Max Metal Custom Motorcycles

The sub-title is “One Motorcycle’s Story.”

I am writing this post because a lot of ‘60, ‘70 ‘and ‘80 motorcycles are being pulled out of retirement in response to gas prices.  The problems with this Goldwing are typical when trying to breath new life into an old bike.  This story is true.  Names have been changed to protect the innocent.

This is the story of an ‘82 Goldwing.  It appeared to be in basic reasonable condition but had not been ridden in about 10 years.  I was asked to just put on new tires, clean the carbs, check the brakes and generally make it safe to ride.  It sounded reasonably simple.

So, I started.

Let’s see if it will turn over, fire and maybe even run.  Add a splash of gas, check the oil, turn the key, hit the switch and …nothing.  Charge the battery.  The battery is shot.  What is that wet spot I see collecting on top of the engine.  It looks strangely like gas.  The bottom of that gas tank doesn’t look too good.  Oh well, I will add it on the list of things to check.  It is not leaking too bad for right now.

A new battery is ordered and installed.  New spark plugs are installed.  There is still gas in the tank.  Turn the key and hit the switch.  The engine turns once…twice..what is that smell?  Where is that smoke coming from?  Why did the engine quit turning over.  The starter fried.  This is becoming more that I bargained for.  Oh well.  Let’s get the starter replaced and go on.

The new starter arrives.  Remove the exhaust (man, that exhaust pipe looks rotten), Loosen the engine and slide it to the side.  Remove the old starter without losing anything inside the engine case.  Install the new starter (four hours of frustration trying to get the starter drive chain and gear splines aligned with the splines on the starter shaft).

While the engine is loose, remove carbs and install the rebuild kits which took two days to locate and another five for delivery.  Chip and soak the varnish out of the carb  bowls, and every little jet and passage.  Two days later, reassemble and install the carbs.  Check fuel flow to the carbs before connecting the new fuel line.  No flow.

The tank has gas.  No gas coming out.  Remove fuel valve from side of tank under seat.  Full of gunk.  Clean valve and run a piece of stiff wire into the tank passage.  It gets blocked. 

Oh well, let’s remove the tank to clean it.  It needs to be fixed anyway.  I sure would like to start this thing to see if runs.

Remove rear tire, fender, swingarm, and everything else in the way.  Slide the tank out from under the seat area toward the rear of the bike.  Those brake pads are shot.  What is that white powdery stuff coming out from around the caliper piston?  I wonder if the front brakes are the same?  Yup!! Just like the back brakes.  AND THE CALIPERS ARE FROZEN!! AND LOOK AT THAT RUBBER BRAKE LINE.  IT HAS SOME MAJOR CRACKING GOING ON.  Man… I hope this thing runs!!

I empty the gas and look in the tank to see the condition.  What a bucket of rust.  Cleaning and using tank liner is out of the question.  Inside the tank are two tubes for the main and reserve settings and both have inaccessible screens on the ends.  Tank liner would plug them up tight.  The bottom is thin with lots of rust pinholes, so something has to be done.  I price a new tank.  $1300 but not available.  This is a problem. 

Only one choice.  Clean the tank and break out the solder.  The tank is cleaned in and out with a strong degreaser, and the pickup tubes are rodded out to make sure they are open.  The tank is allowed to air for several days.  A large area is buffed and coated with solder.

Man, I sure hope this bike runs.

I cannot get the old calipers apart.  New calipers are no longer available.  After two days of looking, I find a source for reconditioned brake calipers and get them on order.  I will see them in about two weeks.  I find and order master cylinder rebuild kits. 

I install the fuel tank and reassemble the rear of the bike using various much needed new parts where required.

I put fuel in the tank.  Fuel is finally coming out.  But it is not getting to the carbs.  The fuel pump has died.  Replace the fuel pump.

I still hope this thing runs.

Finally, the carbs are full of gas, the battery is good, the starter works, the oil is fresh, the timing belts are new.  Now, let’s see if this starts.  Turn the key, hit the switch…… the engine turns and fires.  Let it warm up and then shut it off.

Adjust the engine valves.

Start the engine and balance the carbs.

Install reconditioned calipers with new brake pads.

Rebuild the master cylinders.

Install new wheel bearings and seals.

Put on new tires.

There was a good test ride.

After it was all done, parts cost for this simple request was about $2000 and full labor time would have been about $3000.

This is what was required to just “put on new tires, clean the carbs, check the brakes and generally make it safe to ride”.  Once into the job, there was no stopping until it came out the other side.