Ughh!
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HONDA GL1000 1975/6 Called Merlin.
- Thread starter Adamc
- Start date
Funny that. Manuals seem to have useful information............Funny that we forget they do till they are needed.
Adam you have done an admirable job with those carbs. Obviously someone worked on those carbs before and it appears got in quite a bit of a hurry. Very nice job!
Thanks for the kind words. It was a testing job to do, but so far quite satisfiying getting them back together.
Just need to see if they work now.
OIL DEM CABLES!
Along with the carb rebuild I though it prudent to replace all the control cables.
Some of the exisiting ones are quite worn / frayed or just stiff. More money to the coffers of David Silver Spares!
Clutch / 2 x Throttle and a choke cables came to £107.49
Two throttle cables shown
Anyhoo before installation I like to lube the cables, even if they have PTFE liners.
Some people try and squirt oil down the actual cable housing directly into the hole; and waste a lot of oil.
Best to dribble oil onto the wire itself and let it seep into the housing. An occasional push / pull on the cable draws the oil down further.
I attack the job in this way from both ends.; Its much quicker than using the 'gravity' method.
Onwards and upwards,
Ads.
Along with the carb rebuild I though it prudent to replace all the control cables.
Some of the exisiting ones are quite worn / frayed or just stiff. More money to the coffers of David Silver Spares!
Clutch / 2 x Throttle and a choke cables came to £107.49
Two throttle cables shown
Anyhoo before installation I like to lube the cables, even if they have PTFE liners.
Some people try and squirt oil down the actual cable housing directly into the hole; and waste a lot of oil.
Best to dribble oil onto the wire itself and let it seep into the housing. An occasional push / pull on the cable draws the oil down further.
I attack the job in this way from both ends.; Its much quicker than using the 'gravity' method.
Onwards and upwards,
Ads.
Nice Adam. But wow expensive.
Not looking forward to that myself, empty coffers.
I always hung my in a baggie with oil in it and a rubber band wrapped around it to seal.
Clip it to the wall and let it do it's thing. Works well.
Not looking forward to that myself, empty coffers.
I always hung my in a baggie with oil in it and a rubber band wrapped around it to seal.
Clip it to the wall and let it do it's thing. Works well.
Yep, I used to use your method I call the 'gravity' method.Nice Adam. But wow expensive.
Not looking forward to that myself, empty coffers.
I always hung my in a baggie with oil in it and a rubber band wrapped around it to seal.
Clip it to the wall and let it do it's thing. Works well.
But my way is far quicker with less oil wastage.
Those cables I bought are high quality after market, not even genuine Honda, God knows what they cost!
MERLIN GETS ITS CARBS BACK.
Time for Merlin to get its fuel system operational. All air and fuel plumbing is put back in place.
Throttle cables and choke cable are checked for adjustment. I crank the engine with the fuel supply line disconected on the output side of the mechanical pump; fuel flows so good to go. link up to carb inlet. Several 10sec cranks to fill the four carbs and eventually the bike fires; but will not hold an idle. Try again and now its difficult to start and dies instantly; Bugger!
I can smell petrol again and look down into the plenum as the air box and filter are not yet reinstalled. I can see petrol leaking into the plenum with a stream of small air bubbles coming up from the joint. The plenum has a vertical split with a rubber seal that seals the two portions. Fuel chambers run across this join into the other half to feed carbs on that side.
It seems the seal has failed, and the carbs have to come off again. This was the only seal I could not find avaiable new anywhere. I will have to look again for one or devise another soloution to cover this. Anyhow I removed the carb assembly in less than 10 minutes this time.
Time for Merlin to get its fuel system operational. All air and fuel plumbing is put back in place.
Throttle cables and choke cable are checked for adjustment. I crank the engine with the fuel supply line disconected on the output side of the mechanical pump; fuel flows so good to go. link up to carb inlet. Several 10sec cranks to fill the four carbs and eventually the bike fires; but will not hold an idle. Try again and now its difficult to start and dies instantly; Bugger!
I can smell petrol again and look down into the plenum as the air box and filter are not yet reinstalled. I can see petrol leaking into the plenum with a stream of small air bubbles coming up from the joint. The plenum has a vertical split with a rubber seal that seals the two portions. Fuel chambers run across this join into the other half to feed carbs on that side.
It seems the seal has failed, and the carbs have to come off again. This was the only seal I could not find avaiable new anywhere. I will have to look again for one or devise another soloution to cover this. Anyhow I removed the carb assembly in less than 10 minutes this time.
I see a single carb conversion kit in your future.
A fair shout but I would like to keep this ride as original as possible.
A few years back I went to check out a CB that had been under a tarp for years. Next to it was a GL much like yours but in much more need of restoration. I called a buddy that was versed in Honda’s and asked him what h thought as I knew I could pick it up for cheap. His reply was those bikes can get expensive…
PLENUM SEAL:
Ok a search for the origonal part number turned up a few repo seals Ranging from £12.00 to £70.00, for a thin bit of rubber spaghetti!!
The only genuine OEM ones are in America at around $30.00 plus $40 buck shipping (plus import tax and VAT in UK). SO Ive ordered one from David Silver Spares UK £35.00 + VAT £42.00 total. Its probably a repo but from a reputable dealer so I hope its OK.
Ok a search for the origonal part number turned up a few repo seals Ranging from £12.00 to £70.00, for a thin bit of rubber spaghetti!!
The only genuine OEM ones are in America at around $30.00 plus $40 buck shipping (plus import tax and VAT in UK). SO Ive ordered one from David Silver Spares UK £35.00 + VAT £42.00 total. Its probably a repo but from a reputable dealer so I hope its OK.
Last edited:
Wordman
XS650 Addict
jaybar6
XS650 Addict
Hey, Adamc: Whats happening with that wizard, Merlin?
Hi @jaybar6
New seal just arrived today for the plenum.
I will start dismanteling the carbs again tomorrow at work (Owner is away
)......I cant belive the whole assembly has to be pulled apart to install this bit of rubber!
I have also removed the ABS system from The Brat (R1200GS); need to bleed the conventional system it has now and rebody the tupperware.
Then another look into the intermitent heavy misfire on Taffy too.
Updates to follow soon.
Ads.
jaybar6
XS650 Addict
Those gold wings are more complected than I original thought!Hi @jaybar6
New seal just arrived today for the plenum.
I will start dismanteling the carbs again tomorrow at work (Owner is away
I cant belive the whole assembly has to be pulled apart to install this bit of rubber!
I have also removed the ABS system from The Brat (R1200GS); need to bleed the conventional system it has now and rebody the tupperware.
Then another look into the intermitent heavy misfire on Taffy too.
Updates to follow soon.
Ads.
And the bmw' s - do they all have this ABS fault with the flashing light or is youtube just showing me many videos on the algorithm?
Now Taffy is a mystery, you seem to have attended all aspects of a new build and yet...
jaybar6
XS650 Addict
I can sympathize with you it is very frustrating when there is fault on the bike.Correct on all three counts.
Very frustrating bike season for me I can tell you.
smittyjl3000
XS650 New Member
I had the bagger version of this classic which I was in the middle of converting to what you have when I donated her to charity. Worst discission of my life. I envy you. The one I had was a great bike and I miss her dearly. Fix her up and take good care of her and she will take good care of you.
Welcome aboard, @smittyjl3000. Why not take the time to introduce yourself? Bikes you own/used to own/hope to own? Photos? Cheers, Raymond
