Revised 3-14-2006
Over the past few months I've disassembled several GL500I Honda Silverwings down to the frame, including both parts bikes and the motorcycle that I've owned since new. A bike was assembled from the collective parts especially for the upcoming trip.
Work performed:
Painted frame and swingarm.
Re-packed swingarm bearings.
Installed new steering head tapered roller bearings.
Replaced fork seals and changed fork fluid.
Replaced front brake pads. Inspected brake lines and calipers and rotors. Flushed hydraulics/replaced brake fluid.
Inspected rear brake lining and drum.
Re-packed rear suspension bushings, used Honda Moly 60 paste.
Replaced rear shock with ~20K mile unit from ebay.
Pressurized forks and rear shock with specified air pressure and checked for leaks.
Re-packed driveshaft splines, used T.S. Moly TS-65 moly grease.
Replaced rear end with ~20K mile unit from ebay. Re-packed rear end splines. Replaced o-ring in rear end. Changed rear end fluid.
Checked wheel bearings.
Installed new front and rear tires.
Installed good running ~24K mile engine from parts bike. Prior to installation, installed new parts in engine including cam chain, alternator stator, water pump mechanical seal, front and rear camshaft oil seals, shifter oil seal, water pump housing seal, fan, various o-rings.
Re-torqued head bolts and adjusted valves.
Installed new spark plugs.
Installed new oil filter.
Installed new air filter.
Checked all hoses.
Changed oil, used Honda GN4.
Changed coolant, used pre-mixed Honda silicate-free coolant.
Installed new battery.
Disassembled, cleaned, reassembled, and synchronized carburetors.
Inspected, lubed, and adjusted all control cables.
Installed new foam handlebar grips.
Installed a Lascar voltmeter to monitor electrical system performance.
Installed a trunk relocation kit similar to the one shown here.
Installed a Heat-troller for use with an electrically heated jacket liner.
Performed complete safety and operational inspection.
Took assembled bike for several test rides, about 50 miles as of 2-01-2006.
After 150 miles an Alternator Stator Failure occurred. The engine had to be pulled and the rear engine case had to be removed to replace the stator.
Took a 220 mile ride in the north Georgia mountains on 3-5-2006. No known problems at this time - the bike is running great.
Continuing checkout:
The bike will be ridden often and taken on several weekend camping outings to identify and correct any outstanding issues prior to the big trip.
Photos:
An engine cart was fabricated to make engine removal and installation easier.
Engine removal.
Water pump mechanical seal being pressed into rear engine case.
Engine with rear case removed, note the new cam chain.
A wooden frame was built to hold the bike during final disassembly and early
reassembly.
Photos of the assembled motorcycle can be found here.