Honda Goldwing Gl1800 Gl1800/a 2001 To 2010 Service Manual Repair Manual Cd

US $14.97

Saint-Lambert, Quebec, Canada
Jan 30th

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Honda GL1800, GL1800A Gold Wing Motorcycle Workshop Service Repair Manual 2001-2010 CD this is a mailed Computer Cd this is not printed material at this low price !!! 750+ Pages, Searchable, Printable, Bookmarked, Honda GL1800, GL1800A Gold Wing; Production model years: 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010. All styles covered (all models, and engines). detailed illustrations as well as step by step instructions. All pages are printable written for the do-it-yourself-er as well as the experienced mechanic. provides step-by-step instructions based on the complete dis-assembly of the machine. hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete official full Service Manual for Your Honda GL1800, GL1800A Gold Wing !! * Detailed sub-steps expand on repair procedure information * Notes, cautions and warnings throughout each chapter pinpoint critical information. * Numbered instructions guide you through every repair procedure step by step. * Bold figure number help you quickly match illustrations with instructions. * Detailed illustrations, drawings and photos guide you through every procedure. * Enlarged inset helps you identify and examine parts in detail. * Numbered table of contents find the information you need fast. * Diagnose and repair problems with your machines electrical system. * Troubleshooting and electrical service procedures are combined with detailed wiring diagrams Total Pages: more than 750 pages email me any questions below or if needed right away ASAP!! CONTENTS GENERAL INFORMATION 1 FRAME/BODY PANELS/EXHAUST SYSTEM 2 MAINTENANCE 3 ENGINE AND DRIVE TRAIN LUBRICATION SYSTEM 4 FUEL SYSTEM 5 (Programmed Fuel Injection) COOLING SYSTEM 6 ENGINE REMOVAL/INSTALLATION 7 CYLINDER HEAD/VALVES 8 CLUTCH 9 GEARSHIFT LINKAGE/TRANSMISSION 10 CYLINDER/PISTON/CRANKSHAFT 11 FINAL DRIVE 12 CHASSIS FRONT WHEEL/SUSPENSION/ STEERING 13 REAR WHEEL/SUSPENSION 14 BRAKE SYSTEM (Standard) 15 BRAKE SYSTEM (ABS) 16 ELECTRICAL BATTERY/CHARGING SYSTEM 17 IGNITION SYSTEM 18 STARTER/REVERSE SYSTEM 19 LIGHTS/METERS/SWITCHES 20 CRUISE CONTROL SYSTEM 21 AUDIO SYSTEM 22 WIRING DIAGRAMS 23 TECHNICAL FEATURES 24 TROUBLESHOOTING 25 INDEX 26 SERVICE RULES ············································ 1-2 MODEL IDENTIFICATION······························ 1-2 GENERAL SPECIFICATIONS························· 1-4 LUBRICATION SYSTEM SPECIFICATIONS · 1-6 FUEL SYSTEM (Programmed Fuel Injection) SPECIFICATIONS··········································· 1-6 COOLING SYSTEM SPECIFICATIONS ········· 1-6 CYLINDER HEAD/VALVE SPECIFICATIONS··········································· 1-7 CLUTCH SPECIFICATIONS ··························· 1-7 GEARSHIFT LINKAGE/TRANSMISSION SPECIFICATIONS··········································· 1-8 CYLINDER/PISTON/CRANKSHAFT SPECIFICATIONS··········································· 1-8 FINAL DRIVE SPECIFICATIONS···················· 1-9 FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS··········································· 1-9 REAR WHEEL/SUSPENSION SPECIFICATIONS··········································· 1-9 BRAKE SYSTEM SPECIFICATIONS·············1-10 BATTERY/CHARGING SYSTEM SPECIFICATIONS··········································1-10 IGNITION SYSTEM SPECIFICATIONS ········1-11 STARTER/REVERSE SYSTEM SPECIFICATIONS··········································1-11 LIGHTS/METERS/SWITCHES SPECIFICATIONS··········································1-11 CRUISE CONTROL SYSTEM SPECIFICATIONS··········································1-11 STANDARD TORQUE VALUES···················1-12 ENGINE & FRAME TORQUE VALUES········1-12 LUBRICATION & SEAL POINTS ··················1-19 CABLE & HARNESS ROUTING ···················1-23 EMISSION CONTROL SYSTEMS ················1-69 EMISSION CONTROL INFORMATION LABELS ·························································1-72 SERVICE INFORMATION ······························ 2-2 TROUBLESHOOTING···································· 2-2 BODY PANEL LOCATIONS ··························· 2-3 SIDE COVER··················································· 2-5 ENGINE SIDE COVER···································· 2-5 SEAT······························································· 2-5 FRONT FENDER COVERS····························· 2-6 FRONT LOWER FAIRING ······························ 2-6 METER PANEL··············································· 2-7 REARVIEW MIRROR······································ 2-7 WINDSHIELD ················································· 2-8 INNER FAIRING ············································2-10 FRONT FAIRING ···········································2-10 TOP SHELTER···············································2-11 REAR FENDER A···········································2-13 TRUNK LOWER COVER·······························2-13 TRUNK ··························································2-13 SADDLEBAGS ··············································2-15 REAR FENDER B···········································2-16 SADDLEBAG/TRUNK STAY························2-17 EXHAUST SYSTEM······································2-18 SERVICE INFORMATION ······························ 3-2 MAINTENANCE SCHEDULE························· 3-4 FUEL LINE ······················································ 3-5 THROTTLE OPERATION································ 3-5 AIR CLEANER················································· 3-6 CRANKCASE BREATHER······························ 3-7 SPARK PLUG ················································· 3-8 VALVE CLEARANCE······································ 3-9 ENGINE OIL·················································· 3-11 ENGINE OIL FILTER····································· 3-12 RADIATOR COOLANT································· 3-13 COOLING SYSTEM······································ 3-14 SECONDARY AIR SUPPLY SYSTEM·········· 3-14 EVAPORATIVE EMISSION CONTROL SYSTEM······················································· 3-15 FINAL DRIVE OIL··········································3-15 BRAKE FLUID················································3-16 BRAKE PAD WEAR·······································3-17 BRAKE SYSTEM···········································3-18 BRAKE LIGHT SWITCH ································3-18 HEADLIGHT AIM ··········································3-19 CLUTCH SYSTEM·········································3-19 CLUTCH FLUID ·············································3-19 REVERSE OPERATION·································3-20 SIDE STAND ·················································3-20 SUSPENSION ···············································3-21 NUTS, BOLTS, FASTENERS························3-21 WHEELS/TIRES ············································3-22 STEERING HEAD BEARINGS ······················3-22 LUBRICATION SYSTEM DIAGRAM ············· 4-2 SERVICE INFORMATION ······························ 4-3 TROUBLESHOOTING···································· 4-4 OIL PRESSURE CHECK ··································4-5 OIL STRAINER/PRESSURE RELIEF VALVE·····························································4-6 OIL PUMP························································4-7 COMPONENT LOCATION····························· 5-2 SERVICE INFORMATION ······························ 5-3 TROUBLESHOOTING···································· 5-5 SYSTEM LOCATION······································ 5-6 SYSTEM DIAGRAM······································· 5-7 PGM-FI (PROGRAMMED FUEL INJECTION) SYSTEM························································· 5-8 PGM-FI SELF-DIAGNOSIS MALFUNCTION INDICATOR FAILURE CODES····················· 5-13 PGM-FI TROUBLESHOOTING ···················· 5-16 FUEL LINE INSPECTION ····························· 5-52 FUEL PUMP·················································· 5-54 FUEL TANK ·················································· 5-56 AIR CLEANER HOUSING ···························· 5-57 THROTTLE BODY ·········································5-58 FUEL INJECTORS·········································5-61 FUEL PUMP RELAY······································5-66 BARO/MAP SENSORS·································5-67 IAT SENSOR·················································5-68 CAMSHAFT POSITION SENSOR·················5-68 O2 SENSOR···················································5-69 KNOCK SENSOR ··········································5-69 VEHICLE SPEED SENSOR ···························5-70 ECM (ENGINE CONTROL MODULE)···········5-71 SECONDARY AIR SUPPLY SYSTEM ··········5-71 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM························································5-74 ENGINE IDLE SPEED····································5-75 COMPONENT LOCATION····························· 6-2 SERVICE INFORMATION ······························ 6-3 TROUBLESHOOTING···································· 6-4 SYSTEM TESTING········································· 6-5 COOLANT REPLACEMENT····························6-6 RADIATOR/COOLING FAN····························6-8 WATER PUMP/THERMOSTAT····················6-17 COMPONENT LOCATION····························· 7-2 SERVICE INFORMATION ······························ 7-3 ENGINE REMOVAL ········································7-5 ENGINE INSTALLATION······························7-11 COMPONENT LOCATION····························· 8-2 SERVICE INFORMATION ······························ 8-3 TROUBLESHOOTING···································· 8-5 CYLINDER COMPRESSION··························· 8-6 CYLINDER HEAD COVER REMOVAL··········· 8-6 CAMSHAFT REMOVAL································· 8-7 CAM CHAIN REMOVAL ······························ 8-12 CYLINDER HEAD REMOVAL ······················ 8-14 CYLINDER HEAD DISASSEMBLY ···············8-16 VALVE GUIDE REPLACEMENT···················8-19 VALVE SEAT INSPECTION/REFACING······8-19 CYLINDER HEAD ASSEMBLY ·····················8-22 CYLINDER HEAD INSTALLATION···············8-24 CAM CHAIN INSTALLATION·······················8-26 CAMSHAFT INSTALLATION ·······················8-28 CYLINDER HEAD COVER INSTALLATION·············································8-32 COMPONENT LOCATION····························· 9-2 SERVICE INFORMATION ······························ 9-4 TROUBLESHOOTING···································· 9-6 CLUTCH FLUID REPLACEMENT/AIR BLEEDING ······················································ 9-7 CLUTCH MASTER CYLINDER························9-8 CLUTCH SLAVE CYLINDER·························9-12 CLUTCH·························································9- COMPONENT LOCATION··························· 10-2 SERVICE INFORMATION ···························· 10-4 TROUBLESHOOTING·································· 10-7 GEARSHIFT LINKAGE································· 10-8 REAR CRANKCASE COVER REMOVAL··· 10-11 PRIMARY GEARS/OUTPUT SHAFT REMOVAL·················································· 10-13 CRANKCASE COVER BEARING REPLACEMENT ··········································10-19 PRIMARY GEARS/OUTPUT SHAFT INSTALLATION···········································10-20 REAR CRANKCASE COVER INSTALLATION···········································10-24 TRANSMISSION DISASSEMBLY··············10-26 TRANSMISSION ASSEMBLY····················10-33 COMPONENT LOCATION··························· 11-2 SERVICE INFORMATION ···························· 11-3 TROUBLESHOOTING·································· 11-5 CRANKCASE SEPARATION························ 11-6 PISTON/CONNECTING ROD REMOVAL ··· 11-7 CRANKPIN BEARING ································ 11-11 CRANKSHAFT REMOVAL··························11-13 MAIN JOURNAL BEARING························11-14 CRANKSHAFT INSTALLATION ·················11-16 PISTON/CONNECTING ROD INSTALLATION···········································11-17 CRANKCASE ASSEMBLY··························11-22 COMPONENT LOCATION··························· 12-2 SERVICE INFORMATION ···························· 12-3 TROUBLESHOOTING·································· 12-6 FINAL DRIVE REMOVAL····························· 12-7 FINAL DRIVE DISASSEMBLY/ INSPECTION ·················································12-9 CASE BEARING REPLACEMENT···············12-14 FINAL DRIVE ASSEMBLY··························12-17 FINAL DRIVE INSTALLATION ···················12-22 COMPONENT LOCATION··························· 13-2 SERVICE INFORMATION ···························· 13-3 TROUBLESHOOTING·································· 13-6 HANDLEBAR················································ 13-7 FRONT WHEEL ···········································13-16 FORK ···························································13-24 STEERING STEM········································13-41 COMPONENT LOCATION··························· 14-2 SERVICE INFORMATION ···························· 14-3 TROUBLESHOOTING·································· 14-5 REAR WHEEL············································· 14-14 SHOCK ABSORBER····································14-16 SUSPENSION LINKAGE ····························14-18 SWINGARM················································14-22 SUSPENSION LEVEL RELAY·····················14-29 SYSTEM LOCATION···································· 15-2 SERVICE INFORMATION ···························· 15-3 TROUBLESHOOTING·································· 15-5 BRAKE FLUID REPLACEMENT/AIR BLEEDING ···················································· 15-6 BRAKE PAD/DISC······································ 15-13 FRONT MASTER CYLINDER····················· 15-15 REAR MASTER CYLINDER/BRAKE PEDAL ·························································15-19 SECONDARY MASTER CYLINDER ···········15-24 FRONT BRAKE CALIPER····························15-27 REAR BRAKE CALIPER·······························15-34 DELAY VALVE ············································15-38 PROPORTIONAL CONTROL VALVE (PCV) ··············································15-39 SYSTEM LOCATION···································· 16-2 SERVICE INFORMATION ···························· 16-3 SYSTEM WIRING CONNECTIONS/ LOCATIONS ················································· 16-4 BEFORE STARTING TROUBLESHOOTING·································· 16-5 BEFORE TROUBLESHOOTING····················16-8 TROUBLESHOOTING·································16-10 WHEEL SPEED SENSOR····························16-29 ABS MODULATOR·····································16-31 SYSTEM LOCATION···································· 17-2 SYSTEM DIAGRAM····································· 17-2 SERVICE INFORMATION ···························· 17-3 TROUBLESHOOTING·································· 17-5 BATTERY·······················································17-6 CHARGING SYSTEM INSPECTION·············17-9 ALTERNATOR·············································17-10 SYSTEM LOCATION···································· 18-2 SYSTEM DIAGRAM····································· 18-2 SERVICE INFORMATION ···························· 18-3 TROUBLESHOOTING·································· 18-4 IGNITION SYSTEM INSPECTION··············· 18-5 IGNITION COIL ·············································18-7 IGNITION PULSE GENERATOR···················18-9 PGM-FI IGNITION RELAY ··························18-11 BANK ANGLE SENSOR ·····························18-13 IGNITION TIMING ······································18-14 SYSTEM LOCATION···································· 19-2 STARTER SYSTEM DIAGRAM ··················· 19-2 REVERSE SYSTEM DIAGRAM ··················· 19-3 SERVICE INFORMATION ···························· 19-4 TROUBLESHOOTING·································· 19-6 STARTER/REVERSE MOTOR ··················· 19-17 STARTER RELAY SWITCH A ···················· 19-24 STARTER RELAY SWITCH B····················· 19-25 REVERSE RELAY ······································· 19-26 REVERSE SWITCH ·····································19-27 REVERSE REGULATOR ASSEMBLY·········19-28 REVERSE RESISTOR ASSEMBLY·············19-30 POWER CONTROL RELAY·························19-31 SPEED LIMITER RELAY······························19-33 REVERSE SHIFT RELAY·····························19-34 REVERSE SHIFT ACTUATOR ····················19-36 CRUISE/REVERSE CONTROL MODULE·····················································19-39 REVERSE SHIFT MECHANISM··················19-42 SYSTEM LOCATION···································· 20-2 SERVICE INFORMATION ···························· 20-3 TROUBLESHOOTING·································· 20-4 HEADLIGHT·················································· 20-8 HEADLIGHT ADJUSTER ····························· 20-9 FRONT TURN SIGNAL LIGHT··················· 20-13 SADDLEBAG COMBINATION LIGHT ······· 20-14 TRUNK BRAKE/TAILLIGHT······················· 20-15 LICENSE LIGHT·········································· 20-15 RELAY BOX················································ 20-16 COMBINATION METER····························· 20-17 SPEEDOMETER ········································· 20-20 TACHOMETER ··········································· 20-21 COOLANT TEMPERATURE GAUGE/ ECT SENSOR ············································· 20-22 FUEL GAUGE/LOW FUEL INDICATOR ···· 20-24 NEUTRAL INDICATOR ······························ 20-26 OIL PRESSURE INDICATOR ······················20-27 TURN SIGNAL RELAY································20-27 TURN SIGNAL CANCEL UNIT···················20-28 POSITION LIGHT RELAY····························20-31 HAZARD SWITCH·······································20-32 OPEN AIR TEMPERATURE SENSOR ········20-33 IGNITION SWITCH ·····································20-34 HANDLEBAR SWITCH································20-35 BRAKE SWITCH··········································20-37 CLUTCH SWITCH ·······································20-37 GEAR POSITION SWITCH··························20-38 SIDE STAND SWITCH································20-39 MULTI-DISPLAY CONTROL SWITCH········20-40 HORN ··························································20-40 FAN CONTROL RELAY·······························20-41 POWER TRUNK LOCK SYSTEM················20-42 SYSTEM LOCATION···································· 21-2 SERVICE INFORMATION ···························· 21-3 TROUBLESHOOTING·································· 21-4 CRUISE/REVERSE CONTROL MODULE ······················································ 21-9 IGNITION CRUISE RELAY··························21-11 CRUISE CONTROL SWITCH ······················21-13 CRUISE CANCEL SWITCH ·························21-14 CRUISE ACTUATOR···································21-16 SYSTEM LOCATION···································· 22-2 SERVICE INFORMATION ···························· 22-3 TROUBLESHOOTING·································· 22-4 AUDIO UNIT················································· 22-6 AUDIO SWITCH············································22-9 ANTENNA···················································22-11 SPEAKER·····················································22-12 HEADSET JUNCTION WIRE ······················22-12 SERVICE INFORMATION ···························· 23-3 FUSE BOX···················································· 23-3 SUSPENSION LEVEL CONTROL SYSTEM 23-5 ABS······························································· 23-7 FUEL SYSTEM (Programmed Fuel Injection) ····················· 23-9 COOLING/CHARGING/IGNITION SYSTEM····················································· 23-11 STARTER/REVERSE SYSTEM···················23-12 LIGHTING SYSTEM····································23-13 TURN SIGNAL LIGHTS/HORN··················23-14 COMBINATION METER ·····························23-15 ACC/TRUNK LOCK CONTROL SYSTEM ··23-17 CRUISE CONTROL SYSTEM ·····················23-20 AUDIO SYSTEM ·········································23-22 IDLE AIR CONTROL (IAC) VALVE··············· 24-2 HYDRAULICALLY ASSISTED CLUTCH ······ 24-4 BRAKE SERVO-PRESSURE SENSING ANTI-DIVE SYSTEM···································· 24-5 ELECTRIC REAR SUSPENSION SPRING PRELOAD ADJUSTMENT SYSTEM············24-6 ANTI-LOCK BRAKE SYSTEM (ABS)············24-7 IGNITION COIL WITH BUILT-IN IGNITER ·24-12 ENGINE DOES NOT START OR IS HARD TO START ········································· 25-2 ENGINE LACKS POWER ····························· 25-3 POOR PERFORMANCE AT LOW AND IDLE SPEED···················································25-5 POOR PERFORMANCE AT HIGH SPEED····25-6 POOR HANDLING·········································25-6 26 index