Service

Service

RAY NIERLICH

ADDING COOLANT TO A DR-Z

Q: I own a 2005 Suzuki DR-Z400SM. How do I top up the coolant overflow bottle?

JARRAD ACIUS BERMACUI, NEW SOUTH WALES, AUSTRALIA

A: I like to see just a splash of coolant in the overflow bottle when cold. Since Suzuki was kind enough to place the bottle on your bike in a most inaccessible spot, above the swingarm pivot, topping it off requires some creativity. You could pop the hose off and fill with a syringe. How safe and boring. I cheat by using the cooling system pressure to fill the bottle. It sounds complicated, but it isn’t.

Make sure your radiator is full when cold. Check the bleed screw opposite the radiator cap to be sure all the air is out. Warm up the bike just until you see some coolant forced into the overflow bottle by expansion. Warm, not hot!

Turn the bike off. Slowly and carefully (wear gloves and goggles) twist the radiator cap, releasing the pressure. Leave the cap loose until cool. Top up your radiator once more and refit the radiator cap.

A GOLD WING’S COMPLICATED BINDERS

I bought a used 2008 Honda Gold Wing GL1800 (non ABS)

with 43,000 miles. The foot brake was a little spongy. I read the service manual and bled the brakes. I replaced the fluid with fresh DOT 4.1 proceeded to bleed the brakes and was at first unable to bleed the rear brake caliper. After much persistence, what looked like a “mucus” plug came out. After that, the brakes appeared to be much more responsive.

While bleeding the brakes I noticed that someone had separated the antidive plunger with washers, causing it not to contact as soon as it was designed. I removed the washers and replaced the two bolts with new ones. While braking at speeds below 20 mph, the foot brake chatters. If I brake hard, the brakes work flawlessly. Could the clog of old fluid have anything to do with my problem, or is there a defect in the system that caused someone to put the washers in the anti-dive plunger to

stop the chattering? I have received a recall for the brake system that says the rear brake could hang up and overheat. The letter says there is not a fix but to keep watch over the brakes to see if they are overheating. Thanks for any advice you can provide.

TERRY TURCEAU CYCLEWORLD.COM

A: I problems. doubt the It “clog” certainly caused is a your sign that the system hasn’t had the fluid changed every two years, as recommended. Deferred maintenance is fool’s economy. The Gold Wing 1800 has a clever, but quite complex, braking system: no less than three master cylinders, three calipers (each with three pistons), an anti-dive valve, a delay valve, and a proportional control valve (PCV). Whew!

I have to assume the previous owner shimmed the anti-dive valve to correct some perceived fault, most likely sticking on and giving a harsh ride. I don’t see any valid reason for doing this and would put it back to stock, as you have done. When in doubt, always put modifications back to stock first.

This anti-dive valve, as well as the rest of your system, probably could stand a rebuild. The pulsation is almost certainly from a warped rotor, as on any other bike with disc brakes. Not like any other bike though, the foot pedal works one piston in the rear caliper, one in the right front caliper, and two in the left front caliper. This is where it really gets complicated. With the application of either brake lever, when rolling, the left front caliper rotates up against the third master, applying two more rear pistons as well as more pressure to all the other pistons. So it could be any or all of the three rotors causing the pulsation. I would suspect the rear rotor first, since you say it seems okay on hard braking, and also this is the brake affected by the recall.

Double-check that Honda won’t do something regarding the recall. For a short, college-level course on Gold Wing braking systems, go to one of the Gold Wing forums and read the volumes of info: goldwingfacts.com/forums/2-goldwing-technical-forum/377202-gli8ooanti-dive-update.html.

A MECHANICAL OR TECHNICAL PROBLEM with your beloved ride? Perhaps we can help. Contact us at cwservice@cycleworld.com with your questions. We cannot guarantee a reply to every inquiry.