Page 1 of 2

84 Interstate rebuild

Posted: Sun May 05, 2019 8:05 pm
by zukzombie
I just inherited 2 GL1200's. One is an 84 Interstate. The other is an Aspencade. I have no idea what year it is. There is no VIN stamped on the neck. It has a replacement sticker on the neck with a Honda control number. I am working on the Interstate first. I am rebuilding the brake system right now. I have the carbs off for a rebuild too.
My first problem is that I cannot get the small piston out of the rear master cylinder or clutch master cylinder. They are frozen. Any suggestions? I have PB Blaster in the bore right now.
My second problem I have come across it that the is a calcification clogging the ports with the chrome tubes under each intake manifold. How should I go about clearing these?

Re: 84 Interstate rebuild

Posted: Sun May 05, 2019 8:30 pm
by Track T 2411
First, welcome from Wisconsin!
As for removing the pistons from the master cylinders, judicious application of heat may do the job. I've also seen (but never had to try myself) drilling a small hole into the end of the piston and inserting a drywall screw, which you can then use to pry out the piston. YMMV, of course...

Re: 84 Interstate rebuild

Posted: Sun May 05, 2019 8:35 pm
by RAT
Welcome to the 'Wingdom.

You jumped right in ....

Gord anim-cheers1

Re: 84 Interstate rebuild

Posted: Sun May 05, 2019 8:45 pm
by zukzombie
The bikes have sat garaged since 95. The interstate has 26,500 miles on it. The Aspencade has 9,400 miles. I have the gas tank out of the Interstate and I am working on getting the rust out. The bike was parked with gas in the tank. I have already gotten about 3 cups of rust cake out of the tank. New timing belts, spark plugs, oil change, cooling system flush, fuel filter and tires are also in the plans before being ridden.

Re: 84 Interstate rebuild

Posted: Mon May 06, 2019 10:45 am
by rcmatt007
out of the masters? did you remove the impossible to see and get out circlip?

BTW welcome to NGW, where abouts are you?

Re: 84 Interstate rebuild

Posted: Mon May 06, 2019 8:09 pm
by zukzombie
I have removed the circlip out of both of the master cylinders that I am working on. They were a real pain to get out. Tried soaking them overnight with penetrant oil. There was no change. They are in there solid.

Thanks for the welcome messages. I live in Socal.

Re: 84 Interstate rebuild

Posted: Fri May 10, 2019 10:44 pm
by zukzombie
I finally got the rear master cylinder and clutch master cylinder rebuilt. I ended up boiling the units in a mix of water and Simple Green for about an hour. I then used a drift to tap the inner piston free. The units are back on the bike. I just need to bleed them. It looks like I might have to find a new gas tank. The inside is clean but the supply tube in the bottom is closed up tight. I tried running a guitar string into it but that didn't work. Anyone have any ideas?

Re: 84 Interstate rebuild

Posted: Sat May 11, 2019 8:51 am
by Track T 2411
On the gas tank line, take a piece of clutch cable (or something similar) and run it down the line using a power drill to spin it. It will slowly chew its way through. Make sure you rotate the cable so that it doesn't unwind on you for the first couple of passes. You can also spray some carb cleaner into the line and let it sit to help soften up the gunk.

Re: 84 Interstate rebuild

Posted: Sat May 11, 2019 2:18 pm
by zukzombie
Thanks Track, I'll try that.

Re: 84 Interstate rebuild

Posted: Mon May 20, 2019 12:36 am
by zukzombie
What is the size of the inlet for the fuel filter on an 84 Interstate? I tried doing a search but could not find the answer. I ordered some filters online and the inlet was way too big. The vendor said they were 10mm.

Re: 84 Interstate rebuild

Posted: Mon May 20, 2019 11:14 pm
by zukzombie
Since I got no answers on the correct size for the fuel filter, what size fuel line is used? I don't have a caliper to measure the inlet on the fuel pump or petcock. They are smaller than 1/4 though.

Re: 84 Interstate rebuild

Posted: Tue May 21, 2019 5:54 am
by robin1731
I use 1/4".

.

Re: 84 Interstate rebuild

Posted: Tue May 21, 2019 8:39 pm
by zukzombie
1/4 is larger than the fuel line will accept. Do you guys just use the larger fuel line?

Re: 84 Interstate rebuild

Posted: Tue May 21, 2019 9:55 pm
by robin1731
If you look at a parts fische the fuel line is 5.5mm.

Re: 84 Interstate rebuild

Posted: Tue Aug 13, 2019 11:29 pm
by zukzombie
Ok guys. I need more help. Found that the motor is done for. Found a white crystal substance in the right cylinders. It is worse in the front cylinder. Looks like the bike had been put away with a blown head gasket. I have a second GL1200 that is an Aspencade. It has 9600 miles on it. I plan on swapping in that motor since it cannot be registered. Are there any differences between the motor in the Aspencade and the Interstate? Can the motor be pulled without removing the carbs?