Fitting new GL1500 Mufflers Installation Manual

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Filed Under (Honda) by admin on 08-04-2011

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The stock mufflers on the GL1500 Goldwing tend to rust after a few years. It doesn’t really matter how much you clean them because the design means that they tend to collect condensation which turns into water, then the dreaded tinworm rots them from the inside out. There is a drain hole in each muffler (near the front) to allow some water out, but the hole is really in the wrong place as the mufflers almost always rot at the ends near where the tailpipe is welded on. Replacing mufflers on the GL1500 Goldwing is easy enough and you really don’t need a tutorial for the task. But I did have a camera handy on the day I did the job so you may as well have the benefit of the images. This is a common sight on a GL1500 Goldwing. The mufflers rot from the inside out and eventually the ends just blow off. Believe it or not, these mufflers are on a 1997 GL1500SE with only 7,700 miles that was always stored in a dry garage! I replaced them in April 2004 and they had been almost as bad as this since 2002, but the owner of the Goldwing wasn’t using it much so he didn’t bother replacing them until 2004

POLINI X1 GENERAL INFORMATION AND SPECIFICATIONS

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Filed Under (Polini) by admin on 02-12-2010

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Air cleaner – Clean and reoil daily or after each moto to prevent motor failure and reduced performance. Transmission oil – change after every race, or at end of riding day. Chain – check tension and lubricate before every ride, adjust or replace as needed. Reoil after riding in damp conditions. Clutch – disassemble and clean clutch assembly frequently, every 2-3 races at least. Inspect kickstarter gears at this time. Ignition cover – remove cover and wipe dry after each ride or after washing bike to remove condensation. Piston rings – replace as often as every 3-5 races with expert rider, less often with less aggressive riders. Piston, pin, rod bearing & circlips – replace as often as every 8-10 races with expert rider, less often with less aggressive riders. Coolant – change yearly, make sure there is at least a 50/50 mixture of antifreeze if freezing temperatures are possible. Steering bearings – Check daily for looseness or play. Adjust and regrease as needed. Swingarm – Check often for looseness. Regrease several times a year. Replace bushings if any play is evident. Sprockets – check for worn or curved teeth each time chain is adjusted. Chain roller& wear pads – check roller for free rotation when checking chain. Make sure roller is not bent or damaged. Check chain wear strips on swingarm and chain guide frequently. Replace as needed to prevent chain from damaging motorcycle. Spokes – Check after each race or after each day of riding for looseness or damage. Wheels & tires – check wheels after each race for dents, cracks or other damage. Check tires for cuts, damage or wear. Check tire pressure daily and adjust for riding conditions. Shock – Check shaft area daily for signs of oil leakage or damage. Check swingarm and shock bushings for looseness. Forks – Check forks daily for leaking oil or damage to tubes. Make sure forks are not twisted check for smooth operation. Spark plug – check sparkplug color and condition after each race or end of riding day. Adjust jetting to keep plug from fouling or overheating. Silencer – If bike seems to be getting louder, replace packing and decarbonize inner tube. Expansion pipe – check daily for large dents, damage or leakage. Remove carbon from headpipe when pipe is removed. Have large dents fixed, or any dents within 8″ of the cylinder. Replace o-rings on pipe as needed to maintain a good seal. Footpegs – check daily for proper operation, pegs should spring back into place. Make sure pegs are not bent or overly dull. Handlebars – check bars after any crash for bending. Look for cracks near bar clamps. Replace bars that have been straightened more than 2 or three times, or if bar is badly bent. Aweakened bar can snap suddenly causing injury to rider. Throttle – check throttle for proper operation each time before bike is started. Remove and clean inside of grip and bar as needed. Grips – check grips daily for wear or looseness. Replace as needed. Use grip glue & safety wire to help hold grips in position. Calipers & pads – check pad wear and caliper function daily or after each race. Replace pads and clean calipers as needed. Brake lever – check lever daily for damage or wear. Make sure lever is at proper angle for both seated and standing positions. Leave lever clamp loose enough to allow clamp to rotate during crash rather than breaking lever. Check and adjust freeplay as needed. Brake pedal – Check pedal daily for damage and proper freeplay. Adjust rear caliper as needed. Reeds – Remove and inspect reed block during every ring change. Check reeds for signs of wear, fraying and cracking. Make sure reeds sit flat and seal well. Replace at any sign of wear or damage or at least once a year, more often for expert riders. Nuts & bolts – Check all nuts and bolts regularly. Make sure to check engine mounting bolts and swingarm bolt frequently

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