Aug 11, 2006 9:04 am
by pasvorto
Will these apply to the carbs on an 80 GL1100?

Posted: Mon Aug 14, 2006 7:37 am
by octane
pasvorto wrote:Will these apply to the carbs on an 80 GL1100?
If you mean whether this procedure will apply to the later carbs,
then I have to say that I don't really know about 1100 carbs, except
that they have an acceleration pump and some other differences
but I do think that you can use this thread as a guideline and then you MUST check the 1100 manual for differences.

Posted: Mon Aug 14, 2006 7:47 am
by octane
Hi folks
Sorry to post these pics so late after promising to post them!
Most of them have been on my´PC for quite some time.
Well, a vacation got in the way and then the picture gallery function
of the Forum went south, and then work got in the way and blah blah..

these are 755 carbs.

You're a fool if you don't read Randakks website before diving into a carb rebuild.

This rebuild is based on his
GL1000 Master Carb Overhaul Kit

OK here we go:

First: detach the carbs from the bike.
I'm not going into that here, as it is just a matter of following your
manual. One thing though; I do believe they fail to mention that
removing the air cut valve assembly, make the process a lot easier.

Her they are


'normal' amount of filth and dirt and what have you

Same thing at the back (and a sneak preview of the intestines)


generally a lot of signs of neglect and heavy handed use of silicone liquid gasket or whatever it is


more silicone AND epoxy glue(!). What is going on here?


Posted: Mon Aug 14, 2006 7:53 am
by octane, inside


obviously one or more carbs have been leaking for a very long time:

witch is confirmed by the build up on the engine block


Time to dismantle this thing.
(At that point I had the vacuum chambers off. No need to do that)

Remove the linkages (or rather; as little as possible of it)
to prepare for splitting the plenum/air chamber


Posted: Mon Aug 14, 2006 8:00 am
by octane
through out the process;
take a LOT of pictures.
You will NOT remember what this looked like
next Sunday when you get around to do the assembly of the bugger.-)


try keeping the parts in 'batches'.

..theses are some of the screws that hold together the two haves of the plenum/air chamber

mine took a LOT of struggling to get off

but eventually the gave up the fight against my immense amount of raw muscle power....ho ho

Posted: Mon Aug 14, 2006 8:27 am
by octane
...carefull you don't loose these litttle dowels?


..remove the 4 slow air hoses (between carbs and plenum)
from plenum
and remove bolts inside plenum that attaches the carbs.


carefully remove the two-carb assembly
(you have NOT removed the crome thingie that holds together the two crbs)

Posted: Mon Aug 14, 2006 8:40 am
by octane
...careful, you don't want to loose this little link
that the two carbs.
(it will stay put, but if you go into further dismantling
it's easily lost)

these (two for each carb) are loose.
(you'll not find those on the very earliest GL1000)

remove vacuum chamber and pistons

That is to say; don't split them up into individual carbs.
keep them together two and two.

For various reasons I'm going all the way in this thread.
You don't need to!
...and PHEW it can be a 'bit' confusing if you haven't done it before:
I counted 472 (fourhundredseventytwo) parts here and then everything became a tad blurry.-)
Image not hosted on NGW WF

Now's the time to make a system so you keep things separated and
in 'sets'.

As a minimum for each carb;
Carb body/vacuum chambers/pistons are to be kept as an assembly

I scratch numbers (1 for carb 1 parts and so on) into all the above mentioned parts

Remove needles from pistons.
There's a screw down there: