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Honda 1994 GoldWing GL1500, Service Manual

The Honda 1994 GoldWing GL1500 Service Manual is essential for maintaining and repairing this iconic motorcycle. Easily download the manual for free from manualshive.com to ensure proper care and operation of your GoldWing. Get the detailed instructions and diagrams you need to keep your bike in top condition.

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Summary of Contents for 1994 GoldWing GL1500

Page 1: ...in foot pounds ft Ib See page 1 9 for a specific explanation of the use of metric equivalents A system troubleshooting list fol lows the torque reference drawing and then the service pro cedures begin...

Page 2: ...nformation Service Safety D 1 2 Model Identification D 1 4 Emission Control Systems D 1 5 Emission Control Information labels 1 8 Metric Conversions 1 9 N P S Part Numbers 1 10 Tools 1 11 1 1 goldwing...

Page 3: ...ted Never run the engine in an enclosed area _ _ Used Enginerrransmission on Used engine on or transmission oil in two strokes may cause skin cancer if repeatedly left in contact with the skin for pro...

Page 4: ...rcycle Coolant cont d If coolant contacts your skin wash the affected areas immediately with soap and water If it contacts your eyes flush them thoroughly with fresh water and get immediate medical at...

Page 5: ...mber is found on the final drive case near the pinion flange as shown The engine serial number is stamped on the rear right side of the engine case 19J II VEHICLE 1D9ITIFICATlOOJ IIlUM8ERMIIlI The Veh...

Page 6: ...o keep the emissions system warranty in effect Source of Emissions The combustion process produces carbon monoxide and hydrocarbons Control of hydrocarbons is very important because under certain cond...

Page 7: ...erable amount of hydrocarbons and carbon monoxide into carbon dioxide and water The PAIR check valve prevents reverse air flow through the system The engine control module reacts to high intake manifo...

Page 8: ...NOISE CONTROL SYSTEM IS PROHIBITED Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of mainte nance repair o...

Page 9: ...n It gives basic tune up specifications EMISSION CONTROL INFOR MATHON LABEL Vacuum Hose Routing Diagram label Califomi n model only The Vacuum Hose Routing Diagram Label is on the fuel tank The seat m...

Page 10: ...psi Pounds Sq inch psi 0 0703 Kilograms Sq centimeter kg cm2 lemperature Centigrade CO CO x 1 8 32 Fahrenheit FO Fahrenheit P FO 32 7 1 8 Centigrade CO Capacity Liter I 0 2642 Gallon gal Liter I 1 05...

Page 11: ...92 Method of Manufacture 1 Length of Thread 20 Normal Diameter 06 Length Under the Head 042 Material 0 Surface Treatment Z Semi Standard Numbers seals O rings bearings etc Front Wheel Dust Seal 91251...

Page 12: ...ME4000A 07947 6340100 07965 3710300 DESCRIPTION Oil filter wrench Pilot screw wrench Hydraulic tappet bleeder Valve guide reamer 5 5 mm Shim selection gauge Piston base head Piston base Piston pin dri...

Page 13: ...e 07746 0030100 07746 0030200 07746 0030300 07736 A01000A 07411 0020000 or KS AHM 32 003 MC1012 2 07GMJ 0010000 07746 0030400 Commercially available 07725 0040000 07746 0020400 00746 0010700 Oil press...

Page 14: ...Specifications General 2 2 Standards Service Limits 2 4 Torque Values 2 8 goldwingdocs com...

Page 15: ...802 Ibs California rnodel 365 kg 805 Ibs SE 370 kg 816 Ibs California model 371 kg 818 Ibs I 349 kg 769 Ibs California model 350 kg 771 Ibs Curb Weight A 399 kg 879 Ibs California model 400 kg 882 Ibs...

Page 16: ...fter disassembly 1 Carburetion Battery Ignition Full transistor TOC 800 80 rpm Starting motor A C generator S50 W S OOO rpm For extended high speed riding For cold climate Below SO C 41 F Spark plug g...

Page 17: ...older Journal 1 0 27 000 27 021 1 0630 1 0638 27 05 1 065 Journal oil clearance Both inner 0 045 0 087 0 0018 0 0034 0 14 0 006 Both ends 0 030 0 072 0 0012 0 0028 0 14 0 006 13 0 17 0 kg cm2 185 242...

Page 18: ...00 34 016 1 3386 1 3392 34 04 1 340 Gear bushing 0 0 C2 C3 M4 M5 33 940 33 965 1 3362 1 3372 33 92 1 335 Gear to bushing clearance 0 035 0 076 0 0014 0 0030 0 10 0 004 _ __ Gearshift Shift fork shaft...

Page 19: ...SS 8 Fork tube runout 0 2 0 01 _ Shocks Right shock absorber air pressure 0 4 0 kg cm2 0 57 psi Right shock absorber oil capacity 140 cc 4 7 US oz 4 9 Imp oz Right shock absorber oil Pro Honda Suspens...

Page 20: ...hout spark plug wire Ignition pulse generator coil resistance At 20 C 68 F 400 500 ohms Engine coolant temperature sensor 2 0 3 0 k ohms Intake air temperature sensor 200 400 ohms _ _ _ Starter motor...

Page 21: ...40 190 19 0 137 NOTE 2 5 Alternator Front cover attaching screw 3 4 2 0 2 1 4 NOTE 2 Couple A mounting nut 1 14 58 5 8 42 NOTE 2 Couple B mounting nut 1 14 58 5 8 42 Rear Engine Case Starter one way...

Page 22: ...ar wheel damper holder bolt 5 6 20 2 0 14 Left shock absorber mount bolt Upper 1 8 23 2 3 17 Lower 1 18 70 7 0 51 Right shock absorber mount bolt Upper 1 8 23 2 3 17 Lower 1 8 23 2 3 17 Air hose bolt...

Page 23: ...ake line nut Other Brake disc bolt Miscellaneous Side stand pivot bolt Side stand lock nut Side stand switch mounting bolt Center stand pivot bolt Exhaust pipe joint nut Tail spoiler mounting bolt SE...

Page 24: ...zation 3 20 Carburetor Idle Speed 3 21 Cylinder Compression 3 21 Radiator Coolant 3 22 Cooling System 3 23 Pulse Secondary Air Injection System 3 24 Evaporative Emission Control System 3 24 Battery 3...

Page 25: ...portant parts of the engine It is equipped with a pressure relief valve o The scavenging pump draws oil from the clutch housing in the rear engine cover and sends it to the primary drive and driven ge...

Page 26: ...pose grease ust seal s and dust seals arings aring dust seal lips ace sion plate pivot rence int Honda Moly 60 paste or splines and oil seal equivalent es s sliding surface Hi Temperature silicone rs...

Page 27: ...Maintenance I formation cont d Service n Service Access Guide 3 4 goldwingdocs com...

Page 28: ...ht aim Cooling system _ f Clutch system m Battery Brake fluid left fr Brake system h I __ Clutch system m Brake light switc Reverse operatio Brake system h Carburetor synch Reverse operatio Clutch sys...

Page 29: ...Maintenance Lubrication Diagram HVDRAUUC VALVE ADJUSTER goldwingdocs com...

Page 30: ...ms choke clogged jets high float level air system etc Midmrange p riormance poor Incorrect spark plug heat range Faulty spark plugs Improper ignition timing see Section 17 Low engine compression Low f...

Page 31: ...Sticking float valve Faulty fuel pump Faulty fuel pump relay Clogged fuel tank cap vent hole WEAK OR NO SPARK II Ignition system see Section 16 3 Test cylinder compression LOW COMPRESSION II Low batte...

Page 32: ...disc plate Warped clutch disc plate 5 Check ignition timing INCORRECT CORRECT t 6 Check hydraulic valve NOISE NOT HEARD 1 Improper ignition timing see Section 16 NOISE HEAD __ Clogged hydraulic valve...

Page 33: ...ydraulic valve Improper ignition timing CORRECT 3 Check for leaking intake pipe and vacuum tubes LEAKING lI Loose carburetor insulator Damaged or deteriorated vacuum tubes NO LEAK 4 Perform spark test...

Page 34: ...CAUSE Contaminated oil Use of poor quality oil Clogged oil filter screen Clogged oil filter Oil level too low Faulty oil pump Relief valve stuck open Internal oil leakage Worn crankshaft bearing Clogg...

Page 35: ...I I I I I 3 26 Brake System j 1 I I 3 27 I _ _ _ _ _ _ f _ Brake Light Switch I I I 3 28 o _ _ _ __ _ 1 I W Headlight Aim I I I 3 28 _ _ _ _ _ f _ f f f I j Clutch System I I I 3 29 ill C MChFlui j N...

Page 36: ...arts The light should go off after one or two seconds Engine Oil Filter Change NOTE SINGLE GRADE MULTI GRADE OIL VISCOSITIES J LSi L _ 10 0 10 20 30 40C 20 40 60 80 100 o Change engine oil with the en...

Page 37: ...the dipstick Make sure that there are no oil leaks Recommended oil Honda Ii Stroke Oil or Equivalent API Service Classification SF or SG SAl lOW liC Oil Pressure Check Remove the under cover see page...

Page 38: ...n level ground Remove the oil filler cap Check that the oil level reaches the lower edge of the oil filler cap hole Check for leaks if ttle level is low Pour fresh oil through the oil filler hole unti...

Page 39: ...rioration damage or kinking in the throttle cables Replace any damaged parts If throttle operation is not smooth check the inner cable condition Replace any frayed or kinked cables Make sure throttle...

Page 40: ...ng circuit controlled by a starting enrichment valve The starting enrichment valve opens the enriching circuit via a cable when the choke lever on the handlebar is pulled down Check for smooth choke l...

Page 41: ...emission storage element from the air cleaner element NOTE Do not replace the evaporative emission storage element Discard the air cleaner element in accordance with the maintenance schedule Also repl...

Page 42: ...13 12 Disconnect the spark plug caps and clean any dirt from around the spark plug bases Remove and discard the spark plugs Measure the new spark plug gap with a wire type feeler gauge Spark Plug Gap...

Page 43: ...B 021 XXXXX Vacuum probe 2 07LMJ 001000A or M983X 350 XXXXX Start the engine and adjust the idle speed With the throttle stop screw idle Speed 800 80 rpm Check that the difference in vacuum readings i...

Page 44: ...ccurate readings Stop the engine then disconnect the spark plug caps and remove the spark plugs Turn the engine stop switch OFF Insert the compression gauge Open the throttle all the way and crank the...

Page 45: ...he Upper level line with a 50 50 mixture of distilled water and antifreeze Avoid scalding never remove the radiator cap when the engine is hot The coolant is under pressure If the reserve tank is empt...

Page 46: ...e radiator if the air flow is restricted over more than 20 of the radiating surface Remove the following fairing front cover see page 13 11 under cover see page 13 11 fairing lower cover see page 13 1...

Page 47: ...ween PAIR control valve and intake manifold through PAIR solenoid valve for deterio ration damage or loose connections Make sure the tube is not kinked or pinched For PAIR solenoid valve inspection se...

Page 48: ...arge quantities of water or milk and follow with milk of magnesia or vegetable oil and call a physician When the fluid level nears the lower level refill with dis tilled water to the upper level t CAU...

Page 49: ...Do not allow foreign material to enter the system when filling the reservoir y spili L he Jid on painted astic or rub rts If the level is low check the entire system for leaks Refer to Section 14 for...

Page 50: ...e Pedal Height Om10 mm OmO 4 in Adjust brake pedal height so the pedal is 0 10 mm 0 0 4 in above the upper surface of the foot peg CAUTION _ m m _ Incorrect brake pedal height can cause brake ___dr _...

Page 51: ...headlight beam as specified by local laws ulations __ An improperly adjusted headlight may blind oncoming drivers or it may fail to light the road for a safe distance Adjust the headlight beam vertica...

Page 52: ...is level Check the clutch fluid level If the level nears the lower eve mark remove the cover set plate and diaphragm Fill the reservoir with DOT 4 brake fluid to the upper level mark The clutch reserv...

Page 53: ...reverse gear is engaged Make sure index mark A aligns with the reference mark Measure the index mark B free play Standard 2 3 mm 1 16 118 in REFERENCE MARK INDEX MARK B INDEX MARK A If adjustment is...

Page 54: ...ide a vehicle with faulty suspension Loose worn or damaged suspension parts impair vehicle stability and control Front Check the action of the front forks by compressing them several times Check the e...

Page 55: ...he usable air pressure range under normal conditions is 0 57 psi 0 4 0 kg cm2 57 psi 4 0 kglcm2 Up to maximum weight limit _ AIR VALVE CAP Rear Air Pressure opsi 0 kglcm2 __ _ __ _ __ _ ___C r0_nd_i i...

Page 56: ...eaning sol vent and allow it to dry thoroughly I B_ _ Nevel use gasoline 01 low flash point solvents for cleaning the element A fire or explosion could result DRV I Soak the element in Pro Honda Foam...

Page 57: ...placement NOTE Before disassembly be sure to release air pressure E g the air pressure control sWi _ _ _ Remove the air pump from the frame and disconnect the air hoses from the drier see page 12 31 R...

Page 58: ...ment assembly Remove the element from the element housing Replace the element in accordance with the mainte nance schedule Nuts Bolts Fasteners Check that all chassis nuts and bolts are tightened to c...

Page 59: ...els for rim runout see Sec tion 15 Replace the tires before tread depth at the center of the tire reaches the following limit Minimum Tread Depth Front 1 5 mm 0 06 in Rear 2 0 mm 0 08 in The use of ti...

Page 60: ...hly from full left to full right Check that the control cables are routed correctly and do not interfere with steering Push and pull on the fork sliders and check that there is no free play or loosene...

Page 61: ...fold Pilot Screw Adjustment Fuel Pump Fuel Reserve Sensors Indicator 4 2 4 9 4 15 4 16 4 17 4 18 4 19 4 21 4 23 4 26 4 34 4 36 4 37 4 39 4 40 4 43 FuellevelSensorlGauge Air System Circuit Diagram Engi...

Page 62: ...be serviced with the carburetors disassembled When inspecting the fuel pump reserve sensor level sensor and air system check the system components and lines step by step according to the Troubleshoot...

Page 63: ...Torque Carburetor insulator band screw 5 N m 0 5 kg m 3 6 ft lb t CALIFORNIA MODEL ONLY 4 3 goldwingdocs com...

Page 64: ...Information cont d System location FUEL RESERVE INDICATOR FUEL PUMP FUEL RESERVE SENSOR FUEL LEVEL SENSOR CARBURETOR AIR JET __ _ SOLENOID VALVES PULSE SECONDARY AIR INJECTION SOLENOID VALVE FUEL GAU...

Page 65: ...2 BAN WHT I I I I I I I I I 14P lILK I i lIPOWllTJ I i I FUEL GAUGE IIEDIWHTm l ll i 5 I 0 iil i 0 I 0 f JI I 1f J m OFF V lPOGllNJ iii ENGINE STOP SWI1CHo jiil ACC Ecr SENSO T I R P R SOlEHOOD VAlVE...

Page 66: ...TOP SWITCH TlI Ii I z i I iii W finu ECT SENSOR PAIR SOLENOID VALVE To Pb InlMe Mrolold A RELAY BOX AEL AY BOX FVSE lOX FVSE lOX jMill jMiiil lRI Fi SA L __ JL __ J i d iii i I i iii i l1 liROUCI POIN...

Page 67: ...TUBE I I STORAGE TANK CRANKCASE 11 A I BREATHER CARBURETOR I TUBE B AIR JET NO 3 GRN TUBE CRANKCASE BREATHER SOLENOID VALVE STORAGE TANK DRAIN TUBE NO 1 PINK TUBE II I NO 19 WHT TUBE o 1 CARBURETORS O...

Page 68: ...uel System Service Information cont d Hoses and Tubes Routing Connection California Evaporative Emission EVAPj Control System Hose Routing FUEL TRAY DRAIN TUBE NO 2 HOSE EVAP CANISTER goldwingdocs com...

Page 69: ...ting enrichment valve stuck open or damaged Dirty air cleaner Needle and seat faulty or worn o Faulty carburetor air jet control system see page 4 50 Faulty engine control module or loose or poor cont...

Page 70: ...r poor contact of connector Faulty engine control module Loose or poor contact of connectors Open or short circuit in wire harness Faulty fuel pump Fuel indicator light does not come on within 3 minut...

Page 71: ...erminal Fuel gauge should read empty C UTION _ _ _ __ _ Do not short the terminals for longer than a few seconds or the gauge will be damaged Not Operating Open circuit in BLK BRN I BLK BRN and BRNIWH...

Page 72: ...No 11 YEL rm Normal Perform the system inspection see page I 4 47 Abnormal IASA VALVE Check the IASA valve for its Abnormal F I operation see page 4 48 Normal _ O IASA CHECK VALVE Check the IASA chec...

Page 73: ...KlLT GRN terminals on the wire harness side and ground H with the ignition switch ON Battery voltage should register No Loose or poor contact of connectors Open or short circuit in wire harness 1 Yes...

Page 74: ...VACUUM ACTUATOR Check IAT vacuum actuator operation see page 4 53 Normal Disconnection _ 9 Disconnected hot air pipe Abnormal I Faulty IAT vacuum actuator Faulty installation of IAT vacuum actuator UM...

Page 75: ...ube from the fuel tray Disconnect the fuel pump and reserve sensor A SE connectors from the fuel pump Remove the fuel tank mounting bolts RELAY BOX Remove the following G rear wheel see page 15 10 G r...

Page 76: ...goldwingdocs com...

Page 77: ...he above conditions apply vacuum to the auto fuel valve Vacuum should be maintained and the gasoline should flow out smoothly Replace the fuel valve if necessary VACUUM PUMP itJ BL _ Gasoline is flamm...

Page 78: ...O RING Cover the carburetor main bores with a shop towel to prevent dropping anything into the carburetors For IAT thermal vacuum valve removal see page 4 53 Remove the two screws attaching the tube...

Page 79: ...lter Oil or equivalent or in gear oil SAE 80 90 and squeeze out the excess Install the sub air cleaner housing in the reverse order of removal WASH IN SQUEEZE OUT SOLVENT SOLVENT AND ALLOW TO DRY THOR...

Page 80: ...BE 4 NO 18 WHT TUBE ACTUATOR CABLE Loosen the choke cable holder screw and disconnect the choke cable Disconnect the coolant hoses from the carburetor heat riser Remove carburetor assembly NOTE Place...

Page 81: ...ichment SE valve arm Remove the cotter pin washers collar and spring from the accelerator rod Disconnect the accelerator rod from the accelerator pump arm Remove the cotter pin washer and plastic wash...

Page 82: ...ch carburetor Remove the accelerator pump fuel pipe Check the fuel pipe s O rings for damage or fatigue Use compressed air to clean the accelerator pump fuel passages of the airhorn assembly Use compr...

Page 83: ...a ring and check it for fatigue or damage Remove three screws and the pump cover Remove the spring and diaphragm valve ACCELERATOR PUMP Check the diaphragm rod cover for fatigue or damage Check the s...

Page 84: ...PISTON VACUUM CHAMBER COVER Push the jet needle holder down and turn it counterclock wise 90 degrees with an 8 mm socket Then remove the needle holder spring spring holder jet needle and washer from...

Page 85: ...e the float valve seat from the carburetor body Clean the strainer with clean solvent Make sure the sealing washer is in good condition FLOAT ARM PIN FLOAT VALVE SEALING WASHER Remove the main jet mai...

Page 86: ...ll bits to clean carburetor jets The jets will become enlarged or scratched disturbing the correct mixture ratio Pilot Screw NOTE m The pilot screws are factory pre set and should not be removed unles...

Page 87: ...Reassembly is the reverse of disassembly CAUTION o Do not overtighten the main jet holder and float valve seat Damage to the carburetor will result goldwingdocs com...

Page 88: ...age 4 39 if new pilot screws are installed NOTE _ _ e If you replace the pilot screw in one carburetor you must replace the pilot screws in the other carburetor for proper pilot screw adjustment PILOT...

Page 89: ...MAIN JET HOLDER STRAINER SLOW JET Install the float valve into the valve seat Install the float and float arm pin Float level Inspection With the float valve seated and the float arm just touching the...

Page 90: ...h the tab of the diaphragm aligned with the groove of the carburetor and with the vacuum piston held up to almost full open to prevent pinching the diaphragm between the chamber cover and the carburet...

Page 91: ...securely SPRING PUMP COVEP Install a new O ring on the float chamber Install the accelerator pump onto the chamber Tighten the screws securely Assembly Install new O rings onto the fuel pipe Install...

Page 92: ...Install the washer spring collar accelerator pump arm washer and a new cotter pin on the accelerator rod Install the plastic washers washer and a new cotter pin on the throttle linkage of the right c...

Page 93: ...ews securely TIghten the carburetor airhorn screws securely Install new O rings on the airhorn grooves Check that the choke linkage operates smoothly Check that the throttle linkage operates smoothly...

Page 94: ...Install new tubes if the current tubes are deteriorated or damaged Slide the end of each tube fully onto its fitting Secure with a tube clamp After installing the carburetors on the engine check that...

Page 95: ...Shaft California NOTE _ _ I for identification of tubes not Refer to 49 State Mode shown CLAMP TO EVAP PURGE CONTROL VALVE rr TO EVAP CAV CONTROL VALVE CAJUUJRETOR NO 6 HOSE DRAIN TUEiE 4 35 goldwingd...

Page 96: ...rked hose to the right pipe Take care to avoid pinching or kinking the hoses Secure the hoses with clamps Connect the choke cable to the choke linkage Align the end of the cable outer housing with the...

Page 97: ...crews to the specified torque Torque 5 f lmm 0 5 kg m 3 6 ft Ib Intake Manifold Removall Remove the following air cleaner housing see page 4 18 carburetors see page 4 19 heat guard insulators pulse se...

Page 98: ...ve the six bolts left intake manifold and gasket Install the intake manifolds in the reverse order of removal NOTE L marked manifold to the left side R marked to the right For all vacuum tubes connect...

Page 99: ...h 07LMA MT801 OA 2 Warm the engine to operating temperature Stop and go riding for 10 minutes is sufficient 3 Attach a tachometer according to the manufac turer s instructions 4 Adjust the idle speed...

Page 100: ...the fuel pump outlet line at the fuel filter Hold a graduated beaker under the tube Keep gasoline away from flames or sparks Wipe up spilled gasoline at once Turn the ignition switch ON let fuel flow...

Page 101: ...ir hose and remove the fuel pump assembly from the fuel tank Release the terminal caps from the fuel pump wire terminals Remove the screws and pump wires Disconnect the air and fuel hoses from the pum...

Page 102: ...ll the terminal caps Install the fuel pump into the fuel tank connecting the air hose to the air pipe inside the tank Position the wire clamp over the stud as shown and tighten the nuts securely Conne...

Page 103: ...te colored wire and ground as shown Standard 0 9 1 3 k Ohms 2500 CI 170 F 1000 pm WHT BW WIRE CONNECTOR Indicator Inspection Place the motorcycle on its center stand The fuel indicator light should co...

Page 104: ...Gauge should read empty Float at top Gauge should read full NOTE Do not bend the float arm Allow plenty of time for the gauge to respond Float level Sensor Inspection Check the resistance of the fuel...

Page 105: ...R INTAKE AIR ENGINE COOLANT TEMPERATURE TEMPERATURE SENSOR SENSOR R _ T ARPOSITION SWITCH Neutral 2nd 3rd 4th OD MAIN FUSE B 55A CARBURETOR AIR JET SOLENOID VALVE PULSE SECONDARY AIR INJECTION CONTROL...

Page 106: ...tch in ON 3 At all times ENGINE CONTROl MODULE LINE TERMINALS CONDITION S SPECIFICATION _ Battery voltage input BlKIWHT and ground 1 2 Battery voltage should register w Carburetor air jet solenoid RED...

Page 107: ...apply the specified vacuum Specified Vacuum 200 mmHg 7 9 inHg Start the engine in neutral and make sure that air is not drawn in through NO 4 GRN tube while applying the specified vacuum to the No 3...

Page 108: ...Hg vacuum should be maintained Do not apply more than 560 mmHg 22 0 inHg vacuum Replace the valve if necessary Connect a vacuum pump and pressure pump as shown Tool Pressure pump ST AH 255 MC7 Apply l...

Page 109: ...ified Vacuum 40 mmHg 1 6 inHg Vacuum should hold Replace the valve if vacuum does not hold NO 11 YIELI Connect a vacuum pump as shown Apply vacuum It should not hold NOTE _ _ __ _ _ _ o Do this check...

Page 110: ...SOLENOID VALVE Open and Closed in the table below mean Open Vacuum should not be maintained when it is applied to the solenoid Closed Vacuum should be maintained when it is applied to the solenoid Spe...

Page 111: ...pm shown in the table below The following results should be obtained as the specified vacuum is applied G 1 POSITION SWITCH 6P IBLK CONNECTOR BlK YEL l 6P BlK CONNECTOR SPECifiED VACUUM ENGINE VALVE A...

Page 112: ...connections Intake Air Temperature IAT sensor Inspection Remove the air cleaner housing cover see page 4 18 Remove the IAT sensor from the air cleaner housing cover by removing the nut Disconnect the...

Page 113: ...ll the IAT vacuum actuator in the reverse order of removal o Install the IAT vacuum actuator with its vacuum pipe direction as shown IAT Thermal Vacuum Valve Inspection Remove the air cleaner housing...

Page 114: ...valve orifice Install the valve in the reverse order of removal NO 1 PNK VACUUM PUMP IAT CHECK VALVE NO 3 PNK IAT CHECK VALVE VACUUM PUMP Hot Air Pipe Remove the under cover see page 13 11 Remove the...

Page 115: ...ied Vacuum 200 mmHg 1 9 inHg Start the engine and allow it to idle Vacuum should hold Apply the specified vacuum to the engine control module Specified Vacuum 550 mmHg 21 1 inHg Vacuum applied to the...

Page 116: ...r intake port stops drawing air and that the vacuum holds If air is still drawn in or if the specified vacuum is not maintained check No 1 and No 3 GRN tubes for clogging Replace the PAIR control valv...

Page 117: ...elt shield cover see page 7 6 Remove the bolts gasket and air supply pipe of the NO 3 cylinder Check the pipes and O rings for damage or fatigue Remove the PAIR check valve cover and PAIR check valves...

Page 118: ...m to the valve Specified Vacuum 400 mmHg 15 1 inHg Vacuum should hold Replace the valve if vacuum does not hold Connect a vacuum pump to the valve as shown Apply the specified vacuum to the valve Spec...

Page 119: ...um 40 mmHg 1 6 inHg The specified vacuum should hold Replace the EVAP purge control valve if vacuum does not hold Connect a pressure pump to the No 4 hose fitting that goes to the EVAP canister Apply...

Page 120: ...fold Apply the specified vacuum Specified Vacuum 250 mmHg 9 8 inHg The specified vacuum should hold Replace the EVAP CAV control valve if vacuum does not hold Connect the vacuum pump to the air vent p...

Page 121: ...maintain the set speed 5 Tap the Set Decel switch once The motorcycle speed should decrease by one mph 6 Tap the Resume Accel switch once The motorcycle speed should increase by one mph 7 Press and m...

Page 122: ...or engine stop switch This removes power to the control unit and erases the set speed from memory When inspecting the cruise control system check the system components step by step according to the tr...

Page 123: ...L STARTER RELAY SWITCH I AUTO CRUISE CONTROL UNIT _ I 1 2 3 4 5 6 7 10 II 12 13 14 15 16 l J I I i i i 1 otT 1 EL I k fEL lLU lLU HT IAN lED EL RED BLK BL K N WHT N WHT iP REO MAIN FUSE B SA 22P flLK...

Page 124: ...page 4 70 CRUISE INDICATOR Turn the ignition switch ON and engine stop switch to RUN Check that the cruise indicator lights come on for a few seconds then go off Open or short circuit in wire harness...

Page 125: ...0 Voltage doesn t register Battery voltage should register POWER TO SPEED SENSOR Disconnect the 3P WHT mini connector of the speed sensor under the instrument Measure voltage between the LT GRN BLK an...

Page 126: ...way valve see page 4 78 Test with a cruise control unit know to be good Normal Abnormal Abnormal Abnormal Damaged vacuum accumulator Faulty one way valve Faulty actuator Faulty auto cruise control uni...

Page 127: ...in wire harness Abnormal HOSE Check vacuum hoses for damage or e Faulty vacuum circuit clogging See page 4 78 Normal r UATOR Inspect actuator see page 4 76 T Normal Abnormal it Faulty actuator CRUISE...

Page 128: ...SENSOR Check the speed I sensor see page 19 16 9F Abnormal Faulty speed sensor Normal WIRING Measure the voltage between the control unit NO 2 terminal and ground see page 4 70 CANCEL SWITCH Check th...

Page 129: ...switches brake light switches and gear position switch for proper opera tion before proceeding further HOSE Check vacuum hoses for clogging or damage Normal Abnormal 1 Faulty vacuum circuit CABLES Ch...

Page 130: ...YEL Battery 1 2 Auto cruise switch see page 4 74 2 Engine speed pulse WHT BLK Battery 1 9 Engine control module see page 16 7 3 SeVdecel switch WHT YEL Battery 1 2 3 SeVdecel switch see page 4 74 Auto...

Page 131: ...and between terminal 14 BRN wire and ground Battery voltage should register If battery voltage doesn t register inspect the following Wire harness for open or short circuit Connectors for loose or poo...

Page 132: ...LKlYEL and GRN BLU wires from the terminals on the cruise cancel switch Check for continuity between the switch terminals Clutch lever released No continuity Clutch lever pulled in Continuity Throttle...

Page 133: ...ing inner cover see page 13 12 Disconnect the 2P RED connector from the connector holder behind the ignition control module Check for continuity between the GRN WHT and BRN RED wire terminals Brake pe...

Page 134: ...e Accel switch are shown in the chart Continuity should exist between the color coded wires AUTO CRUISE SWITCH BlK WHT VEl Color FREE WHTI BlKl WHTI BlU VEl VEL FREE Color SETON RESUME ON RESUME SET S...

Page 135: ...able below CAUTION Avoid touching the positive battery test wire to the negative test wire If a test involves two or more negative wires first connect all negative wires to the negative battery wire t...

Page 136: ...le grip does not rotate with vacuum applied check the following Throttle Operation see page 3 16 Removalllnstallation Remove the left fairing inner cover see page 13 12 Disconnect the actuator cable f...

Page 137: ...ut of its routing the actuator arm may be pulled with the inner cable and aligning mark may shift If the aligning mark does not align with the index groove adjust as follows Slide the boot off the adj...

Page 138: ...the vacuum accumulator Connect a vacuum pump as shown and apply vacuum Tool Vacuum pump ST AH 260 MC7 Vacuum should not hold the vacuum gauge should show a gradual bleed attributable to the valve orif...

Page 139: ...pection and Testing 5 7 Coolant Replacement 5 8 Radiator 5 9 Cooling Fan 5 11 Reserve Tank 5 12 Thermostat Carburetor Coolant Thermal Valve Water lines 5 13 Water Pump 5 15 Coolant Temperature Sensor...

Page 140: ...ith a cooling system tester For engine coolant temperature ECT sensor removal and inspection see page 16 15 To identify water tubes see the illustration on page 5 15 When inspecting the coolant temper...

Page 141: ...CC l orse TOWATEA PUMP INTAKE MANIFOLD RISER UI fl J CARBURETOR COOLANT TO WATER PUMP THERMAL VIEWED FROM REAR System location TEMPERATURE GAUGE COOLING FAN THERIIIIlOSTATIC FAN MOTOR SWITCH goldwingd...

Page 142: ...1 IP O t H 1 up auq J i W nJ SLK Ii SL SlK 1JI J 2 IIi IPBLK 1 I 00 u l2t I I FAN jtJ BlU I _SLU J THERMOSTATIC FAN MOTOR SIl1TCH GROUI O POiNT t an Motor Switch GO I R3diQtOf Near Th rmosta Ie A Cool...

Page 143: ...s Faulty pump seal Deteriorated O rings Radiator hose damaged Loose or overtightened hose clamps 1 Faulty relay 3 Burnt fuse 8 or main fuse B COOLANT TEMPERATURE SENSOR Check the coolant temperature s...

Page 144: ...tatic fan motor switch itself see page 5 18 o Loose or poor contact of connectors Open or short circuit in wire harness loose or poor contact of switch terminal Faulty fan motor Faulty thermostatic fa...

Page 145: ...It must hold specified pressure for at least six seconds Replace the radiator cap if it does not hold pressure or if relief pressure is too high or too low NOTE Before installing the cap on the tester...

Page 146: ...arefully and observe all precautions Fill the radiator with a flushing compound for aluminum engines Install the radiator cap start the engine and let it run for 10 minutes Drain the radiator folloWin...

Page 147: ...to cruise accumulator All models Release the radiator boss from the frame rubber hole Disconnect the radiator water hoses 3 connections and remove the left radiator from the frame CAUTION Be careful n...

Page 148: ...e sure the clearance between the radiator and cooling fan shroud is 4 mm 0 16 in max all the way around An improper clearance will cause the system to lose cooling power To get the specified clearance...

Page 149: ...on nector holder from the shroud Remove the junction box section 4 Remove the cooling fan mounting bolts and collars Release the shroud under boss from the frame rubber hole and remove the cooling fan...

Page 150: ...tates in a reverse direction Reserve Tank Removal Remove the ignition coil stay mounting bolts Move the coil down out of the way see page 16 8 Ignition Coil Removal Disconnect the reserve tank breathe...

Page 151: ...ating ele ment to heat the water Keep flammable materials away from the electric heating element Wear insulated gloves and adequate eye prom tection Be sure the thermostat does not touch the bottom or...

Page 152: ...or side Connect a pressure tester to the tube as shown Suspend the carburetor coolant thermal valve com pletely in water heated by an electric heating element Keep flammable materials away from the el...

Page 153: ...D c Y 0 WATER HOSE C i iI 0 WATER HOSE F J V THERMOSTAT COOLANTTEMPERATURE SENSOR _ TO WATER PUMP 12 N m 1 2 kg m 9 ft I Water Pump Mech nic 1 Se 1 Inspection Inspect the telltale hole for signs of me...

Page 154: ...pump rotor c _ Instcnllcntion Install a new O ring to the pump body Install the pump body onto the engine aligning the water pump rotor shaft slot with the oil pump shaft Install a new O ring onto the...

Page 155: ...ture Sensor Removal Drain the coolant see page 5 8 Remove the left radiator and left cooling fan Disconnect the GRN BLU wire terminal from the temper ature sensor Remove the temperature sensor from th...

Page 156: ...hich the switch opens and closes Use an electric heating element to heat the cc olant Kt lp flammable materials away from the electric heating element Wear insulated gloves and adequate eye pro tectio...

Page 157: ...Engine RemovalJlnstaliation Service Information m 6 2 Engine Removal 6 4 Engine Installation 6 6 goldwingdocs com...

Page 158: ...hift arm Section 10 transmission Section 10 crankshatvpiston Section 8 starter clutch and reverse shift system Section 18 A floor jack or other adjustable support is required to support and maneuver t...

Page 159: ...m socket bolt 10 mm flange bolt 8 mm flange bolt Exhaust pipe joint cap nut Engine oil drain bolt 40 N m 4 0 kg m 29 ft Ib 25 N m 2 5 kg m 18 ft Ib 40 N m 4 0 kg m 29 ft Ib 40 N m 4 0 kg m 29 ft Ib 25...

Page 160: ...t pipes Section 7 spark plug wires right timing belt cover for added clearance horn wire terminals alternator Section 17 o clutch slave cylinder Section 9 NOTE Squeeze the clutch lever once and keep i...

Page 161: ...relieved from other bolts until they are removed _ _ Right side Remove the front lower and rear lower engine mounting bolts Remove the front upper engine mounting bolt Disconnect the side stand switch...

Page 162: ...nd front lower mount bolts and nuts 4 Right 5 Left 6 Left 7 Right 8 Right 9 Left 2 Right 3 Left 1 Right Hand tighten mounting bolts and nuts and install parts noted in this order Be careful not to dam...

Page 163: ...2 40 N m 4 0 kg m 29 ft Ib 3 25 N m 2 5 kg m 18 ft Ib 3 pes 4 40 N m 4 0 kg m 29 ft Ib 5 40 N m 4 0 kg m 29 ft Ib 6 40 N m 4 0 kg m 29 Ib I 40 N m 4 0 kg m 29 ft Ib 8 25 N m 2 5 kg m 18 ft Ib 4 pes 9...

Page 164: ...Holder Disassembly 7 8 Cylinder Head Removal 7 10 Cylinder Head Disassembly 7 11 Valve Guide Replacement 7 13 Valve Seat Inspection Refacing 7 14 Cylinder Head Assembly 7 17 Camshaft Holder Assemblyl...

Page 165: ...d possible fracture of the fiberglass material Air in the hydraulic valve adjuster causes excessive tappet noise Remove the adjuster and bleed the air if necessary see page 7 10 Adjust the hydraulic a...

Page 166: ...t valve clearance Burned or bent valves _ Incorrect valve tirning Sticking valve Broken valve spring Cylinder head Leaking or damaged head gasket Warped or cracked cylinder head e Camshaft Worn or dam...

Page 167: ...lleys should be facing up Mark each belt to identify it as left or right and to show its direction of rotation NOTE If the cylinder head will be removed loosen the driven pulley bolts temporarily befo...

Page 168: ...t the belt tensioners for free movement and smooth bearings Check the tensioner spring for fatigue or damage Remove the driven pulley bolt washer and the pulley Tool Universal holder 07725 0030000 CAU...

Page 169: ...emoval cont d _ _ _ _ Remove the shield cover and the gasket SHIELD COVER CamshaWRocker Arm Removal Remove the engine guard see page 6 4 Remove the rear cylinder head covers and the gaskets Remove the...

Page 170: ...es for scoring scratching or damage Check that the oil passages are clear Camshaft Inspection Bolt the camshaft holder in place and torque the bolts Torque 20 Nmm 2 0 kg m 14 ft Ib Measure and record...

Page 171: ...ulic valve adjusters from the camshaft holder NOTE NOTE Remove the stopper plugs and shims from the camshaft holder If the parts are to be reused mark the shims with a felt tip pen so that they can be...

Page 172: ...e to the slipper and stem contact faces Measure the 1 0 of each rocker arm Service limit 25 05 mm 0 986 in Inspect each rocker arm eccentric spindle for wear or damage to the sliding and adjuster cont...

Page 173: ...d Measure the compression stroke with a dial gauge Compression Stroke Service limit 0 30 mm 0 012 in If the stroke is more than the seNice limit repeat the bleeding procedure Cylinder Head Removai Dra...

Page 174: ...Keep each valve and its related parts in sets Tool Valve spring compressor 07757 0010000 Clean any gasket material from the cylinder head Cylinder Head Inspection Clean carbon deposits from the combu...

Page 175: ...and Guide Inspection Clean the intake and exhaust valves thoroughly to remove carbon deposits Inspect each valve for bending scratches or abnormal stem wear Measure and record the 0 0 of each valve s...

Page 176: ...to 275 290 F 130 1 40 C with a lot plate or oven Do not heat the cylinder head beyond 3000 F 150 C Use temperature indicator sticks avail able from welding supply stores to be sure the cylinder head i...

Page 177: ...residue out of the valve guides Valve Seat InspectionlRefacing NOTE Check hydraulic valve adjuster shim selection when ever the valve seats are refaced Apply a light coating of Prussian Blue to the v...

Page 178: ...anufacturer s instructions Use a 45 degree cutter to remove any roughness or irregularities from the seal OLD SEAT WIDTH NOTE Use a 60 degree cutter to remove the bottom 1 4 of the old seat Remove the...

Page 179: ...lve the seat must be lowered using a 30 degree flat cutter If the contact area is too low on the valve the seat must be raised using a 60 degree inner cutter CONTACT 1 00 lOW Refinish the seat to spec...

Page 180: ...ng seats valves springs retainers Compress the valve spring and install the keepers CAUTION To prevent loss of tension do not compress the valve spring amy more than necessary _ m c w _ _ _ m m __ Too...

Page 181: ...embly Install the cylinder head and the head bolts making sure the coolant pipe and a ring are installed correctly see page 5 14 NOTE Coat the 9 mm bolt threads and flange surfaces with molybdenum dis...

Page 182: ...the identification marks made during disassembly ROCKER ARM SHAFT INTAKE VALVE ADJUSTER Clean the camshaft holder thoroughly Blow through all holes and passages with compressed air CAMSHAFT HOLDER ROC...

Page 183: ...of the intake side has a yellow painted mark For shim selection see page 7 24 Tighten the stopper plugs Torque 30 N m 3 0 kgwm 22 ft lb NOTE Align the rocker arm shaft cutouts with the bolt holes in...

Page 184: ...e cylinder head head cover mating sur face facing the intake ports each side Install the two dowel pins onto the cylinder head Install the camshaft holder in the cylinder head aligning the oil holes o...

Page 185: ...r gaskets on the cylinder head Install each shield cover with the rubber gasket glued in the correct position NOTE The shield covers are identified by marks MN5 R right side shield cover MN5 L left si...

Page 186: ..._ _ NOTE Install the tensioner springs with the open ends at the tensioner facing outward Install the washer under the bolt nearest to the drive pulley each side Check that the UP marks on the driven...

Page 187: ...s with 2 kg 4 4 Ib force The belt slack should be 5 7 mm 0 2 0 3 in CAUTION Do not lubricate the belt tensioners Oil will damage the timing belts To protect the sealed tensioner bearirigs do not use s...

Page 188: ...ine the number of shims to be used for the No 1 cylinder valves SHIM SELECTION GAUGE Determine the number of shims to be used for the other cylinder valves in firing order using the same procedure tJ...

Page 189: ...0 012 see page 7 10 Slide the exhaust valve adjusters into the camshaft holder with the oil holes facing up Install the cap on each intake valve adjuster and slide it into position in the camshaft ho...

Page 190: ...holes Torque the bolts Torque 12 N m 1 2 i g m 9 ftmlb Install the cylinder head rear cover with a new gasket NOTE Align the cover holes with the gasket projections Install the timing belt covers with...

Page 191: ...step cover bolts Remove the step cover by releasing its rubber tabs from the chamber protector holes Remove two bolts and chamber protector EXHAUST PIPE RUBBER TABS MUFFLER CHAMBER PROTECTOR 10 N m 1...

Page 192: ...ng the gearshift pedal align the pedal slot with the punch mark on the gearshift shaft Remove two bolts and three nuts and the front exhaust pipe protector Left Side Rear Remove the exhaust pipe see p...

Page 193: ...isconnect the opener cable from the exhaust pipe protector lid Remove the two nuts and the lid from the exhaust pipe protector GEARSHIFT PEDAL Left Side Front Remove the gearshift pedal NOTE When inst...

Page 194: ...ay and drum holder from the cable drum Install the exhaust pipe protector opener in the reverse order of removal After installing the opener check the operation of the exhaust pipe protector lid by tu...

Page 195: ...xhaust pipe joint bolt Remove the exhaust pipe joint cap nuts Disconnect the hot air tube from the exhaust pipe hot air chamber Remove the exhaust pipe Remove the rear exhaust pipe protector Right Sid...

Page 196: ...e the muffler mounting bolt washer and nut Remove the muffler Remove the following mufflers see above one exhaust pipe see previous page Remove the exhaust chamber mounting bolts and nuts Remove the e...

Page 197: ...Scavenging Pump 8 10 Oil Strainer and Main Oil Pump 8 14 Piston Connecting Rod Removal 8 17 Crankpin Bearing 8 21 Piston Connecting Rod Installation 8 23 Crankshaft Removal 8 27 Main Journal Bearing 8...

Page 198: ...ght cylinder head Certain steps are required to prevent valve damage when separating the engine cases without first removing the right cylinder head Section 10 Whenever the case is disassembled remove...

Page 199: ...clutch mounting bolt Alternator drive gear bolt Oil pump driven sprocket bolt Final drive gear lock nut Output shaft lock nut 75 N m 7 5 kg m 54 ft Ib 27 N m 2 7 kg m 20 ft Ib 18 N m 1 8 kg m 13 ft I...

Page 200: ...e scavenging pump draws oil from the clutch housing in the rear engine cover and sends it to the primary drive and driven gears to lubricate and cool them e To remove the main oil pump and scavenging...

Page 201: ...igh Compression Excessive carbon build up on piston head or in com bustion chambers Excessive Smoke Worn cylinder piston or piston rings Improperly installed piston rings Damaged piston or cylinder Ov...

Page 202: ...owing fairing front cover and under cover see page 13 11 water pump see page 5 15 oil pressure switch wire gearshift sensor 6P BLK connector see page 16 13 bolts and front engine cover Remove the dowe...

Page 203: ...Check the O ring and oil seal for damage fatigue or deterioration Replace them if necessary Drive the oil seal out of the holder Drive a new seal into the holder Tools Driver 07749 0010000 Attachment...

Page 204: ...nd gasket Cover Bearing Turn the inner race of each bearing with your finger The bearings should turn smoothly and quietly Check that the outer race of each bearing fits tightly in the rear case cover...

Page 205: ...igue Replace if necessary Drive a new output shaft bearing into the cover Tools Driver on49 0010000 Attachment 62 x 68 mm 07746 0010500 Pilot 30 mm on46 0040700 Press a new needle bearing into the cov...

Page 206: ...ng bolts Remove the scavenging pump by removing its two mounting bolts Remove the dowel pin from the left crankcase Disassembly Remove the following pump cover from the pump body by removing the attac...

Page 207: ...n all removed parts thoroughly Dip them in clean engine oil before reassembly Install a new oil seal into the pump body Install the dowel pins on the pump body Install the inner and outer rotors into...

Page 208: ...scavenging pump to the case Make sure the drive guide is rotating smoothly Installation Install the dowel pin Install the pump on the left crankcase aligning the flat on the pump rotor shaft with the...

Page 209: ...lutch outer holder 07JMB MN501 00 Apply a locking agent to the sprocket bolt threads Install and tighten the washer and bolt holding the clutch outer Torque 18 Nmm 1 8 kg m 13 ft Ib BOSS SPROCKET CWTC...

Page 210: ...nt Install the oil strainer and set ring securely Relief Valve Check Remove the cotter pin valve seat spring and relief valve from the pump body Check the valve for clogging or damage Measure the reli...

Page 211: ...ervice Limit 0 35 mm 0 014 in Remove the rotor shaft spacer and drive pin Measure the side clearance Service limit 0 12 mm 0 005 in Measure the pump body clearance Service limit 0 43 mm 0 017 in Assem...

Page 212: ...th the drive pin Place the spacer into the inner rotor groove Install the dowel pins and pump body NOTE The shaft spacer drive pin and inner rotor are assembled as shown Tighten the pump cover attachi...

Page 213: ...pins Remove the right connecting rod bearing caps Push the connecting rod and piston out through the top of the right cylinder bore Mark them to indicate the correct cylinder No 1 3 and 5 and piston o...

Page 214: ...IVER F I I J O e o 0 o 0 u c L __ __ _ _ Place the piston on the piston base with the piston head toward the arrow on the base Press the piston pin out of the connecting rod with the position pin driv...

Page 215: ...of the piston pin Service limit 18 99 mm 0 748 in Measure the connecting rod small end 1 0 Service limit 18 04 mm 0 710 in Calculate the connecting rod small end to piston pin clearance Service limit...

Page 216: ...1 1 mm 2 80 in Measure each piston 0 0 at three levels in an X axis see above Calculate the piston to cylinder clearance Take the maximum reading to determine the clearance Service limit 0 10 mm 0 004...

Page 217: ...il holes e Do not rotate the connecting rod or crankshaft during the inspection On the crankpin bearings install the bearing caps and rods on the correct crankpins and tighten them evenly Torque 32 N...

Page 218: ...ine the correct replacement bearing color Bearing insert thickness mm in Blue 1 503 1 506 0 05917 0 05929 Black 1 500 1 503 0 05906 0 05917 Brown 1 497 1 500 0 05894 0 05906 Green 1 494 1 497 0 05882...

Page 219: ...m disulfide oil to the cranl pin bearing surfaces CAUTION Make sure the bearing tabs are aligned with the grooves on the rods and caps Piston Connecting Rod Installation Connecting Rod Selection If a...

Page 220: ...51 mm 2 01 in DIMENS ONA 51 mm 2 01 in 07973 65 70210 0 7973 6570300 r PISTON BASE HEAD PISTON BASE J i I i ADJUSTABLE PISTON PIN DRIVER HEAD ADJUSTABl E PISTON PIN DRIVER SHAfT After adjusting the pi...

Page 221: ...in the hydraulic press Using a hydraulic press press the piston pin into the con necting rod until the driver pilot bottoms against the base hydraulic pressure rises slightly Remove the piston assembl...

Page 222: ...nd 5 rod caps on the correct crank pins CAUTION o The bearing caps must be installed in their correct locations or the bearing oil clearance may not be correct This could cause engine damage _ _ _ __...

Page 223: ...ankshaft Inspection Rest the crankshaft on V blocks Set a dial indicator on a center main bearing journal Rotate the crankshaft two revolutions and read the runout at two points Divide the total indic...

Page 224: ...o not rotate the crankshaft during the inspection On the main journal bearings install the main bearing caps and dowel pins on the correct journals o The installation positions of the main bearing cap...

Page 225: ...2 0 0 CODE Record the corresponding engine crankcase bearing support I D codes from the pad on the right side engine case The codes may be I II or III The numerals 1 2 3 and 4 stand for the crankshaft...

Page 226: ...case Install the main bearings onto the right engine case and bearing caps Apply molybdenum disulfide oil to the main bearing surfaces Make sure the bearing tabs are aligned with the grooves on the ca...

Page 227: ...step Apply oil to the main journal cap bolt threads and flange surfaces Install the bearing cap plates and cap bolts Tighten the bolts in a gradual crisscross pattern Torque 10 NGm 1 0 kg m 51 fl Ib...

Page 228: ...nsor pin with the tab as shown Install the O ring onto the oil orifice Install the following a new gasket dowel pins and O ring O rings and oil pipe Shift the transmission into neutral Install the fro...

Page 229: ...stall the removed parts in the reverse order of removal Fill the engine with oil see page 3 14 Fill the engine with coolant see page 5 8 Rear Case Cover Installation Apply sealant to the crankcase sur...

Page 230: ...nstall and tighten a new output shaft lock nut Torque 190 Nmm 19 0 I gmm 131 ft lb Tools Mainshaft holder 07JMB MN50200 Lock nut wrench 30 x 64 mm 07916 MB00001 Stake the output shaft lock nut 2 place...

Page 231: ...ring holder bolts securely Install the following e alternator see page 17 17 o starter motor A SE see page 18 21 I see page 18 51 clutch see Section 9 A SE reverse shift arm see page 18 38 engine see...

Page 232: ...Clutch Service Information 9 2 Troubleshooting 9 4 Clutch Fluid Replacement Air Bleeding 9 5 Clutch Master Cylinder 9 6 Clutch Slave Cylinder 9 9 Clutch 9 10 9 1 goldwingdocs com...

Page 233: ...es get on these parts wipe it off with a clean cloth Clutch service can be done with the engine in the frame To keep the slave cylinder piston from being forced out of the cylinder squeeze the clutch...

Page 234: ...35 N m 3 5 kg m 25 ft Ib 12 N m 1 2 kg m 9tHb 9 3 goldwingdocs com...

Page 235: ...sticking Plates warped Hard to shift into gear Clutch disengaged Gearshift linkage or transmission faulty Section 10 Motorcycle creeps with clutch disengaged o Air bubbles in hydraulic system Low flu...

Page 236: ...n the fluid level in the reservoir is low Use only DOT 4 brake fluid from a sealed container If air is entering the bleeder from around the bleed valve seal the valve with Teflon tape If you don t hav...

Page 237: ...cease to appear in the fluid coming out of the bleed valve Tighten the bleed valve Torque 9 N m 0 9 kg m 7 it Ib Fill the fluid reservoir to the upper level mark with fresh DOT 4 brake fluid from a s...

Page 238: ...fluid Check the primary and secondary cups for damage or deterioration Inspection Check the master cylinder and piston for scoring or other damage Measure the master cylinder 1 0 Service limit 15 93...

Page 239: ...f the master cylinder holder with the index mark on the left handlebar cover Tighten the upper bolt first then tighten the lower bolt Torque 12 N m 1 2 kg m 9 ft Ib Install tile clutch hose on the mas...

Page 240: ...ch lever several times Avoid spilling clutch fluid on painted plastic or rubber parts Place a rag over these parts when ever the liOystem is serviced Remove the clutch hose and bleed pipe if necessary...

Page 241: ...canister California model only see page 4 60 front side covers see page 13 8 Fill and bleed the clutch hydraulic system see page 9 5 Clutch Disassemblyllnspection Drain the engine oil see page 3 13 Re...

Page 242: ...ter race of the release bearing fits tightly in the lifter plate Remove and discard the bearing if the inner race does not turn smoothly and quietly Replace the clutch lifter plate if the outer race d...

Page 243: ...l to the clutch Q To prevent a loss of tension do not compress the diaphragm spring more than necessary to remove the stopper ring Install the clutch center holder onto the clutch pressure plate and t...

Page 244: ...if they show signs of scoring or discoloration Measure each clutch disc thickness Service limit 3 5 mm 0 14 in NOTE Replace the discs and plates as a set Check for plate warpage on a surface plate us...

Page 245: ...B MN501 00 Lock nut wrench 46 mm 07JMA MN501 00 Check the slots in the clutch outer for nicks cuts and indentations made by the friction discs If the surfaces are not smooth or there is evidence of ot...

Page 246: ...1 ftmlb Tool Clutch outer holder 07JMB MN501 00 Lock nut wrench 46 mm 07JMA MN501 00 Stake the lock nut in two places Install the spline washer Coat the discs and plates with clean engine oil A PLATES...

Page 247: ...scs and plates Remove the clutch center assembly from the clutch outer without disturbing the alignment Place spring seat A the clutch spring and spring seat B on the clutch center and compress the sp...

Page 248: ...I l m 13 0 kgwm 94 ft Ib Bend one lock tab of the lock washer up to the lock nut as shown Install the lifter plate and tighten the bolts Torque 10 I l m 1 0 kg m 7 ft Ib Apply grease to the clutch li...

Page 249: ...he clutch lever from the handlebar grip and push the slave cylinder piston in all the way canister California model only page 4 60 left exhaust pipe protector page 7 29 and heat protec tor page 7 32 f...

Page 250: ...hooting 10 5 Gearshift linkage 10 6 Crankcase Separation 10 9 Transmission Disassembly 10 10 Transmission Inspection 10 12 Transmission Assembly 10 14 Crankcase Assembly 10 18 Primary Drivel Driven Ge...

Page 251: ...fS VICE ITEM Gear s hi ft l ink g e Drum center cam plate and stopper arm w _ w _ _ _ _ _ _ _ _ _ _ _ _ __ w _ _ n Shift arm and spindle Crankcase separation REMOVED COMPONENTS Front engine cover thi...

Page 252: ...goldwingdocs com...

Page 253: ...mm 6 mm Shift arm lock bolt Mainshaft lock nut left hand threads Drum center bolt Shift drum lock cam bolt 10 4 35 N m 3 5 kg m 25 ft Ib 26 N m 2 6 kg m 19 ft Ib 12 N m 1 2 kg m 9 ft Ib 25 N m 2 5 kg...

Page 254: ...rum cam grooves damaged A SE Damaged reverse drum lock system Section 18 Transmission jumps out of gear Gear dogs worn Shift shaft bent Shift drum stopper broken Shift forks bent Excessive output shaf...

Page 255: ...plate dowel pins cam plate and dowel pin o Do not drop dowel pins into the engine case Remove the stopper arm If necessary remove the bearing stopper plate and the shift drum bearing out of the engine...

Page 256: ...damage or excessive play Installation Install the washer onto the shift arm Install the shift arm aligning the return spring ends with the pin Install the shift spindle onto the left engine case and...

Page 257: ...e collar and spring as shown Install the stopper arm washer and flange nut Tighten the bolt securely Install the dowel pin in the shift drum Install the cam plate in the shift drum by holding the shif...

Page 258: ...essary components for separation before separating the crankcases see page 10 2 Remove the 22 bolts NOTE _ _ Eight 10 mm bolts have sealing washers Place the engine with the right crankcase down Pull...

Page 259: ...see page 10 9 NOTE The mainshaft can be removed without removing the gearshift linkage Remove the mainshaft Unstake the mainshaft front bearing lock nut with a drill or grinder Hold the mainshaft with...

Page 260: ...5 Remove the countershaft front bearing and pull the countershaft out of the gears Disassemble the countershaft gears Turn the inner race of each bearing with your finger The bearings should turn smoo...

Page 261: ...Nmm 1 2kgm m 9 ft I GL1500 I If necessary remove the shift drum bearing set collar bolt and remove the shift drum bearing set collar and bearing Assemble in the reverse order of disassembly Apply a lo...

Page 262: ...s M4 MS C2 C3 34 04 mm 1 340 in Measure the 0 0 of these gear bushings Service limits M4 MS C2 C3 33 92 mm 1 335 in Calculate the clearance between the gears and bushings Service limit 0 10 mm 0 004 i...

Page 263: ...C2 SHIFTER SHIFTER REAR SIDE COUNTERSHAH Clean all removed parts in solvent Dip them in clean engine oil before they can be reassembled NOTE _ _ _ _ _ _ N h _ o Align the oil holes in the bushings wit...

Page 264: ...stall the bearing holder with the OUTSIDE mark facing out Apply locking agent to the bolt threads and tighten the bolts securely Assemble the C3 gear C3 bushing and center shifter as shown Apply molyb...

Page 265: ...er race of the bearing as shown Install the C5 gear collar C4 gear C3 assembled gear and assembled gears above step to the countershaft as shown Do not drop the washer into the engine case Install the...

Page 266: ...ld the mainshaft with the shaft holder and tighten the lock nut NOTE The mainshaft lock nut has left hand threads Torque 190 Nwm 19 0 kgwm 137 ftmlb Tool Mainshaft holder 07JMB MN50200 Stake the lock...

Page 267: ...oat the cylinders pistons and piston ring grooves with oil Make sure that the piston ring end gaps are staggered as shown on page 8 24 Turn the crankshaft counterclockwise until the T1 2 drive pulley...

Page 268: ...n base B rubber with its notch toward the connecting rod under the No 2 piston timing belt side Install the ring compressors on the pistons so that their tapered sides are facing up and the splits are...

Page 269: ...cables on the piston ring compressor at the same time to separate the two halves Then remove the piston ring compressor To remove the NO 4 center piston ring compressor shift the crankcase away from...

Page 270: ...ng washers Begin with larger diameter bolts first Torque Vah lles 10 mm Case bolts 8 mm Case bolts 6 mm Case bolts 35 N m 3 5 kg m 25 ft Ib 26 N m 2 6 kg m 19 ft Ib 12 N m 1 2 kg m 9 ft Ib SEALING WAS...

Page 271: ...bolt and washer holder and clutch outer Remove the special tools Remove the driven sprocket drive chain and primary driven gear boss as an assembly from the mainshaft Remove the spline washer and prim...

Page 272: ...a new needle bearing into the boss NOTE o Use the installed height shown below Tools Driver 07749 0010000 Attachment 32 x 35 mm 07746 0010100 Pilot 28 mm 07746 0041100 DRIVER ATIACHMENT PIL01 NEEDLE...

Page 273: ...ily install the clutch outer and clutch outer holder so that the oil pump sprocket cannot be rotated Tool Clutch outer holder 07JMB MN50100 Apply a locking agent to the sprocket bolt threads Install a...

Page 274: ...the threads on the countershaft are not damaged Set the transmission in any gear Remove the lock nut by turning it clockwise NOTE The lock nut has a left hand thread Tool Mainshaft holder 07JMB MN5020...

Page 275: ...outer race of the bearing with your finger The bearing should turn smoothly and qUietly Also check that the inner race of the bearing fits tightly on the output shaft Remove the snap ring retainer an...

Page 276: ...ut Shaft 0 0 Collar 100 0 0 Driven Gel ll to Assembly 21 99 mm 0 866 in 22 05 mm 0 868 in 25 95 mm 1 022 in 26 03 mm 1 025 in OUTPUT SHAFT DAMPER SPRING WASHER COLLAR 1 REVERSE DAMPER FINAL DRIVEN GEA...

Page 277: ...ess a new bearing with the sealed side facing up into the output shaft Tool Inner driver B 07746 0020100 Install the cotters and retainer Rotate the retainer 180 degrees and set the retainer tab in th...

Page 278: ...the shaft Install the spring washer with its dished side facing the final drive gear Set the transmission in any gear except neutral Apply a locking agent to the threads of a new lock nut and install...

Page 279: ...Transmission Output Shaft col lt d Install the output shaft as an assembly Install the primary drive and driven gear see page 10 23 10 30 goldwingdocs com...

Page 280: ...ive Service Information 11 2 Troubleshooting 11 3 Gear Case Removal 11 4 Drive Shaft 11 4 Universal Joint 11 5 Gear Case Disassembly 11 6 Gear Case Assembly 11 14 Gear Case Installation 11 17 goldwing...

Page 281: ...BOft O 150 N m 15 0 kg m 108 ft Il l 26N m 2 k _m 20 N m 2 0 kg m 14 Ib Torque Values Pinion bearing retainer Pinion joint nut Gear case cover bolt 10 mm 8mm Final drive gear case mounting nut Final d...

Page 282: ...d drive pinion and splines Worn pinion and ring gears Excessive backlash between pinion and ring gear Oil level too low Oil leak Clogged breather Oil level too high Seals damaged Loose cover bolt Rear...

Page 283: ...thly and quietly case each bearing drive pinion ring gear See page 11 6 for gear case disassembly Drive Shaft Removal Insert the axle and distance collar through the gear case Secure the case in a vis...

Page 284: ...OIL SEAL Removalllnstallation Remove the swing arm see page 12 26 Remove the universal joint from the swing arm Inspect the universal joint There should be no play in the bearings Rotate the shaft an...

Page 285: ...ck is taken Turn the ring gear back and forth to read backlash Standard O 05 O 15 mm O 002m O 006 in Service limit 0 3 mm 0 01 in Remove the dial indicator Turn the ring gear 120 degrees and measure b...

Page 286: ...er If the ring gear stays in the cover do the following Place the cover in a press with the ring gear down Make sure the cover is securely supported Press the ring gear out of the cover Tool Attachmen...

Page 287: ...r and its spacer into the cover see page 11 16 Tighten the cover bolts gradually in a crisscross pattern until the cover evenly touches the gear case Then while rotating the drive pinion tighten the b...

Page 288: ...ing ring gear bearing and or gear case is replaced install a 2 00 mm 0 079 in thicl spacer standard 5 Do not damage the ring gear If the patterns are not correct remove and replace the pinion spacer R...

Page 289: ...cer standard _ Support the bearing inner race with the inner base and press the ring gear into the bearing with a suitable tool Tool Inner base 07965 3710300 Apply gear oil to the case cover oil seal...

Page 290: ...4 holes increased to 10 5 mm or 07924 9690102 Pinion joint holder 07924 ME40000 Shaft puller 07931 ME40000 or 0 931 ME4000A U S A only Pull the bearing outer and inner races off the shaft with the uni...

Page 291: ...E e Position the marked side of the outer race to the out side Remove the O ring and oil seal from the pinion retainer Coat a new O ring with oil and install it on the retainer Apply grease to a new o...

Page 292: ...grease to the oil seal lips Drive a new oil seal into the case Drive a new bearing into the case Tools Driver 07749 0010000 Attachment 62 x 68 mm 07746 0010500 Pilot 35 mm 07746 0040800 NOTE Drive th...

Page 293: ...a pinion retainer lock tab and tighten the bolt Torque 10 N m 1 0 kg m 7 ftmlb NOTE There are two types of lock washers as shown Apply grease to the pinion joint spline Install the pinion joint to th...

Page 294: ...ver Measure the clearance between the ring gear and the ring gear stop pin with a feeler gauge Clearance O 30m O 50 mm O 012m O 024 in Remove the ring gear if the clearance exceeds the standard Heat t...

Page 295: ...hten the cover bolts in a gradual crisscross pattern until the cover evenly touches the final drive case Then while rotating the pinion tighten the bolts to the specified torque in a gradual crisscros...

Page 296: ...the drive shaft oil seal Loosely attach the gear case on the swing arm To ease axle installation do not tighten the gear case mounting nuts until after the axle is installed Make sure the distance co...

Page 297: ...spension Service Information 12 2 Troubleshooting 12 6 Fork Legs 12 11 Shock Absorbers 12 20 Swing Arm 12 16 On Board Air Compressor System 12 31 Handlebar Stem 12 41 Steering Stem 12 41 12 1 goldwing...

Page 298: ...pressures Do not use the side stand when adjusting the ail pressure as you will get false pressure readings gON m 9 0 kg m 65 ft Ib 22 N m 2 2 kg m 16 ft Ib Torque Values Anti dive case socket bolt F...

Page 299: ...ount bolt Right shock absorber mount bolt Upper Lower Upper Lower e _ 15 N m 1 5 kg m 11 ft Ib 12 3 17 ft b 19 N m 1 9 kg m 14 ft Ib Zi 70 N m 7 0 kg m 51 ft Ib 23 N m 2 3 kg m 17 ft Ib 70 N m 7 0 kg...

Page 300: ...Frame Suspension Service Information cont d System Location A SE only LCD UNIT goldwingdocs com...

Page 301: ...White Lab A On Radiator s _ _ _ Near Thermostatic s _ _ _ Fan Motor Switch z z 2P WHT l f t B On Engine Near a f f 12 mIni L T J _ l Coo CJ C v lant Temperature Switch I r C Engine Near I IA l Dipsti...

Page 302: ...r right Weak rear damper Insufficient fluid weight low viscosity 12 6 Hard Suspension Shock absorber improperly adjusted right Incorrect fluid weight high viscosity Too much air pressure rear right Cl...

Page 303: ...K terminal on the wire harness side and ground H with the ignition switch ACC ON or P Battery voltage should register see page 12 36 Yes No Open or short circuit in LT GRN BLK wire or RED wire Loose o...

Page 304: ...or short circuit in BRNNEL wire Open or short circuit in wire harness Loose or poor contact of connector Faulty check switch A bnormal D Faulty air hoses Loose connections of hoses Abnormal Faulty so...

Page 305: ...k the solenoid valve for operation see page 12 33 Fa __N_O __ Open circuit in BRN WHT wire Loose or poor contact of related connectors Abnormal _ _ Faulty solenoid valve rubber seat Clogged air passag...

Page 306: ...WHT connector Measure voltage between LT GRN BLK and ground Battery voltage should register Yes CHECK SWITCH Tum the ignition switch to ACC ON or P Disconnect the instrument 14P BLK connector Measure...

Page 307: ...fork bolt The fork bolt is amder high spring pressure Use care when loosening the bolt Loosen the fork leg upper pinch bolt Loosen the fork leg lower pinch bolts and remove the fork leg NOTE Be caref...

Page 308: ...ed from the fork tube NOTE FORK BOLT ASSEMBLY TOOL AITAC A lJ R l FO TUBE FORK BOLT ASSEMBLY TOOL LOWER iu ACHMENT o A I FORK TUBE Do not make a large gap between the shaft and attachment of the tool...

Page 309: ...shing unless it requires replacement Remove the stopper ring oil lock valve oil lock spring and spring seat from the fork piston Remove the oil seal back up ring and slider bushing from the fork tube...

Page 310: ...er than the service limit Service limit 382 6 mm 15 01 in Check the fork tubes fork sliders and pistons for score marks scratches or abnormal wear Check the fork piston rings for wear or damage Check...

Page 311: ...anti dive case is under spring pressure Use care when removing the case to keep it from becoming a projectile Check the packing spring piston washer and a rings for damage wear or deterioration Repla...

Page 312: ...N m 2 0 kg m 14 ft Ib FORK TUBE BUSHING DUST SEAL STOPPER RING Oil SEAL BACK UP RING 110 SLIDER BUSHING I model left side Assembly Clean all disassembled parts DUSTSEAL BACK UP RING STOPPER RING _ OI...

Page 313: ...on Coat a new oil seal with suspension fluid and install it with the seal mark facing up OIL SEAL BACK UP I IRING OIL LOCK VALVE SPRING OIL LOCI PIECE STOPPER RING FORK TUBE USHING SUDER BUSHING Insta...

Page 314: ...attachment 07947 KF00100 Place the fork slider in a vise with soft jaws CAUTION Install the stopper ring and dust seal If you installed the fork spring earlier remove the fork bolt and fork spring see...

Page 315: ...f the fork tube Tool Fork bolt assembly tool 07KMF MT20300 Wipe oil off the spring and spacer thoroughly using a clean cloth Install the spring with its tightly wound coil end facing down Install the...

Page 316: ...ge 13 17 Remove the shock absorber lower mount bolt and upper mount bolt Remove the left shock absorber upward from the frame Removal Right Place the motorcycle on its center stand Remove the right sa...

Page 317: ...tachment 07959 MB10000 Compress the spring until the spring stopper seat can be removed Remove the stopper seat Disassemble the shock absorber NOTE Compress the spring while tightening the attach ment...

Page 318: ...ompress the spring until the spring stopper seat can be installed Remove the compressor Oil seal Replacement Right A SE models Remove the air valve from the outlet air hose SPRING ATTACHMENT SEAT I mo...

Page 319: ...into the outer case Fill the seal remover pump with Honda Suspension Fluid SS 7 or equivalent Connect the attachment hose to the shock s air valve stem Tool Seal Remover Pump 07971 M01000A EqUivalent...

Page 320: ...al in suspension fluid and install it onto the damper with its lip side toward the damper case CAUTION o Be careful not to damage the oil seal lip during installation Remove the tape from the shock an...

Page 321: ...6 N m 0 6 k mm 4 ftmlb I model Install the air valve with a ring to the air hose Apply suspension fluid to new O rings and connect the air hose to the shock absorber Tighten the air hose bolt to the...

Page 322: ...lly as shown _ All models Install the right saddlebag see page 13 17 Removal LOCK NUT WRENCH LOCK NUT lEfT SIDE ONLY Place the motorcycle on its center stand on a level sur face Remove the following r...

Page 323: ...wear Check the bearing dust seals for damage or wear Replace if necessary NOTE Always replace pivot bearings races and grease holders in pairs Check the grease holders for damage or deformation Check...

Page 324: ...l into the right side Drive the new bearing races squarely into the swing arm Tools Driver 07749 0010000 Attachment 37 x 40 mm 07746 0010200 DRIVER ATIACHMENT Apply grease to the right grease holder d...

Page 325: ...ersal joint in the swing arm with the long splines to the front Position the swing arm in the frame Grease the tips of the pivot bolts and loosely install them NOTE Make sure that the ends of the pivo...

Page 326: ...en retorque the pivot bolt Tool Hex socket 17 mm Install the pivot lock nut on the pivot bolt Hold the pivot bolt and tighten the pivot lock nut to a torque wrench reading of 90 N m 9 0 kg m 65 ft Ib...

Page 327: ...6 kg m 4 ft Ib 8 Special 15 N m 1 5 kg m 11 ft Ib Air Pump Removal Remove the trunk and left saddlebag see page 13 14 Remove the rear fender rear mounting bolt Disconnect the 2P WHT connector at the...

Page 328: ...essary Clean the inside of the body and the cover open ings with compressed air Assemble the drier in the reverse order of dis assembly Ail Pump Inspection Use a 12V battery to energize the pump motor...

Page 329: ...ve drain tube and remove the air distributor as an assembly Solenoid Valve Inspection Connect a pressure pump to the suspension valve yellow label output port and apply pressure Tool Pressure pump ST...

Page 330: ...d GRN RED terminals Standard O 7m 1 3K ohms 20 C 68 F Measure the resistances between the BLKlGRN and LT BLU terminals and LT BLU and GRN RED terminals of the sensor by applying gradually increasing p...

Page 331: ...5 N m 11 5 kg m 11 ft lb 10 N m 1 0 kg m 7 ft Ib REUEf VALVE WHITE LABEL 3 N m 10 3 kg m 2 ft lb NSIONVALVE s 7iowLABELl f 6 N m 10 6 kg m 4 ft lb AIR DISTRIBUTOR BODY Air Pressure Control Switch Insp...

Page 332: ...spection Open the relay box cover under the left rear side cover Turn the ignition switch to ACC ON or P position Depress the P CHECK button The relay primary coil is normal if it clicks Continuity In...

Page 333: ...ster cylin der e Do not twist the brake or clutch hoses Release the right handlebar switch wire harness from the clamp Remove the wire band from the handlebar Remove the handle upper holders and handl...

Page 334: ...the center clamp Install the handlebar cover each side Secure the upper end of the handlebar covers by fasten ing the tab at the upper end Install and secure the handlebar cover set plates with the sc...

Page 335: ...housing to the handlebar aligning the boss of the housing with the hole in the handlebar Set the choke cable holder securely into the housing groove Secure the housing with the screws tighten the forw...

Page 336: ...e housing with the screws tighten the forward screw first then the rear screw Install the brake master cylinder and holder aligning the end of the holder with the arrow mark on the handlebar cover Ins...

Page 337: ...em grommet and slide it all the way to the wire harness CAUTION m Apply a soapy water solution to the wire harness surface to allow the grommet to slide smoothly Remove the retaining screws and move t...

Page 338: ...m socket 07916 3710100 Check the top and bottom bearings and races for wear or damage and replace if necessary CAUT IO N Steering head bearings and races are supplied in matched sets to ensure a preci...

Page 339: ...emover 07953 4250002 Bearing race remover 07946 3710500 NOTE Always remove the top race before driving out the bottom race Install a new bottom race Tools Driver 07749 0010000 Attachment 52 x 55 mm 07...

Page 340: ...stment nut as follows 1 Tighten the adjustment nut to 40 N m 4 0 kg m 29 ft Ib 2 Turn the steering stem lock to Iock five times to seat the bearings 3 Loosen the adjustment nut until it is hand tight...

Page 341: ...mm Torque 100 N m 10 0 kg m 12 ft lb Loosen the lower for pinch and install the fork legs see page 12 19 Install the following o Front fender see page 13 18 o Front wheel see page 15 8 Place a stand...

Page 342: ...py water solution to the wire harness surface to allow sliding the grommet smoothly All models Install the handlebar see page 12 37 A SE models Install the handlebar center cover securely All models F...

Page 343: ...in oay Components Service Information 13 2 Windshield 13 3 Fairing 13 6 Trunk Saddlebags 13 14 Front Fender 13 18 Rear Fender 13 19 Adjustable Passenger Footrests SE 13 20 Footrests 13 22 goldwingdocs...

Page 344: ...Fairin ody Components Service Information When removing a cover be careful not to damage any tab or groove Installation is reverse of removal unless noted otherwise 13 2 goldwingdocs com...

Page 345: ...e the trim from the fairing Remove the screws and windshield Install a new windshield Align the setting plates with the holes of the windshield and tighten the screws securely NOTE Position the two la...

Page 346: ...screw securely Install the grille and visor on the windshield aligning the tab on the grille with the slot in the visor Install then tighten the screws securely Windshield lever Replacement A Sf only...

Page 347: ...ion Measure the windshield lever preload The scale should average 5 0 8 0 kg 11 0 17 6 Ib for the heaviest pre load If the preload is not within the above specification loosen the screw and return to...

Page 348: ...airing _ Components NOTE _ Re m o th det e fairing fol _ _ __ ailed instru t oWing steps 1 __ _ clans se through 4 __ _ _ e pages 13 8 For through 13 12 Step Step 2 Wf INNER COVER RIGHT 13 6 goldwingd...

Page 349: ...Step 3 Step 4 FAIRING FRONT GRILLE goldwingdocs com...

Page 350: ...from the three rubber holes on the frame Free the rubber hole from the top compartment bracket bolt Remove the rear side cover Front Side Cover Release the cover s two bosses from the frame rubber hol...

Page 351: ...es Release the cover front tab from the instrument panel Remove the ignition switch cover Top Inner Cover Remove the top inner cover by releasing its tabs from the fairing Top Compartment Remove the f...

Page 352: ...assette deck Push the lever and remove the radio cassette deck cover from the top compartment Remove the four screws and radio cassette deck from the top compartment CAUTION Route the radio cassette d...

Page 353: ...the upper position Release the windshield trim from the windshield Remove the instrument panel from the fairing Fairing Front Cover Release the cover s two bosses from the rubber holes of the fairing...

Page 354: ...airing Inner Covers Remove the following seat see page 13 8 fairing pockets see pages 13 8 9 ignition switch cover see page 13 9 top inner covers see page 13 9 top compartment see page 13 9 fairing lo...

Page 355: ...g fairing Remove the fairing inner covers see previous page and air ducts see above Remove the headlight see page 19 12 Remove the bolt on both sides and solenoid valve bracket Disconnect the instrume...

Page 356: ...nk Saddlebags NOTE For detailed removal instructions see the next two pages See Section 15 Rear Wheel Removal for instruc tions to remove the trunk and saddlebags as an assembly 13 14 51 0 SADDLEBAG L...

Page 357: ...tabs with the lower cover grooves securely Trunk A I models Remove the trunk lower cover above Open the saddlebags and disconnect the opener cables from the cable stoppers see page 13 16 TAB AND GROO...

Page 358: ...the saddlebags and disconnect the opener cables from the cable stoppers Disconnect the antenna connector and antenna ground wire see page 20 16 Remove the trunk Trunk Opener Open the trunk lid Remove...

Page 359: ...operates properly by turning the key CAUTION If the striker latch is not released completely the lmk lid cannot be opened _ Saddlebag Lowell Covell Remove the screw holders Remove two screws and the s...

Page 360: ...Remove three bolts two collars and clamp Remove the disc cover each side NOTE The upper bolt does not have a collar See the illustration Remove the bolt caps Remove the socket bolts and collars Remov...

Page 361: ...and rear fender A A SE models Remove the screws Remove the reverse control unit and auto cruise control unit from rear fender B by releas ing the unit tabs from the fender grooves Release the air dis...

Page 362: ...CABLE STAY NKARM I _ FOOTREST Footrest Remove the front side cover see page 13 8 Remove the two screws and the footrest bracket cover Slide the link cover boot upward and remove the two socket bolts f...

Page 363: ...move up and down without binding Also check that both footrests are locked securely at the desired position when you release the remote lever Measure footrest remote lever free play at the tip of the...

Page 364: ...her and pin Remove the footrest Remove the socket bolt and bracket cover Remove the two bolts and holder cover Remove the two bolts and collars Remove the holder cover bracket Installation is the reve...

Page 365: ...luid Replacement Air Bleeding 14 5 Brake Pad Replacement s 14 7 Brake Disc Inspection S 14 11 Front Master Cylinder s 14 12 Rear Master Cylinder 14 14 Front Brake Caliper 14 19 Rear Brake Caliper s 14...

Page 366: ...brake which is independent of the unified system I Spilled brake fluid will severely damage instrument lenses the windshield and painted surfaces It is also harmful to some rubber parts Be very caref...

Page 367: ...caliper pin bolt Metal brake line nut Brake pedal bolt 35N m 3 5 kg m 25 ft Ib 12 N m 1 2 kg m 9 ft Ib 6 N m 0 6 kg m 4 ft Ib 23 N m 2 3 kg m 17 ft Ib 12 N m 1 2 kg m 9 ft Ib 2 5 N m 0 25 kg m 1 8 ft...

Page 368: ...lic system sticking Sticking piston s Clogged hydraulic system G Incorrect rear brake pedal adjustment Caliper side slide pin sticking Caliper installed incorrectly Disc or wheel misaligned 14 4 Brake...

Page 369: ...e NOTE _ _ _ s Add fluid when the fluid level in the reservoir is low s Use only DOT 4 brake fluid from a sealed container s If air is entering the bleeder from around the bleed valve seal the valve w...

Page 370: ...NOTE Connect a commercial brake bleeder such as the Mityvac NQ 6860 to the bleed valve Open the bleed valve and pump the brake bleeder until new brake fluid appears coming out of the bleed valve and...

Page 371: ...approved vacuum cleaner or an OSHA approved alternate method designed to minimize the hazard caused by airborne asbestos fibers NOTE e Always replace the brake pads in pairs to assure even disc press...

Page 372: ...own NOTE Make sure that tabs of the pad spring face the wheel side Install the new pads in the caliper If you removed the caliper bracket install it applying sili cone grease to the caliper slide pins...

Page 373: ...pins and pad pin plugs Torque Pad pin 18 N m 1 8 kgmm 13 ft Ib Pad pin plug 2 5 N m 0 25 kg m 1 8 ft Ib NOTE Operate the brake lever to seat the caliper pistons against the pads Install the disc cover...

Page 374: ...e sure that the tabs of the pad spring face the wheel Install the new pads in the caliper Install one pad pin Then push the pads to compress the pad spring while you install the other pin Place the pa...

Page 375: ...caliper pistons t th pads _ __ __ Install the left saddlebag see page 13 17 Brake Disc Inspection Front Remove the disc cover see page 13 18 Rear Remove the left saddlebag see page 13 17 Measure the t...

Page 376: ...CH WIRES WIRES Remove the following brake light switch wires A SE cruise cancel switch wires A SE holder cap brake hose master cylinder holder and master cylinder brake lever switch piston boot BRAKE...

Page 377: ...if worn or damaged Assembly NOTE The master cylinder piston cups and spring must be installed as a set Coat all the parts with clean DOT 4 brake fluid before assembly Install the spring and piston NOT...

Page 378: ...t then tighten the lower bolt Torque 12 N m 1 2 kg m 9 f1 1b Install the brake hose on the master cylinder with the oil bolt and two new sealing washers NOTE MASTER CYLINDER BOLTS J BOLT Rear Master C...

Page 379: ...eep foreign matter out or the performance of the control valve will be affected The pressure control valve cannot be dis assembled Do not attempt to disassemble it Remove the rear brake cruise cancel...

Page 380: ...re the master cylinder 1 0 Service limit 15 925 mm 0 6210 in Check the primary and secondary cups for damage or deterioration Replace if worn or damaged Measure the master piston 0 0 as shown Service...

Page 381: ...1 9 in Check the a ring for fatigue Install the a ring and reservoir joint with its screw A SE Install the rear brake cruise cancel switch to the rear master cylinder with two screws If the joint of t...

Page 382: ...ake rod clevis to the brake arm with the clevis pin Install the washer and new cotter pin Bend the cotter pin as shown A SE Connect the 2P RED connector to the connector holder behind the ignition con...

Page 383: ...he nozzle too close to the inlet e Place a shop towel over the pistons to prevent them from flying oui Examine the pistons and cylinders for scoring scratches or other damage Replace if necessary Push...

Page 384: ...Be careful not to damage the pads installation Install the caliper bracket on the fork leg Tighten the caliper bracket bolt and anti dive piston bolt Torque Caliper bracket bolt 23 N m 2 3 kg m 11 ft...

Page 385: ...lar from the rear brake caliper If the boots are hardened or deteriorated replace them Position the caliper with the pistons facing down and apply short bursts of air pressure to the fluid inlet _ _ D...

Page 386: ...r and the insides of the boots and install them into the caliper CAUTiON Make sure that boots are seated in the caliper grooves Install the pad spring pads and pad pins see page 14 10 CAUTION Be caref...

Page 387: ...return spring Remove the brake arm PEDAL COTTER PIN WASHER Installation Apply grease to the brake pedal shaft and install it to the pivot hole PIVOT HOLE Install the brake pedal return spring and rea...

Page 388: ...em see page 14 5 Remove the following battery and battery holder see page 17 7 o left rear side cover see page 13 8 o left saddlebag see page 13 17 Remove the metal line clamp from the swing arm Disco...

Page 389: ...r master cylinder Remove the center metal line sideways to the right Loosen the front metal line nut using an open ring spanner from the rear master cylinder CENTER METAL LINE NUT CENTER METAL LINE FR...

Page 390: ...TE o Be careful not to twist the metal lines when tightening the metal line nuts Secure the front metal line with the clamp as shown Make sure the brake lines do not contact any moving parts Check for...

Page 391: ...WheelslTires Service Information 15 2 Troubleshooting 15 4 Front Wheel 15 5 Rear Wheel 15 10 Wheel Balancing 15 20 goldwingdocs com...

Page 392: ...pport the motorcycle The motorcycle may be damaged if it is not supported on the indicated jack point see page 15 5 Wheel bearings must not be re used after they have been removed Always use new beari...

Page 393: ...Caliper bracket bolt Anti dive piston bolt Right front caliper bracket bolt I model 12 N m 1 2 kg m 9 ft Ibl 40 N m 4 0 kg m 29 ft Ib 22 N m 2 2 kg m 16 ft Ib 90 N m 9 0 kg m 65 ft Ib 70 N m 7 0 kg m...

Page 394: ...rks Bent frame Forks installed incorrectly Axle installed incorrectly Bent swing arm Wheel installed incorrectly Front wheel wobble or vibration Loose axle front or rear Loose wheel bearings Loose ste...

Page 395: ...box Remove the caliper bracket bolt and anti dive piston bolt Remove either the right or left caliper assembly CAUTION Support the removed caliper with a piece of wire so that it does not hang from th...

Page 396: ...Inspection Place the wheel in a truing stand Spin the wheel slowly and measure the runout with a dial indicator gauge Service limits Radial Runout 2 0 mm 0 08 in Axial RUl1out 2 0 mm 0 08 in Replace...

Page 397: ...nt Remove the bearings and the distance collar from the hub Tools Bearing remover Commercially available NOTE o Do not reuse the removed bearings Install new bearings Assembly _ Do not get grease on t...

Page 398: ...al lip cavity with grease Install the speedometer gear retainer in the left wheel hub Coat the speedometer gear with grease Install the speedometer gear box onto the dust seal aligning the tabs of the...

Page 399: ...he left brake disc and the left brake caliper bracket with a 0 70 mm 0 028 in feeler gauge If the feeler gauge cannot be inserted easily loosen the front axle pinch bolts and move the left fork slider...

Page 400: ...en the left and right saddlebags Inside both remove the cap found at the front of the saddlebag to gain access to the lower rear frame bolt Loosen the lower rear frame bolt each side Loosen the muffle...

Page 401: ...k on the rear section to slide the lower rear frame tubes away from the loosened bolts Lift the rear section off the motorcycle Trunk Saddlebags Removal without a helper Remove the following e trunk l...

Page 402: ...caliper with a wire so that it does not hang from the brake hose Do not twist the brake hose NOTE Do not depress the brake pedal when the caliper is removed or it will be difficult to refit the disc b...

Page 403: ...e the driven flange from the wheel hub CAUTION Be careful not to damage the wheel hub NOTE The pins and nuts cannot be removed Remove the damper holder bolts Tum the damper holder clockwise and align...

Page 404: ...stall new bearings Assembly DISC DUST SEAL DISTANCE COLLAR MOLY 60 PASTE 20 N m 2 0 kg m 14 ft Ibl G O RINGS DRIVEN FLANGE Pack the new bearing cavities with grease Drive in the left bearing mono firs...

Page 405: ..._ _ _ _ mu _ Install each rubber damper with the OUTSIDE mark facing outward Install the damper holder into the wheel hub Align the arrow marks on the damper holder and wheel hub then turn the damper...

Page 406: ...tall the rear wheel onto the final gear case aligning their splines Install the rear axle collar in the dust seal positioning it as shown Position the caliper and bracket as an assembly over the disc...

Page 407: ...l the pinch bolt Install and tighten the left shock absorber lower mount bolt Torque 70 N m 700 kg m 51 ft Ib Install and tighten the rear axle nut Torque 110 N m 11 0 kg m 80 ft Ib Tighten the rear a...

Page 408: ...SECTION LOOSENED BOLT EACH SIDE Install the upper rear frame bolts Push the rear frame forward Tighten the lower rear frame bolts each side Install the cap securely each side Tighten the upper rear fr...

Page 409: ...to new a rings Connect the air hose to the shock absorber Tighten the air hose bolt to the specified torque Torque 6 N m 0 6 kgmm 4 ft Ib NOTE _ _ _ Install the hose vertically as shown All models In...

Page 410: ...the wheel on its axle and clamp the axle in a vise with a shop towel or preferably a vise with soft jaws Spin the wheel allow it to stop and mark the lowest heaviest part of the wheel with chalk Do th...

Page 411: ...16 4 Engine Control Module m 16 7 Ignition Coil w w 16 8 Ignition Pulse Generator 16 10 Gear Position Switch 16 13 Side Stand Switch 16 14 Engine Coolant Temperature Sensor 16 15 Engine Stop Switch 1...

Page 412: ...module electronically varies ignition times according to engine speed and intake manifold vacuum The gear position switCh engine coolant temperature sensor and intake air temperature sensor signal th...

Page 413: ...T V LT GIlII GRY IlLACK YELLOW IILl GRWi RED WMIT IlLK VEL BLU GRII AEO wHT IGNT10N SWITCH i IACe FAN P TLI TU LOCI j OFF i i ACe 0 ON tO K Fa 0 ro I 1O I I I i T _ I I _ S ENGINE STOP SWITCH rrrc r G...

Page 414: ...lfi I A l I II I L __ J __ J i i l i Ii i i I 1 lI l ij 1 J _ ENGINE Z SIlE S1Wl COOLANT S1lITCH TEMPERATURE SENSOR GIlOlJIC P JM 14 Ort NMr F lilolIlrSMlct It tOrt E NNr Coolon T _ SMIc l 11 ii ill...

Page 415: ...unit connectors Good Conmct ENGINE CONTROL MODULE Perform the engine control module system inspection see page 16 7 All normal ROTOR Check that the ignition pulse generator rotor bolt is tight and tha...

Page 416: ...esistance Abnormal Loose or poor contact of the ignition coil 4P connector Open circuit in wire harness IGNITION COIL Measure the ignition primary coil resistance at the 4P WHT connector see page 16 8...

Page 417: ...r contact of connector I m Faulty engine control module Poor performance driveability and poor fuel economy Faulty ignition timing see page 16 17 Fuel system malfunction see Section 4 Engine starts bu...

Page 418: ...NO CONTINUITY with the side stand down _ _ _ _ m CONTINUITY 2 0 3 0 k ohms 20 C 68 F 200 400 ohms 80 C 176 F PNK WHT and GRN BLK GRN WHT and ground PC 1 PC 2 Neutral Second gear Third gear Fourth gea...

Page 419: ...connector from the wire harness Measure the primary coil resistance between the follow ing terminals 1 2 coil YELJWHT and BLK WHT 3 4 coil YEUBLU and BLK WHT 5 6 coil YEURED and BLK WHT Standard 2 6M...

Page 420: ...tion coils Installation Install the ignition coils on the ignition coil stay as shown Route the spark plug wires properly onto the wire clamp as shown Connect the ignition coil wires on the primary te...

Page 421: ...e 13 12 Ignition Pulse Generator Inspection Remove the right fairing lower cover see page 13 12 Disconnect the 4P WHT connector of the connector holder on the right cooling fan 4P WHT CONNECTOR WIRE C...

Page 422: ...T connector Install the following right timing belt see page 7 22 timing belt covers o under cover fairing front cover see page 13 11 and right fairing lower cover see page 13 12 Ignition Pulse Rotor...

Page 423: ...IDE mark facing out aligning the rotor key with the crankshaft keyway Install guide plate A aligning its projection with the pulley hole Install the washer and timing belt drive pulley bolt lighten th...

Page 424: ...BlK CONNECTOR ation ty ty ty ty ty on Terminais Specific LT GRN RED and Continui ground r BLK YEL and ground Continui WHT RED and ground Continui REDIWHT and ground Continui r GRN ORN and ground Conti...

Page 425: ...and GRNIWHT and GRN Continuity raised YEUBLK and GRN No Continuity _ Removal Remove the left front side cover see page 13 8 Remove the side stand switch mounting bolt Release the wire clamps and remov...

Page 426: ...lectric heating element Weal insulated gloves and adequate eye pro tection If resistance is outside the above ranges replace the engine coolant temperature sensor If the engine coolant temperature sen...

Page 427: ...or holder on the right cooling fan Install the following right cooling fan see pages 5 11 right radiator see page 5 10 right fairing lower cover see page 13 12 Fill the cooling system with coolant see...

Page 428: ...rew The timing is correct if the guide plate F 1 2 mark aligns with the timing cover index mark at idle Connect the timing light to the No 3 or NO 4 cylinder spark plug wire and check the ignition tim...

Page 429: ...hrottle stop screw while testing the vacuum advance Place the motorcycle on the center stand start the engine and warm it to operating temperature above 50 C 122 F We the clutch lever to the handlebar...

Page 430: ...ngine coolant temperature sensor in the GL Cool the test engine coolant temperature sensor in the ice water for approximately ten minutes Start the engine and warm it to operating temperature above 50...

Page 431: ...Charging SeNice Information 17 2 Troubleshooting 17 5 Battery 17 7 Charging System Output 17 9 Alternator and Regulatorl Rectifier 17 10 Alternator Drivel Driven Gears 17 19 goldwingdocs com...

Page 432: ...distilled water when necessary Slow charge the battery whenever possible Quick charging should be an emergency procedure only Remove the battery from the vehicle for charging When inspecting the char...

Page 433: ...System location goldwingdocs com...

Page 434: ...LJ I I II 1111 111 r 5 l 1 1 II j i L J i iUI I Ii bJD 1 BUCK YEl YELLOW aLU mUJE 1 REO IlEll I ll ll WHITE GROUND POM Oo Na Dlpsliek FUSE aox r I FUS Ii I IlIA I I I LF1J i I Il tl 1 _rao _ _ OED lM...

Page 435: ...attery BATTERY Inspect the battery using guide lines beginning on page 17 7 Substitute a fully charged battery if necessary CONNECTOR Check the battery termi loose nals alternator WHT terminal and alt...

Page 436: ...bearings see page 17 13 stator coil see page 17 14 rotor coil see page 17 12 ternator and inspect Abnormal age 17 12 _ Short circuit in the condenser page 17 13 Worn brush ge 17 14 Faulty stator coil...

Page 437: ...lation reconnect the negative cable last Remove the nut bolt and battery holder Disconnect the breather tube Remove the battery from the case Check for a cracked or broken case or plates Replace the b...

Page 438: ...0 1 290 at 20 C 68 F Battery Charging Refer to Service Letter 48 June 1987 for additional battery servicing information Also refer to the Honda Battery Tester Christie Battery Charger Operation Manual...

Page 439: ...sult in different readings CAUTION Use an ammeter which can measure current flow in both directions Do not hook an ammeter directly between the battery positive terminal and negative cable of the batt...

Page 440: ...cable to avoid sparking which would otherwise occur when connecting each wire to the alternator Alternator and RegulatorlRectifier Removal Disconnect the battery negative cable Disconnect the alternat...

Page 441: ...bearing and oil seal is required Tool Universal holder 07725 0030000 or commercial equivalent Mark the front and rear cover before removal to identify their original position Remove the three screws a...

Page 442: ...tinuity does exist or the tester needle will not swing replace the condenser Rotor Coil Inspection Inspect the slip rings for discoloration Measure the 0 0 of the slip rings Service limit 26 0 mm 1 02...

Page 443: ...If replacement is necessary melt the solder securing the brushes and pull them out of the brush holder Install new brushes in the brush holder with their marked side facing to the rear cover Set the b...

Page 444: ...e should be light resistance Standard 0 1 0 3 ohms 20 C 68 F Check for continuity between the wire and stator cord There should be no continuity NOTE The green part of the core is insulated Put the te...

Page 445: ...010000 Pilot 20 mm OTT46 0040500 BEARII lG PULLER DRIVER 1 ATTACH MENT Oil Seal Replacement Remove the oil seal from the front cover TI _ __ _ _ Q Do not damage the cover or rotor shaft Apply grease t...

Page 446: ...dering iron capacity about 110 W Using a high temperature 300 C high lead content solder join the stator and regulator rectifier by soldering the stator coil wires on the diode terminals Install the s...

Page 447: ...ts washer and nut Hold coupler B with a tool as shown and tighten the nut to the specified torque Torque 58 N m 508 kg m 42 ft Ib Tool Universal holder 07725 0030000 or equivalent commercially availab...

Page 448: ...rubbers in coupler A Apply oil to the O ring and install it on the front cover Install the two dowel pins Install the alternator onto the engine aligning the tabs of coupler B with the damper rubber g...

Page 449: ...thly and quietly Also check that the outer race of the bearing fits tightly in the case Replacement Remove the bearing from the case Tools Bearing remover 07936 3710300 Remover handle 07936 3710100 Re...

Page 450: ...check that the inner race of the bearing fits tightly on the shaft Inspect the gears or flywheel for damage or wear Press the driven shaft out of the bearing Discard the bearing Remove the alternator...

Page 451: ...SPECIAL DRIVEN SUB WASHER GEAR Assembly FLYWHEELS Apply oil to the damper springs Install the spring and spring seats into the flywheel as shown GEAR SPRING SPRING DRIVEN WASHER SHAFT SPRING XJ SPRIN...

Page 452: ...wn Install the spring washer onto the special washer with its dished side facing the driven gears Install the alternator driven shaft into the flywheel align ing the 110les of the flywheel and shaft P...

Page 453: ...crankshaft Tighten the bolts to the specified torque Torque 27 N m 2 7 kg m 20 fNb Install the primary drive and driven gears see page 10 23 Aligning the serrated teeth of the alternator driven gear...

Page 454: ...ch B 18 26 Reverse Relay Switch 18 27 Relay Box 18 27 Diodes 18 28 Reverse Switch 18 28 Starter Reverse Switch 18 29 Clutch Switch 18 30 Reverse System 18 30 Reverse Control Unit 18 39 Starter Relay R...

Page 455: ...se again it is necessary to return the reverse lever to the OFF position and then return it to the ON position When inspecting the starter reverse system check the system components and wiring step by...

Page 456: ...lUlSE 15A 12 HEAD RELAY 5A RELAY BOX RELAY Np ClIlQMT 3 TAIL MAIN 61GN CRUISE m REVERSE CONTROL UNIT I t GN9 SPEED LIMITER RELAY 3 I 6lVBAT NEUTRAL SWITCH POWER CONTIlOL RELAY 2 SlOE STANO SWITCH 14 R...

Page 457: ...1 D3 T 02 D5 I D4 07 I 01 P V IlIOOE ASSV 8LUIRED BlKiREO 1 VELiA O MAIN FUSE A lOA STARTER RElAV SWITCH A FUSE 9 15A BANK ANGLE BLK WHT _ _ RElAV dt SENSOR FUSE II 15A VEL A O IllKJLTGRNTIJ STARTER R...

Page 458: ...eck the relay switch 4P RED connector for loose or poor contact Loose or poor contact of the relay switch A connector nnection STARTER RELAY SWITCH B CONNECTIONS Bad Check starter relay switch B termi...

Page 459: ...3 Loose or poor contact of 22P RED and 6P BLK connectors Faulty reverse diode assembly see page 18 28 Open or short circuit in main or sub wire harness No WIRING CONNECTORSIDIODES Disconnect the rever...

Page 460: ...h switch ltral and the reverse diode assembly see page 18 28 Good No Good WIRING COMPONENTS CON Disconnect the 3PGRN conne connector holder behind the cr unit Measure voltage between and GRN I Wires o...

Page 461: ...everse lever to the OFF position and then return it to the ON position o Inspect the following before troubleshooting the reverse system Be sure the transmission gear is in neutral position Be sure th...

Page 462: ...e motorcycle lunges at the beginning of reverse operation see page 18 11 No REVERSE RESISTOR Check the reverse resistor see page 18 42 1 0 Faulty resistor 4 Faulty reverse control unit Open or short c...

Page 463: ...n reverse SPEED LIMITER RELAY Check the speed limiter relay see page 18 44 _ _ _ _ _ d Normal r RESISTOR Che or Se geLAbn rma Faulty resistor L2 8 42 _ 1 r r 1 ill ill SPEED LIMITER RELAY LINE Check t...

Page 464: ...al POWER CONTROL RElAY s Remove Normal the power control relay s and inspect the Ii relay s see page 18 43 Abnormal w The motorcycle lunges at the beginning of reverse operation REVERSE CABLE Check th...

Page 465: ...er th m the he dlight goes out Go to Headlight goes off during reverse operation see page 19 5 During reverse oper tlon the motor Id es Misadjusted reverse cable see page 3 30 Faulty reverse shift sys...

Page 466: ...ct the starter motor cable from the motor Remove the motor mounting bolts and motor from the engine Disassembly Remove the motor attaching bolts and separate the motor reduction gear case from the sta...

Page 467: ...ould be conti nuity Check for continuity between the motor cable terminal and motor case There should be no continuity Inspect the commutator bars for discoloration Bars dis colored in pairs indicate...

Page 468: ...uld be no continuity Remove the brush holder Remove the terminal from the motor case Remove the brushes COMMUTATOR BAR Reduction Gear Case Disassemblyllnspection Remove the snap ring and washers from...

Page 469: ...excessive or abnormal wear GEARS REVERSE REDUCTION GEARS I Check the starter reduction gears for excessive or abnor mal wear Check the planetary gear needle bearings for damage or excessive wear START...

Page 470: ...e Turn the reverse shaft with your finger The bearing should turn smoothly and quietly If necessary replace the reverse gear case assembly Reduction Gea r Case Assembly REVERSE SHAFT t GEAR HOLDER DOW...

Page 471: ...he dowel pin Check the gears for rotation They should rotate freely Pack the bearing cavities with grease Install the bearing onto the starter shaft Install the starter shaft and bearing into the star...

Page 472: ...rs and snap ring onto the starter shaft NOTE Install the thinner washer inside the thicker one out side Check the reduction gear case for rotation Motor Assembly SCREW e J Z T WASHERS SNAP RING i i i...

Page 473: ...ushes into the brush holder Pack the bearing cavities with grease Install the armature into the case Install the O ring Install the rear cover aligning the tab of the brush holder with the slot in the...

Page 474: ...ess onto the wire clamp Install the wire harness onto the wire clamp Install the connector onto the connector holder Install the following e battery case and battery see page 17 7 e right front side c...

Page 475: ...iversal holder and remove the starter clutch bolt Tool Universal holder 07725 0030000 Remove the washer and bearing Remove the starter clutch assembly Inspection Disassembly Make sure that the starter...

Page 476: ...o the starter clutch outer with its flange side facing up as shown Install the starter clutch cover Apply a locking agent to the starter one way clutch socket bolt threads as shown Install and tighten...

Page 477: ...ly onto the crankshaft Install the bearing washer and starter clutch bolt Install the washer with its chamfered surface facing out m _ _ _ _ m _ _ Install the washer with its chamfered surface facing...

Page 478: ...d the power supply line is closed Incline the bank angle sensor approximately 49 degrees to the left or right with the ignition switch ON The bank angle sensor is normal if relay 6 clicks and the powe...

Page 479: ...nd 12 V battery to starter relay switch A as shown The switch is normal if there is continuity STARTER RELAY SWITCH A BATTERY 12 i Starter Relay Switch B A SE Models Remove the right front side cover...

Page 480: ...e relay switch as shown The switch is normal if there is continuity Relay Box A SE Models Operation Inspection Remove the left rear side cover see page 13 8 Open the relay box cover Relay 3 and 6 When...

Page 481: ...06 07 08 G Probe 6 10 3 6 10 10 1 5 e Probe 11 7 7 9 9 8 2 4 _ b Reverse direction No continuity DIODE 01 02 03 04 05 06 07 08 _ F G Probe 11 7 7 9 9 8 2 u e Probe 6 10 3 6 10 10 1 5 L NOTE o The pre...

Page 482: ...EW SEALING WASHER Starter Reverse Switch A SE Models Inspection Remove the right fairing lower cover see page 13 12 Disconnect the 9P RED connector from the connector holder on the right cooling fan 9...

Page 483: ...Remove the reverse joint bolt and reverse lever from the reverse drum Remove the fairing inner covers see page 13 12 Disconnect the reverse cables from the reverse drum Remove the reverse drum Disconn...

Page 484: ...r _ cC o Mark the cables to indicate their original position before disconnecting them NOTE Reverse Shift System Removal Disconnect the reverse cables from the shift arm Remove the shift arm bolt and...

Page 485: ...ller pin from the shaft Remove the snap ring and disassemble the shaft assembly Check the needle bearings for damage or excessive wear Check the reverse shift gear teeth for excessive or abnormal wear...

Page 486: ...wear BALL BEARING GEAR Shift Dmm lock System Removal Remove the following starter clutch see page 18 22 e primary driven gear see page 10 22 Q oil pump sprocket bolt and washer oil pump sprocket driv...

Page 487: ...aring Tools Attachment 20 mm 1 0 07746 0020400 Pilot 20 mm 07746 0040500 Needle bearing Remove the starter drive gear see page 18 32 Hold the gear holder in a vise with a block as shown and drive the...

Page 488: ...9 ft Ib With the transmission in neutral check the arm assembly for operation Install the following m drive chain guide o oil pump sprocket drive chain and primary driven gear boss as an assembly NOT...

Page 489: ...to the needle bearings Apply molybdenum disulfide oil to the shift gear teeth and reverse shifter holes and groove Install the washer needle bearings reverse shift gear and washer onto the reverse shi...

Page 490: ...h the stopper shaft while aligning the shaft cut outs with the shift drum locI arm boss Install the reverse idle gear with its flat surface facing inside Install the washer Install the starter idle ge...

Page 491: ...d spring collar to the shifter shaft as shown Make sure the locations of the spring hooks shift arm tabs and plate tab are as shown _ _ Apply a locking agent to the threads of the reverse shifter shaf...

Page 492: ...ect the 14P WHT connector of the reverse control unit and check it for loose contacts or corroded terminals Using the chart on the next page measure the indicated connector terminals on the wire harne...

Page 493: ...same color wire terminals _ _ _ U LT GRN RED and Transmission in neutral Continuity should exist ground _ __ WHT and ground H Ignition switch ON Battery voltage should Reverse lever switch ON register...

Page 494: ...20 V should appear between the speed limiter fuse terminals Starter Relay Regulator A SE Models Wiring Inspection Remove the seat see page 13 8 and trunk see page 13 14 Disconnect the 4P RED connector...

Page 495: ...N position Start the engine raise the side stand and put the reverse lever in the ON position With the 4P RED connector connected set the tester probes to BRN RED and GRN wire terminals When the start...

Page 496: ...unit Relay 1 Connect the ORN wire to the GRN wire with a jump wire wire harness side Turn the ignition switch ON and position the reverse lever in the ON position The relay is normal if it clicks Rela...

Page 497: ...r relay Connect an ohmmeter and 12 V battery to the speed limiter relay as shown The relay is normal if there is continuity Reverse Lever Switch A SE Models Inspection Remove the left fairing inner co...

Page 498: ...ng step by step according to the troubleshooting chart For the starter clutch servicing see page 18 22 For the fuel pump shut off bank angle sensor inspection see page 18 25 For starter relay switch i...

Page 499: ...Allarn lor co JC i k1i toP REOlm STARTERRELAV I S TC jMAIN I i FUSE 8 A U li DIODES 6 c S I I I i I I GEA SENSOR D C D A II J Dln l i q SlOE STA SWITCH GROUND POINT A Ql I ROOilltor Ntlir ThtflllOSI...

Page 500: ...Y SWITCH With the ignition Click STARTER RELAY SWITCH Check starter switch ON push the starter switch You should relay switch for continuity see page 18 26 hear the starter relay switch click see page...

Page 501: ...0 Yes FUEL PUMP SHUT OFF BANK ANGLE SENSOR Inspect the bank angle sensor see page 18 25 RELAY 6 Check relay 6 for continuity see page 18 27 No continuity No Good o Faulty bank angle sensor o Faulty re...

Page 502: ...13 Reduction Gear Case Disassemblyllnspection Remove the gear holder Remove the starter reduction gears Remove the dowel pin STARTER MOTOR Check the starter reduction gears for excessive or abnor mal...

Page 503: ...pin into the gear case Apply grease to the gear teeth Install the sun gear aligning the gear groove with the dowel pin Install the planetary gears onto the shaft Install the gear holder aligning the h...

Page 504: ...ing battery case and battery see page 17 8 right front side cover see page 13 8 Diode I Model Remove the right fairing inner cover see page 13 12 Remove the diode from the main wire harness Check the...

Page 505: ...heck the bearing condition The bearing should turn smoothly and quietly Also check that the outer race of the bearing fits tightly in the holder Replace the bearing if necessary see page 18 33 Install...

Page 506: ...licenselAccessory light 19 15 Instruments 19 16 Ignition Switch 19 20 left Handlebar Switches 19 22 Brake light Switches 19 23 Oil Pressure Switch 19 23 Relay Box 19 24 Parking Diode 19 24 Self Cancel...

Page 507: ...tween the two points An ohmmeter is needed to measure the resistance of a circuit as when there is specific coil resistance involved or when checking for high resistance by corroded connections For th...

Page 508: ...X2 I TACHOMETEg IE SlOE STANO INDICATOR f2V3 SENSOR I IF 4W i I I Ie l OW FUEl INDICATOR 12V3 4W ii i I i OW 1 1 OL M ILi i Ii T L jUCIlUISESETINOICATOR 12VU W _ fj _ _ ICIlUISEON L A C D I I INOICATO...

Page 509: ...3 5 7 t 10 I 0 i lij 0 0 1 rn rrf r J rrrr i iO O L nni A j Unnnnfl t Ii i J i t IiIiI iIi i i i i tjfl U Ii iio r71 I 1 81i Ii Ii i Ii iiif I I i I I I II 1tI Y L Ir II I I I J I I 8 T I L l 1 J II...

Page 510: ...meUoper Coolant Temoerature DlostlCk S tCI1 GNITION SWITCH 0 7 TRUNK LIGHT S REAR BRAKE L OPTION LIGHT SWITCH L 2P RED 2p BLU ltIi IiIIfmII lOCK OFF ACC ON Ie fO P J It t 1 I j I I I TTT Rt lT CORNERI...

Page 511: ...ll CD i RELAY 3 TU1N SIGI W RELAY IlU lI ACK m mLOO 1IIllJ lILlIE GRN SUN 1IIIEll IIIIEll WHT limE FUSE 8 ISA WHT GRN L C 1lU IGI mON SWITCH i FUSE 2 ISA WHT BATTERY 12 1 20AH MAIN FUSE A 3M TURN SIGN...

Page 512: ...age 19 22 Loose or poor contact of related connectors Open or short circuit in related wire harness Headlight goos off during reverse operation A SE only Faulty reverse lever switch see page 18 44 Fau...

Page 513: ...eration 1 1 Faulty turn signal relay RELAY Exchange the turn signal relay for the hazard relay and check the turn signal operation again TURN SIGNAL SWITCH Check the turn signal switch for continuity...

Page 514: ...d sensor Tum signals do not cancel manually A SE only SWITCH Check the turn signal switch for continuity see page 19 22 Normal Abnormal Faulty turn signal switch CONNECTIONS Inspect the following Loos...

Page 515: ...Light bulb not securely installed A SE Faulty relay 7 see page 19 24 Hazard system does not operate Faulty hazard relay Faulty hazard switch Open or short circuit in wire harness Loose or poor contact...

Page 516: ...11 Yes Faulty L CD unit Loose connectors Open circuit in instruments sub wire harness between the 20P WHT and 10P WHT 2OP WHT AND 14P BLK CONNECTORS No Loose or poor contact of the power INPUT line c...

Page 517: ...the 14P BLK instru ments and 3P BLK rear fender connectors Check the continuity end to end of each wire There should be continuity between the same colors Yes Open or short circuit in wire harness Lo...

Page 518: ...poor contact 6P WHT connector of the radio cassette deck Check the connector for loose or poor contact Good contact No WIRING Perform the main harness check continuity of the NO 4 Power and NO 5 Disp...

Page 519: ...hing screws Remove the headlight by removing the four mounting bolts NOTE _ _ m _ _ _ e The lower mounting bolts have screw threads in their heads Bulb Replacement Remove the headlight connector and r...

Page 520: ...prop erly The lower bolts have screw threads in their heads Turn Signals Brake Lights Front Tum Signal Position lights Remove the front turn signal position light lens by remov ing the screw Remove th...

Page 521: ...se Replace it with a new one turning it c1ocl wise Brake and Taillights Saddlebags Remove the screw covers and screws Remove the saddlebag lower cover m 8e careful of the alignment of the cover and sa...

Page 522: ...ng screws The cover will crack Accessory light Remove the trunk lower cover by removing the four mounting screws SCREWS LIGHT COVER TRUNK L OWIi R COVER Pull the accessory light bulb socket out of the...

Page 523: ...L C O replacement see page 19 19 CAUTION _ _ _ _ o Do not tum the gauges upside down because they will leak damper oil Do not damage the LC D unit flat cables Speed Sensor Inspection A SE only Check t...

Page 524: ...eter Inspection Remove the instruments with the 20P WHT I model 14P WHT connectors connected see page 19 16 Check the YEUBLU wire for continuity between the tachometer terminal and the engine control...

Page 525: ...ectric tachometer terminal screws and two tachometer mounting screws Remove the tachometer from the case A SE Disconnect the 3P WHT connector to the speed sensor Remove the two screws Remove the speed...

Page 526: ...the L G D unit from the base If you want to remove the gauges remove the rear side of the L CD unit see above All Models Remove the gauge terminal screws and gauge panel screws Remove the gauges CAUT...

Page 527: ...see page 13 12 Disconnect the 8P BLK connector from the connector holder on the left cooling fan Check continuity of the terminals on the ignition switch in each position NOTE The continuity check may...

Page 528: ...turn it to P park IMPACT DRIVER P POSITION Release the wire from the wire clamp Push the lugs from the slots and remove the contact base Assembly Assemble in the reverse order of removal Installation...

Page 529: ...rn signals horn must be replaced as an assembly Remove the left and right fairing lower covers see page 13 12 Disconnect the 9P BLK 6P GRN and 4P WHT connec tors from the connector holders on the cool...

Page 530: ...ctic m If the oil pressure indicator light does not come on inspect the POWER TO PRESSURE SWITCH line first as follows Remove the under cover see page 13 11 Pry off the rubber cover and disconnect the...

Page 531: ...uity should exist NO No continuity should exist Parking Diode Inspection A SE only Remove the right saddlebag see page 13 17 Remove the parking diode LT GRNIYEL BRN from the main wire harness NOTE o T...

Page 532: ..._ TERMINAL CONDITION S SPECIFICATION ge input WHT GRN Ignition switch ON Battery voltage should register _ __ _ _ _ __ _ f u _ _ _ _ _ _ _ ON PNK Turn signal switch R or L Continuity should exist _ Tu...

Page 533: ...n the left cooling fan Check for continuity between the same color GRY 3P WHT and 4P WHT connectors Continuity should exist at all times Measure voltage as follows Between WHT GRN and ground Battery v...

Page 534: ...ove the turn signal can cel control unit enough to disconnect the unit connector NOTE If necessary slide the steering stem grommet more Disconnect the turn signal cancel control unit connector and rem...

Page 535: ...LT GRN BLK and ground Battery voltage should exist with the ignition switch ON Between PNK WHT and ground About 5 volts should exist with the ignition switch ON and the relay 3P BLK connected to the...

Page 536: ...hers and rubber cushions Disconnect the wire connector and remove the high mount accessory light from the tail spoiler Install the high mount accessory light in the reverse order of removal Torque Mou...

Page 537: ...B probe Tester e probe Result C Terminal S Terminal Continuity S Terminal C Terminal No Continuity _ C Terminal T Terminal Approx 510Q T Terminal C Terminal No Continuity Cornering light Replacement S...

Page 538: ...Audio Service Information 20 2 Troubleshooting 20 5 Speaker 20 14 Muting Search Switch 20 14 CB Switch Fader Control 20 15 Antenna 20 16 Radio Cassette Deck 20 17 CB Transceiver 20 21 goldwingdocs com...

Page 539: ...periodically clean the head with a commercially available cleaning cassette As preventive mainte nance clean the head about every 30 hours of use If preventive maintenance is delayed until the head be...

Page 540: ...NTROLLER OPTION mM llP llIlNJ L IIP WHT r _ _ 0 i CB TRANSCEIVER C C is _ l5 llP GRY 0 I 5A I I lOA I IHnmrmmmmrnn IiI l II UPi PflrrpI C LflJLFT milfMlilfliIiiil1Iiliiifii hhhhhhf ol i c rolUTlllIGiS...

Page 541: ...I I I Ii I L __ I L __ L _ ii W 1 w 11 I 5 I III I 5TARTtR AEUY GROUNO POINT SWITOI A A On Radiator Ne ThermostatIC Fan Motor SMlch On Encine Near Coolant TenlIleI al e Sw1tcn I e On Enaine NN DipslJd...

Page 542: ...I o I o RADIO F J5 101 F J5 CllCUT IUCIl i P II ACe llA 11 I A LI l U lI l LI Cl lI l U lJ cr_ OM L8fT L_ _ 3 8 m Q ri r c Dr cc iiJ 3 iii goldwingdocs com...

Page 543: ...Audio System Location IGNITION SWITCH FRONT SPEAKER MAIN FUSE A 20 4 RADIO 8 CASSETTE DECK A 8 SE RADIO II goldwingdocs com...

Page 544: ...Audio stem Location IGNITION SWITCH FRONT SPEAK ER MAIN FUSE A 20 4 RADIO CASSETTE DECK A SE RADIO I goldwingdocs com...

Page 545: ...re terminals of the 18P WHT connector wire harness side Battery voltage should register with the ignition switch in ACC ON or P loose or poor contact Loose or poor contact of the radio and cassette de...

Page 546: ...the No 31ine see page 20 17 IContinuity Loose or poor contact of the connector Faulty muting search switch Open or short circuit in wire harness Faulty radio and cassette deck Weak or noisy reception...

Page 547: ...in channels will be automatically see SERVICE INFORMATION CONNECTOR Disconnect the 18P WHT connector of the radio and cassette deck Check the connector for loose or poor contact Good contact WIRING Me...

Page 548: ...eck Uneven tape speed A and SE models TAPE Exchange the tape and check the Satisfactory playing speed StiII no satisfactory CASSETTE DECK Check the inside of the Dirty cassette deck for dirt clean it...

Page 549: ...the REDIYEL and GRN BLK H terminals of the 16P GRY connector wire harness side Battery voltage should register at all times IYes 11 l Ol O FaultyCBtransceiverunit Channel cannot be changed UNIT VOLTA...

Page 550: ...K lever There should be 0 V with the TALK lever depressed No CB SWITCH Check the TALK lever for No Continuity I l UlllIllUllY Faulty CB switch IContinuity Open circuit in wire harness Loose or poor co...

Page 551: ...er RADIO AND CASSETTE DECK Listen to th J No sound I radio or cassette tape sound w u Nor 1 sound WIRING Pertorm the main wire harness check No of the No 2AF circuit see page 20 21 continuity I w RADI...

Page 552: ...itted see page 20 10 e The CB signals may be affected by jamming or interference Try using an open channel e The CB signals are interfered with by mountains or buildings ANTENNA Check the antenna for...

Page 553: ...smission or reception and 0 V during other conditions I Yes WIRING Perform the main wire harness check No continuity of the NO 5 MUTE circuit see page 20 21 II CB output cannot be transmitted or CB si...

Page 554: ...nnected to the speaker terminals Installation Install the speaker in the reverse order of removal NOTE Connect the RED GRN wire R ch and BLU GRN wire L ch to the front speaker terminals Speaker termin...

Page 555: ...CT Fader Control Disconnect the 6P BLK connector from the connector holder on tfie left cooling fan Turn the fader control knob counterclockwise fully and measure the resistances between the terminals...

Page 556: ...for continuity as shown Replace if necessary Normal 1 Continuity 2 No Continuity Antenna Base Replacement Remove the right trunk side pocket by removing the three attaching screws SE only Remove the...

Page 557: ...BACKUP 29 DATA SWITCH UP S SEARCH 19 MUTE ON 30 LOAD SWITCH DOWN _ 9 IGNITION 20 GNDAF 31 CLOCK SWITCH ACC t 10 7t SET MIC 21 SPEAKER AT OUT 32 GND DATA E DR HEADSET MIG 22 MIC IN 33 BLANKING 11 PA _...

Page 558: ...ring left pocket n 11 RED BLU 6P RED mini On the rear fender m 12 WHT i 6P RED mini Inside the fairing left pocket n 13 VEL 6P RED mini Inside the fairing left pocket 6P RED mini On the rear fender 14...

Page 559: ...it System Number 6 A SE only AVC circuit 7 Starter reverse I Starter switch circuit 8 Antenna circuit Check the wires for continuity as shown NORMAL 1 Continuity 2 Continuity 3 No Continuity 2 9 CB 19...

Page 560: ...INPUT microphone signal ground headset OUTPUT ground headset OUTPUT R channel headset OUTPUT L channel fIRE HARNESS CAUTION At installation route the radio cassette deck wire harness properly as shown...

Page 561: ..._ _ 6 MICIN 14 BACK UP 7 SPEAKER AT OUT 15 STARTER REVERSE SWITCH 8 GROUNDAF l ___ CB TRANSCEIVER UNIT I 16P GRV COI UI IECTOR Circuit Other Number System Terminal Color Terminal Other Terminal locati...

Page 562: ...ver cont d Circuit Number System Terminal Color Other Terminal Color Other Terminaillocation 10 Antenna circuit Check the wire for continuity as shown NORMAL 1 Continuity 2 Continuity 3 No continuity...

Page 563: ...Index goldwingdocs com...

Page 564: ...5 11 Cooling System 3 23 Cooling System Inspection Testing 5 7 Cornering Light SE 19 30 Crankcase Assembly 10 18 Crankcase Breather 3 19 Crankcase Separation 10 9 Crankpin Bearing 8 21 Crankshaft Ins...

Page 565: ...al 8 6 Rear Fender 13 19 Rear Master Cylinder 14 14 Rear Wheel 15 10 Relay Box Starter Reverse 18 21 Relay Box Lights Switches Instruments 19 24 Index Reverse Control Unit 18 39 Reverse Level Switch 1...

Page 566: ...ine Control System 3 0 3 4 Gauges 7 4 7 8 Ground Distribution 2 10 2 16 Handlebar Switch Illumination 9 5 Hazard Lights 9 6 9 8 Headlights 8 0 8 2 Horn 5 0 5 1 Illumination Lights 7 5 7 9 Indicators 7...

Page 567: ...tics show how all the components within a circuit work together current flow from the power source top of page to ground bottom of page switch positions shown at rest as if the ignition was off specia...

Page 568: ...ear Speaker To S285 on page 9 11 Wires A wavy line means the wire is broken by the binding of the book but continues on the next page Wire insulation can be one color or one color with another color s...

Page 569: ...mponent is shown The name of the component appears next to its upper right corner Notes about component function follow its name 11 I I I I b dI BRAKE SWITCH Closed with pedal depressed Empty Cavity T...

Page 570: ...e shown in their normal rest position with power off This means power is supplied when the ignition switch is in ON r r I fUSEe I L I OontH eotio GRN BLK Current rating Shield Normally Closed Contact...

Page 571: ...goldwingdocs com...

Page 572: ...ic Other circuits getting their power from the same point or grounding at the same point are not shown However if other circuits actually share some wires with the circuit shown the shared wires of th...

Page 573: ...f I I P ACC p nt P I OFF OFF ACC ACC J LT GRN BLK __Y LK BLU ORN YEUBLK C58 R RED RED See Ground I Distribution page 2 10 Gl00 W H T WHT II BLK Starting 5251 System MAIN WHT YEURED FUSE B BATTERY 55A...

Page 574: ...S1i1ii6m5 d RELIEF I I SOLENOID I VALVE I Page 5 5 L GRN BANK I I ANGLE I SENSOR I Pages 3 8 L and 3 12 GRN r ll I I I I I I b J C94 LEFT COR NERING LIGHT RELAY Page 9 3 r l I I L COO RIGHT HORN Page...

Page 575: ...photographs _omponent Ph t o Auxiliary Input Connector 55 Behind left fairing pocket Bank Angle Sensor Asp SE 32 Component or Below right rear of seat Connector Number on frame rail N b f C 3mBl t t...

Page 576: ...all components in the repaired circuit in all modes to make sure you ve fixed the entire problem If the problem was a blown fuse be sure to test all of the circuits on that fuse Make sure no new prob...

Page 577: ...d cor rosion between its contact surfaces can cause electrical problems 1 Connect one lead of test light to a known good ground or if you are using a voltmeter be sure you connect its negative lead to...

Page 578: ...volt indicates a problem 1 Connect the positive lead of a voltmeter to the end of the wire or to the side of the connector or switch closest to the battery 2 Connect the negative lead to the other end...

Page 579: ...the harness Continue this at convenient points about six inches apart while watching the test light or voltmeter 4 When the test light blinks or the voltmeter needle moves there is a short to ground...

Page 580: ...rrent pulses through sheet metal and plastic As long as the meter is between the fuse and the short the needle will move with each cur rent pulse Once you move the meter past the point of the short th...

Page 581: ...ine with the ground cable disconnected or you will sem verely damage the wiring While You re Working Make sure connectors are clean and have no loose pins or receptacles Make sure multiple pin connect...

Page 582: ...a Stop Relay Turn signal cancel control unit Turn sign 3 Stop 15 Brake lights 4 Fan 10 Cooling fans 5 Head 15 Headlights Instrument panel indicators 6 Air Pump 10 Auto level control system 7 Parking 1...

Page 583: ...ators 6 Not Used 7 Parking 10 Parking lights 8 Tail 15 Accessory lights Instrument panel gauges Instrument panel indicators Meter Cornering lights Headlight relays License plate light Position lights...

Page 584: ...is turned on this will indicate tape direction of play fast forward or rewind direction Controlled by headset speaker control knob Indicates that sounds are present on the headsets and not the speake...

Page 585: ...1 19 goldwingdocs com...

Page 586: ...II IIIE iiIIIIIIiI mlllll lnm BLK BLK LTiejGmRiiliNnmC 1 011111311111111 I i Q MM 4M S103 C73 IS278 LTGRN AIR PRESSURE LT GRN BLK LT GRN BLK I CONTROL I SWiTCH p llllllll i IIIIIII 1CG6 I I ASSEMBLY C...

Page 587: ...stribution page 2 12 t a G100 BRN BLU C70 6 IContact I I I L t 9 RIGHT CORNERING LIGHT RELAY Page 9 3 corat d BRN WHT S116 BRN WHT lC96 IContact I I I L d LEFT CORNERING LIGHT RELAY Page 9 3 To 8113 o...

Page 588: ...NT BRAKE II I LIGHT SWITCH I Page9 16 6 WHT GRN WHT GRN WHT GRN WHT GRN I N CD I II roilI POSITION I RELAV I I I Page 9 7 I 1 dB L _ See Ground Distribution page 2 12 BLK BLK p IIIIIIIIIIIiii S S105 S...

Page 589: ...C32 BLKiLT GAN See Engine Control System Starting System Charging System Reverse System Cruise Control BRN RED BAN RED C57 r Cll W A T 1 BANK I I ANGLE I I SENSOR I I Page 3 14 O _ o o _ I STARTER I...

Page 590: ...TOR odI Page 3 28 BLU BLU RIGHT NOISE FILTER Page 3 28 C110 BLU From IGNITION SWITCH on page2 1 BRN C56 1 LICENSE PLATE 1 LIGHT Page 9 13 BRN BRN pIIII ElIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII...

Page 591: ...N WHT I I I I I l _ RIGHT SIDE TRUNK MARKER LIGHT Page 9 1 piI IIIIIIIIIII IIIIIIIIIII IIIIIIIIIII IIIIIIIIIII IIIIIIIIIII IIIIIIIIIII IIIIIIIIIII IIIIIIIIIII S209 BRN GRN GRN BRN Il r I lEFT I I i BR...

Page 592: ...SE I II ACCESS RY II TERMINAL Ib WHT WHT WHT S ED Starting System 8251 MAIN WHT YEL RED FUSE B 41 55A STARTER Page 3 26 r B RELAY A I I Page 3 17 I f41 C41 ALTERNATOR Page 3 26 RED BLK BRN RED Starti...

Page 593: ...L mil HIGH BRNIWHT I RELAY Page 8 3 lH RH _ _J HEADLIGHT POSITION LIGHTS Page 8 2 1 DE lc7o BRNIWHT r 1 I I L aoll C94 RIGHT CORNERING LIGHT RELAY Optional BRNIWHT Page 9 4 5416 i N lC96 BRNIWHT r 1...

Page 594: ...2 BAN 1 C10 BAN S413 D I piIIIIIII D S412 BAN BAN C188 Optional BLU BLU RIGHT LEFT NOISE NOISE FILTER FILTER BRN C85 BLU BLU BRN I RIGHT LEFT D S472 I M I RADIATOR I RADIATOR I I FAN I FAN MOTOR MOTOR...

Page 595: ...tem Starting System li i C93 Charging System WHT GRN WHT GRN BRNIWHT CB7 p OLEFT r 1 0 TURN I I I fi 1 HORN I COMBINA I p I SIGNAL I I I ITIO j STARTER I I I F A SWITCH N II PUSH I WIT H HER I I I Pag...

Page 596: ...Lw Page7 8 and 5 4 I I GAUGE R f I GRN BU Page 7 4 S168 I _ lIilIIe illllIIIIII lIIIIIIIII 5a GRN BU I L_ 4 C108 ____ I GRN BlKI GRN BlK GRN BlK IP II FUEL I IlEVEL lIIIIIIIII we we we u iIIIIIIIffi...

Page 597: ...GRN IN LINE I CAPACITOR I D RIGHT COR B NERING LIGHT I Page9 3 C183 Asp GRN C178 SE C69 GRN GRN GRN With CB Radio P FUEL I I PUMP I Page 3 2 dI C186 Asp GRN C127 SE e178 SE C33 GRN r ENGINE CONTROL MO...

Page 598: ...TRUNK RADIO SWITCH CONTROL CANCEL LIGHT CASSETTE DRIVER VALVE CONTROL SWITCH lEFT DECK Pages 10 21 UNIT UNIT Page 9 18 HORN Page 10 1 and 10 25 Page 4 3 Page 9 6 fF ft Page 5 0 lP 0 p p I I 1 1 I 1 I...

Page 599: ...R LIGHT Page 9 1 I GRNl GR 5267 oED 5266 LEFT ACCESSORY TRUNK LIGHT ASSEMBLY LIGHT Pages 9 ii 9 12 9 16 Page 9 19 r F i I TURN BRAKE 1 I SIGNAL LIGHT LIGHT I l H J 5159 GRN GRN GRN S158 _ GRN LICENSE...

Page 600: ...TOR ILLUMIN I POSITION LIGHT LIGHT POSITION I ATION I RIGHT FAIRING LIGHT Page8 1 Page LIGHT I _ I MARKER LIGHT Page 8 1 8 1 Page 8 0 1 Page 9 0 t 1 I _ I GRN _ I I _ I _ 1 _ I _ I I I _ I GRNI GRNI G...

Page 601: ...goldwingdocs com...

Page 602: ...G103 and G104 Int Circuit Schematic GRNIBLK C10G 1F 1 FUEL I I lEVEl I I SENDER Low Ii Page7 8 GRNIBLK C112 GRNIBLK GRNIBLK GRNIBLK C72 GRNIBLK LTGRN BATTERY GRNIBLK C22 BLK GRNIWHT 0103 BLK Gi04 BLK...

Page 603: ...IIIIiiiIIIIIII1 IId S I GRN 1IIIII IIIII 1IIIII IIIII 1IIIII IIIII 1IIIII IIIII 1IIIII IIIII 1IIIIIIIIIIIII1IIIIIIIIIIIII1IIIII IIIII lI_IIIIIIIIIIIIII__IIIIIIIIIIIIII_IIIIIIIIIIIIII lI 5467 IS155 GRN...

Page 604: ...I SWITCH Optional Page9 18 GRN BLK CIlS GRN F SIDE I I STAND I SWITCH L I Pages 3 5 and 7 2 GRN C28 GRN GRN GRN P CB I I SWITCH I I DRIVER S L Page 10 23 C20 PI RADIO CLOCK I Page 10 6 I I L 12 C1 GR...

Page 605: ...SOR Page 9 1 Page 9 9 Page3 16 GRN 1F il tp il I I I I I I I I I GRN L JJ L r 87 C86 S461 GRN GRN CD Cl1 GRN I GRN GRN 5449 CD S450 GRN Cl0 GRN GRN 5458 lIIIiI IrnIi d RIGHT SIDE TRUNK MARKER LIGHT Op...

Page 606: ...NEL I SIGNAl ILLUMINATION BEAM Pages 7 2 iNDICATOR TACHOMETER liGHTS iNDICATOR 7 9 and 9 10 I IF _ I _ I I I _ I _ I _ I I eN G r eN eN I S592 I I I I r LEFT LEFT RIGHT RIGHT I LEfT TURN SPEEDO I HEAD...

Page 607: ...goldwingdocs com...

Page 608: ...ing System Bank Angle Sensor WHT OFF BLI JWHT BLK WHT BLK WHT _ Start Reverse 1 1i lI ENGINE 1 STOP SWITCH 1 1 t t Mt AIIII BLK Lf GRN C57 CARBURETOR AIR JET BLK WHT I C57 NOID BLK WHT VALVE 2 WHT RED...

Page 609: ...eck L 22 2 9 2 11 resistance F C49 See Starting System Starting System GRNIWHT GRNIWHT Reverse System Reverse System GRN ORN S257 iIE JIII pages 3 15 and 3 31 LT GRNI BLKI WHTI REDI GRNI Indicators 1...

Page 610: ..._ r r 63 w C49 I C60 IGNITION IGNITION PULSE PULSE PNKlWHT WHTIYEL GENERATOR GENERATOR C314 2 INTAKE AIR TEMPER ATURE IAT SENSOR C314 GRN BLK BLU Asp Without CBRadio BLU C184 BLKlBlU iF 9i FUEL PUMP...

Page 611: ...cOi1t d 3 3 goldwingdocs com...

Page 612: ...ELAY I I I I I L Starting System Bank Angle Sensor WHT BLK WHT BLK WHT BLKlLT GRN C43 r s 48 1 1 BLKlLT GRN C72 r St l JINATION BLKlLTGRN I g NE I SWITCH C1 mJ w w r nt_ 19 I OFF SWITCH I 5489 I I BLK...

Page 613: ...de I ECM Neutral 2nd 3rd 4th Dnve Stand I SOlid state I Input Input Input Input Input Input I Do not check I 22 21 20 19 7 23 resistance T t G r N _H wI GR lfl ftf 4 5 ng RED YEL RED WHT DRN GRN DRN G...

Page 614: ...EL WHT BLU VEL J C314 INTAKE AIR TEMPER ATURE IAT SENSOR C314 C60 ENGINE COOLANT TEMPER ATURE I ECT SENSOR GRN BLK GRN BLK 5301 GRN BLK 1 GRN BLK BL_U m mw_ _ 2ii S496 p iIIlllI Il aII IIII mc a1l PNK...

Page 615: ...a ground signal to the ECM with the side stand switch in UP and is open in DOWN F Troubleshooting SYMPTOM Engine cranks but does not start Engine runs poorly Intake Air Temperature IAT Sensor The inta...

Page 616: ...e 4 5 Sensor Common GRN BLK Continuity to ECT sensor IAT sensor and ignition pulse generators 5 Ignition Pulse Generator 1 Input WHT YEL Resistance to GRN BLK sensor common is 400 500 ohms at 68 F 20...

Page 617: ...f not check BLKlYEL circuit for an open or short to ground between ECM and gear position switch If circuit is OK service gear position switch J 3RD Gear Input WHT RED Continuity to ground with transmi...

Page 618: ...Resistance to GRN BLK ECM sensor common is 2k to 3k ohms at 68 F 20 C 18 5 F and 200 to 400 ohms at 176 F 80 C __ _ If not go to test K 17 4 M Output Signal E models only WHT BLK 16 3 12l to cruise c...

Page 619: ...CM and ignition pulse generators for an open If no replace ignition pulse generator Test D fuel Pump Control Test Gasoline is flammable and is explosive under certain conditions Do not smoke or allow...

Page 620: ...istance should be about 32 ohms If yes service RED WHT circuits for an open between C120 and ECM If no replace CAJ solenoid valve Test I Carburetor Air Jet CAJ Solenoid Valve 3 Input Test 1 Disconnect...

Page 621: ...If yes check GRN BLK and PNK WHT circuits for an open between sensor and ECM If no replace sensor Test l Intake Ail Temperature IAT Sensor Input Test 1 Disconnect C314 IAT sensor Connect ohmmeter acr...

Page 622: ...I I HT I REDIWHT L p f33 C32 HT REDIWHT BLK LT GRN 1 C11 See HT REDIWHT 0 Con pag BANK C57 ANGLE SENSOR BLK LTGRN 6 GRN I Ie C11 GRN See Ground I Distribution page2 11 I W W G100 YEURED C92 KWHT BLU R...

Page 623: ...T BLKlWHT r INSTRU 1 IMENT NEUTRAl I PANEL 1 INDICATOR 1 1 rID L _ J LTGRN RED LT GRN RED I C66 LTGRN RED C55 Reverse System BLK STARTER REVERSE MOTOR 1 IIiI_PN III K_ EI Reverse System BLK GRN ORN LT...

Page 624: ...IME I LOCK ON I _ I I r 1 1 I OFFACC I I I BOX I FAN IGN I I I d TAIl METER I BlK I POSITION I See Power BLK Y C58 E Distribution I page 2 9 S10 I I I I I I I I I I I I RED WHT I I I I I I I I I I L _...

Page 625: ...e 2 6 BLK C41 8486 YElIRED GRN RED BRN WI n LTGRN RED C94 GRN RED LTGRN RED STARTER MOTOR M BLK GEAR 2 3 I POSITION I SWITCH 6 0D I C59 LTGRN RED SIDE STAND SWITCH See Ground Distribution page 2 18 C3...

Page 626: ...ay A energizes and applies battery voltage to the coil and contacts of starter relay B when the reverse switch is in the FORWARD position Starter relay B energizes and applies voltage to the starter r...

Page 627: ...and gear do test 01 selector in NEUTRAL _ Neutral indicator does not light but starter Open circuit to instrument panel bulb operates with clutch lever released bulb or reverse diode assembly Int Mod...

Page 628: ...or voltage between BLK battery feed circuit and C41 BRN RED using a test light If yes go to step 4 If no sevice BRN RED circuit for an open between starter relay A and 8302 4 Check for battery voltage...

Page 629: ...oltage between VEL RED and BLK RED circuits If yes go to step 4 If no check BLK RED circuit between reverse switch relay and reverse diode assembly for an open If OK replace reverse diode assembly 4 C...

Page 630: ...the BLK and BLK with PNK circuits at starter relay B With gear selector in NEUTRAL and reverse lever switch in FORWARD depress starter reverse switch Starter motor should crank If yes replace starter...

Page 631: ...lay A BlK circuit from battery If yes go to step 3 If no repair BlK circuit 3 With ignition switch ON and gearshift in NEUTRAL check for voltage between BlK battery feed circuit and C41 BRN RED using...

Page 632: ...utch switch connector With side stand switch Up check continuity of GRN WHT circuit to ground If yes go to step 2 If no check GRN WHT circuit side stand switch and GRN circuit at C28 for an open 2 Dis...

Page 633: ...3 25 goldwingdocs com...

Page 634: ...16 100 See Power Distribution 4 S251 page 2 0 or 2 6 WHT With CBRadio I I I I I I I I BLKlLT GRN RED WHT WHT C33 W Cia WHT GRN 1 C11 WHT IN L1NE CAPACITOR B BLK Engine Control System iIE lIIlIE lII S1...

Page 635: ...MPTOM DIAGNOSIS I Battery is overcharged or undercharged TEST A Power and Ground Check 1 Check for battery voltage at alternator terminal B If yes go to step 2 If no service WHT circuit for an open Bl...

Page 636: ...I 1M 0 _ 11 BLKlBLU C22 C109 BLU IF LEFT NOISE FILTER LEFT RADIATOR FAN MOTOR BLU BLU w jb 9l RIGHT NOISE FILTER iF RIGHT RADIATOR FAN MOTOR BLK BU LEFT RIGHT NOISE NOISE FILTER FILTER BLK C110 BLK BL...

Page 637: ...3 29 goldwingdocs com...

Page 638: ...LKlLT GRN FUSE RELAY TAIL I BOX I r B J II GRN gSee Power Distribution BRNIWHT 1page 2 1 I See Ground C73 I Distribution I It I page 2 12 I iii I BRNIWHT DSee Indicators f page 7 0 1 JIL Gl00 D BLKlLT...

Page 639: ...se C32 GRNIORN GRN ORN IHOTINON I 0 FUSE RELAY I BOX RVS START I FUSE 1 5A J C92 r I I I 0 BRN WHT BRNIWHT REVERSE WHT DIODE J BLU BLK Y C92 E WHT BLKlWHT C32 BLKlWHT I 07 I YEL RED S303 a te MIF d ii...

Page 640: ...TROL I Monitors I UNIT Motor I I Voltage J IL BLK To REVERSE DIODE ASSEMBLY on page 3 31 GRN RED GRN RED STARTER REVERSE MOTOR BlK BATTERY VEL I See Ground Distribution I page 2 10 Gl00 WHT r GRY DRN...

Page 641: ...rgize the reverse relay switch The reverse relay switch contacts close to provide a one second path to ground This pulls the contacts of starter relay A closed At the same time that pin 14 outputs to...

Page 642: ...e 65A do self test B pin 12 Faulty reverse control unit Replace with known good reverse control unit _ _ _ _ _ _ _ _ Reverse system operates for only a few seconds then quits Reverse indicator turns o...

Page 643: ...st F If all the above are OK check red circuits to power relay controls for battery voltage with ignition ON starter reverse switch in REVERSE and the starter reverse switch pushed If voltage is not p...

Page 644: ...e control unit If all measurements are correct service YEL RED circuit for an open L _ _ _ _ _ 3 36 C42 HARNESS SIDE Starter Relay Regulator Output LT BLU Voltage drops from 1 5 volts to avolts with t...

Page 645: ...on in neutral check for continuity to ground If not check LT GRN RED circuit for an open If OK see if neutral indicator illuminates in bulb test and then stays illuminated If bulb doesn t light during...

Page 646: ...easurements are OK go to the next step 4 Service WHT BLU circuit for an open SElF TEST 0 Side Stand Switch 1 With the ignition ON and side stand DOWN check to see if side stand indicator lights If yes...

Page 647: ...f necessary If all measurements are OK go to self test H SELF TEST G Speed limiter Relay Test 1 With relay disconnected apply 12 volts across the coil and measure continuity across contacts continuity...

Page 648: ...n I page 2 12 G100 GRN RED WHT BLK S241 wr Brake Lights GeM i GRN YEL _ _ _ B i C33 j F CRUISE I Brake RPM I CONTROL UNiT I Disable Input I Solid state Input Do not check I I resistance L _ d WHT RED...

Page 649: ...To RIGHT COMBINATION WHTII SWITCH on page 4 2 n C55 I See Ground WHT I Distribution C66 page 2 11 WHT F G _ O _ 1 tl S240 WHT WHT r _ fiI INSTRUMENT I ISE r s ed o p u bl b T CN UISE IPANEL I INDICAT...

Page 650: ...GRN BLU l C138 W C94 GRNIWHT i GRN BLUA GRNIWHT C132 GRN BLU1 BLKIY wHT B HT YELI 5 THROTTLE r Ca j Ig itk n Re S t 1 CRUISE CANCEL I Input Accellnput Decellnput CONTROL SWITCH 1UN T Open with 1 4th...

Page 651: ...RUISE I Vent Valve Vacuum Valve I CONTROL I Switched To Switched To I UNIT Ground Ground I Solid state I Ground Do not check bw J resistance I C135 GRN See Ground S165 DllHlIIIIIIIIII mill mill mill D...

Page 652: ...ds the cruise SET indicator control line It then looks at the speed signal outputs from the instrument panel and the engine speed from the ECM lt uses the ECM speed signal to control vehicle speed and...

Page 653: ...n tor does not light briefly BLUIWHT circuit open switch is first turned to Faulty instrument panel ith cruise set related syrnptom Perform Isolation Procedure ccmt d SY Any other cruise Cruise SET in...

Page 654: ...go to test F r Zero volts with RESUME ACCEL switch released If not service cruise control switch I I Cruise Cancel Input BRN RED Battery voltage with ignition switch ON engine stop switch in RUN cruis...

Page 655: ...heck GRN ORN circuit and gear position switch for an open or short to ground 13 Cruise SET Indicator Control Output BLU WHT Battery voltage with ignition switch ON and engine stop switch in RUN If not...

Page 656: ...f throttle turns and holds If not go to test L I BAN BLK C33 FEMALE HALF C33 FEMALE HALF BRN With ignition switch ON cruise switch ON engine stop switch in RUN and ground GRN BLK wire of the cruise va...

Page 657: ...le released check for battery voltage at GRNIWHT circuit If yes check rear brake cruise cancel switch and BRN RED circuit for an open between C133 and cruise control unit Replace repair as necessary I...

Page 658: ...t BRNIWHT circuit If yes go to step 4 If no go to step 2 2 Disconnect cruise valve relay connector Check for battery voltage at BRN RED circuits If yes go to step 3 If no service BRN RED circuit for a...

Page 659: ...ine stop switch in RUN and turn ignition ON Check that cruise ON indicator lights briefly If yes service BLU ORN circuit between instrument panel and cruise control unit If no go to step 2 2 Disconnec...

Page 660: ...ntrol valve unit Start engine and check for vacuum If yes go to step 2 If no service vacuum line system for a blockage or leak 2 Stop engine and connect vacuum pump to cruise control actuator Operate...

Page 661: ...4 13 goldwingdocs com...

Page 662: ...ion S168 IIIIIIIIII IIIIIIIIII IIIIIIIIII IIII G IIII R IIII NIIIIIIIIII IIIIIIIIII _44page2 11 GRN I 4 G100 C93 lTGRNl lTGRN lTGRN IIIII S201 GRN OT IN ON C HOT T All TIMES I r EilKT l I gfs r I S105...

Page 663: ...J LTGRN LTGRNI C93 LTGRN LTGRN 1ffiIIIIIIIIiI I IIiiiIiR _1IIilIII 5501 LEFT HORN RIGHT HORN Optional GRN GRN See Ground Distribution page 2 17 GRN 5156 _ See Ground GRN Distribution 5468 _ III III I...

Page 664: ...REDIYEL C89 51 01 iW Ji iit Ji iit1 t REDIYEL S102 p JC U 3IIIIIClIII IIIIE 2I111111E U 3IIIII1II 31111 HOUR MINUTE SELECTOR SWITCH HOT AT ALL TIMES IHOT IN ON ACC OR PARK r _ FUSE I I RELAY BACK UP...

Page 665: ...goldwingdocs com...

Page 666: ...BRN BLU See Ground Distribution page 2 10 _ _ _ BLKlGRN LT BLU A GRN RED BRN BLU GRNIYEiC91 IF it _ INSTRUMENT I _ _ _ _ _ LCD I PANEL I I Check Switch Relay Control I UNIT I I I B B Sensor Input BBPS...

Page 667: ...it ID5236 I L T TGR L I d BRNWHT i C103 BRNI WHT 11 LT GRN BLKI mI lt JiiiiiiiiitJIi _ ID S237 With I C71 Without BRN WHT CB Radio LT GRN BU CB Radio C10 L OT PARK F FUSE I j I RELAY I PARKING I BOX...

Page 668: ...METER POSITION I BOX I FUSE BLK I 15A I I I I IWHT YEL I I I I I I r 18 011 PRESSURE SWITCH Open above 1 3 psi 0 1 0 2 kg cm2 S132 B iiIIIIIIIIIIIl imIllll OUIIIIIIIl imllllllllGiiIIIIIIIIIIIl imIlll...

Page 669: ...I 1 cn BRNIWHTW S430 m m IIICaIII Marker Lights BRNIWHTI it C6G BRNIWHTIlil 8431 II m m IIICaIII Indicators BLKlBRN g r l l NSTRUMENT PANEL I OIL I I PRESSURE I I INDICATOR I I b I See Ground Distribu...

Page 670: ...BLKiWHT I D ME l R Fueland BLKlBRN lJ li t 8132 re l W I S W a we t2j sm aure I BLKlBRN i BRN iOVERDRIVE I SIDE STAND REVERSE OIL PRESSUFI INDICATOR CDNEUTRAL I I INDICATOR INDICATOR INDICATOR 0 INDIC...

Page 671: ...T BLU BLU I WHT WHT I F 0 I I IGN HEADLIGHTS I I CRUISE HIGH I I RELAY RELAY I L J REDiWHT GRN rC57 I See Cruise Control BLK WHT page 4 1 1 l C55 WHT J J WHT lc66 ill 8240 WHT WHT LL BLU r r d i J 1 T...

Page 672: ...til BRNIWHT 8 5601 See Power S430 8 iiIiIiiP Marker BLU BLK C24 Distribu 1 Lights BLU BLK tion page 2 9 BRNIWHT Headlights BLKlBRN BRNIWHT1 4 C66 r F i I u I SIDE STAND OIL NEUTRAL OVERDRIVE INDICATO...

Page 673: ...goldwingdocs com...

Page 674: ...BlKl 1 C66 eCekd i Pulser GRN BlK 55 __ __ _ _ C55 C22 GRN BlK GRN BlK C112 GRN BlK S143 w w I See Ground I Distribution page 2 1 O G100 G103 w tI ENGINE COOLANT TEMPERATURE ECT GAUGE SENDER IseeGrOu...

Page 675: ...0 I I RELAY I I I I BRNIWHT BRNIWHT BRNIWHT BRNIWHT INSTRUMENT I PANEL I I I 8 GRN See Ground S293 BIIIIIi lII l Distribution page 2 14 GRN ILWMINATION LIGHTS GRN ll llllllIIIIIIIIII IIIIIIIIII IIIII...

Page 676: ...BLLJr _ C107 I C16 WHT BLU F LCD I Ignltlon Speed I UNIT I Ace Input I Solid I Wheel I state I Speed Ground Ground I t Ofutput f1 i J 1 WHT BLK LK 11 N L 1 GRN L C16 C73 I G 0 91 RADIO WHT fBLK I See...

Page 677: ...nput Speed I MODULE I A Output ECM I Common Asp SE I L __ __ J ocr w r C49 C63 GRN BLK WHT BLK WHT YEL WHT BLU li C33 WHT BLK C135 CRUISE I Speed Input I CONTROL I I UNIT I I Asp 8 8E I I b _ IGNITION...

Page 678: ...ion page 2 16 Ohms Il G100 G103 GRN BlK GRN BLK BLKiBRN GRN BLK BRN WHT S415 I I See Power Distribution 1 page 2 7 f cn BRN WHT BRN WHT 8430 w BlK BRN fIF 1 ENGINE COOLANT TEMPERATURE ECT GAUGE SENSOR...

Page 679: ...s wonie66 BRN WHT __ J ILLUMINATION LIGHTS GRN BRN WHT 8591 _ IIiLJIIIIIIIII_d GRN I lllllliillllllllll iIIIIIIIIII iIIIIIIIIII iIIIIIIIIII _iIIIIIIIIII iIIIIIIIIII iIIIIIIIIII iIIIIIIIIII iIIIIIIIIII...

Page 680: ...WHT GRN I re w we w iiiiiiii S212 100 BRN WHT GRN RIGHT HEAD LIGHT POSITION LIGHT C92 Indicators Neutral Indicator BLKlWHT FORWARD REVERSE C92 LEVER BRN SWITCH WHT BLU C57 RIGHT I COMBINATION I SWITCH...

Page 681: ...ghts r I I I I I 5174 Automatic Level Control WHT BLK BLU BL l 24 1 1 WHT BLK GRN w i BLU LK 031 1 BLU BLK LOW HIGH HIGH LOW LEFT LEFT RIGHT HEAD HEADLIGHT HEADLIGHT LIGHT POSITION LIGHT BRNI WHT GRN...

Page 682: ...page 2 17 GRN G100 C57 See Power Distribution page 2 9 See Power Distribution page 2 7 LEFT HEAD LIGHT POSITION LIGHT GRN GRN S415 e a I lIInE BRNiWHT V CG S212 BRNiWHT BRNiWHT RIGHT HEAD LIGHT POSITI...

Page 683: ...GH BEAM I INDICATOR I Illumination i 0 I I Lights I 0 dl I See Ground I Distribution 1 page 2 20 GRN I CGG GRN GRN S477 9 S175 GRN 1C24 l ii WHTiBLK From LEFT COMBINATION SWITCH on page 8 2 GRN C72 GR...

Page 684: ...5176 5476 1 H IC f l RIGHT FAIRING MARKER LIGHT GRN I C6S GRN I 5171 GIi11iRI I N Right Front Turn 5471 I Signal Position Light GRN 5172 _JLIlil RIlil N_ Instrument Panel 5 I Illumination hWllllillIll...

Page 685: ...IIIIIBIIIIIIIBIIIIIIIBIIIIIIIBIIIIIIIBIIIIIIIBIIIIIIIBIIIIIIIBIIIIIIIBIIIIIIIBIIIIIIIBIIIIIII B_ 5161 I 5461 GRN GRN 5149 B_ 5449 1 GRN I C10 GRN r I C192 D J GRNI I I GRN BRNI BRNI WHT WHT _ 5267 526...

Page 686: ...U Dlstnbutlon page 2 2 0 I LTGRNIYEL LTGRNI I TAIL I S142 Automatic I MAIN I 1 Level Control I RELAY LT GRNfYEL 1 1 COG IClO o See Power Distribution I See Ground IN LINE i page 2 1 I Distribution DI...

Page 687: ...urn Signal Position Light Park BUlb LEFT CORNERING LIGHT GRN IIC95 GRN r t T C191 SE I I C192 Asp L _ _mI TSee Ground Distribution I page2 11or2 13 G100 BRNIWHT ORNIWHT T E J H J HOT AT ALL TIMES r HO...

Page 688: ...ION I COIIIIBINATION I __ _ _ _ _ LIGHT SWITCH I SWITCH I h Part otTum I I Signal Switch I I I L BRNIWHT ORNIWHT IT BlUIWHT BRNIWHT GRN RED BlU fC69 RED BlUJl RIGHT CORNERING LIGHT See Ground Distribu...

Page 689: ...RADIO SWITCH ASSEMBLY I I CEl I SWITCH I ILLUMINA 1 TION I I BRNIWHTj 1 C23 C57 BRNIWHT I I I I I I I Ib _ LEFT COMBINATION SWITCH Position Lights TURN HAZARD ILLUMINATION IP I I I I I I I GRN GRN GRN...

Page 690: ...ch C99 Wheel Speed Input See Ground Distribution page 2 11 GRN 11 l IlIIIII l IlIIIII l IlIIIII d G100 TURN SIGNAL r i CANCEL CONTROL UNIT Solid state T Do not check BLK resistance C99 BLU j BLK C90 B...

Page 691: ...I 1 0 1 I __ _________ HORNfTURN I LTGRN BLK I RELAY I I I LT GRN BLK iF T _ HAZARD FLASHER RELAY C88 PNK WHT PNK WHT To 8215 on page 9 1 0 See Ground I Distribution 1 page2 12 GRN _ G100 From S217 on...

Page 692: ...TAiL METER IBOX l 1 TION I _1 1_IUDllII I S106 I WHTIYEL 15A I J I I TAil I I f I 8 See Ground Distribution S415 page 2 12 BLK See Power Distribution page 2 9 BRNiWHT IIIIl See Power U Distribution p...

Page 693: ...ON ACC OR PAR e fUSE 1 I I RELAY I HORNrrURN BLK See Power ACC IBOX I STOP RELAY S105 Ii Distribution FUSE I I FUSE BLKI page 2 9 10A _ _ 15A CD f I HORN I I Y I L 1 f JLT GRNIBLK WHT GRN GRN WHT GRN...

Page 694: ...Light Relay C66 LT BLU LT BLU ORN Left Cornering Light Relay ORN WHT ORN S219 pi i1i IIIIII U From C93 on page 9 6 or 9 8 LEFT FRONT TURN SIGNAL POSITION LIGHT ORN POSITION TURN ORN wHT From FUSE REL...

Page 695: ...und Distribution pages 2 13 and 2 19 LT BLU i TRUNK I LIGHT LEFT REAR RIGHT REAR I ASSEMBLY TURN TURN I SIGNAL W SIGNAL I G II H J GRN 5158 _ 5458 I GRN I ___mJ S459 5159 GRN I11III _1IIII1IIII 1J G I...

Page 696: ...t S BRN 1 Left Rear 1 BR H lit 232SJ W iiiiiiiW N T iiiiiiiW If Side lI 5 BRN ICB4 Marker BRNiWHT 1 Light f CB5 IC75 BRN BRN 1IIi MIIIIIi MIIIIIi MIIIIIi MIIIIIi MIIIIIi MIIIIIi MIIIIIi MIIiIIIIlllli...

Page 697: ...T I TC76 BRN 5211 _GI I RiliiN_m4b Right I Accessory BRN Light r 1 I RIGHT I BRAKE I lIGHT I I TAILLIGHT I l AKE J GRN S157 GRN 1 I C76 GRN S158 5112 BRN piIIIIIII lIi IIIIIIIIIII _IIIIIII IIIIIIIIIII...

Page 698: ...king and License Plate Lights Int Circuit Schematic See Power Distribution page 2 7 BRN BRN See Power Distribution page 2 9 BRN CENTER liGHT ASSEMBLY Optional BRN S i CBS BRN _ _ _ _ _ _ 9 14 goldwing...

Page 699: ...C76 GRN II S458 I C56 BRN GRN BRNIWHT 5412 BRN C77 _lilllllllllf lIIIIIIIf 1IIIIIIIfIIIIII1IIIIIIIfIIIIII1IIIIIIIfIIIIIIm 1IIIIIIIfIIIIII1IIIIIIIfIIIIII1IIIIIIIfIIIIII1IIIIIIIfIIIIII1IIIIIIIfIIIIII1I...

Page 700: ...YEL S305 GRNIYEL G100 S242 GRNIYEL F iii aII _ iiiii jt a ww l G CCl C76 I C77 Spoiler IC75 GRNIYEL Brake GRNIYEL GRNIYEL C78 CB5 Taillight GRNIYEL l rDLE_ r L lmmr r l lGD IEBAG IBAG BRAKE ASSEMBLY B...

Page 701: ...RELAY I I I F 9 I z z S107 SeeGround I See Power Distribution Distribution G100 GRN ORN page 2 9 page 2 17 I WHT GRN WHT GRN WHT GRN WHT GRN WHT GRN z I C57 S108 C81 STOP I FRONT BRAKE LIGHTS I LIGHT...

Page 702: ...tionallnt TRUNK LIGHT SWITCH Optionallnt Closed when trunk lid is opened Instrument Panel LCD Unit Radial Cassette Deck RED YEL CB Transceiver Optional r 9 VANITY MIRROR LIGHT SWITCH _ lI Optionallnt...

Page 703: ...EEIiIII I GRN I 8161 JIIIIIII It 8461 I See Ground GRN A Distribution F I pages2 13 I and 2 19 _J C192 GRN Y I Gl00 GRN GRN BRN BLU Brake Light and Taillights M M_ iiiiii ED 8160 5460 Left Brake Ligh...

Page 704: ...10 I GRN RED III Brake BRNIWHT 5305 Lights 5208 E2llCOlmEOlln GRNIYEL l B Jl C329 BrakeSwitch Taillight ir Input 6 12 Volt Input TAILLIGHT Switched Output CONTROL YEL VC329 MODULE X C330 YEL C331 YEL...

Page 705: ...goldwingdocs com...

Page 706: ...sceiver RED YEL I t t CB Transceiver I Sl 03 optional S102 1 l E n men optional for Asp LT for Asp RED YEL CB GRN RED YEL Transceiver BLK optional for 9 1 Cl Asp 19 C2 f1gnition Mem S er I u TTE Input...

Page 707: ...301 r I r 1C303 GRY BLK RED GRN BRNIBLK 1 GRyIWHT BLUIYEL BRNIWHT C302 r _ 1 C71 GRYIWHT p T BLU GRY BLK RED GRN BRN BLK SPEAKER SPEAKER GRN GRN BLK RED GRN S287 lID a S289 lID 11 imE i LEFT LEFT 1 AI...

Page 708: ...ED GRN BLK I I S200 iIIIIE2_ a a _ I RED I I BLU I I I I I I I 5130 _IIii IIii_ _IIii I RIIii _ IIIIii lI n Ilii _11111 _ _ 1 nG Without Passenger Controller With Passenger Controller A CB Transceiver...

Page 709: ...5260 __E_ E 2II i i lIIIIII i lIIIIII i lIIIIII i lIIIIII1IIIIIIIIIII RED BLK BLUiBLK r GRN BLK II F I I bH I NE I I SWITCH I II MUTE TUNE b N I UP _ _ t OFF O Q _JJ LEFT COMBINATION BLUiBLK REDiBLK...

Page 710: ...RNIBlK C130 _ GRY BlK BlU YE RED YE BRN BlK Left Right FADER GRY BlK BlU YEl GRY WHT BRN WHT C130 BRN WHT BRN BlK 1 f5 tW t t JIijIll lt BlU GRN GRY REDI VEL BRN WHT C302 LEFT REAR SPEAKER RIGHT FRONT...

Page 711: ...10 5 goldwingdocs com...

Page 712: ...Y ENERGIZ IF IRIGHT I Engine I COMBINATION rSAT2 II Control SWITCH I I 1 I IFREE I 1 I PUSH STARTER I STJ SWITCH 1 1 1 Ib J REDIYEL See Power CB S102 lIII 3 Distribution Transceiver page 2 6 optional...

Page 713: ...BlK _ I WHT I SHIELD BlK 1 1 i I BlK From RADIO CLOCK cavity 15 and MUTE SEARCH SWITCH on page 10 11 C55 I 1 IBLUI I VEL 1 SHIELD I I I C136 l I SHIELD BlK WHT BlK I 1 1 WHT I SHIELD SHIELD 1 I BlK BL...

Page 714: ...D I BLU I S262 re J F _ _ i I I I I I I S130 I I 1 BLK LT GRN RED GRNIBLK i Cl0 i M YEL LT GRN RED cr I I I I C55 I ISHiELD I IREDI I YEL LT GRN RED GRN BLK IBLU I I I I I I I I LTGRN YEL RED With Wit...

Page 715: ...TUNE UP RED BLK RED BLK C21 CB Transceiver I I 1 G I Gloal W 8259 E A II 1 r r I C304 f 0 PASSENGER I Up On Up Transmit I CONTROLLER I I Optional Solid state J resistance ON MUTE BLU BLK BLU BLK GRN...

Page 716: ...w m I G O d r 1C130 I i GRY BLI BLUiGRN BRN BLK RED GRN GRN WG r LEFT o C55RIGHT G100 FRONT FRONT SPEAKER SPEAKER BLU GRN With Rear Speaker optional r _ mmm RADIO I I CLOCK I ISolid state Ground Do no...

Page 717: ...n is requested by pushing the corresponding button a ground signal from the GRN BLK circuit is applied to the respective BLU BLK RED BLK or VEL RED circuits to the radio If equipped with a passenger c...

Page 718: ...ed speaker wires or faulty speakers radio cassette deck do test D W m One or more speakers are inoperative Faulty speaker s Asp model with rear speakers Open or shorted speaker wires faulty fader or r...

Page 719: ...r controller and radio cassette deck Faulty radio cassette deck do test J w _ Driver s headset does not work but Open GRN BLK circuit BLK circuit or passenger headset is OK faulty driver s headset do...

Page 720: ...operate repair speedometer If cruise control does not work go to cruise control If cruise and turn signals operate properly disconnect radio cassette deck connector C1 and connect voltmeter at C1 pin...

Page 721: ...N and GRY BLK circuit for an open If the wires are OK replace the radio cassette deck 6 Disconnect fader connector With ignition in ACC tune in a strong station Adjust balance control towards RIGHT an...

Page 722: ...go to step 2 If no check GRY BLK and BLU YEL circuits for an open If the wires are OK replace the radio cassette player 2 Connect voltmeter across RED YEL and BRN BLK circuits from the radio With volt...

Page 723: ...o top step 4 If not OK repair suspect circuit for a short to ground 4 Check continuity of circuits in headset jumper cable If OK go to step 5 If not OK replace headset jumper 5 Connect a known good dr...

Page 724: ...for 5 volts at GRN BLK circuit with radio on If yes go to step 2 If no service GRN BLK wire for an open 2 Disconnect radio connector C1 and connect ohmmeter between GRN BLK circuit and BLU BLK circuit...

Page 725: ...rn radio on Press left combination switch TUNE UP button and check for 5 volts If yes go to step 4 If no service RED BLK circuit for an open 4 Connect ohmmeter between VEL RED circuit and ground Press...

Page 726: ...TCH I I FREE PUSH IREVERSE I I 1ISWITCH I I b mJ lIlIll mO J YEljRED C57 YEljRED If D YEURED 5198 It RIGHT FRONT SPEAKER BRN BLK See Power Distribution page 2 0 i_ _ iIIIIIIffi S281 S289 ltme a RED GR...

Page 727: ...nput L rr l J l J C306 WHT IT _ _ j S283 ORN GRY WHT r TRANSMIT SWITCH FREE w CHANNEL SELECT SWITCH See Ground Distribution page2 1L C20 GRN GRY ORN WHT I II iF i I TRANSMIT 1 llCHANNEl I I SWITCH FRE...

Page 728: ...runk Light YEURED REDIYEL flI M See Power G O j I 1 b2 O lE roJI iIIIIIIE U LT GRN BLKI REDIYEr u rC306 r _ l o CB I Ignition Input Memory Input Start Input I TRANSCEIVER I CB Muted DUring I Solid sta...

Page 729: ...9I CB SWITCH DRiVER S UP DOWN DOWN GRY FREE UP UP CHANNEL SELECT SWITCH Channel Select Inputs C20 GRN Transmit r CEI _ J TRANSMIT SWiTCH WHT FREE FREE C304 PASSENGER S CONTROLLER UP DOWN _ i 91 CHANNE...

Page 730: ...page 2 0 LT GRN BLK 5140 ilE _ atic Control LT GRNiBLK LT GRN BLK LT GRN BLK Turn Signals LT GRN BLK RED YEL YEL RED RIGHT FRONT TWEETER Optional Fader may be installed here See page 10 1 if equipped...

Page 731: ...iIIIIIII l I S284 ORN GRY Jl C20 rr J II CB SWITCH DRIVER WHT ORN GRY C304 PASSENGER S CONTROLLER r 11 I I I TRANS CHANNEL I I l1li IT FREE SELECT I I SWITCH I SWITCH I I UP DOWN I I w _ _ I t J GRN C...

Page 732: ...en channel select input c or faulty CB transceiver do o Faulty transmitter switch circ open control circuit between do test B I Open power or ground circu SYMPTOM CB transceiver does not transmit and...

Page 733: ...d GRN circuits at switch side of connector s Check for continuity with transmit switch held in TALK If yes go to step 4 If no replace driver s CB switch 4 Reconnect connector C20 and C23 SE model and...

Page 734: ...ct switch toward UP If yes go to step 2 If no service ORN circuit for an open 3 Connect an ohmmeter to the harness side of C304 at the GRY circuit Check continuity to ground while holding the driver s...

Page 735: ...goldwingdocs com...

Page 736: ...nit 5 Behind left fairing inner cover on left side of fuel tank Cruise Valve Relay 9 Behind left fairing inner cover near front of fuel tank Engine Control Module ECM 26 YEl 24 Behind right fairing in...

Page 737: ...2 Behind right side cover forward of battery Main Fuse B 55A 2 Behind right side cover forward of battery Oil Pressure Switch 11 On lower right front of engine Passenger Controller On right side of tr...

Page 738: ...frame rail Starter Relay Regulator 1 Behind left saddlebag Starter Reverse Motor Asp SE On lower right rear of engine Throttle Cancel Switch 9 Near left side of air cleaner box on frame rail Trunk li...

Page 739: ...rear of trunk C57 9 RED 21 Right side of fairing bet1ind marker light C58 a BLK 12 Behind left front side of fairing CS9 6 SlK 21 Right side of fairing behind marker light C60 2 BLU 21 Behind right fr...

Page 740: ...iring C97 2 GRN Asp 10 Behind left fairing pocket C97 2 GRN nt 55 Behind left fairing pocket C97 2 GRN SE 59 Behind left fairing pocket C9B 3 BlK 13 Left front of fairing behind turn signal light C99...

Page 741: ...top of fuel tank C184 i BLK SE 67 Below seat on top of fuel tank C184 i BlK without CB 42 Below seat on top of fuel tank CHI5 i WHT 43 Below seat on top of fuel tank C186 1 WHT 43 Below seat on top o...

Page 742: ...r front of fuel tank C315 2 YEL Int 51 Behind left fairing inner cover near front of fuel tank C316 3 BRN 29 Behind right side cover under battery box C330 2 BLK 39 Below left side of trunk C331 2 BlK...

Page 743: ...11 7 goldwingdocs com...

Page 744: ...ved 2 Right Side Below Battery Rear Side Cover and Battery Box Removed 3 left Rear of Engine Front Side Cover Removed 4 Rear of Alternator Removed from C44 2 WHT 5 left Side Next to Fuel Tank Inner Co...

Page 745: ...Behind left Side of Fairing Fairing inner Cover Removed 11 left Rear of Fairing Inner Cover Removed 9 Behind left Side of Fairing Fairing Inner Cover Removed 12 Behind left Side of Fairing 1i lirii lt...

Page 746: ...torcycle Behind Position light 14 Below left Radiator Front Cover Removed 15 Behind left Fairing Front Cover 16 Right Air Cleaner Housing Area 17 lower Right Front of Engine Under Cover Removed 18 Rig...

Page 747: ...ng lower Fairing Cover Removed 20 Below Right Fairing Pocket Fairing Removed 22 Below Rear of Seat 23 Rear of Right Fairing Pocket 21 Right Side of Fairing Fairing Removed 24 Right Side Inner Cover Re...

Page 748: ...ht Rear of Engine Front Side Cover Removed 27 Right Rear of Engine Front Side Cover Removed 12 4 28 left Side left Side Cover Removed FUSEIRELAY BOX 29 Right Side Beiow Battery Rear Side Cover and Bat...

Page 749: ...4 Below Rear of Trunk Trunk lower Cover Removed 32 Right Side Saddlebag Removed 33 lower Rear of Right Saddlebag Saddlebag lower Cover Removed 35 Inside Trunk on left Side of lid 36 Top Rear Under Tru...

Page 750: ...37 Top Rear Under Trunk Trunk Removed 38 Top Rear Under Trunk Trunk Removed 39 Under Seat Trunk Removed 12 6 40 Under Rear of Seat Seat Removed 41 Under Front of Seat Seat Removed 42 Top of Fuel Tank...

Page 751: ...44 Fuel Pump Assembly Removed from Fuel 43 Top of Fuel Tank Seat Removed With CB Radio 45 Top of Engine Top Compartment and Air Cleaner Housing Removed 48 Right Side of Handlebar C320 1 WHT C321 1 WH...

Page 752: ...otographs 49 Left Side of Handlebar CLUTCH CRUISE CANCEL SWITCH 50 Below Rear of Seat 51 Left Side of Fuel Tank 52 Below left Fairing Pocket 53 Behind Front Right Side Cover 54 Inside Right Fairing Po...

Page 753: ...LEFT COMBINATION SWITCH 55 Below left Fairing Pocket 56 Right Side Inner Cover Removed 57 Right Front Fairing Lower Cover Removed 58 On left Fan Shroud 59 On Right Fan Shroud goldwingdocs com...

Page 754: ...Top Right Front of Engine ENGINE COOLANT TEMPERATURE Eel SENSOR 2o GRN 62 Top left Front of Engine 63 Rear of Instrument Cluster lnt 64 Top Right Handlebar 65 Below Left Fairing Pocket 66 Below Right...

Page 755: ...67 Below Seat on Top of Fuel Tank 68 Behind Right Front Side Cover 69 Below left Fairing Pocket 12 11 goldwingdocs com...

Page 756: ...4 Carburetor Air Jet CAJ Solenoid Valve 3 Asp and SE 3 0 Int 3 4 CB Radio Switch Assembly 2 12 9 5 CB Switch Driver s Asp and SE 2 12 10 21 10 25 13 O Int 2 18 10 23 CB Switch Illumination 9 5 CB Tran...

Page 757: ...7 Int 9 9 Head Fuse 15A Asp and SE 2 1 7 1 8 1 Int 2 7 7 2 8 3 Headlights High Relay Asp and SE 2 1 2 12 7 1 8 1 Int 2 7 2 17 7 2 8 3 Headlights Low Relay Asp and SE 2 1 2 12 8 1 Int 2 7 2 17 8 3 Hea...

Page 758: ...Int 2 20 7 9 Increase Decrease Switch 5 5 In Line Capacitor A 3 26 In Line Capacitor B 3 26 In Line Capacitor C 2 12 5 5 In line Capacitor D 2 11 2 17 3 2 3 6 In line Diode A 3 17 In line Diode B 2 4...

Page 759: ...sembly 3 15 3 31 8 0 Reverse Indicator 3 30 7 0 Reverse Lever Switch 2 2 3 14 3 31 7 0 8 0 Reverse Resistors 3 32 Reverse Switch 3 15 3 31 Reverse Switch Relay 3 15 3 31 Right Accessory Light Asp and...

Page 760: ...6 9 20 Int 2 7 9 17 Stop Lights Relay Asp and SE 2 1 2 12 4 0 9 16 9 20 Int 2 7 2 17 9 17 Tachometer Asp and SE 2 14 7 4 Int 2 20 7 8 Tail Main Relay Asp and SE 2 1 2 12 3 30 6 0 7 0 7 4 7 5 8 0 9 0 9...

Page 761: ...13 5 goldwingdocs com...

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