2001-2003 HONDA GL1800/ A ECM Replacement/ Cooling System

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Filed Under (Honda) by admin on 13-12-2011

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Use the Cylinder Head Inspection Kit for the Cyl- inder Head Inspection procedure. Use the kit for each GL1800/A you inspect. Do NOT dispose of kit items. 1) 19X20 mm cap (2) (cap B) 2) 8X15 mm cap (cap A) 3) Hose plug 4) Bottle/cap w/feed hose 5) Harness clips (10) 6) Harness tape 7) Inspection mirror A limited number of additional Cylinder Head Inspection Kits are available: call TechLine at 800-421-1900, ext. 1 if you need one. Kit con- tents are NOT available separately as parts. NOTE: • The following late ‘03 models do not have nto have their cylinder heads inspected: • Perform the following procedure with the engine at room temperature. • Both Left and Right cylinder heads must be inspected. • Use the Cylinder Head Inspection Kit for the following procedure. 1. Remove the front lower fairing. (See S/M, 2-6) 2. Remove and suspend the rear brake reser- voir, being careful not to stress the brake hose. (See S/M, 15-A-8)

HONDA GL1800 CB RADIO KIT INSTALLATION And REMOVAL

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Filed Under (Honda) by admin on 20-11-2011

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These instructions are for installation of the CB radio. For operation of the CB radio, refer to the Owner’s Manual and FCC Rule Book furnished with the CB radio. • Install the antenna which is sold separately between the installation of the rear trunk and the routing of the wire harness. • It is not necessary to drill four 7 mm holes and install the plate when you are also installing the CD changer. 1. Refer to the Service Manual to remove the right and left side covers and disconnect the negative terminal from the battery

2002-2003 HONDA GL1800 BANK ANGLE SENSOR MOUNTING SCREWS REPAIR MANUAL

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

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REPAIR PROCEDURE 1. Insert the ignition key into the lock cylinder and open the fairing pocket lid by turning the key clockwise. Remove the two trim clips by pushing the cen- ter pins in. Remove the two screws. Disconnect the opener  cable and remove the right fairing pocket. 2. To access the bank angle sensor, remove the two mounting screws  securing the connector holder. Place the holder to the side. 3. To check for the proper screw size, slightly tighten both bank angle sensor screws. If the screws are tight, reassemble the unit and apply the identification mark. If the screws spin in the holes, proceed to Step 4. 4. Using a magnetic screwdriver, remove and discard one of the two 4 mm screws securing the bank angle sensor assembly. Replace with a 5 x 12 mm self-tapping screw (see the PARTS INFORMATION section on page 3 for the proper screw for this repair). Repeat for the other screw. 5. Reinstall the removed parts in the reverse order of removal. IDENTIFICATION Apply a white paint dot in the center of the under- side of the right fairing pocket lid as shown. This will indicate that the Safety Recall has been per- formed on this unit

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2006 Honda GL1800 AirbagCB Radio Squeal REPAIR PROCEDURE

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

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To remedy this problem, a ferrite core harness kit is now available for installation. 2006 GL1800 VIIIA (Airbagmodels) with optional CBRadio. Install a ferrite harness core kit according to the installation instructions that are packaged with the kit. ÒÑÌÛæ • The kit includes both a rider and a passenger harness; it’s necessary to install both harnesses to eliminate the squealing noise. • Passengers must route the headset cord as shown. If routed otherwise, it will be too close to the motorcycle’s antenna, which can create an interference. Subharness installation can be confirmed by removing the left-side fairing pocket, and check- ingtoseeifthe harness is already installed. Ferrite CoreHarness Kit (1 required) P/N: 08E95-MCA-100WA H/C: 8607665 ÒÑÌÛæCallTechLineat (800) 421-1900 to order parts. Due to the limited number of affected units and parts availability, ordering will be controlled until May 31,2007. Normal warranty claim submission require- mentsapply. Submit one claim per VIN. Template: GL19 Flat RateTime: 0.3 hours

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Fitting Hondaline Heated Grips to Honda GL1800

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

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Then remove the right side fairing trim piece, starting at the bottom inner and working your way upwards. Unscrew the single Allen head bolt holding the lock panel in place and remove the panel. Now to remove the old grips. Tip; If you have chrome cap ends fitted, protect the chrome on the screw by putting some tape on the end of the screwdriver If you’re a cheapskate, and want to save the old grips, run a thin screwdriver or a hacksaw blade around the inside of the grip to loosen the old glue and it will come away easily. Repeat on the right side grip. The Honda instructions tell you to remove the whole throttle grip & boss but you don’t need to go to all that hassle of unscrewing the switch assembly to get at it. Just remove the rubber grip same as described for the left side After removing the switch panel from the Goldwing, drill a 45mm hole with a holesaw. The spot to drill is marked on the inside of the panel. Then just screw the controller knob assembly into position with the three screws provided (second picture) Spread some glue (the Honda stuff if you can get it, or just plain old rubber cement as I’ve used on my last four Goldwings without problems). Spread it more towards the ends and middle of the bar as it will get pushed inward as you push the grips on anyway

2001 Honda GL1800 Oxygen Sensor Replacement Manual

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Filed Under (Honda) by admin on 05-04-2011

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REPAIR PROCEDURE 1. Remove the top shelter (see page 2-10 in the Service Manual). 2. Remove the left and right O 2 sensors from the exhaust pipes. • You do not have to remove the exhaust pipes to remove the O 2 sensors. • Be sure to note the wire routing for proper reassembly. 3. Install the new O 2 sensors and route the wires properly (see pages 1-33 and 1-34 in the 2001- Service Manual). 4. Connect the black 4P female coupler of the sub- harness kit to the wire harness side black 4P male coupler (for the left-side O 2 sensor). 5. Connect the new left O 2 sensor to the black 4P coupler on the sub-harness. 6. Route the sub-harness from left to right, across the front edge of the fuel tank and secure it with the clip on the cruise actuator 7. Cut off the right 4P male O 2 sensor coupler (on the wire harness side). 8. Install a PVC cap onto the end of the Black/yellow wire and Green/red wire (these are the wires that were connected to the coupler that was removed in step 7). Fold each cap back and tape it securely to its wire; these wires are no longer used. • Do not cut the wires off, just tape them back. • The tape is supplied in the replacement kit. 9. Strip the ends of the White and Black/red wires (which were connected to the coupler that was removed in step 7) on the wire harness side and the 2P coupler on the sub-harness. Install a heat shrink tube on each wire of the sub harness. 10. Twist the ends of the White and Black/red wires of the sub-harness 2P coupler to the White and Black/red wires of the main harness. 11. Solder the wires using the solder from the kit. 12. Use a heat gun to secure the heat-shrink tubing over the soldered wires. 13. Connect the right O 2 sensor coupler to the white 4P male coupler on the sub harness.

HONDA GL1800 Windshield Panel Light Installation Manual

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Filed Under (Honda) by admin on 04-03-2011

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Note: Read instructions thoroughly before installing. 1. Place bike on center stand. 2. Remove the following per manual instructions. A. Rear view Mirror (Figure 1) -Remove the meter panel. -Remove the trim clip, screw and mirror cover. -Remove the three screws, bracket and mirror. -Disconnect the turn signal light 3P connector. B. Windshield Garnish (Figure 2) -Remove the left and right rearview mirrors per above instructions. -Remove the two bolts, washers and mounting rubbers. -Release the four bosses from the grommets and remove the windshield garnish. 3. Line up the windshield panel light in the windshield vent opening as shown in figure 3. Mark spots for final application. 4. Remove tape backing and carefully apply light at pre-marked spots. 5. Splice wires to mirror light as follows: a. Black to Ground b. Red to Orange/white wire to left mirror. 6. Reassemble all parts removed

HONDA GL1800 Chrome Mesh Grill Accents Installation Manual

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Filed Under (Honda) by admin on 04-03-2011

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NOTE: Read instructions thoroughly before installing. Work one side at a time. 1. Place bike on center stand. 2. Thoroughly clean outside surface of the chrome air intake area where inserts will be install with rubbing alcohol pads- provided. 3. Using the silicone provided, run a bead of silicone as shown in figure 1 or on the original side fairing in the same manner. 4. Carefully place insert mesh into place. 5. Press the accent into place. 6. Using two wire ties, secure the chrome accent by wrapping the wire ties through the original radiator grill as shown in figure 2. Note: You may want to use masking tape or a soft material to protect the chrome or painted surface while placing the piece on the bike. 7. Repeat on the other side. 8. Wait at least 12 hours before removing wire ties.

HONDA GL1800 WINDSHIELD VENT INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 04-03-2011

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NOTE: CAUTION is required when drilling and cutting to prevent cracking and scratching the windshield material. A professional glass service is highly recommended for this purpose. Should you attempt to install the windshield vent on your own, follow the instructions below. Add On Inc. will not be held liable or responsible for any damage to the windshield. 1. Place bike on center stand. 2. Cut out the template provided and center on windshield approximately 2 ¾” above the tint line. Tape the template to windshield using masking tape. Use enough masking tape to cover the area to be cut out to prevent scratching. If using a power sabre saw to cut the pattern out, put masking tape on the foot to prevent scratching the windshield. Drill the four corners using a sharp power sabre saw, electric drill (using a 7/16″ drill bit), and or hack saw. 3. Smooth cut edges with sand paper. 3. Install the vent. The two pieces will snap together in the windshield. Use chrome screws provided to secure vent in the windshield.

HONDA GL1800 BACKREST (INSERT) INSTALLATION MANUAL

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Filed Under (Honda) by admin on 04-03-2011

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1. Place motorcycle on center stand. 2. Remove the two passenger handles and seat. 3. Install the base mount between the seat mounts (picture 1) and mark the two holes on seat base. 4. Drill two 9/32″ holes in the seat base. 5. In the middle of the two seams and in the center of the seat, install the boot (picture 2). 6. With a long serrated knife cut a hole in the seat inside the boot opening. You must clear a path in the foam from the cut to the two 9/32″ holes. 7. Insert the long bar through the hole into the seat from the outside with the hole tube facing forward (picture 3). 8. Bolt the base mount to the long bar using bolts and lock washers. 9. Attach the chrome pad mount to the long bar protruding through seat (picture 4). 10. Attach the pad to the pad mount with the mounting bracket (picture 5). 11. Reinstall the seat and adjust the pad angle (picture 6). Reattach passenger handles