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2001-2002 GL1800 A ABS Speed Sensor Wire Clamp Location INSPECTION/ REPAIR PROCEDURES

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Filed Under (Honda) by admin on 29-01-2011

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1. If the VIN is within the preceeding range, inspect the front ABS speed sensor wire clamp according to the following illustrations. 2001-2002 GL1800A ABS Speed Sensor Wire Clamp Location INCORRECT Installation CORRECT Installation Service Bulletin American Honda Motor Co., Inc. 2001-2002 GL1800 ABS Speed Sensor Wire Clamp Location 0112 GL1800 #9*GL1800 #9*0112*2001-2002 GL1800 ABS Speed Sensor Wire Clamp Location*GL1800, ABS Speed Sensor Wire Clamp Location*Motorcycle*1800 2 of 2 ©2001 American Honda Motor Co., Inc. – All Rights Reserved GL1800 #9 DECEMBER 2001 IDENTIFICATION There is no identification mark associated with this Service Bulletin. PARTS INFORMATION There is no parts information associated with this Service Bulletin. WARRANTY INFORMATION The normal warranty claim submission requirements apply. Submit one warranty claim per VIN with the following information only: Inspected and REPAIRED Template: GL#9 Hours: 0.2 hours Parts: None If the clamp is installed correctly on top of the speed sensor, no further action is necessary. 3. If the clamp is installed incorrectly under the speed sensor, remove and reinstall the clamp and speed sensor correctly. Torque the bolts,. Torque: 12 N • m (1.2 kgf • m, 9 lbf • ft) If the speed sensor wire clamp for the front ABS speed sensor is installed incorrectly, the ABS speed sensor air gap may be out of specification. This does not affect ABS speed sensor operation, but the clamp should be installed correctly. Inspect and repair all affected units using the Inspection/Repair procedures listed below. Inspect all unsold units and customer units brought in for service. AFFECTED UNITS 2001-2002 GL1800A units as follows: MODEL 2001 GL1800A All units 2002 GL1800A 1HFSC474*2A100001 – 1HFSC474*2A101643 * = denotes check digit Any unit in the above VIN range may be affected and should be inspected according to the procedures in this Service Bulletin. All units outside of the above VIN range do not require inspection. CUSTOMER NOTIFICATION There is no customer notification associated with this Service Bulletin.

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HONDA GL1500CD/ VALKYRIE Specifications

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Filed Under (Honda) by admin on 29-01-2011

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position when it comes to the environment. We continue to develop low-emission technologies for our current and future motorcycles, ATVs, scooters and personal watercraft. We already produce models that exceed the stringent 2008 CARB emissions requirements years ahead of schedule. And that’s the kind of performance everybody can appreciate. BE A RESPONSIBLE RIDER. Riding a motorcycle is an exercise in responsibility—to yourself, to others, to the environment and to the sport. So remember, wear a helmet, eye protection and protective clothing whenever you ride. Never ride under the influence of drugs or alcohol, and never use the street as a racetrack. Inspect your motorcycle before riding, read your owner’s manual, and see your local Honda Dealer concerning reimbursement through the Honda Rider’s Club of America™for Motorcycle Safety Foundation (MSF) rider training.* Always obey local laws, use common sense, and respect the rights of others when you ride. Make sure you have a proper license when riding on public roads, and never modify your motorcycle’s exhaust system. 03 SPECIFICATIONS ACCESSORIES VALKYRIE Log on to our website at honda.com for more information about Honda Genuine Accessories . On a bike like the Valkyrie, you can never have too much chrome. And that’s precisely why we offer our Chrome Sidecovers and Chrome Swingarm-Pivot cover to help really brighten up these areas. Here’s one of our most popular Valkyrie accessory options. These Leather Saddlebags look great, hold plenty, and match some of the other leather accessories we have available. Got a long trip planned, or is winter right around the corner? Then make sure you take a look at-or should we say take a look through-a Honda Genuine Accessories Windshield for your new Valkyrie. GL1500CD 1520cc liquid-cooled horizontally opposed six-cylinder with belt-driven overhead camshafts Six 28mm constant-velocity carburetors 71.0 x 64.0mm Solid-state digital Five-speed constant-mesh Shaft 150/80R-17 radial 180/70R-16 radial Dual-disc with twin-piston calipers 28.9 inches 66.5 inches 5.3 gallons, including 1.1 gallon reserve 681 pounds Black Windshield, leather saddlebags, chrome exhaust tips, chrome rear carrier, CB transceiver kit, passenger CB talk switch, studded backrest pad, studded main seat, studded rear seat, deluxe backrest pad

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2001 – 2002 GL1800/ GL1800A Rear Tire Inspection

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Filed Under (Honda) by admin on 27-11-2010

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1. Inspect the motorcycle for a punch mark as described in Identification on page 2. If a punch mark is present no further action is necessary, return the unit to the customer. 2. Qualify the unit/customer as follows: •Is the tire on the motorcycle the original factory installed tire? •Is the air pressure loss more than three psi per month? Note: Refer to page 145 in the Owner’s Manual. “Even tires that are in good condition may lose one to two psi per month if not checked and adjusted regularly” . If the GL1800 meets the above qualifications, proceed with the repair procedure. 3. Place the motorcycle on a lift and secure it on the centerstand. 4. Remove the rear wheel as described on page 14-9 of the Service Manual. 5. Starting at the valve stem/balance mark area, carefully remove the rear tire from the wheel. Be sure to use plenty of commercially available tire lubricant on the inside and outside of both beads. 6. Carefully inspect the entire circumference of both tire beads. Inspect both the inside and outside of the bead for any distortion or injuries. See examples of injuries below. 2001 – 2002 GL1800/GL1800A Rear Tire Inspection GL1800 #6 OCTOBER 2001 MTB 9430 (0109) CUSTOMER INFORMATION: The information in this bulletin is intended for use only by skilled technicians who have the proper tools, equipment, and training to correctly and safely maintain your Honda. These procedures should not be attempted by “do-ityourselfers,” and you should not assume this bulletin applies to your Honda, or that your Honda has the condition described. To determine whether this information applies, contact an authorized Honda dealer. Service Bulletin American Honda Motor Co., Inc. 2001-2002 GL1800/GL1800A Rear Tire Inspection 0110 GL1800 #6*GL1800 #6*0110*2001-2002 GL1800/GL1800A Rear Tire Inspection*GL1800/GL1800A, Rear Tire Inspection, Bead, Tread*Motorcycle*1800 2 of 4 ©2001 American Honda Motor Co., Inc. – All Rights Reserved GL1800 #6 OCTOBER 2001 Inside BeadInjury Outside BeadInjury Outside BeadInjury 7. Carefully inspect the entire circumference of both tire beads. Inspect both the inside and outside of the bead for any distortion or injuries. See examples of injuries below. 8. If there is no evidence of bead damage, re-install the tire on the rim. Be sure to use plenty of commercially available tire lubricant on the inside and outside of both beads. Be sure to align the balance dot with the valve stem. Inflate the tire to 41 psi. Install the wheel assembly on the motorcycle and proceed to the Identification and then to the Warranty section. 9. If any damage or injury is present replace the tire and valve stem. Be sure to use plenty of commercially available tire lubricant on the inside and outside of both beads. Balance the new tire as necessary

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INSTRUCTIONS ON HOW TO R & R YOUR Swingarm

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Filed Under (Tips and Review) by admin on 12-12-2010

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• Upgrade Your Pre- 2002 FL Or FXR Rear Fork & Get Rid Of The Crappy & Dangerous (Cleve Blocks) & Replace Them With A Stable System. • R & R your Swing Arm, Belt Drive, Swing Arm Pivot Shaft, and Rear Wheel. The paragraphs below are a photo journey into the replacement of a FL or FXR swing arm. To upgrade the pre 2002 FL, here is a How-To on cheaply replacing the poor parts Harley stuck you with. Now – Let’s Get Er’ Done • Pre- 2002 had weak swing arms and are known to fail. The cleve blocks are the cause of “Rear Steer” or “Rear Fork Deflection”. Harley came up with a patch in 2002, using bearings. Because the pre 2002 transmissions have a 5/8″ mounting hole for the 5/8″ swing arm pivot shaft, a conversion unit has been made. No transmission removal for boring is necessary. Under no circumstances, do I recommend drilling out the transmission case with a hand drill. The drill will “wander” (drift)! • Solution: Go to either a trike shop/manufacturer, e-Bay, or shop and buy a new style swingarm. Harley made an additional upgrade in 2007, try and buy this type 2007 & above). If upgrading to a 2008, Harley use 25mm (smaller than 1″) axles & wheel bearings, you will have to use 25mm bearings. With that said, let’s get on with it. • In the case of a 2007 swingarm; buy and do not pay over $40 for the swing arm and axle. You must use the corresponding axle as a ¾” axle set-up is different (along with wheel bearings & spacers). You positively can not use a pre -2002 HD stock wheel because the wheel bearing spacer will fit into the wheel. Buy 2002 & above style wheels as they (9 spoke) are cheep. • You are going to have to either bore out your stock rear caliper bracket or better still, upgrade your whole rear brake to the new model & sell yours on e-Bay. • I recommend doing the following before hand and have it ready for installation; Remove bearings et al. from the 2002 & later swing arm via press. Bike Work: • Jack up your bike using a center jack. Secure the bike so it will not fall over. You can also use a motorcycle jack. I use a motorcycle dolly

2001-2002 Honda GL1800/A Frame Weld Inspection PROCEDURE

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Filed Under (Honda) by admin on 22-04-2011

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IMPORTANT: During these procedures you may be using and referring to the following materials, originally sent to you with Service Bulletin GL1800 #14. • 2002-2003 GL1800/A Frame Weld Safety Recall Dealer Procedures (S0510) • Frame Weld Inspection Chart (S0516) • 2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual (S0511) • 2002-2003 GL1800/A Frame Weld Safety Recall Cracked Weld Repair Manual (S0515) • Welding Template Box (S0512)If you need additional copies of these materi- als you may order them at no cost from Resolve at (440) 572-0725. 1. Position the motorcycle on a firm, level surface, in an area where there is enough room to safely lay it on its left side. 2. Remove the left side mirror by following the nstructions on page 2-7 of the Service Manual. 3. Remove the left engine side cover by following the nstructions on page 2-5 of the Service Manual. 4. Remove the antenna whip(s). 5. Remove the coolant reserve tank by fol- lowing the instructions on page 6-7 of the Service Manual. 6. Place thick, non-abrasive padding (such as furniture blankets) on the ground to protect the motorcycle when you lay it on its side. 7. Lock the handlebars to the RIGHT, using the ignition key. 8. Using two people, gently lay the motor- cycle down on its LEFT side on the pad- ding. The motorcycle will first rest on the wheels and left engine and saddlebag guards. Continue to lean the motorcycle to the left until it rests on the left handlebar end and left engine and saddlebag guards. The motorcycle should be laying on the padding, with its engine guard, saddlebag guard, and handlebar end resting on the padding – no painted parts should be con- tacting the padding. 9. Clean the frame crossmember with acetone. 10. Draw a line on each side of the grinding template (S0512) 30 mm from the for- ward edge, stopping  between the two arrows, as illustrated below. 11. Put this template on the frame and, using a fine-tipped felt marker (such as a Sharpie), draw a 30 mm line on both crossmember welds. Start this line at the forward edge of the grinding template and stop between the two arrows as shown in the illustration on the next page.Now remove the grinding template

2002-2003 Honda GL1800/ A Frame Weld REPAIR PROCEDURE OVERVIEW

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Filed Under (Honda) by admin on 14-12-2010

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If your inspection identifies a crack or cracks in or on either Left or Right lower crossmember frame welds, STOP – call your DSM or TechLine for further instructions. • If your inspection reveals no cracks, proceed to REPAIR PROCEDURE. NOTE: Verification of repair can also be found in the Dealer Responsibility Report and on the Honda Interactive Network (iN). If you have any questions about verification, please contact TechLine before proceeding. IMPORTANT: For complete Dealer and Welder Repair procedures, refer to the following items: • 2002-2003 GL1800/A Frame Weld Safety Recall Dealer Booklet (S0510) • Frame Weld Inspection Chart (S0513) You MUST provide your TIG welder with the following items: • 2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual (S0511) • Welding Template Box (S0512) All of the above items were shipped to you with this Service Bulletin. If you need additional copies of the Dealer Booklet , Welding Manual , Welding Template Box , or Frame Weld Inspection Chart , you may order them at no cost from DDS at (440) 572-0725. For your reference, a brief repair procedure overview is provided below. Disassembly Overview You will be removing the following components from the vehicle as instructed in the Dealer Booklet : • Handlebar weights • Rear view mirrors • Swingarm pivot covers • Rider foot pegs • Seat • Side covers/Engine side covers • Fairing pockets • Fairing molding • Meter panel • Top shelter • Battery • Fuel tank • Main wiring harness ground • Front lower fairing • Front exhaust pipe protector • Muffler/exhaust pipe • Antenna Whip(s) • Coolant reserve tank • Center stand NOTE: You will need to remove any accessories that may contact the ground during the Welding and Re-assembly procedures. IMPORTANT: You MUST cover the following with RED duct tape for welder identification pur- poses: • Negative (-) and positive (+) battery cables • Fuel return hose end • Fuel feed hose end • Main wiring harness ground • Alternator • Exhaust ports Welding Overview A qualified TIG welder will weld the frame following the procedures in the 2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual . Re-assembly Overview You will be inspecting the new TIG welds, painting the frame, and re-assembling the vehicle as detailed in the Dealer Booklet and Frame Weld Inspection Chart (S0513)

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2001-2002 GL1800/ A CB Radio Replacement/ REPAIR PROCEDURE

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Filed Under (Honda) by admin on 29-01-2011

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For authorization, call the CB Exchange Radio Order Desk toll free: (888) 997-7278 . The CB Exchange Radio Order Desk hours are Monday thru Friday, 8:30am – 8:00pm EST. BEFORE STARTING ANY REPAIR ON THE CB RADIO, YOU MUST FIRST CALL THE ORDER DESK FOR AUTHORIZATION. Part Number: 08E95-MCA-101RM Honda Code: 7066319 3. After calling the CB Radio Order Desk, an exchange transceiver will be shipped overnight (freight prepaid). 4. Replace the faulty CB Transceiver with the exchange unit (see REPAIR PROCEDURE ). . Remove the seat (see the GL1800 Service Manual, page 2-4). 2. Remove the right rear side cover (page 2-4). 3. Remove the right-hand fairing molding (page 2-8). 4. Remove the right hand top shelter setting bolts and mounting nut (page 2-9). It is not necessary to remove the left-hand fairing molding, shelter bolts, or shelter. 5. Disconnect the 14P CD coupler under the rear seat. Remove and set aside the CD Changer (if equipped). (Continued on page 2) Some customers may experience weak radio transmissions and/or the need to use abnormally high squelch settings for reception on the Hondaline CB Radio. To correct this condition, the CB Transceiver unit must be replaced as described in this Service Bulletin. Do not order a CB kit from parts stock. Follow the ordering procedures in this Service Bulletin. AFFECTED MOTORCYCLES 2001 – 2002 GL1800/A ORDERING AND REPLACING THE CB TRANSCEIVER 1. Before calling the CB Exchange Radio Order Desk, have the following information ready: • VIN • Failure Information (i.e., symptom) • Warranty Status 2. For authorization, call the CB Exchange Radio Order Desk toll free: (888) 997-7278 . The CB

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2001-2002 HONDA GL1800/A CD Changer Replacement

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Filed Under (Honda) by admin on 03-03-2011

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2001-2002 GL1800/A CD Changer Replacement ORDERING AND REPLACING THE CD CHANGER 1. Before calling the CD Changer Order Desk, have the following information ready: • VIN • Failure Information (i.e., symptom) • Warranty Status 2. To order, call the CD Changer Order Desk toll free: (888) 997-7278 . The CD Changer Order Desk hours are Monday thru Friday, 8:30am – 8:00pm EST. Part Number: 08A06-MCA-100RM Honda Code: 7097009 3. After calling the CD Changer Order Desk, an exchange CD Changer will be shipped overnight (freight prepaid). 4. Replace the faulty CD Changer with the exchange unit (see REPAIR PROCEDURE ). DO NOT remove the faulty CD Changer until you receive the exchange unit. DO NOT ATTEMPT TO REMOVE ANY STUCK CD’S. CHANGERS DAMAGED IN THIS WAY WILL BE RETURNED TO THE DEALER AND NO CORE CREDIT WILL BE ALLOWED. You will be billed $300.00 for the replacement unit. You must return the faulty CD Changer for a core credit and file a warranty claim to receive your total reimbursement (see TRANSACTION SUMMARY on page 3 for details). REPAIR PROCEDURE 1. Refer to the Installation Instructions included with the replacement CD Changer. 2. NOTE: You MUST remove the shipping bracket from the replacement unit before you complete the installation. If a CD is stuck inside the faulty unit, leave it there : • The vendor needs it for diagnosing and testing. • If you try to remove it, you’ll damage the unit. • The vendor will return the unit if it has been damaged during attempted CD removal. Fill in the customer information on the Audio System Diagnosis and Core Return form. The vendor will remove the CD and mail it back to the customer. IDENTIFICATION No identification is necessary for this repair

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2002 GL 1800 Reverse Cable Inspection/ Adjustment PROCEDURE

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Filed Under (Honda) by admin on 29-01-2011

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INSPECTION/ADJUSTMENT PROCEDURE 1. Remove the right engine side cover (see S/M Page 2-4). 2. Check the cable clearance on the N (neutral) and R (reverse) cables. Note: It is not necessary to remove the center inner fairing or inspect the reverse shift actuator. . 6. Push the reverse shift switch to “OFF” and turn off the ignition. 7. Tighten the reverse cable lock nuts. 8. Reinstall the right engine side cover. PARTS INFORMATION No parts are required for this procedure. WARRANTY INFORMATION Normal warranty. After completion of the inspection/adjustment, submit one claim per VIN using the following information only: Template #: GL#5 Flat Rate Time = 0.3 hours The reverse cable lock nuts may not have been properly tightened on some GL1800 units. We have developed a procedure to inspect and adjust any affected units. Please follow the INSPECTION/ ADJUSTMENT procedures included in this Service Bulletin. AFFECTED UNITS 2002 GL1800 units with VIN range: 1HFSC470*2A102303 through 1HFSC470*2A102622 * indicates check digit Any unit in the above VIN range may be affected and should be inspected according to the procedures in this Service Bulletin. All units outside of the above VIN range do not require inspection.

2002 Chetak And 2003 Legend Evaporative Emission Control System Hookup

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Filed Under (Bajaj) by admin on 31-10-2010

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2002 Legend engines have the carburetor air vent hose connected between the 2 way valve and the canister, with a 108 main jet in the carburetor. The 2003 Legend engines have the air vent connected as shown in this diagram and the main jet increased to 120 to compensate for the reduced bowl pressure. All 2003, and subsequent Legend and Chetak engines, will have this hookup as shown with 120 size main jets. Warning: Seemingly small changes can make a big difference in altering the fuel/air ratio. Disconnect hoses or make changes at your peril. There is no horsepower to be gained by disconnecting this passive emission control system

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