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Complete GL1800 Maintenance video now available at
http://www.angelridevideos.com
New antifreeze, distilled water, and clean drain pan at the ready
New antifreeze, distilled water, and clean drain pan at the ready
Remove the allen screw on both sides of the lower cowl
Remove the allen screw on both sides of the lower cowl
Remove the allen screw on the upper portion of the lower cowl, both sides
Remove the allen screw on the upper portion of the lower cowl, both sides
Pull out both plastic pop rivets
Pull out both plastic pop rivets
Pop rivet pulled free
Pop rivet pulled free
Remove the lower allen screws, on both sides
Remove the lower allen screws, on both sides
Pull the black plastic portion forward to allow the lower cowl to slip out
Pull the black plastic portion forward to allow the lower cowl to slip out
Carefully pull the tab out from under the fairng side panel. The plastic will give enough to allow you to flew it some
Carefully pull the tab out from under the fairng side panel. The plastic will give enough to allow you to flew it some
By grasping the side of the fairing side panel, you can pull it out just enough to free the tab for the lower cowl
By grasping the side of the fairing side panel, you can pull it out just enough to free the tab for the lower cowl
Here you can see the lower cowl pulled free from the black plastic upper cover
Here you can see the lower cowl pulled free from the black plastic upper cover
Now you need to remove the right fairing pocket.
Now you need to remove the right fairing pocket.
Disconnect the lock cable
Disconnect the lock cable
Now you can access the radiator cap
Now you can access the radiator cap
Take the cap off so the fluid can drain
Take the cap off so the fluid can drain
Here is the drain plug.  It is a 8mm bolt inside the round port.
Here is the drain plug. It is a 8mm bolt inside the round port.
Simply unbolt it with a 8mm socket
Simply unbolt it with a 8mm socket
And out comes the fluid
And out comes the fluid
It may take as much as 15 minutes to fully drain, as it trickles out pretty slow.
It may take as much as 15 minutes to fully drain, as it trickles out pretty slow.
Once you have it all out, put the bike on the side stand and you should be able to get some more.
Once you have it all out, put the bike on the side stand and you should be able to get some more.
Here is a look at the bolt that hold the overflow reservoir in place
Here is a look at the bolt that hold the overflow reservoir in place
Remove the bolt.
Remove the bolt.
And pull down and to the right on the reservoir to remove
And pull down and to the right on the reservoir to remove
Disconnect the two hoses on the top of the reservoir
Disconnect the two hoses on the top of the reservoir
Here is the grimy reservoir after it is free. Drain, clean, and refill it before you reinstall it.
Here is the grimy reservoir after it is free. Drain, clean, and refill it before you reinstall it.
Here is a sheet of alluminum I bought at Lowes for $5 to make a shield out of for the reservoir bottom.
Here is a sheet of alluminum I bought at Lowes for $5 to make a shield out of for the reservoir bottom.
Size and cut the sheild to fit
Size and cut the sheild to fit
I bent it so that it would hold onto the reservoir
I bent it so that it would hold onto the reservoir
From the side, you can see the sheild bent around the reservoir.
From the side, you can see the sheild bent around the reservoir.
Here is a look at the bottom
Here is a look at the bottom
Sheild installed
Sheild installed
And refilled with new coolant
And refilled with new coolant
I used a bit of safety wire to hold the fron edge of the sheild in place. The wire runs up around the top of the reservoir
I used a bit of safety wire to hold the fron edge of the sheild in place. The wire runs up around the top of the reservoir
Here is my foolproof way of mixing antifreeze. Use a graduated flask and fill to a set point (500 cc's is used here)
Here is my foolproof way of mixing antifreeze. Use a graduated flask and fill to a set point (500 cc's is used here)
Now pour that in a clean container.
Now pour that in a clean container.
Fill the flask back to the same point with distilled water.
Fill the flask back to the same point with distilled water.
And pour that into the container.  Keep repeating until the container is nearly full.
And pour that into the container. Keep repeating until the container is nearly full.
I also added 3.5 ounces of Water Wetter to the system to help cooling. This is purely optional, but I like this stuff.
I also added 3.5 ounces of Water Wetter to the system to help cooling. This is purely optional, but I like this stuff.
Now just fill the system. Pour slowly, as it won't accept the fluid very fast. Notice the new fluid color matches my bike :^)
Now just fill the system. Pour slowly, as it won't accept the fluid very fast. Notice the new fluid color matches my bike :^)
Once you have it full, run the engine and snap the throttle to burp out any trapped air. Then top off the system.
Once you have it full, run the engine and snap the throttle to burp out any trapped air. Then top off the system.
The Great Pumpkin Rides Again!
The Great Pumpkin Rides Again!
DCP_1086.JPG
DCP_1086.JPG
DCP_1088.JPG
DCP_1088.JPG
Field repair of coolant overflow tank using JB Weld
Field repair of coolant overflow tank using JB Weld
100_1488.jpg
100_1488.jpg
Leak 003.jpg
Leak 003.jpg