84 Interstate rebuild

A forum for stories, pics and updates of your resto's. Be it a barn find, Grampas hand me down or a bike being brought back to it's former glory.If you are restoring it, show us your stuff!

Moderators: Brant, Sagebrush, Forum Moderators

Post Reply
zukzombie
Tin Member
Tin Member
Posts: 11
Joined: Sun Mar 10, 2019 2:17 am

84 Interstate rebuild

#1

Post 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?
User avatar
Track T 2411
Honored Life Member
Honored Life Member
Posts: 8482
Joined: Thu May 29, 2008 9:37 pm
My Album: http://www.ngwclub.com/gallery/v/wingmans/Track+T+2411/
Location: Prairie du Sac Wisconsin

Re: 84 Interstate rebuild

#2

Post 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...
"I have no special talent. I am only passionately curious." - Albert Einstein

"He that is good with a hammer tends to think everything is a nail" - Abraham Maslow

"If you can't take the time to do it right the first time, how are you ever going to find the time to do it over?" -Unknown

Current Rides:
'Grumpy' - '81 Standard, now fully dressed.
'Layla' - '81 Standard w/dealer installed fairing and Hondaline bags.
'Scarlett' '76 'Survivor' nekkid as a j-bird!

Under Construction:
The 'Jalopy' '78-'79 Mash-up
'Quikie' '81 gl1100I back on the lift, project with the step-son!

In The Shed:
'81 gl1100I barn find aka "Josie, the farmer's daughter." (almost comatose build)
'77 gl1000, roller parts bike.
'82 gl1100I, 'Old Crusty' titled roller parts bike (free!)
'82 gl1100I, My first 'Wing, and an expensive lesson!
New2U Bike? Read Me.
User avatar
Rat
Photo Gallery Admin
Photo Gallery Admin
Posts: 15457
Joined: Fri Oct 21, 2005 9:59 pm
My Album: https://www.ngwclub.com/gallery/v/wingmans/rat/
RIP: cookie
Location: Toronto .... Canada

Re: 84 Interstate rebuild

#3

Post by Rat »

Welcome to the 'Wingdom.

You jumped right in ....

Gord anim-cheers1
"I'd rather Ride than Shine"
‘14 KLR650 ... not a rat ... yet
‘84 GL1200i ‘R2B6' (Rat to Be 6, the last, adopted by twowings)
My Original 'RAT' was a hybrid '82 CB900/1100F
zukzombie
Tin Member
Tin Member
Posts: 11
Joined: Sun Mar 10, 2019 2:17 am

Re: 84 Interstate rebuild

#4

Post 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.
User avatar
rcmatt007
Treasurer
Treasurer
Posts: 31305
Joined: Fri Oct 21, 2005 12:48 pm
My Album: http://www.ngwclub.com/gallery/v/wingmans/rcmatt007/
Location: New River Valley, Virginia

Re: 84 Interstate rebuild

#5

Post 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?
-Rodger-
all it takes for evil to prosper is the want of a few good men to do nothing-Edmund Burke
The question is not how much time do you have, it is what you do with the time that you have Gandalf
"One of the greatest dignities of humankind is that each successive generation is invested in the welfare of each new generation." Fred Rodgers
"it takes 10,000 hours to become an expert" ancient saying
78 constantly modified/customized since 1978, BOTM June 2015 de-evolving this very moment viewtopic.php?f=30&t=65511
76 Ltd "cookies bike" ALMOST DONE
79 project, finished, FOR SALE
'86 1200 (Beth's)(FOR SALE) with motorvation sidecar (sidecar sold) , July 2017 BOTM
'17 HD Road king and 08 HD Heritage softail (Beth's) (FOR SALE). I guess you can say we have MBS
zukzombie
Tin Member
Tin Member
Posts: 11
Joined: Sun Mar 10, 2019 2:17 am

Re: 84 Interstate rebuild

#6

Post 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.
zukzombie
Tin Member
Tin Member
Posts: 11
Joined: Sun Mar 10, 2019 2:17 am

Re: 84 Interstate rebuild

#7

Post 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?
User avatar
Track T 2411
Honored Life Member
Honored Life Member
Posts: 8482
Joined: Thu May 29, 2008 9:37 pm
My Album: http://www.ngwclub.com/gallery/v/wingmans/Track+T+2411/
Location: Prairie du Sac Wisconsin

Re: 84 Interstate rebuild

#8

Post 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.
"I have no special talent. I am only passionately curious." - Albert Einstein

"He that is good with a hammer tends to think everything is a nail" - Abraham Maslow

"If you can't take the time to do it right the first time, how are you ever going to find the time to do it over?" -Unknown

Current Rides:
'Grumpy' - '81 Standard, now fully dressed.
'Layla' - '81 Standard w/dealer installed fairing and Hondaline bags.
'Scarlett' '76 'Survivor' nekkid as a j-bird!

Under Construction:
The 'Jalopy' '78-'79 Mash-up
'Quikie' '81 gl1100I back on the lift, project with the step-son!

In The Shed:
'81 gl1100I barn find aka "Josie, the farmer's daughter." (almost comatose build)
'77 gl1000, roller parts bike.
'82 gl1100I, 'Old Crusty' titled roller parts bike (free!)
'82 gl1100I, My first 'Wing, and an expensive lesson!
New2U Bike? Read Me.
zukzombie
Tin Member
Tin Member
Posts: 11
Joined: Sun Mar 10, 2019 2:17 am

Re: 84 Interstate rebuild

#9

Post by zukzombie »

Thanks Track, I'll try that.
zukzombie
Tin Member
Tin Member
Posts: 11
Joined: Sun Mar 10, 2019 2:17 am

Re: 84 Interstate rebuild

#10

Post 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.
zukzombie
Tin Member
Tin Member
Posts: 11
Joined: Sun Mar 10, 2019 2:17 am

Re: 84 Interstate rebuild

#11

Post 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.
User avatar
robin1731
Membership Admin
Membership Admin
Posts: 21724
Joined: Mon May 29, 2006 8:31 am
Location: Decatur, Indiana

Re: 84 Interstate rebuild

#12

Post by robin1731 »

I use 1/4".

.
1976 Goldwing Super Sport
1985 Honda Elite
1976 KZ900 Dragbike
1992 ZX7 Dragbike (KZ900 style motor w/NOS)
and a rotation of various purchases
Randakk approved Carb Rebuilder
zukzombie
Tin Member
Tin Member
Posts: 11
Joined: Sun Mar 10, 2019 2:17 am

Re: 84 Interstate rebuild

#13

Post by zukzombie »

1/4 is larger than the fuel line will accept. Do you guys just use the larger fuel line?
User avatar
robin1731
Membership Admin
Membership Admin
Posts: 21724
Joined: Mon May 29, 2006 8:31 am
Location: Decatur, Indiana

Re: 84 Interstate rebuild

#14

Post by robin1731 »

If you look at a parts fische the fuel line is 5.5mm.
1976 Goldwing Super Sport
1985 Honda Elite
1976 KZ900 Dragbike
1992 ZX7 Dragbike (KZ900 style motor w/NOS)
and a rotation of various purchases
Randakk approved Carb Rebuilder
zukzombie
Tin Member
Tin Member
Posts: 11
Joined: Sun Mar 10, 2019 2:17 am

Re: 84 Interstate rebuild

#15

Post 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?
Post Reply
  • Similar Topics
    Replies
    Views
    Last post

Return to “Members Restorations and Projects”