Carburetor Rebuild, GL1100
Contents
1. M A a www nakedgoldWings com sy 4 Carburetor Rebui id by Roady This thread by Steve Roady Mate was posted on the Naked Goldwings Forum 30 June 2008 Click Here to read the entire original thread Roady 2008 2013 all rights reserved Revised 11 11 2013 Please read the Disclaimer on page 14 of this document This is not a reinvention of the wheel With so many excellent sources already available this is intended to fill in some gaps and touch on some details of my 81 GL1100 carburetor overhaul Mechanic in is not my trade that s graphic arts computers and documentation But I do know what a spanner is and have rebuilt a few carbs VWs and XS1100 If you re like me you can take things apart pretty easy Putting them back together is another thing Most manuals walk you through disassembly and then you get the famous Reassemble in the reverse order That always gets me in trouble because I read right to left top to bottom Backward reading has always meant trouble The focus here is going to be cleaning and reassembly For the rest I ll assume that you ll be doing the Howard Halasz efficient and straight forward procedure as supplied by Randakk You won t find that process here It would be foolish to rebuild your GL1100 carbs without using Randakk s GL1100 Master Kit Combo This brilliant kit includes Randakk s GL1100 Master Carb Overhaul Kit and Howard Halasz GL1100 Carburetor Repair Guide2. Stand the carbs up with the intakes secured Rubber furniture coasters work good just don t let the assembly slip and crash to the floor no I di nt Carburetor Rebuild GL1100 The angle you want is where the floats have just settled on the valves but are not compressing the springs inside Measure from the bottom of the float to the gasket surface It needs to be 15 5 mm along the entire length Mine were correct near the valve but about 12 at the lower as in pic end Bend the tang to adjust See the blowup inside the pic below That is the tang It s in the center of the hinge and bends without a whole lot of force Do avoid bending where the floats are attached or anywhere else fer 3 This is the v aey mw 1 EI i Tang to bend Don t bend anything else 13 You may proceed when the floats are perfect Put the new o rings on the Float Bowls tighten the screws l TPITITT Time to Bench Sync the set Previously I had recommended Alley Kat s method of bench syncing the carbs by using a wire or needle as a feeler gauge That was before Mike Nixon noted GL Carb Guru joined this board He brought to my attention that the wire needle method can cause nicking of the throttle plate which permanently ruins the plate and introduces unregulated air And you know that he s seen the guts of enough of these carbs to know what he s talking about So how to get a decent bench sync Simply l
3. clean clean Hold it up to a light and peer through to the other side to see And clean out the inside with a bit of light aluminum foil I just loves makin tools Carburetor Rebuild GL1100 Screw in and tighten the holder then the Main Jet Put the washer and screen onto the float valve holder Turn the carb right side up slide it in and then tighten Make sure that the float pin moves freely in it s hinges Clean the hinges with foil or a small file it must move smoothly Install the valve and slide in the pin Install the float Drain Screw with its new o ring Attach the Float Bowl do not install the o ring gasket You ll need to set the floats after the carbs are assembled Onward to the vacuum pistons Clean and smooth is what you want here Use lightweight foil to buff the Carb Body Ks ih Note another bad pic Airjet Cover Piston Guide and Sealing Ring should not be installed yet 10 inside of the Vacuum Chamber Then clean clean clean all the newly buffed parts Again with the brake carb parts cleaner and compressed air Install the plug with its new o ring into the slide Carburetor Rebuild GL1100 Compare the length of the springs They should be equal Put the four Vacuum assemblies together and place them upside down on the bench They should move freely and settle to darn near the same height Do NOT mix these up They are
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5. day remove big parts and then strain the little parts E Catching Tiny Parts Strainer Count to make sure they re all present amp accounted for 6 There s those tiny buggers Note Get another carb into the carb dip now Clean off the excess dip Spray with carb cleaner or brake parts cleaner or back to soap and water Again what do the directions on the carb dip say Look closely at all mating surfaces Scrape lightly to remove gasket and o ring gunk Carbs are aluminum so be careful not to scratch the surfaces with your steel tools Get the gunk out of all o ring journals g Super Light Touch Ww Boot Scratchile Repeat Do not scratch the surfaces or you re looking at leaky carbs and will need to open them up again Tough stuff will often come off with a concentrated spray from the brake parts cleaner You can get big cans of this stuff from Wally Mart for like a buck Carburetor Rebuild GL1100 Now for all the holes and channels Follow the red lines in these images as a general guide Spray compressed air parts cleaner water pic whatever it takes to clear out all of these As Randakk says Everything Affects Everything so make sure you clear all of these Plenum end Idle Mixture Pilot Screw Carburetor Rebuild GL1100 Light shining into Drain Screw Vacuum Chamber That little hole goes into the center where the slide fits Clean it Cutoff valve c
6. paired with the carbs Screw down the Airjet Cover Piston Guide This screw is another close match to the cutoff and bowl ones I didn t separate these from their plastic covers during the overhaul Install springs pistons and caps on Z2 and 4 Leave them off of 1 and 3 Carburetor Rebuild GL1100 Specials for Carb 3 If you haven t already remove the Fuel Inlet Port clean it all up and replace the two o rings You may have to remove the linkage that s blocking access There s a lock washer behind the hold down bracket This 1s not in the book Randakk pointed me to the correct section on his Tech Tips page and I had to do this after the carbs were all attached to the plenums Not fun that way It goes back together as shown here mx That was Removed The fuel inlet barb actually goes the other way round as shown below Accelerator assembly clear all of the holes in the carb a ree pee um m dt oh Bien mn E Clean out the holes in the cap much like those in the Air Cutoff covers Install the diaphragm spring and cover Don t forget the little o ring or she ll leak Put a little grease on the shaft and slide the gaiter onto the shaft Special for Carb 4 Sorry no image of this Attach the choke lever with the new cotter key Final Assembly Collect carbs 2 and 4 fuel tubes springs and o rings Put the o rings on the tubes and slide one end of each into one o
7. soak in carb cleaner for a few hours or overnight I liked the result from Yamaha Carb cleaner mixed 1 part with 2 parts water While the first is in the carb cleaner take the next apart and wash it Keep the assembly line in order so you don t mix up the parts Remove the Vacuum Chamber piston sealing ring and airjet cover piston guide the black plastic part held in by a phillips screw under the cover Toss all removed parts into the soapy wash bucket NOTE Pic is wrong your carbs are separated now PM E B 4 MTA T NR a mi b REM quide TUM Flip the carb over and remove the 3 float bowl screws I had a leak on the left 2 amp 4 side and the reason was obvious when I saw the smashed and cracking float bowl o rings But I had done several soaks over the winter to try to clean the carbs so the bowls themselves were pretty clean Carburetor Rebuild GL1100 Float Aas J q ig Unscrew the Main Jet Secure the Needle Jet Holder with a 7mm open end wrench if it wants to turn too Remove the Needle Jet Holder Turn the carb over and use a suitable soft punch mine s a 2 Ticonderoga to knock out the Needle Jet from the vacuum slide side Carburetor Rebuild GL1100 Here are the parts of the Main jet assembly Neti i Aichi dei A Nieeele ei lele Idle Jets 82 and 83 Idle Jets should now be unscrewed On 80 81s these jets are pressed in and supposedly un removable Tho
8. 23 Cable shutrmant 5 Flame a trap 2 of 15 Cable abutment 24 Cabie clamp 7 Seal 1G Choke link rod 25 Screw 79 81 GL1100 Ar chamber half i Splt pin 3 off 26 Fuel hose r 9 Suy Jv rd sni 1 E Sheek ann Carburettor Linkage TO Stay 19 Dowel 10 off 28 Spang Haynes Owners Workshop Manual p 92 79 81 GL1100 Carburettor Haynes Owners Workshop Manual p 88 Fig 3 8 Carburettor i Carburattor body Vacuum chamber J Screw 2 off 3 Seating ring 8 t aot uae E 38 Screw 3 off lug foot chamber 39 Fi 6 O ring t Drain screw 244 Main jet 32 Diaphragm cover d Peg 2 E D Needle retaining 17 Sealing washer 25 Needie jet holder 33 Diaphragm spring 40 Gaiter screw 18 Screw 3 off 26 Needie jet 34 Diaphragm air cut gt Fuel feed union 8 Piston needie 19 Float needle clip 27 Pilot screw off valve 42 Choke dust cap J Vacuum piston 20 Float needles 8 Spring 35 Diaphragm aperating 43 Accelerator pump 10 Seal 21 Needle seat 29 Washer rod erating biy 11 Float 22 Sealing washer 30 O ring 36 Spring asc ER TE 2 O ring 23 Filter screen SI Screw 2 off 37 Diaphragm cover piston guide l Turn d with your ofher hand Separate the carbs and screens from the plenum halves Keep each carb s parts separate from here on out Discard all o rings I had a special trash bucket for discarded parts just in case didn t need anything but I saved it all Work the carbs one at a time Disassemble it wash it and then
9. I ordered mine Sunday night and had it on Wednesday morning it felt like my birthday You could source your kit from the Honda dealer or through various websites but you ll be missing some valuable parts get parts you don t need jets amp needles and parts that don t fit Plus you ll no doubt pay more While you re waiting for your Randakk kit to come do my Carb Removal GL1100 procedure some cleaning planning and as much reading as you can Valuable Resources Octane s GL1000 tutorial The NGW Project Bike Carburetor rebuild If you can match half of his methods you ll do a blazingly great job on your carbs Carb Rebuild GL1100v2 Carb Tech Tips at the Randakk s Cycle Shakk website At least read GL1100 Carb Details Randakk s Carb Synchronization Procedure The official Honda Service Manual Get a printed manual it s very convenient If you want to download one the Haynes Owners Workshop Manual pictured above is available Read through pages 92 to 101 Tools Chemicals Bins and a Jig Tools Use drivers and wrenches that fit tightly and you ll ruin very few screws and bolts Treat yourself to a new quality 2 JIS screwdriver with a good handle You ll also need a 3 JIS screwdriver and likely a pair of vicegrips JIS 1s the Japanese Industrial Standard cross blade screw JIS screws have a small dot punched in the head and have a flat bottom in the hole If you can t find them locally they
10. are available all over the Internet eg Amazon m Tinana m T Lots of light and this flashlight Pencil and Paper Q tips and lots of rags and paper towels Assorted brushes Dental Pick or Xacto knife Toothpicks Homemade Extractor bent wire Drift for Main jet 2 Ticonderoga 9 Measure for Float 10 7 8 and 10 mm Open End Wrenches 11 Various Slotted and JIS screwdrivers 12 Needlenose Pliers Chemicals solvents and sprays Brake cleaner carb cleaner WD 40 PB Blaster anti seize lube strong bathroom cleaner whatever it takes to get the carbs clean Lots of clean shop rags paper towels toothbrush etc Some aluminum loving Carb Cleaner like Yamaha Carb Cleaner it mixes part to 2 parts water COND DN tn WN 2 Use gloves when you re working with these chemicals Many are quite caustic the brake and carb cleaning fluids will devour rubber parts and can easily eat your skin Tubs containers and bins Oh My You ll need 10 or 12 of various sizes Trash like coffee cans orange juice and laundry detergent bottles Plus small ones for the tiny parts The Jig is up This simple jig will hold the carb rack without denting any important parts or flattening the floats It works whether the rack is right side up or upside down That patent application better go through soon Ta i52 Compressed Air Since this is Po Boy talkin here fancy air Compie SOS are out of the question So I butte
11. d this here up agir n LE wall and iiis Viu it to the Be Lean into 1t with the shoulder and both hands are free Let s Get Down to It Randakk GL1100 Master Carb Overhaul Kit contents 1 O rings for float bowl carb to plenum intake idle mix includes tiny washer vacuum plug and float drain 2 Air cutoff kit 3 Accelerator pump kit use extra o ring in attached bag 4 Carb to plenum fuel o rings Carburetor Rebuild GL1100 5 Fuel joint pipe o rings 4 large 4 small Plus 2 large for the fuel inlet barb on carb 3 Brand new 3 plenum screws Plenum o ring Cotter keys for linkage Fuel petcock rebuild kit 10 Fuel filter The Carbs have Left the Bike Clean up the outside with large doses of carb cleaner and brake parts cleaner OoN Follow the directions in Howard s book to remove some of the linkage You don t want to take it all off unless there s a problem that needs fixing To separate the plenum halves you ll need a good well fitting 3 Phillips screwdriver If you can t move one try clamping vicegrips on the shaft Push hard on the screwdriver and turn with the grips Works every time Discard the 5 screws Watch for the little straw Carburetor Rebuild GL1100 Fig 3 4 Carburettor linkage 6 T RH front carburettor 2 RH rear carburettor 11 HT guide 2 off J LH from carburettor 12 Screw 8 off 4 LH rear carburettor 13 Throttle puiley assembly B Al chamber half fd Screw
12. f the carb bodies Note Float bowls should be on Loosen the sync lock nut and screw all the way Slip the accelerator linkage together between the two washers Make abso F in lutely sure that there is a washer above the linkage and one below Slide in the spring 12 Take a close look Spring in position Are you certain that the linkage is fitted BETWEEN the two washers Push the carbs together being careful not to bend the tubes Repeat that for carbs 1 and 3 Refer to Howard s book for this next step It s important that the Li l o ring and Bigger o ring are placed in the correct holes or again leakage Install the large carb to plenum o rings Sorry no image for 2 and 4 The two small o rings go one on each carb same side and close to each other Next time I rebuild a set of 1100 carbs wayyyy in the future I ll add a pic promise Carburetor Rebuild GL1100 Remember that straw It s time to put it in its hole Put the beautiful new plenum gasket in its journal and mate the plenum halves Oh boy New plenum screws Don t forget to include the Choke Bracket under the one by carb 3 before you tighten it down Don t ask Yummy New Stuff Assemble the linkage with the new cotter keys If you replace all of the keys you should end up with one leftover Moving right along and getting close to done Float Level Adjustment Time to set those float levels Remove the float bowls
13. ld be able to get almost an extra turn on the screws This will reduce air leaks at that connection Pilot Screw Adjustment There s a special tool required to adjust the Pilot Idle Mixture screws called a Pilot Screw Adjuster imagine that Motion Pro has them starting at 29 99 and going way up from there I rode down to the Honda dealer and pal ed up with a mechanic who let me borrow his brand spankin new never been used 125 tool I did finally order the tool from Motorcycle Superstore To adjust the screws you must first get a black marker and score through the Idle Drop procedure outlined by Honda in their manual To meet emission standards Honda developed the idle drop method and it ensures that your bike will run lean at idle Not good Puffy75 advises us to do it differently Doing it his way will get you a better idle and quicker warm ups First attach an accurate external tachometer Warm up the bike and set the idle to 950 Pick an idle mixture screw and turn it in out to achieve the highest RPM Leave it there Reset to 950 RPM Do another screw Repeat until all 4 have been set Then do a sync and you can come back and adjust the pilot screws again if you like Carburetor Rebuild GL1100 Synchronicity Everything worked out good for me with all of the bench syncing and such She started right up on the first crank and ran like a dream sort of Check out my Video in the Dark on YouTube to see the fi
14. ook into and around the outlet port of 23 carb and locate the bypass outlet It will be right along the line of the resting butterfly Note the relationship of the outlet to the edge of the butterfly Now adjust the 1 3 sync screw so that 1 s butterfly position matches 3 Flip round to the other side and adjust 72 and 74 so they match each other Then adjust the left bank s sync screw so the 2 amp 4 set match up to 3 The 2 4 sync screw is between those two carbs The left side s screw is aft of 4 carb Thanks to Mike Nixon for the pic 14 Fill the Bowls with Gas Use a syringe to fill the carbs with gas through the fuel inlet fitting Test it by rotating the throttle and watching for gas spritzing into the carbs Check that all of the choke and throttle linkage works smoothly Ready to go back on the bike Use a syringe to fill the carbs with gas through the fuel inlet fitting Test it by rotating the throttle and watching for gas spritzing into the carbs Check that all of the choke and throttle linkage works smoothly Now the famous line Reassemble in the reverse order in the Carb Removal GL1100 procedure Also Howard s book has some excellent advice on the installation procedure Here s a new 26 Sept 09 tip on tightening the clamps on the rubber intake runners When everything is buttoned up and you ve got the bike running and well warmed up re tighten the ring clamps With the rubber warm you shou
15. over has two channels to clean When you are more than satisfied with your cleanliness and starting to question if anal retentive is hyphenated or just two words Take stock of the parts and arrange them for reassembly Find all the necessary o rings and new washers 8 Do not mix up the float bowl screws accelerator pump screws and air cutoff screws They are the same size and thread but different lengths Use a too long screw and you ll be searching for a new carb body Loeil cre IPS ete fer w Air Coren Cay Ge Wek Feet 10 uius ACCH cid e Paige Gla aS Assemble the Air Cutoff Valve Line up the diaphragm big end of spring goes down small o ring in place top mates with knob in cover tighten the screws Put the spring tiny washer and o ring in separate attached baggie toss other one onto the Pilot Screw Turn the carb right side up vacuum chamber side up and screw it in Go in just until you feel it touch bottom do NOT over tighten Then back it off 1 1 4 turns 80 81 3 turns for 82 83 Idle Mixture Pilot Screw E Cx Qu pam F AES E wy Priny Spring Vasher b T i EM ld tomy Needle Jet goes in next open end looks like a tube goes toward the vacuum chamber convex end toward float bowl Drop it in and line it up Carburetor Rebuild GL1100 Then the Needle Jet Holder Double check the twelve little holes to make sure they are clean
16. rst minutes of the startup As for vacuum sync well I spent quite a bit of time making a homemade manometer Only spent about 10 but it just didn t work for me I think my tubing was too small When I started the bike all of the Marvel Mystery Oil got drawn out of the tubes and into the intakes That sucks I ended up getting in touch with Ritalz through the NGW Club who let me come over and use his set of mercury sticks Definitely the way to go For more info on how to sync em read Randakk s Carb Synchronization Procedure There you go All done Now get out there and RIDE Roady 30 June 2008 With help from Disclaimer Members of NGWClub com NGW forums strive to help fellow members and guests We give advice as friends and share technical tips with each other Any mechanical tasks that you take upon yourself as a result of instructions in the forums or this document is done so at your own risk You alone will be responsible for ANY undertakings and or consequences you may suffer as a result of misguidance IF YOU AIN T SURE DON T DO IT When you decide to tackle a project ensure that you have the know how to carry out these repairs and modifications NGW members and administrators will not be held responsible for any errors or results encountered Intellectual Property Notice Feel free to link to this material However the content published here is the property of the author and is protected under United
17. ugh I haven t done it it appears that they can be removed with just a bit of extra effort See Evo A Vulpes Video to find out how it s done I ll be trying this method next time To get out the Pilot screw s parts you ll need to make a small hook tool Remove the screw and spring There is a tiny washer and an o ring down in there DERE bia P i 4 4 eT fal Extractor TT 8 a This is the pile of small parts you ll pull from the carb Again discard all of the o rings There is a replacement tiny washer for the Pilot and a Float valve washer so toss those too Wo per 2 d m T OM aa cem M al 3 ly i 7 m pe 7 ee m x r 5 r t m 3 od i a T t pm zd f 4 j ia D r d E Li LI d i Now all of this goes into a soapy bath Use a strong bathroom cleaner of some kind my choice BAM put on your rubber gloves and scrub everything with a brush not a wire brush Rinse and repeat until all greasy stuff is removed and you re getting happy Then everything goes into the carb dip for a nice long soak Follow the instructions on the bottle Do not use the stuff from the auto store get either Honda or Yamaha carb dip and follow those directions I soaked each overnight Count the little parts that you put in to soak ms a i i H amp i k 5 amp C i J i Y LI r Note Put the next carb s parts into the soapy bath Next
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