Honda GL 1000 Shop Manual Download

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Summary of Contents for GL 1000

Page 1: ...RTER 16 IGNITION I 17 LIGHTS SWITCHES AND INSTRUMENTS tI BATTERY AND CHARGING SYSTEM THIS BOOK 1 1 Sr E clal information for more efficient and convenient GL 1000 SHOP MANUAL 1978 AmerIcan Honda Motor Co Inc U S A 7 78 This manual contains inf rmaticln for several model years You may notice some minor appearance differences from your mo torl vclle TABLE OFCONTENTS The GL 1000 Manual is divided int...

Page 2: ...LE SERIAL NUMBERS 1 2 NPS PART NUMBERS 1 3 METRIC CONVERSIONS 1 4 WORKING PRACTICE 1 5 SERVICE PARTS 1 6 TOOLS AND MATERIALS 1 8 GENERAL SPECIFICATIONS 1 17 GL 1000 SHOP MANUAL 1 19 16 American Honda Motor Co Printed in U S A II ...

Page 3: ...erial number is 1 rn orl on of the side of the crankcase The final drive serial number is located on the left side of the final drive case near the CARBURETOR IDENTIFICATION NUMBER 1 2 L l000SHOP MANUAL 1978 American Honda Motor Co Inc Printed in 7 78 ...

Page 4: ...nufacture UU of thread Nominal Diameter under the head Treatment 921 V VVI J V 1 20 042 o Z WHEEL SEAL Function Detail Number Number where first Classification 91 2 51 3 p ecI ClI Numbers LEFT SIDE COVER Color Code 83700 371 305ZA ZA GL 1000SHOP MANUAL 1 3 1976 American Honda Motor Co Inc Printed in U S A 7 78 ...

Page 5: ...lts use the following conversion factors GIVEN MULTIPLY BY 25 40 0 6214 1 TO OBTAIN ft Ibl UUUllUl in lb ilnl1r IIY1 meter kg ml K ii grelm en1 imE ter kg em Inches in Meter m Mile mil inch psi ilnrlr lrYl n centimeter kg cm2 FahrAnihAit FO Cel 1ltigr ade CO Gallon gal qt I 3 785 I 1 L l000SHOP MANUAL 1976 American Honda Motor Co Inc in 4 Miles hour mph Kilometer hour km hr ...

Page 6: ...the GL 1000 technician should become familiar with the tools listed in this section New tools required to maintain this are in bold face type and these special tools are many operations If customer co mplal nts are on the work and are refer to the sections this manuaL GENERAL SERVICE PRECAUTIONS 1 replace and cotter pins with new ones When assembling make sure the seals are mstallea correctly snap...

Page 7: ...IDxW 6 5 x 1 5 mm oil orifice 1 per side 4 1 x 1 5 mm oil orifice 1 per side 4 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 2 0 1 1 1 Adjuster Filter Rear Dowel Dowel I Manifold Tank Nut Master Wheel Final Assembly Alternator Wires Oil Pump 1 lt LIUdl Switch Oil Filler Plug t 1 nn Pump Front Cover Water LOCATION Water lines I flinrl r Head As emlblv O RINGS SERVICE PARTS 1 6 GL 1000SHOP MANUAL ...

Page 8: ... Hand Cylinder Head Tac horneter Drive Oil Pump Scavenge Pump Case Left Fork Drive Assembly 27 x x 9 x 43 x 9 4 8 x 14 x 5 4 10 x 25 x 7 11x15x3 14 x 24 x 5 25 x 54 x 7 x 54 x 7 18 x 29 x 7 14 x 28 x 7 35 x 55 x 8 x 48 x 11 32 x 67 x 8 x 52 x 8 70 x 90 x 8 LOCATION LD x 0 0 x W I DUST SEALS w I I Wheel Wheel Swing Arm 22 x x 8 30 x 45 x 9 5 x 46 x 10 5 GL 1000 SHOP MANUAL 1 7 1976 American Honda M...

Page 9: ... End Wrench 8x9mm Open End Wrench 10x12mm Open End Wrench 10 14mm Open End Wrench 7x19mm Open End Wrench 11x13mm Open End lSOI Wrench 19 nmm Open End ISO Wrench 24x27mm Open End liSa Wrench 10x12mm Offset Box Wrench 12x14mm Offset Box 14x17mm Box Wrench 17x19mm Offset Box TOOL NAME AND DESCRIPTION Wrench 21 x23mm Offset 80x Screw Driver 200mm Plastic Handle Screw Driver Stubby Screw Driver 100mm W...

Page 10: ...CHASE PURCHASE PURCHASE PURCHASE PURCHASE PURCHASE TOOL NAME Glaze 3 8 Inch Drill Motor Amp Meter Soldering Iron Cylinder Leak Tester Oil Drain Container Tester Cooling System Battery Hydrometer Wheel Alignment Fixture Gasoline Container Safety Spring Lock Cap Type Plastic Two Gallon Contllin er Funnel Auto Trans Type Electric Hot Plate Battery Acid Container Battery Charger GL l000 SHOP MANUAL 19...

Page 11: ... LOCAL PURCHASE Work Bench LOCAL PURCHASE LOCAL PURCHASE Motorcycle Lift M9 Fn vy Engine Adapter Stand _ LOCAL PURCHASE Bench Grinder 40046 M975A 023 XXXXX Engine 64431 M9259 999 64431 Engine tand PURCHASE Hole Gauge PURCHASE Spring Pressure Tester LOCA PURCHASE Spring Pull Scale grams ounces 11884 Cylinder Gauge Set 35 80mm 1 25240 07345 0020000 Magnetic Stand I 41291 07140 99914 V Block 5 Inch 2...

Page 12: ...ONDA CODE f f I SPECIAL ASSEMBlY DISASSEMBLY TOOLS Clutch Center 41303 07916 3710000 Handle Driver Attachment 07 EE 3 71 0000 Race Removal Tool Lower Race Race Installation Attachment Upper and Lower Races _ 1 Handle Driver Attachment Bearing Driver Upper and lower steering races and lower bearing Valve Guide Remover and Installer Use with 07949 3710000 07946 3710500 07946 3710700 07949 6110000 07...

Page 13: ...10200 Weight Sliding 41313 07936 3710300 41319 07945 3710400 Remover Bearing Fork pivot needle bearing remover 41326 41327 07948 3710100 07948 3710200 Remover A For front fork seal Remover S Oil Seal For shaft seal Use and weight 41311 and 4131 0200 respectiviely Piston and Cr mk caSie 0000 Piston Base Set of two t 5i 30 11 tY g 73 65m Q 1 AA ssembIVIDisaSSemblY Tool Set Piston Pin 5 inl LOCAL PUR...

Page 14: ...drive shaft damper Timing Tools 63068 07999 3710000 Timing Inspection Plug Wrenches and Spanners 41301 07910 3710000 Wrench Final Retainer 1 41303 07916 3710000 Wrench 16mm socket for assembling and disassembling clutch 61076 07920 6340001 Wrench Lock 50mm For fuel unit disassembling LOCAL PURCHASE Hollow Wrench Set 00155 07902 0010000 36mm Pin Spanner 64765 07916 3710100 Steering Stem Socket 3782...

Page 15: ...1 250101 001 f OJ LOCAL PURCHASE 10 1 50101 ODI LOCAL PURCHASE 12x1 20101 001 _ LOCAL PURCHASE Die 12x1 50101 250101 aD LOCAL PURCHASE 12 1 750101 OD LOCAL PURCHASE Die 14 1 50101 380101 00 LOCAL PURCHASE Die 14 2 00101 380101 001 LOCAL PURCHASE Die 5 6 80101 06193 01689 0030000 Helisert Set 10m01 Spark Plug 25243 07692 0010000 Terminal Kit LOCAL PURCHASE Valve Seat Grinder 1 14 GL 1000SHOP MANUAL...

Page 16: ...embly LOCAL PURCHASE DOT 3 Brake Brake LOCAL PURCHASE L_ _ LOCAL PURCHASE Molybdenum Disulfide Cam Followers Fuel Pump LOCAL PURCHASE Disulfide Head Bolts LOCAL PURCHASE LOCAL PURCHASE Multipurpose Grease NLGl 2 LOCAL PURCHASE Multipurpose Grease N LG 1 2M LOCAL PURCHASE Automatic Transmission Fluid Front Fork LOCAL PURCHASE Ethylene Glycol Antifreeze 39419 M894X 278 100IL Hondaline Oil 10W 40 416...

Page 17: ...e Wheel Base ACCELERATION AND PASSING ABIUTY timl Ini C21rP passing times and distances that can be met or exc eec led the Honda GL 1000 The pass assumes an initial speed of 20 MPH and a limiting pass assumes an Initial of 50 MPH and a limit 80 MPH of MPH The high speed N The In t n nn lfinn n A AnfArI represents results skilled drivers under road and and the information may not be correct under o...

Page 18: ...y not be correct under other conditions StolPphlg Distance from 60 m 1 m 175 ft VelhlCle Caoclcit v Load Limit Cold tire pressures to Front Rear Vehicle l 8Ipac lty front Rear Tire Size Front Rear H19 4 50H17A 4 50H17 7879 Tire Brand Front Rear 21 F 2 Briejges tonel ENGINE 17 Sump I orced and Water Go led 4 trrlkp Flat Four X 61 4 mm 2 834 X cc 1 0 cu 1 Belt i Bore and Stn kp Valve Train Lubricati...

Page 19: ...rce of and a common sense procedure when to locate a As technical innovations so must the technician s ability to qu isolate any that may occur ouIDlesh Qting suglge iticins refer to the of this troublesllocltlrlg list should be used as a gu when trying to a a rule Never overlook the 1 18 GL1000 SHOP MANUAL 1976 American Motor Co I 7 78 ...

Page 20: ...2 MAINTENANCE OPERATIONS MAINTENANCE SCHEDULE 2 2 TORQUE SPECIFICATIONS 2 3 LUBRICANTS AND COOLANT 2 5 GL l000 SHOP MANUAL 2 1 1976 American Honda Motor Co Inc Printed in U sA 7 78 I ...

Page 21: ... Honda dealer unless the owner has proper tools and service data and is mechanically qualified the interest of safety we recommend these items be serviced by an authorized Honda dealer NOTES 1 More frequent service may be when in rain or at full throttle 2 More frequent service may be when riding in dusty areas 31 For odometer repeat at the interval established here til UJ I a UJ J hr f l 7 7 z o ...

Page 22: ...0 290 18 21 Flange bolt 6 152 100 140 7 10 Flange bolt 6 x 110 100 140 7 10 bolt 6 x 35 100 140 7 10 Oil bolt 350 400 25 29 Flange bolt 12 40 800 900 58 65 Lock nut 6mm 380 420 27 30 Flange bolt 6 22 100 140 7 10 Hex bolt 8 x 22 250 290 18 21 Connecting rod cap nut 250 290 18 21 Exhaust pipes Clutch center Alternator bearing holder Starter rachet Connecting rods Alternator flywheel assembly Cylind...

Page 23: ...ut 8 mm 180 250 13 18 Front brake pipes Brake pipe 130 150 9 11 Front disc calipers Hex bolt 10 x 50 300 400 22 29 Front wheel axle Wheel axle 550 650 40 47 Front brake disc Hex bolt 8 x 113 270 330 20 24 Rear brake disc UBS nut 8 mm 270 330 20 24 Rear wheel axle Wheel axle nut 800 1000 58 72 Rear fork pivot lock nut Lock nut 23 mm 800 1200 58 87 Rear brake caliper Hex bolt 12 x 60 500 600 36 43 R...

Page 24: ...tainer Use of additives is unnecessary and will increase expenses Emline oil should be changed at the intervals in the maintenance sci eciule CAPACITY TYPE Engine Oil CAPACITY TYPE Transmission Oil 3 2 liters 3 5 liters 3A U S Quarts 3 7 U S Quarts Final Drive Hub Oil Lubricated by Engine Oil CAPACITY TYPE Front Fork Oil 210 cc 7 202 Gear Oil SAE90 SAE80 CAPACITY Each Leg TYPE Fluid TYPE Refill 17...

Page 25: ...LVE CLEARANCE ADJUSTMENT 3 9 COMPRESSION TEST 3 11 SPARK PLUG MAINTENANCE 3 12 CONTACT BREAKER POINTS 3 13 STATIC IGNITION TIMING 3 14 DYNAMIC IGNITION TIMING 3 16 CHOKE THROTTLE IDLE SPEED 3 17 CARBURETOR SYNCHRONIZATION 3 18 GL 1000 SHOP MANUAL 3 1 1978 American Honda Motor Co Inc Printed in U S A 7 78 I ...

Page 26: ... mum Advance 2 600 rpm For cold climate NGK D7EA or ND V l U C NGK or ND X24ES U NGK D9EA or ND X27 to to 0 028 in Contact Breaker Points Dual Denso to O 4mm 0 012 to 6 in Tension 650 to grams 1 4 to 1 9 Ib MF 1 12 171 PSI Intake 0 10mm 0 004 F At At I rn r rnL 64 k l1 r rY L 60 GL 1000SHOP MANUAL 1978 American Honda Motor Co Inc In 7 78 ...

Page 27: ...TUNE UP SERVICE INFORMATION GL 1000SHOP MANUAL 3 3 1976 American Honda Motor Co Inc Printed in U S A 7 78 ...

Page 28: ... 000 rpm 1 1 1 model number Ventu ri bore Values operation the must Cold means room temperature or less possi e IIl UUlt lUllt lIU 1 nlll A after an cool down UIl L U services are done restore to m t rr r lI l rl nPlrfnrm nt on a new mr tnrf J f IA or to Whenever services are all chassis nuts and bolts should be checked that they are 1 inh1 no rl to correct values Refer to pages and 2 4 for comple...

Page 29: ... of fuel or incorrect fuel 2 F 3 Innitin n 1 i Tl lm prc bl rms 4 Fuel filter cloggEld 5 6 will not start cold weather 1 Choke t i too lean 2 Ice in 3 4 5 ec tlon 16 9 Section 9 1 flow stoPPl d not start Etngine hnilir n in or fuel pump 1 cc ntinUies to run with ianitic n Exce si le carbon ild up in GL 1000 SHOP MANUAL 1976 American Honda Motor Co Inc Printed in U S A 7 78 3 5 ...

Page 30: ... too close n hl l rnc choke dirty Section 9 IViIiM lln A n pl f n nar tll A poor 1 2 3 4 5 6 Bac kfiires Kic l bacl s E xplosh ms in Muffler due to dirt or water in or or If IQnltlCln is too far 1 r r1 r ll pnl ltl may occur when the 2 Retarded ition tin r 3 Late valve 4 Lean mixture 5 or stic kirlg valve exhaust 11 1111 1 or broken exhaust valve n lnllf Burnt exhaust valvels 6 7 1 1 2 3 3 6 GL 10...

Page 31: ...r i 1rl ml nt cover 1 TUNE UP AIR FILTER MAINTENANCE AIR FILTER MAINTENANCE Remove the air filter element and clean with air 5 Check the condition of the air filter and reinstall air filter cover in is retained a G L 1 000 models nut INSPECT FILTER SEALS GL 1000 SHOP MANUAL 1978 American Honda Motor Co Inc Printad in U S A 78 3 7 ...

Page 32: ...onden ed cralnkca e vapors are accumu tn t r n1r i t which must C NKCASE BREATHER the f n nt in NP nr p the flow restrlctor from and the con 1 FRESH AIR CRANKCASE EMISSIONS FLOW RESTRICTOR 4 Insert the flow tr tr r n H t 1I the COlltamE r STORAGE CONTAINER and The tn r o container should be every kilometers service may be if the is operated in weather or at full throttle of drain tube above the co...

Page 33: ... is at TDe of com pression stroke 2 left front intake 2 left front exhaust 3 intake 4 left rear exhaust NOTE The two fi in n POSltlClnS r11 Cl ihf1 r1 above are and alilJnl1nerlt of the timing mark may im ic ate either When one has been ascertained by intake valve the nosifilon can be reached the one full cr m shaft fl l UII Ullill GL 1000SHOP MANUAL 1978 American Honda Motor Co Inc Printed in U s...

Page 34: ...ll l 3 a gauge between the vaIva stem and screw The correct valve tappet clearance is 0 1 Omm If is VALVE TAPPET ADJUSTING TOOL H C 26250 P N 07908 3230000 TAPPET CLEARANCE MM IN LOCK NUT TORQUE 120 160 KG CM 104 139 IN LB 3 10 000 MANUAL 1978 American Honda Motor Co I U S A ...

Page 35: ...e open spark wells After the spark plugs have use a stiff wire to water the NOTE Before spark clean the area around the base of to dirt or debris MPRESSION TEST GL 1000SHOPMANUAL 3 11 1978 American Honda Motor Co Inc Printed in U s A 7 78 ...

Page 36: ...e and side plolrfr nrh should have a constant thickness which appear worn or cracked or hinn or insulators Remove foul a sandblast 2 3 IJlfllrl 1r lr 1 r I tF tY1I P gauge will measure oIO i t r r i gap O 7mm 4 nstall caps wrench for Rp r OI nf r t the spark is done without the force of a wrench in order to the the in the lI n 1 head can be reused remain with the same and with which were 2 ...

Page 37: ...n set should be re gap a 1 lY nf gauge between the contact su correct contact is 0 3 0 4 mm 2 4 f the contact bn ak er screws and move the contact breaker 5 Clean contact electrical contact cleaner to remove oil or dirt C NTACT BREAKER PINTS 6 adjus tirlg each contact Inhh n the contact breaker screws and recheck I h r i the contact cam a thin film of grease 8 tim GL1000 SHOP MANUAL 1978 American ...

Page 38: ...CT POINT LEADS MUST BE CONNECTED the contact ING N TI If the is cOlmelctE d in series with one of the contact and the contact are the will go off when the open b Attach one corltin uit a If the COlnnElctE d in nm anel one of the COlltaict the will come on when open to make a 3 14 GL 1000 SHOP MANUAL 1978 Am lrican Honda Motor Co_ I U S A ...

Page 39: ...T SET for 3 4 cylinders 3 4 BASE PLATE __ I timing is the con will indicate that the open when the tim n mark with and rotate the base plate to ad vance timing or counterclockwise to retard timing the base screws and 1 o ho gap and tim nn 2 ATIC IGNITION TIMING 1 GL l000SHOP MANUAL 1978 American Honda Motor Co Inc Printed in U S A 7 78 3 15 ...

Page 40: ...e b a c NA Ie IGNITION TI 2 IGNITION TIMING FOR 1 CYLINDERS 3 FULL ADVANCE TIMING MARK follow the adilus tml nt nr cp dlJlre described in IDLE TIMING MARK FOR 3 4 CYLINDERS Step 2 page 3 15 IDLE TIMING MARK FOR 1 2 CYLINDERS stnobiosc opic tlm lnn cylinder GL 1QOOSHOP MANUAL 1978 American Honda Motor Co Inc U S A 7 78 b a 3 16 ...

Page 41: ...on so the wtlerevE r it is nel9aleis the wide white line lone tllrnirlCl the Turn the adjuster clockwise to in crease or counterclockwise to de re ase t lin n IDLE SPEED CHOKE THROTTLE GL l000SHOP MANUAL 1918 American Honda Motor Co Inc Printed in U S A 7 78 3 17 ...

Page 42: ...TION 1 vacuum gauge tor screws the carburetor spacers install vacuum hose and the vacuum gauge set 2 Start the nn I 1 to idle VACUUM GAUGE SET HIe 47978 3 18 GL 1000SHOP MANUAL 1978 American Honda Motor Co Inc in UeS A 7 78 ...

Page 43: ...the 1 and 3 carbu Acliustn1e1H is correct when 1 and 3 show I rriVL mcltelv the same vacuum gauge O1 h ron the lock nut 5 ADJUSTING SCREW SYNCHRONIZE 2 TO 4 SYNCHRONIZE LEFT PAIR TO RIGHT PAIR 1f ADJUSTING j SCREW Ul5iCOnm 1ct the rPlln t l11 ad ap tor screws L UU l I the QUJru nut at the Imka 4 to lInf I t n a 7 GL l000SHOP MANUAL 1978 American Honda Motor Co Inc Printed in U S A 7 78 3 19 ...

Page 44: ...4 ENGINEREMOVAL INSTALLATION SERVICE INFORMATION 4 2 REMOVAL 4 4 INSTALLATION 4 12 GL 1000 SHOP MANUAL 4 1 1976 American Honda Motor Co Inc Printed In U S A 7 78 I ...

Page 45: ... rl before nnw is removed in the engine is rernOVal le A or c lUJU I dU Il SI IPI lOlrt is I t LIU111 l U to support and maneuver the The lower removal carburetor l RIT1hlv may be rloi I lorl frame to removal NOTE Ah1V8 fS clean the oil screen when the is removed Access to the screen is lower nnlht ll ll1lfl side of the crankcase Tools and M ltp ri 111 He 41 4 2 GL l000SHOP MANUAL 1976 AmeriCan Ho...

Page 46: ...TION SERVICE INFORMATION 1 10mm cap nut 2 8mm nuts 3 12 x 65 Rl 12 x 80 LI 4 12 x 274 2 5 2 9 18 21 ft lbJ 2 5 2 9 18 21 ft lbJ 3 0 4 0 22 29 ft Ibl GL 1000 SHOP UAL 1976 American Honda Motor Co Inc Printed In U S A 7 78 4 3 ...

Page 47: ...e the coolant and detach the return I at the filler neck It is not necessary to drain the reserve tank nepl lce the drain when the system is Remove the drain and ra liator cap to drain the cooling Drain coolant into a clean pan 1 the Oil emove the drain and the oil center bolt the oil filter to drain oilrrom RelPla ce the drain L 000 978 Amenc an ...

Page 48: ...uts Loosen the Land R exhaust MUFFLER MOUNTING BOLT rrt Remove the Land R muffler mou bolts the pegs and remove the muffler Loosen the L R bolts Ti It the muffler c pmhlv forward and remove the Land R exhaust GOOD SHOP MANUAL mariesn Honda Motor Co Inc Printed U S A 7 78 4 5 ...

Page 49: ...cover disconnect negative Disconnect the breaker connectors and 11 nn 1 l1rnr St rt u Cable Hemclval U iCOnnect the starter at starter Ui connl2lct the thE rrrlostatcover from the water pu mp cover Motor Co ...

Page 50: ... wires at the remove the r lrli t out l t mhhl as a Harness Unrcolupling Removal caps the Detach the on if the are it is not necessary to oetaci l the c ar nlirAtii lI GL 1000SHOP MANUAL 976 American Honda Motor Co Inc Printed in U S A 7 78 ...

Page 51: ...Air Case Remolval breather hOldlna the air cleaner case to the air n lrrln r 4 8 GL 1000 SHOP tV L 1976 T Jean Honda MOlor 7 78 Inc ...

Page 52: ...INSTALLATION REMOVAL at the adjuster and remove the cable ends from the be Set the in the 0 FF Dos iticm detach the two hoses at the pump GL 1000 SHOP MANUAL 4 9 1976 American Honda Motor Co Inc Printed in U S A 7 78 ...

Page 53: ...Clutch Detach the crankcase breather hose Shrould Removal Co I ...

Page 54: ...EMOVAL mount bolt Removal a R Rem ve the rear mount Remove the hll inttt must be continuously adjius1ted removal and IJrEliVerlt damage to mounting wire GL 1000SHOP MANUAL 1976 American Honda Motor Co Inc Printed in U S A 7 78 4 11 ...

Page 55: ... fnl w lrrl on the the snap USE MULTI PURPOSE GREASE NlGI 2 I and mounts in tinlhtl n the fnllmNlflO sequence trl l m tllhA nut En line Mo unt Installation Calrefl lUy align the mounting surfaces with jack damage to mounting bolt threads wire harnesses and cables 1 2 3 6 7 8 4 5 4 12 G 1 1 000 SHOP MANUAL 1976 American Honda Motor CQ Inc ln U S A 7 18 ...

Page 56: ...6 7 8 9 9 harness connections in left side service cOlmOiar1 mlmt 10 Air cleaner ass embly 11 12 13 Radiator t n1h I and fan wires 14 Alternator connector 15 Breaker wires 16 terminal 7 18 Acliw t the throttle cable to provide 15 at hand Radiator Servicing l Y nk l with oil and coolant as rlp rihe r1 8 GL 1000 MANUAL 1976 Amllrlcan Honda Co Inc Printlld in U S A 78 4 13 ...

Page 57: ...sses for proper mutl ng and Contact Breaker Lead rr Motor Cable Generator Cable Filler Tube Flow Tube Motor lead 13 Choke Cable 14 15 Breather Tube A 1 16 Breather Tube B 1 17 Front Brake Wire 18 Switch Wires 4 14 ...

Page 58: ...AFT AND ROCKER ARM REMOVAL 5 9 CYLINDER HEAD REMOVAL 5 12 VALVE AND GUIDE INSPECTION 5 15 VALVE GUIDE REPLACEMENT 5 16 VALVE SEAT INSPECTION AND GRINDING 5 17 CYLINDER HEAD ASSEMBLY 5 18 CYLINDER HEAD INSTALLATION 5 19 GL 1QOO SHOP MANUAL 5 1976 American Honda Motor Co Inc Printed in U S A 7 78 I ...

Page 59: ...2 in mm 1 437 inl mm 1 180 1 1 1 9 inl 1 mm 1 061 1 in mm 1 in to mm 1 063 1 in 27 05 mm 1 R ri n clearance 040 to 077 mm 0 0015 v v v Camshaft center Journal 00 to 24 970 mm 0 982 0 983 SAI I P limit mm 980 K nrln 10 mm 1 limit 25 05 mm 0 986 in R rirl clearance 050 to 087 mm 0 0019 in Clearance A lOU H 0 1 mm O 004 LD L 1000SHOP MANUAL 1978 American Honda Motor Co Inc 1n U s A 7 78 ...

Page 60: ...ENGINE TOP END REPAIR SERVICE INFORMATION GL l000SHOP MANUAL 5 3 1976 American Honda Motor Co Inc Printed in U s A 7 78 ...

Page 61: ...ntake or exhaust Service limit Valve to Guide clearance Intake 1 to mm 0 0004 P lI limit mm 0 0031 Exhaust 0 05 to 0 07 mm 0 0020 V V JtC o Service limit 0 10 mm head di lm tpr mm 1 Exhaust mm 1 260 Valve seat width 1 4 mm 0 055 1 1 lYn no across head Service limit 0 10 mm V V Camshaft Drive Belts Toothed rubber reinforced with fihpY nbcc 000 SHOP MANUAL 19 6 Arnerican Honda Motor Co inc U S A 7 7...

Page 62: ... be taken to the camshaft drive belts from contaminated with oil which will cause the rubber to swell and affect the camshaft Do not twist the or bend them to a radius of less than 25 mm to avoid fracture of the material Tools and Materials Valve HC Valve Guide It rn prl nstaller HC 4872 Valve Guide Reamer HC Valve Seat Grinder 5 7 mm Prussian Blue GL l000 SHOP MANUAL 1978 American Honda Motor Co ...

Page 63: ...be by a Tnr 1 nn of the engine with rnmr1YI l inn test sou ndi ng rod or steth scope Low Com Jlfesision or VIICVII lI Corrlpression 1 2 belt 4 Comi m l si m Too on head Exce5 siile Noise Contaminated Enoifle Oil or Coolant head See Section 7 nder head 5 6 ...

Page 64: ...ator rotor bolt clockwise until T 1 mark on the nV l rlPPI lines with the case index mark Check al of cam arrows the cover index belt with an arrow to direction and or left side with do not use a screwdriver or other nr leI1f damage to the belt mJ l tpl I FROM BE AND GHTEN COVER INDEX MARK instrument for removal GL l000 SHOP MANUAL 1976 American Honda Motor Co Inc Printed In U s A 7 78 5 7 ...

Page 65: ...nt or cleaning the front case SPIN ROLLERS CHECK FOR SMOOTH ROTATION When rotate renno ed and cylinder is at it is possible to po sitiion of interference be twl en valves piston in either dir ec1tioln Do not use the darna le to move away from by rotating crclnl shaft in either direction from T O C as indicated by the tape or chalk gerlerat r rotor bolt to rotate the cral ksllaft bolt 5 8 GL 1000 S...

Page 66: ...DER He 41301 HAme the pu ENGINE TOP END REPAIR CAMSHAFTAND ROCKER ARM REMOVAL C SHAFT ANDR KER ARMRE AL Hemcwe the p Hln r RI pump and tachometer L 1000 MANUAL 1976 Amp rica Honda Co Inc Printed in U S A 7 78 5 9 ...

Page 67: ...LEFT HAND HEAD me the cover ao varl e mechanism and to identi fv side NOTE Remove the arm on the arm for proper arms I df ntifv 5 10 GL 1000SHOP MANUAL 1976 American Honda Motor Co In U S A 7 78 ...

Page 68: ... n chipping or flat ROCKER I SHAFT 0 0 SERVICE LIMIT 13 94 mm ARM 1 0 SERVICE LIMIT 14 05 mm oil passages are clear n inn scr1atcl1es or evidence of Make sure Calnst1laft Bea nng Clearance the camshaft into the Me asw e and record the I of page 5 12 GL 1000 SHOP MANUAL 1976 American Honda Motor Co Inc Printed in U S A 7 78 5 11 ...

Page 69: ...087 mm 0019 0034 inl END BEARING CLEARANCE 040 to 017 mm 0015 to 003 inl each cam lobe for wear with a cam if lobe wear exce ds CYllN RHEAD RE OVAL screws and remove head EXHAUST LOBE SERVICE liMIT 36 5 mm 1 437 inl INTAKE LOBE SERVICE LIMIT 5 12 GL l000 SHOP MANUAL 1978 American Honda Motor Co Inc in U S A 7 78 ...

Page 70: ...RerrlOve the cylinder head ENGINE TOP END REPAIR CYLINDER HEAD REMOVAL on o the head the oil orifice dowels and GL l000 SHOP MANUAL 1976 American Honda Motor Co Inc Printed In U S A 7 78 5 13 ...

Page 71: ...RH 0 DISASSEMBLY Remove the valve ng5 and Check the valve areas eelIret L11 lia SKets will come soaked in SOI V811It the easier if WBIrD aOe in an X nl 1 lQ n SHOP MANUAL 1976 American Honda Motor Co I in 778 ...

Page 72: ...determined between the valve stem the movement in the gu clearance cle aralnce exceeds 1i tArlmiru if a new stand ard dil1nen siom would tolerance as necessary VALVE STEM TO GUIDE CLEARANCE SERVICE LIMITS INTAKE 0 08 mm 0 0031 in EXHAUST 0 10 mm 0 0039 in G L 1000 SHOP MANUAL 1976 American Honda Motor Co Inc Printed in U S A 7 78 5 15 ...

Page 73: ...GUIDE FROM THE TOP OF __ 7 lI j THE HEAD WITH THE HEAD STill HOT INSTAll A NEW GUIDE to 1000C Use gloves when handling the hot CVllndler head EGUIDE REPLACEMENT the new valve gu ides after installation Use cwttirll l oil on the reamer during 5 16 GL 1000 SHOP MANUAL 1978 American Honda Motor Co Inc 1 U S A 7 78 ...

Page 74: ...ed or worn rstltlac e the valve Follow the refclcer manu1fac1tUrl lr s RECOMMENDED VALVE SEAT WIDTH 1 4 MM CU1ttlrl Q the apply lappirlg rn nn nrl to face and 0 9 1 1 mm 0 036 0 043 in 45 using light pressure head and valve clean of reS ldual compound Check valve seat area for GL 1000SHOP MANUAL 5 7 1978 Arnerican Honda Motor Co Inc Printed in U S A 1 78 ...

Page 75: ...CYLINDER HEAD ASSEMBLY M 8SiJre the free and outer valve n in Instal the and cotters of the inner the valve stems with a hammer to be t iln the cotters are 5 18 000 MAN American Honda in 7 78 Co I ...

Page 76: ...P END REPAIR CYLINDER HEAD ASSEMBLY INTAKE A INTAKE B note on bottom tfmlfnn mark on the I PF tain that on then CYLINDER HEAD INS LLATION GL 1000 SHOP MANUAL 1978 American Honda Motor Co I Printed in U S A 7 78 ...

Page 77: ...0 to 510 kg em 38 41 ft lbl carnstlatt with the gear in the the f Ilm h tT in the same X 1rt o n cvlmdier head away excessive sealant 6 mm 100 to 140 R H CAM 84 120 in Ibl 5 20 GL 1000 SHOP MANUAL 1978 American Honda Motor Co in U S A 7 78 ...

Page 78: ...e the seat the Install the heat shields NOTE To insure proper a iCllnmAnf cam belt cover with a Make sure the neutral wire is behind the hand TORQUE 500 550 36 40 ft Ib belt drive sura that both are and the bolt 1 tClrQlJed dis ssemble and ke walv for wear GL 1000 SHOP MANUAL 5 21 1976 American Honda Motor Co Inc Printed in U s_A_ 7 78 ...

Page 79: ...he T mark VALVE TIMING MARKS TENSIONER BOLTS VALVE TIMING MARKS R IDENTIFIES RIGHT PULLEY pressure counter clockwise on the Irn h t t With tensioner bolts the tensioner bolts R h rk valve adjus1tm ent nrr rl to 3 5 22 ...

Page 80: ...nloved Install the advance rn h ni rn in the left l Vllnl1 e r sure advancer is t nl rpf th on the rn h tt the cam Rotate the and process on the right to tUrllHJIO Section I nrll1itinn of the cover Install valve covers exhaust and covers GL 1000SHOP MANUAL 1976 American Honda Motor Co Inc 5 23 Printed in U S A 7 78 ...

Page 81: ...ENGINE CASE REMOVAL 6 7 PISTON AND ROD REMOVAL 6 8 PISTON INSPECTION 6 11 CYLINDER INSPECTION 6 12 CRANKSHAFT REMOVAL AND INSPECTION 6 14 BEARING INSPECTION 6 16 BEARING SELECTION 6 18 ENGINE ASSEMBLY 6 20 GL 1000 SHOP MANUAL 1918 American Honda Motor Co Inc 6 1 Printed in U S A 7 18 I ...

Page 82: ...SERVICE INFORMATION seccmd 1 5 1 52 mm 0591 in mm L11 04 1110 to 0 045 mm 2 0027 in mm in to 0 9 mm hp rlrH clearance 0 02 to 0 04 mm mm Am gnclm Honda Motor Co Inc 7 78 ...

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Page 85: ...INE LOWER END REPAIR KICK STARTER INSPECTION KICK STARTER MECHANISM INSPECTION cover rear HII cover the kick starter ratchet and teeth for wear GL 1000SHOP MANUAL 5 1978 American Motor Co Inc U U S A 7 78 ...

Page 86: ...UIDE BOLT cs STARTER PINiON f KICK STARTER SHAFT STARTERARM KICKJOINT DUST SEAl S KICK J J KICK STARTER SHAFT are the kick starter arm and on starter ihri t the starter arm and Rel lm s the circlios if worn or loose Am erlc Honda Motor Co 78 ...

Page 87: ...ollne rear cover clutch cover Hernmle the scavenge pump bolt cover case It is not necessary to remove the the starter HernO fe the Remove the 19 left case bolts Remove the three o case bolts GL 1000 SHOP MANUAL 1976 American Honda Motor Co Inc Printed jn U S A 7 78 7 ...

Page 88: ...ase 1bp ev mt malge place shop tnu lAII pistoln to them from tnllnS 1ission when the PISTONAND R REMOVAL Check co nnlectmlQ rod side clearance If cleara nce Remove the side rods and pis ton s and mark them to the walls L j SHOP MANUAL 1976 American Honda Motor Co Inc U S A ...

Page 89: ...GE just above travel ridge must be removed with an automotive ridge reamer rfilo lnvina right hand pis tons pistons and to tnrOI HIfl the lindeI hand rods and pistons and mark to are not GL 1000 SHOP MANUAL 1976 American Honda Motor Co inc Printed in U S A 7 78 6 9 ...

Page 90: ...0 050 mm 0 0008 in with press removal tool the and rod on removal tool the driver and collar on the Press the the fJl lUI I 6 10 GL 1000SHOP V1AI IW AL 1918 American Motor in U S A 7 78 ...

Page 91: ...NSPECTION NOTE should only be reused in extrenlelv low mileage engines r Vllnl1 I U seirvi e may ni ITlPtpr at the pistons show wear oev ona repilac melilt is necessary NOTE GL l000SHOP MANUAL 6 1 1978 American Honda Motor Co Inc Printed in U S A 7 78 ...

Page 92: ...wear and out of round both at linrl ir do not vo v de laj e them TAPER SERVICE LIMIT 0 05 MM INSIDE DIAMETER SERVICE LIMIT 12 1 MM CHECK FOR OUT QF ROUNO AT A AND B AXIS AT THREE LOCATIONS MAXIMUM DIAMETER VARIATION BETWEEN CYLINDERS IS 0 10 MM ...

Page 93: ...luld be installed with the the cylinder head installa tion on the pistons enough in not gaps in the oil L r 20 mm OR MORE 20 mm OR MORE 1 1 end gaps 1 f _ 1 1200 i CD 01 I I GL 1000SHOP MAN UAL 6 13 1976 American Honda Motor Co Ine Printed in U S A 7 78 ...

Page 94: ...e spray oiler and the oil c t r tt r the transmission mainshaft and nl lim nt driven gear remove it the nnm lrv HemClVe the rr lnll hl ltt caps and lift the rr nk h ltt case 6 14 L l00Q SHOP MANUAL 1976 Amarica Honda MOlor Co Inc in U S A 7 78 ...

Page 95: ...READING SERVICE LIMIT 0 05 mm 0019 in TAPER SERVICE LIMIT 0 004 mm 0 0002 in OUT OF ROUN D SERVICE LIMIT 0 008 mm 0 0003 in EB the crankshaft main journals and for nd with a micrometer crelnkshaitt cannot be retUlir OO Relplal or crank ins r rar IUIlt or out runout is beyond GL 1000SHOP MANUAL 1976 American Honda Motor Co Inc Printed In U S A 7 78 6 15 ...

Page 96: ...nn and install the r lnkc h ft of across each oil hole lostell the main h I correct NOTE not rotate the nlnl h lftduring the inspec tion measure I WO rl plastig au e on each 6 16 000 SHOP MANUAL 1976 American Honda Motor Co I in 1 78 ...

Page 97: ...EARING INSECTION AS lemlble the rod in each rod cap a across rod cranktJin pla inQ plastitlsuliJe across the NOTE HfHTIm e the caps measure the GL 1000 SHOP MANUAL Do 17 1978 American Honda MOlor Co Inc U Printed in U S A 7 78 ...

Page 98: ...and rod ROD BEARING SELECTION 8 3 BROWN BLACK BLUE i J Z 2 N m m 1 2 GREEN BROWN BLACK 0 0 2 mG l i J Xl 1 YEllOW GREEN BROWN 0 0 A B C CRANKSHAFT CONNECTING ROD JOURNAL SIZE CODeS 6 18 000 SHOP MANUAL 1976 American Honda Motor Co Inc in 7 78 ...

Page 99: ...he hs annn llJU JI and crank codes to rt t mint re laCeim nt ho n color ENGINE LOWER END REPAIR BEARING SELECTION MAIN BEARING SELECTION ttl m Cor 111 BROWN BLACK BLUE 0 0 N x mz oe Z B or 11 GREEN BROWN BLACK 000 Oe o m o cn ooo Om A or 1 lYE GREEN BROWN c i 1 2 3 CRANKSHAFT MAIN JOURNAL SIZE CODES GL 1000SHOPMANUAL t J 19 976 American Honda Motor Co Inc U Printed in U S A 7 78 ...

Page 100: ... IUII Ut i are installed hAl rirHI clearance with to final assembly Be sure bearing caps are installed in their correct location and the cap arrows to the NOTE Lubricate bolt threads underside molybdenum NOTE 6 20 GL 1QOOSHOP MANUAL 1976 American Honda Motor Co Inc U s A 7 78 ...

Page 101: ...nd AI the passage locator tab with the inder block groove Rod inserts for 1 and 3 do not have oil holes ENGINE LOWER END REPAIR ENGINE ASSEMBLY GL 1000 SHOP MANUAL 1976 Americ n Honda Motor Co I Printed U S A 7 78 6 21 ...

Page 102: ...m All OTHERS 6mm the seat llint IAr have a to enter the a ring o I r to the case ini in n The X sequence for the 10 mm case bolts 10 mm l lLJ I 8 mm L L U 6 mm 1 compressor o o o 6 22 000 SHOP MANUAL 1976 American Honda Motor Co in 7 78 ...

Page 103: ...CREW AND BOLT SIZES 6x RIGHT ENGINE CASE x 70 6x 110 6 x 35 SCREWS 6 x 35 SCREWS FRONT COVER 22 SCREWS TO 1 1009338 6 22 BOLTS AFTER SER it 1009339 GL l000SHOP MANUAL 1976 American Honda Motor Co Inc Printed in U s A 7 78 6 23 ...

Page 104: ...2 TROUBLESHOOTING 7 5 ENGINE OIL LEVEL 7 6 ENGINE OIL FILTER CHANGE 7 7 OIL PRESSURE CHECK 7 8 OIL PUMP REMOVAL 7 8 OIL PUMP INSPECTION 7 9 OIL CONTAMINATION 7 12 GL 1000 SHOP MANUAL 7 1 1978 American Honda Motor Co Inc Printed in U S A 7 78 I ...

Page 105: ...e int pnrlpr for t r ul t SE will show this t it lnr1J lflnn oil ad litives is unnecessary and wi I ng expenses No n l lei enJerlt viegetallle or castor based oils are not recommended Alternatives or LUVV U SAE 20 or 20W Kepl2lceable paper plp rn nt rpm or20W SAE 20W 50 cold hot MAN Arnerican Honda Motor Co Inc USA 7 78 ...

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Page 107: ......

Page 108: ...to oil 2 often en uQ h 3 1 2 valve stuck open 3 oil screen 4 Main oil pump worn Oil Prll lllrR 1 2 3 Torinrt orifice No 1 2 3 4 too low sheared or from Oil pump drive chain broken pump drive oil pump Oil in COlolant 1 GL 1000SHOP MANUAL 1976 American Honde Motor Co Inc Printed in U s A 7 78 7 5 ...

Page 109: ...rn H1 goes the n n rUilning If RECOMMENDED OIL level at the oil in The oil level betwl en the upper and If the oil level 1 1 1 seen turn the remove the cap and add to the to the upper mark 2 USE 4 STROKE L or an equ AP 0 0 cilaS5 ifi atiion SE ...

Page 110: ...l drain sure its 111 A l Icol H r 4 5 ENGINE OIL FILTER CHANGE bolt to a I1i 1nrnl l1f marks match I _ the oil Remove and used n I f f the on the and filter case and if necessary_ new filter element in the case Be sure and washer are on the bolt 4 GL l000SHOP MANUAL 1978 American Honda Moto Co Inc 7 7 Printed in U S A 7 78 ...

Page 111: ...ssure gauge to check oil pressure COLD PSI 18 5 60 12 ILPUMPS Main Oil HemClve the radiator as rI ih r in Sec1tion 8 Drain the oil clim and remove the R rnr o the ann as rlc f riht rl in ectlOn 4 ne cover clutch drive chain in Section 10 CO ...

Page 112: ...avenge pump OIL PUMP INSPECTION 1 the pump covers the pumps rl rr nCi wear Measure pump clearance Measure pump clearance LUBRICATION SYSTEM OIL PUMP INSPECTION GL 0 1000 SHOP MANUAL 7 9 978 merican Honda Motor Coo Inc Printed in U S A 7 0 78 ...

Page 113: ... MARK MAIN 011 PUMP COVER MAIN OIL PUMP and As emlbly and InstaUaticm the pump over the pump and reassemble outer rotor inner rotor marks on the main oil outer rotor s must be out rotors are installed the pump body clutch n hl l ne covers Use new and Q3Sike1ts Be sure the pressure in main oil pump moves 7 10 L 1000 SHOP MANUA 1978 American Motor in 7 78 ...

Page 114: ...E d Also the oil filter be and the oil should If the oil strainer is to be removed with the in the the proc eClul Section 10 LUBRICATION SYSTEM OIL PRESSURE WARNING SWITCH OIL STRAINER OIL PRESSURE ARNING SWITCH of the oil pressure I lrnlnn is in 17 MAN l 7 11 American J Printed in U S A ...

Page 115: ...ru ctll ms regarding sludge remover P __ oil filter OIL CONTAMINATION If r 1 rnin 1 ir n is remove the valve train for access ca tjrlg core plugs See 5 for valve train removal If no evidence of coolant is at the core plugs remove the cvlinider heads inspect the head gas ke1ts See Section 5 for cylinder head removal procedure When oil is present l l mn Af t iJ l1 gum and sludge remover to 7 12 L 10...

Page 116: ... 2 TROUBLESHOOTING 8 5 COOLANT LEVEL CHECK 8 6 FLUSHING COOLANT REPLACEMENT 8 6 SYSTEM TESTING INSPECTION 8 8 RADIATOR FAN 8 10 WATER PUMP 8 12 THERMOSTAT 8 13 GL 1000SHOP MANUAL 8 1 1978 American Honda Motor Co Inc Printed in U S A 7 78 I ...

Page 117: ... Coolant Radiator and en1J1n12 Reserve tank AL 4 Total V TPim F ng Point 4 nrn rn ts r 50 Distllled water s trl Jh n 45 0 istiIled water lied water 45 ptrlvl nfi to 1 05 em 1 to 1 Fan Motor 12V DC Rotation Counterclockwise from load rpm rpm to 1 208 to 21 to 970 e 1990 to at 2030 Fl 8 2 Gl 1000 SHOP MANUAL American Honda Motor Co Inc in U A 1 18 ...

Page 118: ...N OPENING RANGE BYPASS FLOW UNTil THERMOSTAT OPENS THERMOSTAT GAUGE SENSOR FAN SWITCH WATER PUMP NO FLOW THROUGH RADIATOR UNTIL THERMOSTAT BEGINS TO OPEN TO GL 1000SHOP MANUAL 8 1976 American Honda Motor Co Inc J Printed in U S A 7 78 ...

Page 119: ...ling fAln Do NOT use alcohol based antifreeze coolant at cap on reserve Do not remove raclia tor cap except to refill or drain the I t n Do not remove could result radiator cap when the is hot The coolant is under pressure and severe scalding and Materials Anltltr 7t l tester Raldiator pressure tester pan and hot recommended for aluminum 41033 or burner for Chl ckina thermostat 8 4 GL 1000 SHOP MA...

Page 120: ... sensor 3 T I r rnr t t stuck open a mb ient telllCter atlJre 1 5 7 1 11 5 rlinn unit or water holdl ng pressure hoses or water hn lrllinn pressure ng into cylinders or kink in hose from reserve tank to radiator GL 1000SHOP MANUAL 1978 American Honda Motor Co Inc Printed in U S A 7 78 8 5 ...

Page 121: ... a If coolant level is un screw the reserve tank filler cap add to the level up to the F Ul b 1 Unscrew and remove the reserve tank filler cap The tube must be removed coolant in order to avoid coolant when the radiator cap is loosened or removed FLUSHING COOLANT REPLACEMENT 8 6 GL 1000SHOP IV1A U LlI 1978 American Honda Motor Co_ Inc 7 78 ...

Page 122: ...e of its holder Empty and the 5 Fill with 11 1 c orrlpolunid n II n n for use in aluminum block engines Install the radia tor cap Run the 10 minutes at normal operating temperature then drain repeating 1 4 1 1I 15 1m9 cOlnpoUl 1ds are usually highly toxic and corrosive Observe all precautions indicated by the cOlnp ound s manufacturer radiator with plain water Run engine drain repeating 1 through ...

Page 123: ...ap and slpll10n otherwise reserve tank coolant will out and over and ranloved Do not loosen or remove the radia tor cap while the is hot Scalding hot coolant may be ra when the cap is 10 JISIUled Test the radiator cap as in the il Ra the radiator cap if it does not hold pressure or if pressure is too or too low 8 8 GL 1000 SHOP MANUAL 1978 American Honda Motor in 7 78 I nc ...

Page 124: ...rm pressure test and check for leaks after reoiairs Excessive pressure can IYI l the raclia1tor Do not exceed 1 123 kg cm2 15 9 psi 2 Release tester pressu re 3 the n nln the pressure rii the tester pump to to exceed 1 123 l nll rrIL necessary nn iinn the tester cap stem to one side lrlIlIV inldi atE s a cylinder in turn Gauge needle vibra r ldnr lpr is out as 4 I Ylnl tlnn of the t t Y pressure t...

Page 125: ...co olant Ul connlect the reserve tank RA tAT R AND FAN Hprn fp the radiator and fan as an pn hli Remove the fan shroud and fan KPn ljO the radiator and wire screen the motor and fan Dil connect the fan motor relno virUl the radiator 8 10 ...

Page 126: ...re water Stt illht pn bent radiator fins two screwdrivers as shown in the ac C lm rJl In vi rIG illustration RSlolalce the radiator if tyirt rl over more than FAN MOTOR TESTING nnn f t the motor to a 12 volt h i O and check The motor should run GL l000SHOP MANUA 1978 An erican Honda Motor Co Inc Printed in U S A 7 78 8 11 ...

Page 127: ...rad iatlor and the oil filter and the water pump cover cover ioc nlCIn of all PUMP the water pump use and Qaskel s Do not to pump If it is worn or n lm Uli rl Remove the water pump and in n t it worn ngs 8 12 GL1000SHOP MANUA 1978 American H ooda Motor Co Inc U 5A 7 78 ...

Page 128: ...ides or bottom of the container a new on the thermostat cover HeIJla e thermostat if valve open at room or if it resPolnds at other those the thermostat for rl lIYl tUl r rl the thermostat in NOTE If remlovilrl l illustrated UVII n assernble with new rings Use thread seallant on VALVE LIFT 8 mm 0 32 in MINIMUM WHEN HEATED TO FOR FIVE MINUTES and tel1npeniture sel1ldirlQ unit GL 1000 SHOP MANUAL 19...

Page 129: ...IRCUIT DIAGRAMS 9 5 FUEL FILTER FUEL LINE 9 11 FUEL PUMP 9 12 CARBURETOR AND AIR CHAMBER 9 13 AIR CUTOFF VALVE 9 20 FLOAT LEVEL 9 21 IDLE MIXTURE ADJUSTMENT 9 22 HIGH ALTITUDE ADJUSTMENT 9 23 GL 1000SHOP MANUAL 9 1 1978 American Honda Motor Co Inc Printed in U S A 7 78 I ...

Page 130: ...h U TC r 1rn llr chamber screws screws to 42 h lrrlh r screws 40 to Throttle center bolt to Th f dctl link to carburetor nuts Use when t v n or open flames HiW I V i work in a well ventilated area and away from disaSSI lml irlg fuel I 1 m 10Ccitioins of a rings Replace with new ones The float bowls drain The carburetors and carburetor I screws can be removed to residual gasoline can be disassemble...

Page 131: ......

Page 132: ......

Page 133: ...FUEL SYS rEM CARBURETOR CIRCUIT DIAGRAMS FUEL GAUGE RESERVE PICKUP MAIN FUEL PiCKUP GL 1000 SHOP MANUAL 976 American Honda Motor Co Inc Printed in U S A 7 78 9 5 ...

Page 134: ...Internal VACUUM PISTON l_ q SECONDARY AIR CIRCUIT THROTTLE VALVE If r PilOT OUTLET PilOT SCREW LIMITER CAP MAIN NOZZLE PRIMARY MAIN fUEL JET SECONDARY MAiN FUEL JET ...

Page 135: ...RETOR OVERCOMES THE VALVE DIAPHRAGM 3 E SPRING PRESSURE CAUSING E VACUUM THE VALVE TO CLOSE L WHEN THE VALVE IS CLOSED AIR TO THE SLOW SPEED CIRCUIT IS METERED THROUGH A LEAK HOLE IN THE BODY CREATING A RICH FUEL MIXTURE TO PREVENT BACKFIRING ON DECELERATION AIR CUTOFF VALVE AIR INLET AIR CUTOFF VALVE SLOW AIR JET ENGINE SLOW SPEED FUEL IS INTRODUCED TO THE SLOW FUEl JET CHAMBER THRU THE PRIMARY M...

Page 136: ...PRiMARY FUEL CIRCUIT 1 4 TO 1 2 OPEN THROTTLE VACUUM PiSTON DOWN VACCUM PISTON THROTTLE VALVE 1 4 TO 1 2 OPEN PRIMARY MAIN FUEL JET 9 8 GL 1000SHOP MANUAL 1976 American Honda Motor Co loc io U S A 7 78 ...

Page 137: ...IRCUIT 1 2 TO FULL OPEN VACUUM PISTON RAISED VACUUM PISTON SECONDARY AIR CIRCUIT PRIMARY AIR CIRCUIT THROTTLE 1 2 TO FUll OPEN VALVE PRIMARY MAIN FUEL JET SECONDARY MAIN FUEL JET GL 1000 SHOP MANUAL 9 9 1976 American Honda Motor Co Inc Printed in U S A 7 78 ...

Page 138: ...9 10 LEFT CHOKE LEVER GL l000 SHOP MANUAL 1976 American Honda Motor Co Inc in U S A 7 78 SPRING 75 MODEL ONLY RIGHT CHOKE LEVER ...

Page 139: ...he 2 The fuel filter should be replacE d v U vu v kilometers vv FUEL FILTER FUEL FILTER REPL CEMENT 3 4 5 An arrow on indicates fuel flow direction Be sure to install the filter with the directional arrow pOlintE d toward the pump UEL LI E I SPECTION 9 11 ...

Page 140: ...ine with a measure pump nn tn lT pressure UUlUlH line Defee ts such as a I k rli lr hr ll1rYl pump not meet nl ijFi ti n remove the cover fnr Ail lin matter is I onion 9 1 01 1000 SHOP MANUAl 1978 American Honda Motor Co I In 7 78 ...

Page 141: ...ft out the air cleaner case Remove the air cutoff valve Di connloct the cab e at Dil connect the choke from the carburetor DiscQr ne ct the hose at the pump the carburetor as ennbily with a rubber hammer to loosen it Un rp w the the air cleaner case to the carburetor Removal the service and remove the too Remove nut then remove the air cleaner case cover CARBURETOR AND AIR CHAMBER GL1000SHOP MANUA...

Page 142: ... Ve the IInKarle inka le as an onnhil J at ch amlber screw is located on the apart the O ring mC Urltil1lg surface may be damaged umjenilde of Cna mlJier LJI sccmrlec t the slow air hoses at the air chamber and remove the five screws hOlldllng the air chamber 1 1 01 1 101 O I t the air chamber into 9 14 G 1 1000 SHOP MANUAL 1978 American Honda Motor Co Inc In U S A 7 78 ...

Page 143: ...ND AIR CHAMBER flat and remove the two bolts atl acnlrlg each carburetor to the air chamber Remove the wire screen from the chamber nndr1llnn each GL l000SHOP MANUAL 1978 American Honda Motor Co Inc Printed In U S A 7 78 9 15 ...

Page 144: ...r into the center the vacuum to remove screw in Do not interchalilge vacuum piStorlS or vacuum covers be twlElen the vacuum for t 1 h or other rl lI l 1P Make sure that the moves up and down in the carburetor 16 ...

Page 145: ...RBURETOR AND AIR CHAMBER Rp nr e the slow air the and remove the slow G December 31 1977 press slow air which cannot be removed cap over GL100Q SHOP MANUAL 1978 American Honda Motor Co Inc 9 17 Printed in U S A 1 78 ...

Page 146: ...attactled to the 18 GL 1000 SHOP MANUAL 1976 American Motor Co i 778 ...

Page 147: ...k and at the choke 3 Install air screen and the carburetors to air chamber 4 the air r h lmlnPF and connect the slow 6 the number 4 II hl Irp irnr 6 Attach the I and the en lagea r IU L the linll l ll IP of the number 3 carburetor necessary 7 Install the on the carburetor as enlbly GLIOOO SHOP MANUAL 19 1976 American Honda Motor Co Inc 9 Printed in U s A 778 ...

Page 148: ...nd Air Ui co nnecl the air valve and remove the two screws 1 1 t llr the valve to the air rh IT a ssemt IV Be not to is needed and passages for TOI P f l1 VALVE i i Make sure the seat in their grooves Reinstall the valve on the retor n hl 9 20 GL 1000 SHOP MANUAL 1978 America Honda Motor Co Inc In 7 78 ...

Page 149: ...FLOAT LEVEL arm Be sure the marlifold n n n t are not or mis aligned FUEL SYSTEM AIR CUTOFF VALVE GL 1000 SHOP MANUAL 9 21 1976 American Honda Motor Co I r1c Printed in U s A 7 78 ...

Page 150: ...ble for all emission cOlltn IIEld Gl1 IU la U t and it is not necessary to idle carburetor n Il Yh l1l1 out adjustment prolceelurl lS 2 7 P ILOT SCREW INITIAL SETTING 2 TURNS OUT seat screw s seat will occur tiahtElned against 2 Svnf tuonb l carburetors with an accurate tachometer rpm a dial which reads in 100 rpm graduations AdllUl t 4 9 22 lJUI t t JI in or out to the highest speed obtainable Re...

Page 151: ...stop screw if necessary to obtain an Install the on the cap 4 for each of the nn inir 1 1 carburetors in turn screw caps positioning them so the lug on the carburetor body fits between the lugs 7 idle to 950 1 rpm HIGH ALTITUDE ADJUSTMENT The carburetor The idle may have to be I d UJl I lt U is 100 rpm 2 000 M 6 500 ft GL 1000 SHOP MANUAL 9 23 1978 American Honda Motor Co Inc Printed in U S A 7 78...

Page 152: ...CH SERVICE INFORMATION 10 2 TROUBLESHOOTING 10 4 FREE PLAY ADJUSTMENT 10 5 CLUTCH REPAIRS 10 6 ENGINE FLUSHING PROCEDURE 10 9 GL 1000 SHOP MANUAL 1n 1 1976 American Honda Motor Co Inc u Printed in U S A 7 78 I ...

Page 153: ...n in to 0 141 in force cornores sed length tpr I P limit 8 kg mm mm 52 4 Ib 0 903 in in center nut to to 30 ft lbl 6 mm case bolts 1 to 1 to 121 in Ib YO o adijus tment are only oPl3ra1tiOllS which can be performed with Hpl Ulir or of other r nrnr nr nro stand to Section 4 the engine be removed and placed on an 10 2 GL 1 000 SHOP MANUAL 1976 American Honda Motor Co Inc U S A 7 78 ...

Page 154: ...OUTER CLUTCH SERVICE INFORMATION CLUTCH PLATE DISC CENTER NUT TAB WASHER FTER PLATE BOLT 6 LIFTER PIECE UFTER COVER GL l000SHOP MANUAL 10 3 1978 American Honda Motor Co Inc Primed in U S A 7 78 ...

Page 155: ... wrench HC41 HC 41 HC Vernier n Feeler gauge For clutch 10mm Socket holder Clutch Mr nf f1 TROUBLESHOOTING nn r tir n can usually be corrected by aUJu Clutch 1 2 3 When AClceIE rat ing No free worn Snr n n weak 1 2 dalllal Ied or ...

Page 156: ...YADJUSTMENT F E PL ADJUS lower lock nut and adjlus ter in to create ITl lvinni at the cover nee DIaV aOluster at the clutch the rider when GL l000SHOF MANUAL 1976 American Honda Motor CO inc Printed in U s A 7 78 10 5 ...

Page 157: ...with the engine To remove the outer or pump the must be removed Cover and lifter Rem llval Rernm 6 the CLUTCH REPAIRS nnlrll nn the nut tr alglhtEm the 10 6 GL 1000SHOP MANUAL 1976 American Honda Motor Co Inc in U S A 7 78 ...

Page 158: ...utch center Inspe t for or ex ce si i e wear ines HemClvEl the the pressure NOTE outer drum cannot be rernOll ad with in CLUTCH CENTER DAMPER PLATE OUTER DRUM 8 t CIRCUP SPLINED WASHER GL 1000 SHOP MANUAL 1976 American Honda Motor Inc Printed in U S A 10 7 ...

Page 159: ...3 42 TO 3 58 mm 3 2 mm SERVICE 10 8 GL 1000 SHOP MANUAL 1976 American Honda Motor Co I 7 78 ...

Page 160: ... and flushed of any debris by the following procedure This procedure only applies when the engine is still in the frame 1 Clean the clutch outer drum with a lint free solvent soaked rag 2 Drain the oil 3 Remove the right head pipe 4 Loosen bottom engine mounting bolt next to the oil screen cover 5 Remove the four oil screen cover securing screws 6 Use an offset screwdriver or a chisel to remove th...

Page 161: ...ver 16 Replace the front oil screen cover screw with a hex head bolt approximately 3 mm shorter than the original securing screw to facilitate future removal and installation of the oil screen cover 17 Retorque the lowerel1gine mounting bolt to 550 to 650 kg em 40 47 ft Ib 1 Install the muffler and head pipe 19 Fill crankcase with new engine oil 20 Runthe for approximately 5 minutes 21 Remove and ...

Page 162: ...re removed Remove mm circlip located on the in h f t in the center of the clutch Rem we the scavenge pump to remove the clutch chain sprocket Fv unin the and wear if ex ces sively worn and I n k t GL 1000 SHOP MANUAL 1978 American Honda Motor Co Inc Printed in U S A 7 78 1 11 ...

Page 163: ...isc Ins tallatiion Install the follo l lino tab washer ipeclal nut The friction with the oil grooves raclia1 inQ Clclckwi se direction as illl l tr atj l ri PRESSURE PLATE GROOVES CLOCKWISE CLUTCH CENTER 10 1 Inc ...

Page 164: ...CLUTCH REPAIRS HER COVER COVER bolts bolts in small inf YOYY10 nt lltpl r lt 1fl bolts in a rn r rn c n tt rn to avoid hr leinn L l000 MANUAL American Honda Motor Co Inc U s A 10 13 ...

Page 165: ...ECHANISM 11 5 CRANKCASE DISASSEMBLY 11 7 SHIFT SHAFT 11 8 TRANSMISSION DISASSEMBLY 11 9 OUTPUT SHAFT 11 14 TRANSMISSION REASSEMBLY 11 15 CRANKCASE REASSEMBLY 11 18 CASE SCREW AND BOLT SIZES 11 20 GL l000SHOP MANUAL 111 1976 American Honda Motor Co Inc Printed in U S A 7 78 I ...

Page 166: ... 65 in in in to 04 to 0 5112 0 040 0 082 mm 0 0016 0 0032 in 0 040 0 082 mm 0 0016 0 0032 in J IUV mm 1 to 7 15 mm Sh mm U u J Jin 8 to V Vvvf in to 18 to 7 to 10 ft Ib nstalled Values 10mm 8mm 6 mm 1 11 2 000 SHOP MANUAL 1976 Honda Motor Co Inc in U S A 7 78 ...

Page 167: ...333 1 091 0 939 0 825 TEETH 24 CRANKSHAFT 41 MAINSHAFT 18 MAINSHAFT 45 COUNTERSHAFT 24 MAINSHAFT 41 COUNTERSHAFT 27 MAINSHAFT 36 COUNTERSHAFT 31 MAINSHAFT 34 COUNTERSHAFT 33 MAINSHAFT 31 COUNTERSHAFT 40 COUNTERSHAFT 33 OUTPUT SHAFT OVERALL RATIO 11 977 8 183 6 388 5 256 4 500 GL l000SHOP MANUAL 11 3 1976 American Honda Motor Co Inc Printed in U S A 7 78 ...

Page 168: ...nsmission rp i re cases must removal and rl f rihclrl in 4 and Materials TROUBLE SHOOTING to Into 1 Improper clutch adjusl mEmt too much free 2 bent 3 bent 4 claw bent 5 loose 6 bent 7 cam grooves darna Jed 1 2 3 4 of 11 4 GL o l000 1978 American Honda MOlor Co Inc U S A 778 ...

Page 169: ...NISM WATER PUMP COVER Oil DRAIN BOI T the remove the oil cover GEARSHIFT MECHANIS D ram the co I o ant the locations of th l eCM8 oeation see 1 and collar 1976 GL 1000S American H HOP MANU onda Mot AL 1 Primed in uor Co Inc 1 5 S A 7 78 ...

Page 170: ...eutral stoppl lr the wear __ SHIFT DRUM STOPPER as rll lrih prl in more extensive Iint n 1 transmission the be the en J line Remove Section 4 11 GI 1000 MANUAL 1976 American Honda Motor Co Inc U S A 7 78 ...

Page 171: ...lUll cover inder head l l Tlr n 5 and collars NOTE It IS not necessar JL h Y to remove the nt h 1 ead unless the are to be NOTE case bolts o o 19 left case Remove are tll1 1l1l ll bolts uell n and in oil return the left lOO JmlhP NOTE 1976 GL 10ClO S American H HOP MANU onda Mot AL 11 Printed in uo r Co Inc 7 S A 7 78 ...

Page 172: ... Distorts to prevent them onto the transmission case is rernovelr1 case up ornr the gear drum Slide the case 1 1 1 up install the case SHIFTSHAFT Hprnr l the shift Reinstall the shift shaft 11 8 000 SHOP MANUAL 1976 Honda Motor Co I ne in U S A 7 78 ...

Page 173: ...TRANS DISASS lyN Remove the guide TRANSMISSION SHIFT SHAFT Slide fork shaft out the case Note the 976 Ameri SHOP MANUAL Motor C 11 Printed in U 0 Inc 9 S A 7 78 ...

Page 174: ... liMIT 6 1mm SHAFT 0 0 12 966 TO 12 984mm SERVICE LIMIT 12 90mm GROOVE WIDTH 7 05 TO 7 1 DRUM MINOR 0 0 11 966 TO SERVICE LIMIT 11 95mm DRUM MAJOR 0 0 35 959 TO 35 980mm I the drum grooves shou ld be free of or 11 10 GL l000 SHOP MANUAL 1976 American Honda MOlor Co I in U S A 7 78 ...

Page 175: ...Maiinstlaft Removal TRANSMISSION TRANSMISSION DISASSEMBLY spray t ectlon 10 GL WOOSHOPMANUAI 1111 1976 American Honda Motor Co Inc Printed In U S A 7 78 ...

Page 176: ...cap Note the locatilons spacers if any lo n c the 1975 1977 29 14mm 1978 1979 11 1 GI 1000 SHOP MANUAL 1978 American Honda Motor Printed 7 72 ...

Page 177: ...TRANSMISSION TRANSMISSION DISASSEMBLY Removal i drive gear GL 1000SHOPMANUAL 1113 1978 American Honda Motor Co Inc Printed in U S A 7 78 ...

Page 178: ...OUTPUT SHAFT without a hvnl l lIti The Slll ina COlnpl essor can be press To diS lssemble compress cotters 11 14 GL 1000SHOP MANUAL 1976 American Honda Motor Co Inc In U S A 7 78 ...

Page 179: ...MBLY 5MM OUTPUT SHAFT GEAR WASHER MAINSHAFT ISSION Y inS1 allil lQ the gear bushings be certain the shaft and bushing oil holes are ali lneld TRANS REASS GL 1000 SHOP MANUAL 1976 Americlln Honda Motor Co Inc Printed in U S A 7 78 11 15 ...

Page 180: ...11 16 GL 1000 SHOP MANUAL 1976 American Honda Motor Co in ...

Page 181: ...and Installation gear set maiinshlaft oil seOlarator I nrl the and seat the h n rt tab on the oil into the case indentaticm nl n n 1 oil cirli U I aticm tfuoluah GL l000SHOPMANUAL 1117 1976 American Honda Motor Co Inc Printed In U S A 7 78 ...

Page 182: ...S 6MM and seat NOTE The X pattern 1 n rnlliA sequence for the mm case 10mm 8 mm to 6 mm 100 to 1 the case into positilon shift arm into the NOTE The left cvlindlers have a chamfer that to enter the a o o o 1 3 1000 SHOP MANUAL 1976 American Hand Motor Co Inc in U s A 7 18 ...

Page 183: ...IVE STOPPER SHIFT DRUM STOPPER T n belt tiec tlon 10 for and the front COlier the case If it not seat against cases rotate the water pump imglell er until it pump insitall aticm see 4 GL l000SHOPMANUAL 1119 1976 American Honda Motor Co Inc Printed in U S A 7 78 ...

Page 184: ...SCREW AND SOLT SIZES 22 SCREWS TO I f 1009338 6 lI 22 BOLTS AFTER SER it 1009339 10 J 120 6 x 35 SCI EIJ S 6 J 35 SCREWS RIGHT ENGINE CASE J 70 O 6x 110 6 x 35 11 20 ...

Page 185: ...VE SERVICE INFORMATION 12 2 TROUBLES HOOTING 12 4 DRIVE HUB 12 5 DRIVE SHAFT 12 14 INSTALLATION OF DRIVE SYSTEM 12 17 MAINTENANCE 12 20 GL 1000SHOP MANUAL 12 1 1978 American Honda Motor Co inc Printed in U S A 7 78 ...

Page 186: ...l SAE 90 above E below aII 1111111 t C R 0 0071 in spacer increments l h lnfll in spacer size will cause a fYJI rnrn change in backlash to 2 43 Ib 48 to 76 in oz turn 12 2 GL 1000 SHOP MANUAL 1976 American Honda Motor Co Inc In U S A 7 78 ...

Page 187: ...FINAL DRIVE SERVICE INFORMATION FINAL DRIVEN fLANGE RING GEAR GL 1000SHOf MANUAL 12 3 1976 American Honda Motor Co Inc Printed In U S A 7 78 ...

Page 188: ...n of a th or thicker gear control spacer located between the ring gear and bearing If the rear gear or gear become damaged drive hub must be rel lla ed as an disass1emlbly is all possible causes of PrlJblenlS Tools Driver Vtl IJ Plier vI jJ Plier Rp t lil U r Wrench Pinion Holder Driller TR UBLESHOOTING 1 L 1000 SHOP MANUAL 1976 American Honda Motor Co Inc in U S A 7 78 ...

Page 189: ...o interferring RemClve the cotter rear axle I Iornr o both lower shock absorber bolts and the rear cal 1 in over the arm way to nrl VF nt darnalJe when wheel is removed Di enga le the rear wheel from the hub drive ine and remove the GL1000SHOP MANUAL 1976 American Honda Motor Co Inc Printed in U S A 7 78 12 5 ...

Page 190: ...PRELOAD RETAINER u Iv r msta II the left to the atti3china nuts gear and RemClve the gear wi 12 6 GL 1000 SHOP MANUAL 1976 American Honda Motor Co Inc_ in U S A 7 78 ...

Page 191: ... cover gear control spacer location hub vent holes AllNa r nl I the seal To aid in disasSiembly case cover to Drive the gear from the gear case cover with a plclStllC h 1m mfH or use a press GL 1000 SHOP MANUAL 1976 American Honda Motor Co Inc Printed in U S A 7 78 12 7 ...

Page 192: ...NOTE new ho ri nn with nn rtinn of the area up opelratiion be 1 Il j flll threaej of BEARING DRIVER 12 8 GL 1000SHOP MANUAL 1916 American Honda Motor Co Inc in U S A 7 78 ...

Page 193: ...clve the pinion ine not remove the rear bearing If gear or beiarllllQli are the drive hub must be replaced as an assembly Seal Removal Th rl the seal remover tool into Install the remover use the slldlrlQ to remove seal Do not re use the Reln01 e the SLIDING WEIGHT HC 41312 HC41311 GL 1000SHOP MANUAL 12 9 1976 American Honda Motor Co Inc Printed in U S A 7 78 ...

Page 194: ...seal comr orlents are pinion preload en agemeln t hub bac kta sh o not re use the case h l ir thr o in the driving out the oil Do not re use the seal 12 10 GL l 000 SHOP MANUAL 1976 American Honda Motor Co Inc in U s A 7 78 ...

Page 195: ...l l jYH1 nstaH the Install the front the case into position with the cOllpling washer nut to sPE cijfic ti ms nstall the nut the 1 nut and washer to remove grease GL 1000 SHOP MANUAL 12 11 1976 American Honda Motor Co Printed in U S A 1 78 ...

Page 196: ...ttach a measure the holder at one r nh ltin n the PINION PRelOAD 1100G 1 54 2 43Ib HOLDER 11 HC41305 reClullred to movement may exceed orelloC3ld limits to Remove the nrj l n 11 1 rl taimlr a new seal 1 ...

Page 197: ... of O 040mm ch anllie in spacer thickness rlQj r R A or increase ba kliash bal kl ash is too use a thinn spacer If is use a spacer PRELOAD 1140 21100 2 5 4 61bl tab check under if correct cannot be ob1 ainled check the oil or retainer necessary as an hl rl GL 1000 SHOP MANUAL 12 13 1976 American Honda Motor Co Inc Printed in U S A 7 78 ...

Page 198: ...ose and rear arm Drive Remove the rear wheel and the drive DRIVE SHAFT Loosen the lock nuts on both sides and back out both Detach the rubber boot and remove 12 14 000 SHOP MANUAL 1976 American Honda Motor 7 78 ...

Page 199: ...tlv to nrll IIAI lt damage to the rear not the _ _ BEARING COVER 1976 1979 in the Hn t t the should be no universal and If there is any p fln rH g the must be rel llac ed GL 1000SHOP MANUAL 1976 American Honda Motor Co Inc Printed In U S A 7 78 12 15 ...

Page 200: ...LASH O 3mm un shaiuid be rep laceid not show eXI asl ive b ll klash but still have worn or EXC8l siv elv worn NOTE For arm inspe ctilon see page 1 9 arrows MULTIPURPOSE GREASE NLGI 2 2 MULTIPURPOSE GREASE NLGI 2 MoS2 ADDITIVE 12 16 GL 1000 SHOP MANUAL 1976 Am rlcan Honda Motor Co Inc In 7 78 ...

Page 201: ...SHAFT Lubricate the and nstall the shaft into the arm the boot and n n lf P if it cut or worn FINAL DRIVE INSTALLATION OF DRIVE SYSTEM INSTALLATION DRIVE SYSTEM L1000SHOP MANUAL Amaric an Honda Motor Co Inc Printed 12 1 ...

Page 202: ...both lock nuts and the for of movement Do not when tiglhtenirlQ 12 18 rear GUUIJIIIIIQ GL l000 1976 Amarican Honda In 1 78 ...

Page 203: ...FINAL DRIVE INSTALLATION OF DRIVE SYSTEM tnr nIlP the lower h h 1 bolts vent the the nut and install a new cotter bottom GL 1QOOSHOPMANUAL 1219 1976 American Honda Motor Co Inc Printed in U S A 7 78 ...

Page 204: ...ltevel should reach the If is below the add the recommended lubricant until it reaches the filler neck threads the filler cap Do not allow foreign matter to enter the final case GL 1000SHOP MANUAL 12 20 1978 American Honda Motor Co Inc m U S A 7 78 HVPOID GEAR OIL SAE 90 ABOVE SOC 41 F SAE SO BELOW SOC 41 F ...

Page 205: ...the is in good condition and reinstall the drain Fill the gear case to the filler with of the recom mended Reinstall the filler cap FINAL DRIVE M INTENANCE HYPOIO GEAR OIL SAE 90 ABOVE 50C 410F SAl 80 ABOVE 50C 410F L l000SHOP MANUAL 12 21 1978 American Honda Motor Co Inc Printed in U s A 7 78 ...

Page 206: ...77 BEARING REPLACEMENT 1978 1979 STEM REMOVAL 1978 1979 BEARING REPLACEMENT REAR SUSPENSION SWING ARM INSPECTION FUEL TANK REMOVAL MAIN STAND REMOVAL SIDE STAND INSPECTION AND REPLACEMENT FRAME INSPECTION 13 2 13 4 13 6 13 7 13 8 13 12 13 13 13 15 13 16 13 18 13 19 13 21 13 23 13 26 13 28 13 29 13 29 I G L 000 SHOP MAN UA L 1978 American Honda Motor Co Inc Printed in U S A 7 78 13 1 ...

Page 207: ...47 kg 194 Bmm 94 1 1kg 167 6mm Plus Minus 6kg 151 mm 39 1 kg 1 94kg 1 ransm issiCln Fluid maximum force to retract Free Rear Side Bolts Caster 62 de lrel S 1 elescopic Fork Travel 1 Values 13 2 L l 000 SHOP MANUA L 1978 American Honda Motor in 778 lnc ...

Page 208: ...FRAME AND SUSPENSION GL 1000SHOP MANUAL 1976 American Honda Motor Co Inc Printed In U S A 7 78 13 3 ...

Page 209: ...remover Rp rirlnremoverh lnMlp a nn stem u a Tools and M ltelrial s Ball race driver HC41323 hollow set wrench Oil seal remover HC 41 seal HC 41 spanner 061 Pin spanner HC 061 Rear shock compressor HC I Outside mll r ml l tl lr TR UBLESHOOTING Wobble or Vibration in MOltolrcvcle 1 Loose axle Loose wheel h ri I 3 Loose cto rinn stem nut or h lri ln o 4 Loose on rear sWipension 5 tire and wheel 7 8 ...

Page 210: ...otc riinn stem h ri Side or Does Not Straight 1 2 3 4 5 1 Incorrect in 2 Too much clearance inside Rrt l o n fork c nl im1t Broken rear nl lnrllc l 5 rear shocks GL 1000SHOP MANUAL 13 5 1976 American Honda Motor Co Inc Printed In U S A 7 78 ...

Page 211: ...Do not a velhlcle Wllth S SPENSION INSPE TI N vehicle stalbilitv control NOTE Check that the control cables are l o rr l fl f and not mf rtll r 1 Motor ...

Page 212: ...FRAME SUSPENSION SUSPENSION INSPECTION SERVICE OPERATIONS GL 1000 SHOP MANUAL 13 7 1918 American Honda Motor Co Inc Printed In U S A 7 78 ...

Page 213: ...FRONT FORK DISASSEMBLY Rt rnrulI the and front axle holders Jack up the clear the wheel 13 8 GL HIOOSHOP MANUAL 1978 American Honda Motor Co Inc In U S A 7 78 ...

Page 214: ... If the Loosen the Check the free of the fork Aelplc u e it if it does not FREE LENGTH STANDARD 519mm 20 4 SERVICE LIMIT 495mm 19 5 in 1 i thi WClunld portion of the TOP BOTTOM GL 1000SHOP MANUAL 1976 American Honda Motor Co nc 13 9 Printed In U s A 1 78 ...

Page 215: ... SERVICE LIMIT 36 900mm 1 4627 inl DUST SEAL SE ST SEAL RiNG reverse in seallarlt to the threads bottom socket bolt in using the fork the tool into the stem upper and 13 10 GL1000SHOP MANUAL 1978 Honda Motor Co in U S A 7 78 ...

Page 216: ...SUSPENSION FRONT FORK three corners of the for clearance nuts to the then tnl 1 the rear nuts and remove the gauge gauge If the gauge cannot be in Pl h nuts Measure the clearance the and the rear of the with a 1 ...

Page 217: ...master cvllinl ler in an Pri1lVtUlt the damaging to prevent air from system liernO fe the front HANDLE BAR REPLACEMENT the starter 13 12 GL1000 1976 m nc an ...

Page 218: ... screws the cover switch clamp bolts lift the of the crown PULL WIRE THROUGH WITH LOOM wiring to the ends of and it through the handlebar wire to new Wiring thrnlltlh the handlebar FORK BRIDGE REMOVAL GL 1000SHOP MANUAL 13 13 1976 American Honda Motor Co Inc Printed in U S A 7 78 ...

Page 219: ...cap the off REMOVE NUT WITH PIN SPANNER TOOL HC 06155 2 STEERING STEM CAP STEERING STEM NUT 13 14 L 1000 SHOP MANUAL 1976 American Honda Motor Co Inc In U S A 7 78 ...

Page 220: ...ME AND SUSPENSION 1975 1977 STEM REMOVAL nut covers as Rerrlove the i inn and removal pro cedlure see 1975 1977 STEM REMOVAL GL l000 SHOP MANUAL 1978 American Honda Motor Co inc 13 15 Printed in U S A 7 78 ...

Page 221: ...IIY HerTIm e inst ect the races 1975 1977 BEARING REPLACEMENT upper head race lower race If the motorcycle has been involved in an examine area arolllnd the steering head cracks DRIVEOUI UPPER RAC BALL RACE DRIVER TOOL He 41323 OR eQUIVALENT STEERING HEAD 13 16 L IUUU SHOP MANUAL 1978 American Honda Motor Co nc in U s A 7 78 ...

Page 222: ...ce FRAME AND SUSPENSION BEARING REPLACEMENT All RACE DRIVER TOOL HC 41323 OR EOUIVAlENT I PilOT LOWER BORE LOWER BAllS LOWER CONE RACE DUST SEAL DUST SEAL WASHER GL 1000 SHOP M ANUAL 13 1 1976 American Handa Motor Co Inc 7 Printed in U S A 7 78 ...

Page 223: ...18 STEel rotates nstall the stem in the the nut until i ti I movement 1978 1979 STEM REMOVAL Remove the FOR and fork ren10val prC GeIr ul O see page covers as a unit 13 18 GL 1000 SHOP MANUAL 1978 American Honda Motor Co Inc U S A 7 78 ...

Page 224: ...head and races are ied in matched sets to ensure a nY n fit and install rnrnnlptp sets do not mix reDlaee ment or races Remove the and grease Remove the lower h r1nn and dust seal from the Zt rirln stem Remove the nut from the of the stem and remove the stem 1978 1979 BEARING REPLACEMENT GL 1000 SHOP MANUAL 1978 Amerlcan Honda Motor Co Inc 13 19 Printed in U S A 7 78 ...

Page 225: ...AI LATION ATTACHMENT HC 64767 delforlmatioln or NOTE If fp l l lrIN head are re lla ed due to collision dalmage mspel lt the for BEARING DRIVER ATTACHMENT HC 64767 13 20 GL l000SHOP MANUAL 1976 American Honda Motor Co Inc In U S A 7 78 ...

Page 226: ...rings Then loosen the nut and it to a final value of 1 5 7 11 131bs ft Pack the lower with grease and insert the stem into the frame s head Pack upper grease and install the grease holder and upper h rirHl on the stem Reinstal the fork headl and handlebars REAR SUSPENSION GL 1000SHOP MANUAL 1978 American Honda Motor Co Inc 13 21 Printed In U S A 7 78 ...

Page 227: ...SPRING REAR SHOCK ABSORBER COMPRESSOR HC 29827 Comrlre s the the eye remove the eye LOCK NUT J PI IP the rear as I n r h A in section 12 arm ...

Page 228: ...collar FRAME AND SUSPENSION SWING ARM INSPECTION SWING ARM the needle hp lrlnn If the np lr inn dam lged remove them from OPp site 000 OP MANUAL 13 23 meriCM1 Motor ...

Page 229: ...a new h irl PIVOT NUT REMOVER HC 41315 FLAT sIDe PIVOT NUT SLIDe HAMMER HC 41312 FRAME 13 24 GL 100a MANUAL 1976 American Honda Motor Co I 7 78 ...

Page 230: ...E AND SUSPENSION SWING ARM INSPECTION SWING ARM APPLY MULTIPURPOSE NI GI 2 GREASE TO THE SHADED AREAS SHOCK I BUSHING THRUST BUSHING GL1000 SHOP MANUAL 976 American Honda Motor Co Printed in USA 7 78 13 25 ...

Page 231: ...FUELTANK REMOVAL cover r u r away from Hpm p the H Irnrl both seat the seat I H nl lA t and turn rear rail as a 13 26 L 1000 SHOP MANUAL 1978 American Honda Motor Co in 7 78 ...

Page 232: ...E AND SUSPENSION FUELTANK REMOVAL Remove the fou r service cornp 3rtrne 1t Remove the h l1 tAY COIVlPi Rl MENTMOUNTING BOLTS BATTERY BOX MOUNTING BOLTS GL l000 SHOP MANUAL 1976 An19rrcan Honda MOtor Co Printed in US A 7 78 13 27 ...

Page 233: ...IN STAND REMOVAL onV fO the Loosen the the the stand for cracks or other Lubricate the reirlstclll the stand 13 28 000 SHOP MANUAL 1976 American Honda Motor Co Printed 7 78 ...

Page 234: ...o retract the is excessive inspect the pivot area for debris replacement pad marked 260lbs FRAME INSPECTION section n nl l t the enQine mount FRAMEAND SUSPENSION MAIN STAND REMOVAL GL 1000SHOP MANUAL 13 29 1976 American Honda Motor Co Inc_ Printed in U S A_ 7 78 ...

Page 235: ...DISASSEMBLY REAR PADS AND CALIPER DISASSEMBLY MASTE CYLINDER REMOVAL AND DISASSEMBLY WHEEL INSPECTION FRONT AND REAR WHEEL DISASSEMBLY AXLE AND DISC INSPECTION FRONT AND REAR WHEEL ASSEMBLY SPEEDOMETER DRIVE TIRES 14 2 14 5 14 6 14 7 14 9 14 13 14 16 14 22 14 25 14 29 14 31 14 32 14 34 14 34 III GL 1000SHOP MANUAL 14 1 1978 American Honda Motor Co Inc Printed in U S A 7 78 ...

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Page 237: ......

Page 238: ......

Page 239: ......

Page 240: ...se N 1 2 Silil nn seal grease Wheel Assemblies Bearing retainer wrench HC 29B23 HI nrln driver attachment HC 41 attachment handle HC 29824 indicator Tire pressure gauge TROUBLESHOOTING Brakes Chatter or Squeal 1 contaminated 2 runout on disc s 3 iper installed Inl inrn tliV 4 Disc or wheel misaligned Brakes Grab or Pull to One Side 1 contaminated 2 Defect in one side of front braking SYSitem 3 Dis...

Page 241: ...PnJ t ur with DOT 3 upper level BRAKE FLUID LEVEL REAR MASTER CYLINDER 3 WAY JOINT FRONT MASTER CYLINDER to the reservoir is ren10vina the cap brake hoses and fi t1Hnr 1 1 01 1 1 1 or cracked both and rear 14 6 ...

Page 242: ...ke fluid on the brake Stoppilrlg power will proiceclura on both front and I nlln AI B BLEEDI proce BRAKES AND WHEEL ASSEMBLIES BRAKE FLUID REPLACEMENT BRAKE FLUID REPLACEMENT dure DIAPHRAGM BRAKE BLEEDING ...

Page 243: ... prevent air purnpe d into the sv tern prc ce dl u e on both front and NOTE NOTE 15mm SPACER PREVENTS OVERTRAVEL DURING THE BLEEDING PROCEDURE NOTE If there is air in the system lever will feel spongy 14 8 GL 1000 SHOP MANUAL 1976 American Honda Motor Co Inc in U S A 1 78 ...

Page 244: ...LACEMENT FRONT A REPLACE AIVlltiVS repllace the brake pads in to assure even pressure It is not necessary to remove oil to the brake to In most cases it is not to GL 1000 SHOP MANUAL 14 9 1978 Americlln Honda Motor Co Inc Printed in U s A 7 78 ...

Page 245: ...brake fluid which drains AI III 1 refill the fluid 1 1 n nh in under the bolt banjo discormectil1g the brake line 14 10 GL 1000 SHOP MANUAL 1976 American Honda Motor Co Inc In U s A 7 78 ...

Page 246: ...ALIPER INSIDE DIAMETER 38 1 to mm 1 5005 1 50HI PISTON oUTSIDE DIAMETER ternOieratUl e SIIIC ne grease diameter and diameter if be vond service limits the seal or deteriorated GL l000SHOP MANUAL 1978 American Honda Motor Co Inc 14 11 Printed in U S A 7 78 ...

Page 247: ...acket Bolts 300 400 22 29 ft Ibl rV 18X25mm Bo 150 200 i 11 14 ft Ibl lIllllIl O t l Bleed Valve to the lnir from a B the brake n ihcln on page 1 the lin FRONT CALIPER ASSEMBLY 14 12 L l000 SHOP MANUAL 1976 American Honda Motor Co Inc _ in US_A 7 78 ...

Page 248: ...r Hell10ve the boot When the brake line cover the end of the to nrp u mf contamination and secure the hose to the fork BRAKES AND WHEEL ASSEMBLIES FRONT MASTER CYLINDER DISASSEMBLY FRONT MASTER CYLINDER S SE SLY GL 1000 SHOP MANUAL 1 13 1976 American Honda Mowr Co Inc 4 Printed in U S A 78 ...

Page 249: ...T MASTER i CYLINDER BODY 1979 MASTER PISTON PRiMARY CUP the master 1 11 n 1l r NT MASTER NDER INSPECTI 1976 1918 STANDARD 17 460 17 503 mm 0 6874 0 6891 in SERV 17 515 mm LIMIT Ifl l tQ in 1979 STANDARD 15 870 15 913 mm 0 6248 0 6265 in SERVICE 15 925 mm IMIT in 14 14 GL 1000SHOP MANUAL 1978 American Honda Motor Co Inc In U S A 7 78 ...

Page 250: ...and the bolts making sure the high mating surface the holder is on and the bolt is brake line bolt and two washers I brake lever and bolt nut Fill the r l pn Air and bleed the system as rll r rilhArl on page 14 8 is in in the reservoir screws 1 ins1 talling the cups do not to turn inside out Be certain the circlip is in groove FRONT MASTER CYLINDER ASSEMBLY GL l 000 SHOP MANUAL 1978 American Honda...

Page 251: ...BRAKES AND WHEEL ASSEMBLIES REAR BRAKE SYSTEM REAR MASTER CYLINDER REAR DISC AND CALIPER BRAKE 14 16 L Motor BRAKE LINE TO BRAKE HOSE PRIMARY CUP IPISTON AND SPRING IIE SECONDARY CUP RUBBER BOOT ...

Page 252: ...allation cover deoress the pad Inf ltlrln remove the top to remove then remove the BRAKE AND WHEEL ASSEMBLIES REAR BRAKE PAD REPLACEMENT REAR BRAKE PAD REPLACEMENT GL 1 000 SHOP MANUAL 1978 American Honda Motor Co Inc 14 17 Printed In U S A 7 78 ...

Page 253: ...k a ll nl lhg r secure bolt Remove the axle nut and axle line AvoidspiUing brake flu id on painted up on the pu II it out over the rnlllffl the __ container 14 18 GL 1000 SHOP MANUAL 1976 American Honda Motor Co Inc in U S A 7 78 ...

Page 254: ...IPER DISAS8EMBLV as cover and the two S rlar ltA the lin Herrlove the R CALIPER DISASSE BLY boots The should be marked to caliper side they were remlJved GL 1000 SHOP MANUAL 1978 American Honda Motor Co Inc 14 19 Printed In U S A 7 78 ...

Page 255: ...0 mm 1 5031 1 5051 in 42 772 42 822 mm 684 1 686 in pistor s for and IVltla SIJ ft the nll t ir PISTON 0 0 1915 1977 REAR CALIPER INSPECTION 38 245 mm 1 5007 in 14 20 GL 1000 SHOP MANUAL 1978 American Honda Motor Co Inc in U S A 7 78 ...

Page 256: ... 300 KG eM 8 TO 21 FT lB Fill the to the upper and the rear brake as described on page 14 8 both halves and install the two bolts and l r1ihi o n them Install the line CALIPER BOLTS removed Make sure each is reinstalled in the same I r from which it was GL l000SHOPMANUAL 14 21 1978 American Honda Motor Co inc Printed in U S A 7 78 ...

Page 257: ...on pan u TER CYLINDER REMOVAL cover eye STER CYLINDER SASSEMBLY Remove MASTER CYLINDER CHECK VALVE SPRING PRIMARY CUP If PUSH ROD CIACLIP PISTON AND SECONDARY CUP cup 14 22 ...

Page 258: ...HEEL ASSEMBLIES REAR CALIPER ASSEMBLY MASTER CYLINDER INSP ION master 1 111 1 1 diarnet er of the STER CYLINDER ASSEMBLY CHECK _ _lliiiiI VALVE NUT ROD EYE l nulD RESERVOIR GL 1000 SHOP MANUAL 1978 American Honda Motor Co Inc 14 23 Printed in U S A 8 ...

Page 259: ...14 24 Co Inc ...

Page 260: ...BRAKE AND WHEEL ASSEMBLIES WHEEL INSPECTION 1975 1977 SPEEDOMETER GEAR HOUSING AXLE GL 1000SHOP MANUAL 1978 American Honda Motor Co Inc 14 25 Printed in U S A 7 78 ...

Page 261: ...1978 1979 DISC DUST SEAL WHEEL BEARING RETAINER BEARING FINAL DRIVE FLANGE COLLAR GEAR BOX RETAINER AXLE NUT 14 26 GL 1000SHOP MANUAL 1978 American Honda Motor Co Inc U S A 7 78 ...

Page 262: ... 1 0 mm 0 0 004 illl 1975 1977 oTO 0 5 mm O 0 002 inl SERVICE LIMIT 2 0 mm inl COMSTAR WHEEL SHOWN 1978 1979 be N Wire sp Ke 1 Check and tinhtlJ n the wheels check to make sure that the wheel runout is within limits WHEEL BALANCING WHEEL INSPE G 000 SHOP MANUAL American Honda Motor Co Inc 14 27 Printed in U s A 7 78 ...

Page 263: ...d on the floor do not step When chlmging wheel is removed on the spc kes When a motorcycle equipped with ComStar wheels is loaded on a transportation the wheels may be down as shown to secure the motorcycle Place tie on rim only do not tie down lines on SPllkEI are used as tie down points they may resultiing in excessive wheel runout NOTE CORRECT WHEEL TIE DOWN ComS tar wheels cannot be removed an...

Page 264: ...SLY page If the bearings are removed should be replaced new ones RIGHT SIDE SIDE AXLE Cl DISC BEARING Dusl AL I lr RLdJ RETAiNER COLLAR SPEEDOMETER GEAR HOUSING DISC Cl 1 NUT RETAINER COVER RETAINER GASKET GL 1000 SHOP MANUAL 1978 American Honda Motor Inc Prlntlld In U S A 14 29 ...

Page 265: ...RWHEEl SEMBlY If the are rel1nov ed new i must be im talllec J flANGE FIXING BOLT COLLA 14 30 GL 1000 SHOP MANUAL 1978 America Honda Motor Co Inc In U S A 7 78 ...

Page 266: ...L ASSEMBLIES AXLE INSPECTION ON hand roulghr ess or iJIV rotate and AXLE INS Set the measure rear bushings will cause 01 INSPECTION GL l000 SHOP MANUAL 14 31 1978 American Honda Motor Co Inc Printed In U S A 7 18 ...

Page 267: ...aklrlQ sure that it is fully seated is facing out NOTE Be certain the distance collar is in installing the bearings to I the retainer with the same that was used to remove 14 32 GL l000SHOP MANUAL 1978 American Honda Motor Co Inc In U S A 7 78 ...

Page 268: ... EMBLY f o itiC n the distance collar in the wheel bearing side of the disc and nuts flange Multipurpose MOS2 additives according f nrlrlit lnn of the bearing thl I rI are damaged GL 1000SHOP MANUAL 1978 American Honda Motor Co Inc Printed In U S A 78 14 33 ...

Page 269: ...SPEEDOMETER DRIVE TIRES to 200 Ib load Rear Should be checked Front 40 Ibs 163 14 34 GL l000SHOP MANUAL 1978 American Honda Motor Co I in U S A 7 78 ...

Page 270: ...amage to or rim and on the rim resultina inner tube damage may occur Tire brand Front SUPE R 21F2 Bridgestone D F6 Dunlop Front 3 50H19 Rear 4 50H17 GL l000 78 79 R SPEED F6 Dunlop Front 21F2 Bridgestone Tire brand NOTE R1m bands are not used on COlnstar wheels because the inner tube does not on Comstar wheeis bands are used on wire wheels to nrr tAj t inner tube from hlr il n Rear R SPEED R2 Brid...

Page 271: ...15 ELECTRIC STA SERVICE INFORMATION 15 2 TROUBLESHOOTING 15 4 STARTER MOTOR 15 5 STARTER RELAY 15 8 GL 1000SHOP MANUAL 15 1 1976 American Honda Motor Co Inc Printed in U S A 7 78 I ...

Page 272: ... to crankshaft sec cOintinw us Under Load 8 5 750 480 3 0 o Brush Brush gr 9 7 Values bolts 1 to 1 washer head bolts for flAr pr tnr hp lnl H1 100 to 1 be removed and installed with the n linA to service the starter the the and M ltAr i li 1 ...

Page 273: ...I FUSE 30A I 1 I IGNITION J SWITCH BK START SWITCH STARTER RELAY STARTER MOTOR COMMUTATOR AND BRUSHES NEUTRAL LIGHT LG R NEUTRAL SWITCH NEUTRA l DIODE CLUTCH SWITCH j STARTER MOTOR GL l000SHOP MANUAL 15 3 1976 American Honda Motor Co Inc Printed in U S A 7 78 ...

Page 274: ...r disconnected wire or cable 7 Neutral diode open or drive V Tel TI Exce si ire I f i t I P in circuit drive t n t 1 Motor Turns Engine Slowly 1 Low Tor 2 3 But Does Not Turn clutch But Engine Does Not Start Back on Starting Improper I I n 15 4 GL 1000 SHOP MANUAL 1976 American Honda Motor Co nc In U S A 7 78 ...

Page 275: ...sprocket will in the hmJsinig BRUSH SPRINGS TENSION 60 to sao grams SERVICE LIMIT 400 grams bn Jshes measure brush brush spring oF i Brush Inspection RemcM the starter motor case screws cover and the I Look fOr spacers on the armature ends them in proper REMOVE ARMATURE I gear Arrnature Removal armature motor case SPACERS MAY BE INCLUDED Gl l000SHOP MANUAl 1916 American Honda Motor Co Inc Printed ...

Page 276: ...on the commutator t1e twl en pairs commutator bars and between commutator bars armature Re ph ce starter motor if armature coils are or to armature 00 f SHAFT MINIMUM DIAMETER 27mm SEGMENTS INSULATION MINIMUM HEIGHT 2mm 15 6 SHOP MANUAL AmerIcan Honda Motor Co Inc in U S A 7 78 ...

Page 277: ...USE A NEW O RING Stlutl r t lwtcn Inspection rotated TORX HEAD SCREWS 13 ROLLERS INSIDE often without en lne or emit a loud as the is being starter OAI Ierat r must be removed been removed from iec tlOn 41 Worn or cnrroided cause 000 SHOP MANUAL 978 American Honda Motor Co inc Printed in U S A 7 78 15 7 ...

Page 278: ...tarter relay disconnect the negative battery cable battery UillJllI q the two small nnm H at the connectors Hemtlvl the two cables and the term out of the done with 15 8 Gl 1 lOO SHOP MANUAL 1976 American Honda Motor Co I U S A 7 78 ...

Page 279: ... SERVICE INFORMATION 16 2 TROUBLESHOOTING 16 4 IGNITION COILS 16 5 BALLAST RESISTOR 16 5 SPARK ADVANCE MECHANISM 16 6 CAPACITOR 16 6 Gl l000SHOP MANUAL 16 1 1978 American Honda Motor Co Inc Printed in U S A 7 78 I ...

Page 280: ...limate For extended to Contact Breaker Points Dual to Innl tlr coil tl811aSl resistor marks F l indicator for F 2 indicator static or BTDC 1975 1977 1 ArlvarlCf Mark Advance 1 IUI lvlrm m Advance timing BTOC 1978 1979 to 1 104 to 1 in Ib to 14 Be sure that the h l1 TO is rli lnnClc irln the ignition system 16 2 GL 1 000 SHOP MANUAL 1978 American Honda Motor Co Inc in U SA 7 78 ...

Page 281: ...GINE STOP SWITCH BUTTON RIGHT COIL ENGINE STOP SWITCH I BAllAST I RESISTOR CONTACT YIR i BREAKER r i r BK Rqc ENGINE START I BUTTON T Bk SWITCH 1 R MAIN FUSE Bk V TO R BATTERY HEADLIGHT CIRCUIT GL 1000SHOP MANUAL 16 3 1976 American Honda Motor Co Inc Printed in U s A 7 713 ...

Page 282: ...it a or fouled b gap c coil d e Loose or bare wire f Intermittent short circuit in a or not nnt ninn h rf1lnn lnlt I1IP refer to Section 14 Ba kfllres When Running a b 3 Inn t n n i ir f1 a b 4 Low 1 1 o En line Kicks Improper IQflltlon tinn r n 2 16 4 GL l000 SHOP MANUAL 1976 American Honda Motor Co I in 7 78 ...

Page 283: ...GNITION COILS BOTH COILS MUST JUMP 8mm GAP Sk Sr R Bk BALLAST RESISTOR Sk SERVICE TESTER RESISTOR IGNITION COIL Use caution during coil performance tests voltage is present and may cause shc cks B LLAST RESISTOR the ohmmeter and 3 0 OHMS 10 Sk Br GL 1000SHOP MANUAL 1978 American Honda Motor Co Inc Printed in U S A 7 78 16 5 ...

Page 284: ...CITOR Do not Illrlri l ltp mechanism advance locate d on the may be tested the HelnstiEll1 the NOTE two i prutr lfp Vl lltCh tester lead to the rF rn linirIO C8IP8 it f lead and measure second 16 6 01 1000 SHOP MANUAL 1978 American Honda Motor Co Inc in U S A 7 78 ...

Page 285: ... INSTRUMENTS HEADLIGHT AND TAIL LIGHT BULB REPLACEMENT RESERVE LIGHTING SYSTEM HORN FUSES AND WIRING 1975 1977 WIRING DIAGRAM 1978 1979 WIRING DIAGRAM 17 2 17 7 17 9 17 12 7 13 17 19 17 20 17 24 17 27 17 28 I GL 1000SHOP MANUAL 171 1978 American Honda Motor Co Inc Pr rHed in U S A 7 78 ...

Page 286: ...ct ON circu its are on tail light running lights and instrument lights am on lights can be The can be The cannot be ren1ov ed PARK The tail is on but all other circuits are off The can be removed pressure switch on at pressures below 0 2 KOIso cm out at to 0 4 k fllc n m switch 7 volt rating on at 98 to 1020 C to 21 Fan off at to 199 to psi Auxiliary voltage regulator for tennpeirature and fuel ga...

Page 287: ... INSTRUMENTS SERVICE INFORMATION RESISTOR FOR RVE LIGHTING SYSTEM REGULATOR LI TURN SIGNAL SWITCHES FRONT BRAKE SWITCH TEMPERATURESEI S AND FAN SWITCH GL 1000 SHOP MANUAL 1976 American Honda Motor Co Inc Printed 778 17 3 ...

Page 288: ...17 4 L l000 SHOP MANUAL Af11arican Motor USA TURN SIGNAL BUZZER RELAY 78 79 ...

Page 289: ...ION 7 volts Test gauge tprrnin ll V1olti 1ge of buzzer In r lt when turn and innltir n switch is on Pink to Blue 1 9 ohms to Glow is locked in full left or full position GL 1000 SHOP MANUAL 17 5 1978 American Honda Motor Co Inc Printed in U S A 7 78 ...

Page 290: ... Br Brown P Pink G Green R Red Gr W White LB Blue Y Yellow the continu the electrical path through t nn1 inllit i check can usually be made without rnn r f1 the part from the mC1fr rrvr lp the wires and a continuity tester or vnlt I Ihlmrnplrpr to the terminals or connections tester is useful when to find out whether or not there is an pll f t if J 1 connection between the two If the quality of th...

Page 291: ...at has open circuit On When Switch Is Turned ON or disconnected harness All lights Come On but Dimly When Switch Is Turned ON 1 low 2 or switch has excessive resistance 1 2 3 Do When H Switch Is Operated L Indlicator Does Not Light When Headlight Beam Is Burned Out 1 HEAD indicator burned out 2 in 3 4 switching unit defective GL 1000 SHOP MANUAL 17 7 1976 American Honda Motor Co Inc Printed in U S...

Page 292: ...lor 2 3 Is Burned Out Tail jndlicator bulb out fuse out lin Tir n C IstFlm switching unit def ec1tive out Hp pnlp li nhtinn l TPtYl I l t hinn unit np tpt ti p open circuit Not Light When Tail Light Is Burned Out 1 Bulb burned out 2 3 4 Function 1 2 3 or r nl TIn nnl nt 4 1 defective 2 Wire loose 17 8 GL 1000 MANUAL 1976 American Honda Motor in ...

Page 293: ...l h if necessary Bk G Y REAR BRAKE SWITCH fRONT BRAKE SWITCH brake recluil S bleeding the to BRAKE APPLIED CONTINUITY BRAKE NOT APPLIED NO CONTINUITY rp rlll l 1 the neutral switch remove oil screen cover lower mounting bolt neutral switch retainer the as on page oand remove the neutral IN NEUTRAl CONTINUITY IN ANY GEAR NO CONTINUITY GL 1000 SHOP MANUAL 1978 American Honda Motor Co Inc Printed in ...

Page 294: ...DLE to to B to W lO to to W Tl DMl HB LB HEADLIGHT lEFT 2 HI LO lEFT RIGHT 2 OFF RIGHT ENGINE STOP SWITCH KB KW START BUTTON with button r1 nr r1 with button released with button releas ed with button ne lnr rl button Bk to Bk to 1 10 MOlor Co I ...

Page 295: ...itch with clutch rell aSI d and amllied Rel lal e if necessary CLUTCH SWITCH CLUTCH APPLIED CONTINUITY CLUTCH RELEASED NO CONTINUITY Removal the wires RF m I lever and cable wln n case has a small protrusion t lIIl lrn the clutch GL l000 SHOP MANUAL 1976 American Honda Motor Co Inc Printed in U S A 77B 17 11 ...

Page 296: ...N NO CONTINUITY BELOW 93 97oC 199 207 F SWITCH CLOSED CONTINUITY 98 102oC 208 215 fl DIODE IDENTIFICATION COLOR CODE NEUTRAL LIGHT Light Green Red Green Red IGNITION BY PASS Yellow Red Black Brown lOW BEAM RESERVE LIGHTING Pink Green HIGH BEAM RESERVE LIGHTING White Green 17 12 GL 1000SHOP MANUAL 1976 American Honda Motor Co inc in U S A 7 78 ...

Page 297: ...EL GAUGE G Bk G GROUND AUXILIARY VOLTAGE REGULATOR BATTERY 1 7V INSTRU ENTS Identiifv the wire colors at the connector are no on REGULATOR OUTPUT VOLTAGE SHOU LD BE 7 VOLTS G Bk TERMINAL VOLT OHMMETER GL 1000SHOP MANUAL 1978 American Honda Motor Co Inc Printed in U S A 7 78 17 13 ...

Page 298: ...sult TemJ eratlJre Sensor Resistance sensor the sensor in a pan and the the sensor as TelmlJen ltUire Gauge Function sensor and as shown The temperature gauge operates on 7 Do not apply 12 volts dirlf Ctliv to gauge U JlJt U the sensor in a pan oil test Do not let the sensor or thermometer touch pan or false will r n rnn lFA the gauge rea oin gs to thermometer as the oil 76 77 17 14 GL IOOOSHOP MA...

Page 299: ...P OF FLOAT TRAVEL fULL 10 15 OHMS level oPElrates on 7 volts directly to A special mm wrench 61076 is needed to remove the sensor from the tank Function Test Te the a tested sensor and aU Klllary Ifnllt illE l regu as GL 1000 SHOP MANUAL 17 15 1978 Amelican Honda Motor Co Inc Printed in U S A 7 78 ...

Page 300: ...icates a in the electrical Determine and correct the cause the malfunction The voltmeter can be checked nlnnl tin j it to a known I T I h pr f rUl the gauge tes tirlQ with a variable nl T source start at 6 V and raise the to 16 V The gauge read within a range of 0 6 V Voltmeter 17 16 000 MANUAL 1978 American Honda Motor Co Inc Printed in U S A 78 ...

Page 301: ... Screws Box Accessory Telm are to power 12 V D C accessories not exceeding 60 watts H current r rn nrl may blow the the h i Ta J plclrtrir 1 leads Uti ize the retain cl on the frame on either side of the terminal to route accessory leads away from hot ne parts and L 1000 SHOP MANUA 17 1 1978 American Honda Motor Co Inc 7 Printed in U S A 7 78 ...

Page 302: ...nstrument remove the cable and the meter set screws the meter out pry out the and remove the Turn SiSlnals Remove the lens to remove the bulb Buzzer Turn If does not work or flasher is check the COlmpionents and connections the circu it before Y oIO I r 17 18 ...

Page 303: ... remove the from the the bulb and remove the bulb Re assemble in reverse order of disass1emlbly iw tirlQ screw NOTE UIU the aim to conform with local laws and reglulcltic1ns LICENSE PLATE BRACKET improperly adjusted headlight may oncoming drivers or it may fail to light the for a safe To the or any of the I remove the and then remove the Do not overtighten screws lens mounting 1979 Do not finnAf n...

Page 304: ...LIGHTING SYSTEM VOLTAGE REGULATOR CURRENT TURN SIGNAL BUZZER RELAY 78 791 17 20 are not reserve liglltirlg svs tem A c ih srl on pages 1 L 1000 1 American Honda in 7 78 ...

Page 305: ...TRUMENTS RESERVE LIGHTING SYSTEM RESERVE LIGHTING SWITCHING UNIT 75 71 FUSE BOX 15 71 TO SWITCHING UNIT t 8 WIRE CONNECTOR OPEN SIDE TO BATTERY Gl 10aa SHOP MANUAL 17 21 1978 American Honda Motor Co Inc Printed in U S A 7 78 ...

Page 306: ...is defective G tube I Br tube RESERVE LIGHTING UNIT when with the the across the and G leads must be 10 to 13 volts If the is either unit or the resistor is r o tor Ti o the resistor VoltalJe at the Resistor the tail exists across vOltacle across the to 6 volts is nIT O irldj at s a problem in 17 22 ...

Page 307: ...the IYUltirllli1 1 must and low OIOOE IDENTIFICATION COLOR CODE LOW BEAM RESERVE LIGHTING Pink Green HIGH BEAM RESERVE LIGHTING White Green CONTINUITY IN ONE DIRECTION NO CONTINUITY IN OTHER DIRECTION GL1000 SHOP MANUAL 1976 American Honda MOlor Co Inc Printed in U S A 7 78 17 23 ...

Page 308: ...to and nrr l HH linn corltirlUi1 v bE tween horn Fuses NOTE Make sure new fuse is the same as the old one make sure the cause of a out has been corrected before the is 1975 1977 11 24 L 1000 SHOP MANUAL 1978 American Honda Motor Co Inc In U S A 7 78 ...

Page 309: ... SWITCHES AND INSTRUMENTS HORN FUSES AND WIRING 8r 8 T1 Tz A FUSE LOAD Bk Y RESERVE LIGHTING UNIT WIRE HARNESS lUG GROUND 1975 1 Gl l000SHOP MANUAL 17 25 1978 American Honda Motor Co Inc Printed in U s A 7 78 ...

Page 310: ...tch Left Handlebar Switch Left Handlebar Switch Ignition Coil AmnAlr t f llt MeterI Thermostatic Fan Switch Temperature Sensor Oil Pressure Switch 17 26 1918 1919 GL l000 SHOP MANUAL 1978 American Honda Motor Co inc in U S A 7 78 ...

Page 311: ...HTS SWITCHES AND INSTRUMENTS 1975 1977 WIRING DIAGRAM RREA TURN SIGNAL LIGHT 12VJ2c 1212 11 r M G Gr Y C R R C g B II ltf E P e B 8f Cla e S BlaCk G G lG l Gree lB gc B11 GLl 000 SHOP MANUAL J I 1978 American Honda Motor Co Inc Printed in U S A 7 78 17 27 ...

Page 312: ...TURN SIGNAL TURN SIGNAL BUZZER RELAY R 8H b Y d8 Y 8k ij Y 80Y 6 o 0 REAR STOP LIGHT SWITCH REGULATOR coNTACT BREAKER STARTING MOTOR G Green R Rtd W While Bp Brown Bk 8Iack LG etlt Green y yellow B Sklt p Pink Orlnlt Gr Gre1 lB lC 8 ...

Page 313: ...1SBATTERY CHARGING SYSTEM SERVICE INFORMATION 18 2 TROUBLESHOOTING 18 4 BATTERY 18 5 CHARGING SYSTEM 18 6 AC GENERATOR REMOVAL 18 9 GENERATOR DRIVE INSPECTION 18 11 MANUAL 18 1 Co Inc in U S A 7 78 I ...

Page 314: ...r head bolt R j tpy V acid level shou ld be checked and filled with distilled water when necessary h c nn the h t or l quic k lch lrQinQ should is nn tprrp rl be done in an emergency slow charging po ssit le If must be All rn lYnlnn SV teITl CIDmipo nents can be tested on the must be removed from the but to service the AC Qellerat r 18 2 Co ...

Page 315: ...RY CHARGING SYSTEM SERVICE INFORMATION BATTERY AC GENERATOR MAIN FUSE IGNITION SWITCH 30A af 4 RIW R R 1 I I I I I I I I I I y J I I L J VOLTAGE REGULATOR GL 1000 SHOP MANUAL 18 3 1976 American Honda Motor Co Inc Printed in U S A 7 78 ...

Page 316: ...ed On 1 2 low Running 1 Weak h irf o a low 11 1 1 0 plpf tl r I l1rp level b or more dead cells Intermittent Power 1 2 3 4 5 in if iinn system system h ri r wire or connec tion De fel til e silicon rectifier Defective 18 4 GL iOOOSHOP MANUAL 1978 Ameri n Honda Motor Co Inc In U S A 7 78 ...

Page 317: ...with water RNAl Drink quantities of water or Follow milk magnesia beaten eg9 or vegetable oil ph sic ian immediately Eyes water and get prompt medical attention Batteries produce sparks flame ci l ar lttEls away Ventilate when charging or using in space Always shield eyes when working near KEEP OUT OF ILOREN Discormeict the neQl3ti f9 n l1 tp r v cables then the pO ithle the cable last R II1rtA v ...

Page 318: ...XIMUM CHARGE RATE 2 AMPS CHARGE UNTIL SPECIFIC GRAVITY REACHES 1 260 to 1 280 THE READING SHOULD REMAIN STABLE FOR AT LEAST ONE HOUR AFTER CHARGING BATTERY CABLE UPPER LOWER FULLY CHARGED BATTERY CHARGING SYSTEM SHOULD READ AT LEAST 14 5 V AND 3 AMPS 18 6 GL1000SHOP MANUAL 1978 American Honda MotOr Co I in U S A 778 ...

Page 319: ...t betweEm any DISCONNECT WIRING HARNESS CONNECTOR GENERATOR CONTINUITY BETWEEN ALL YELLOW WIRES NO CONTINUITY FROM ANY YELLOW WIRE TO GROUND VOLT OHMMETER mlmmm Do not use a high vollta 1e source such as an inSU lltlcm rl si5itarl e between two OetweEm two l 1000 SHOP MANUAL 976 A merican Honda Motor Co Inc Printed U S A 7 78 18 7 ...

Page 320: ...ed White 5 40 ohms REVE BIAS Y n C 1 G _ lJI I l lH 3 arE ilIIl z Q G Red White to Yellow 1 2000 ohms min RedlWhite to Yellow 2 2000 ohms min RedlWhite to Yellow 3 2000 ohms min to Green 2000 ohms min Yellow 2 to Green 2000 ohms min Yellow 3 to Green 2000 ohms min REVERSE AMMETER YELLOW BLACK i I I 1 0 I I I reCIUli ltClr n prt nrrnaf l p with 18 8 OOOSHOP MANUAL 1976 American Honda Motor Co Inc i...

Page 321: ...UNNING CLUTCH STARTER DRIVE SPROCKET AC GENERATOR REMOVAL Removal cover and rear Remove cover engine must be removed from the DI TOre the AC generator can be renrlov ed Remove the engine as described in Section GL 1000SHOP MANUAL 18 9 1976 American Honda Motor Co Inc Printed in U S A 7 78 ...

Page 322: ...r weighs pounds Be IJrei J8lred to sUPpOrt it when it comes shaft R rnr I the rotor The springs are of the starter overrunning clutch ass embly may fall out when the rotor is renrlO iI ed 18 10 L 1000SHO MANUAL 1976 AmerIcan Honda Motor Co Inc in U S A 1 78 ...

Page 323: ...INSPECTION or often cause the starter to without engine or emit a loud screeching noise as the is TORX HEAD CREWS T40 TORX BIT OR SOCKET REQUIRED 3 ROLLERS INSIDE GL OOOSHOP MANUAL 1976 American Honda Motor Co Inc Printed in U S A 1 78 18 11 ...

Page 324: ...SHAFT DAMPER PlATES Do not compress the necessary to remove cotters H mfn the gears 18 12 GL 1000SHOP MANUAL 1976 American Honda Motor Co Inc in U S A 7 78 ...

Page 325: ... d H l the Re ass emble the drive assembly gears damper rubbers cover NOTE The spring compressor can be used a press Do not compress the spring more than to install the cotters GL 1000SHOP MANUAL 18 13 1976 American Honda Motor Co Inc Printed in U s A 7 78 ...

Page 326: ...ain holder tab and bolt Install the stator coils in the rear cover Instal rear n mn cover and the clutch cover enllune accord inQ to Sec tion 4 18 14 Gl 1000 SHOP MANUAl 1976 American Honda Motor Co Inc in U S A 7 78 ...

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Honda GL 1000, Shop Manual

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