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

993-192 LED Light, 993-193 Marker Light CHROME RAIL BAR LIGHT INSTALLATION MANUAL

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Filed Under (Honda) by admin on 28-02-2011

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Read instructions thoroughly before installing. 1. Place bike on center stand. 2. Place chrome plate on to the desired position on the rail covering both the top and bottom rail with the chrome plate. 3. Insert light into the hole on the chrome plate and attached with brackets, washer and bolts provided in figure 1. Tighten securely. 4. Wire light into bike’s running or brake lights. If adding more than one light, wire lights in series.

HARLEY DAVIDSON CHROME FUEL TANK TRIM PANEL INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 25-02-2011

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INSTALLATION 1. Refer to the Owner’s Manual and follow the instructions given to remove the seat. Retain all seat mounting hard- ware. Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near gasoline. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00002a) 2. See the Figure 5. Remove the original fuel filler cap (A) from the tank and set it aside. Obtain a small diameter Harley-Davidson fuel filler cap (B) and screw it into the fuel filler opening. For Model XL883C, or other models equipped with Genuine Motor Parts Large Capacity Fuel Tank 3. To ensure surface cleanliness, clean the top of the fuel tank with a mixture of 50 to 70% isopropyl alcohol and 30 to 50% distilled water. Allow to dry thoroughly. 4. Measure and mark the centerline of the fuel tank, with a wax pencil or water-based marker, at the rear of the tank as shown in Figure 3. Proceed to Step 10. For Model XL1200C 2 1 is 01910 1. Original fuel tank trim panel liner 2. Fishing line (or string) Figure 1. Removing the Existing Trim Panel (XL 1200C) 5. See Figure 1. Insert the fishing line (2) between the rear of the fuel tank and the liner (1) on the underside of the original trim panel. NOTE Raise the ends of the fishing line away from the fuel tank to avoid scuffing the tank finish 6. Using a side-to-side “sawing” motion, work the fishing line toward the front of the fuel tank to break the adhesive bond between the trim panel and the tank. 7. Carefully pull the trim panel and liner off of the tank and discard it. NOTE Be careful not to scratch the paint on the fuel tank when removing the adhesive

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HONDA GL1800/A Frame Weld Installation PROCEDURE

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Filed Under (Honda) by admin on 23-11-2010

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you need additional copies of these materials 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 instructions on page 2-7 of the Service Manual. 3. Remove the left engine side cover by following the instructions on page 2-5 of the Service Manual. 4. Remove the antenna whip(s) . 5. Remove the coolant reserve tank by following 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 motorcycle down on its LEFT side on the padding . 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 contacting the padding. 9. Clean the frame crossmember with acetone and place the grinding template (S0512) on the crossmember as shown below. 10. Using a suitable felt marker, draw a 30 mm line on both crossmember welds. Use the edge of the template as a rule and draw the lines between the two sets of arrows as shown in the illustration. Remove the grinding template