Honda GL1200A Shop Manual Download Page 298

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Summary of Contents for GL1200A

Page 1: ...SHOP MANUAL d GL1 200C J Jr GL1 200A ...

Page 2: ...iod Sections 1 through 3 apply to the whole motorcycle while sections 4 through 20 describe parts of the motorcycle grouped act ording to location find the section you want on this page then turn to the table of contents on page 1 of that section Most sections start with an assembly or system illustration service information and troubleshooting for the section The subsequent pages give detailed pr...

Page 3: ... or sparks near he bottery especially wIllIe charging it SERVICE RULES 1 2 3 4 5 6 7 8 Use genuine HONDA or HONDA recommended parts and lubricants or their equivalent Parts that do not meet HONDA s design specifications may damage the motorcycle Use the special tools designed for this product Use only metric tools when servicing this motorcycle Metric bolts nuts and screws are not interchangeable ...

Page 4: ...NERAL INFORMATION MODEL IDENTIFICATION GOLD WING GL12000 FRAME SERIAL NUMBER The frame serial number is stamped on the right side of the steering head 1 2 HONDA GL1200D GL1200A GOLD WING ASPENCADE GL1200A ...

Page 5: ...uretor identification numbers are stamped on the 13ch carburetor bodies GENERAL INFORMATION A FINAL DRIVE SERIAL NUMBER The final drive serial number is on the final drive case near the pinion flange as shown The color label is attached to the location shown When ordering a color coded part always specify its designated color 1 3 ...

Page 6: ...ance Intake Exhaust Hydraulic valve adjuster system Idle speed 950 min I rpm ITEM GOLD WING GOLD WING ASPENCADE GL1200D GL 1200Aj Overall length 2 505 mm 98 6 in Overall width 970 mm 38 2 in Overall height 1 510 mm 59 4 in Wheelbase 1 610mm 63 4in I I Seat height 780 mm 30 7 in I Ground clearance 140 mm 5 S in I Dry weight 318 kg 701Ibs 328 kg 723 lbsl Curb weight 342 kg 754 Ibsl 353 kg 778 Ibsl F...

Page 7: ... rebuild Ignition Battery Ignition Full transistor I Ignition timing F mark 10 BTDC I Full advance 45 BTDC Starting system Starting motor Alternator A C generator 360W S OOO min t rpm Battery capacity I 2V 20A I Standard NGK DPA8EA 9 I NO X24EPA U9 C 0 0 For cold climate NGK DPR7EA 9 u Below SoC 41 c F NO X22EPR U9 For extended high NGK DPR9EA 9 speed riding NO X27EPR U9 Spark plug gap 0 8 0 9 mm ...

Page 8: ...in plug 1 6 10_14 1 0_1 4 7 10 Fi l3l drive gtar ca cover boll 18mm 8 8 23 28 2 3 2 8 17 20 110mml 2 10 45 50 4 5 5 0 33 36 Fmal drive pinIon joint nut 16 100 120 10 0 12 0 72 87 Enginemounl bolt nUl 112mml 3 12 55 65 5 5 6 5 40 47 110mml 3 10 30 40 3 0 4 0 22 29 18mm 8 18 25 1 8 2 5 13 18 Sub frame cap nUl 3 0 30 40 3 0 4 0 22 29 GL1200D FoolPeg boll nUl 2 12 55 65 5 5 6 5 40 47 Passenger footpeg...

Page 9: ...iston pin dis assembly tool kit 07973 MG90100 Use with 07973 6570002 11 Pilot driver 07973 MG90200 11 Pilot collar 07973 MG90300 I 11 Piston base 07973 MG90400 11 Piston pin guide 07973 MG90500 11 Piston base 07958 MG90000 10 Piston slider 07955 MG90000 10 Engine case assembly guide 07973 3710000 10 Steering stem socket 07916 3710100 12 Ball race remover 07953 4250002 12 Bearing race remover 07946...

Page 10: ...tachment 32 x 35 mm 07746 0010100 9 10 14 Pilot 15 mm 07746 0040300 9 12 Attachment 25 mm 1 0 07746 0030200 0 Attachment 20 mm I D 07746 0020400 10 Driver 07746 0020100 10 Attachment 42 x 47 mm 07746 001 0300 10 12 14 Pilot 17 mm Pilot 20 mm Attachment 37 x 40 mm Attachment 30 mm I D Driver Bearing remover collet 15 mm Bearing remover collet 20 mm Bearing remover expander Bearing puller VALVE SEAT...

Page 11: ...spring free length 17 5 0 69 16 010 63 I z 1 Hydraul ic tappet adjuster compression stroke with 0 0 30 O 0 Q12 0 3 0 012l max Iu kerosene IN 35 8 1 41 35 6 1 40 Cam lobe height EX I 35 80 41 35 6 1 401 I Center 24 934 24 950 0 9817 0 9823 24 91 0 981 Journal D O Bath ends 26 954 26 970 1 0612 1 0618 26 91 1 059 Center 25 000 25 021 0 9843 0 9851 25 05 0 986 I Journal 1 0 Both ends 27 000 27 021 1 ...

Page 12: ...P 5 3 kg em 75 psi I Oil pressure Idle speed 100 kP 1 0 kg em 14 psi I Hot At80 C 176 F 5 000 min rpm 520 kPa 5 2 kgfcm 74 psi Shift fork shaft 0 0 12 966 12 984 0 5105 0 51121 12 90 0 5081 L C 13 000 13 018 0 5118 0 51251 13 04 0 5131 Shift fork 1 0 13 05 0 514 I R 13 000 13 027 0 5118 0 51291 IMinor diameter 11 966 11 984 0 4711 0 4718 11 95 0 470 Shift drum Groove width 7 05 7 15 0 278 0 281 Sh...

Page 13: ...f 1t c p c ty 259 5 cm 18 78 US OZ 9 11 Imp ozl Rear shOCk ab orbet oil ATF Cylinder 1 0 G type 15 870 15 913 0 6248 0 6265 15 925 0 62701 Front brake Except G 1Ypa 12 700 12 743 0 5000 0 50171 12 75510 50221 maSter cylinder Piston D D G type 15 827 15 854 0 6231 0 62421 15 815 0 62261 Except G type 12 684 12 657 0 4994 0 49831 12 645 0 49781 Right caliper G 1Ype 32 030 32 080 1 2610 1 26301 32 09...

Page 14: ... 0 30 0 012 Final gear backlash I 0 10 lOOO 1 Z pit erence at 3 points I Final gear assembly preload 0 2 0 4 N m 2 0 4 0 kg em 1 7 3 5 in Ibs I R mg gear to eaes stopper clearance 0 3 0 6 0 01 0 02 I ELECTRICAL Firing order 1 3 2 4 Ignition timing OF mark 10 STOC Ignition timingl UII WithOUt vacuum advance 32 BTDC advance With vacuum advance 45 STDC NGK DPR8EA 9 Standard NO X24EPR U9 For cold clim...

Page 15: ...200min rpm Starter motor Bru h length 12 13 mm 10 47 0 51 in 7 5 m 0 30 jn I Brush spring tension 560 680 9 19 8 24 0oz1 440 9 11 5 5 Ol Oil pressure switch continuity pressure 0 2 0 4 kg em 2 8 5 7 psi I Fan motor switch No continuity temperature 93 97 C 119 207 F CO llinu ty temperature 102 C 208 216 D FI At 60 C 140 F I u 104 n Coolant temperature sensor At 8S C 18S F 0 U re i tl Al 110 C 1230 ...

Page 16: ...HONDA GL1200D GL1200A _ I on O 1 MI F lOA 2 _ u 1 _ 3 _ H 0 t 5 I 0 il m 1 1 t ow _ r w 1 0 g 1_ _ __ _ 11V l _ l s 0 0 2 _ _ 5 T _ 1 1 _ O oh It m _to t 4 _ 1M GL1200D E F ED SW C_ M _ eo r 1 M _ _ _ I I M ...

Page 17: ...GENERAL INFORMATION OIL L OJ _ rt I I L o n j 1 1 CO L l _ T c _ 0 _ _ Vo o W _ 0 O li iiJ Y l 11HZ J I _ 1 1 _ o _ 0 oj t u o U ca oo U E F EO SW 0030Z MG9 7000 1 1 5 ...

Page 18: ...II 0 HONDA GL1200D GLI200A rr O O C 1 _ I EfJl W r I ON _I L l J c __ ro N i _ I oQ u 0 0 _ _ 0 J i SO 0030Z MG9 9600 ...

Page 19: ...GENERAL INFORMATION 1 11 _ r e _ _ _ _ II i_ _ _ to _ z 3 JOo _ 1 _ _ l i l _ u _ _ CWIIU _ 1 H t c_ _ _ _ _ _ 0 1 lU l _ _ I L __ 2 _ _ GL12000 SO 1 16 ...

Page 20: ... _ r _ _ n r p L u _ s i 00 _ 2 3 A l U _ _ _ M 00 1 0 I UI 5 00 _ looo L C 5 0 _ on 00 1 _ 0 0 _ mI lo J l j _ l __ OOCO I __ 2 I _ _ 7 l _ _ i ll otTO In _ o _ G11200D SA TOo o wmo m c_ Jo tot J ru Ill _ 40 _ _ _ _ __ I I _ I ...

Page 21: ...L INFORMATION _ r Q3 q 1 MI Qj H l D3 _IIOII L 0 m ffllJJiJ 1Jj W SAl 0030Z MG9 7600 _ I 0 0 _ _ 0 _ 7 h o 1Il u r 01TOM r _ m oz n _ i l 0 lOOSOO l Trr l i I I _ t _ 1 1 o t OIl II U 1 j_ 01 _ 10 ON 0 1 1 7 ...

Page 22: ...DA GL1200D GL1200A G11200D SA 11 0 IM W _ _ No s Fr 2 3 I r T co _ _ 6 nn 1 100 0 __ _ _ J a 1 H r CUII _l U T __ I 0 0 _ C 2 J 1 0 0 c 1 00 r _ m C W 100 m C_ _ S 1 o Ji40 C fl III _ A OIl _ 100 1 III _ I N w _ ...

Page 23: ...GENERAL INFORMATION 7600 DO OJ MG9 _ w 0 w w w i l SA 0030Z e IM I t lO _ Ul Il_ 1 fr4l l _ 0 I OJ n _ lJ C on I 0 00 10 1 _ J _ 1 1 ...

Page 24: ...rA HONDA GL12000 GL1200A _ 10 01 l_ _ V T R _ _ 0 0 _ _ _ _ M 1 1 I I I _ ED llm lm Ii s e I 0 G11200A SD 1TO c_ W _ I 0 0 TOO n 0 I I _ o c ft _ _ ...

Page 25: ...GENERAL INFORMATION _ _1 _ 0 _ II 0 1111 4 7 I tI b _ _ r t B _ __ _ _ liB _ fDl tl _ I dr 1 1 fL Jl J L __ J _ _ SO 0030Z MG9 9700 1 19 ...

Page 26: ...r iJ HONDA GL1200D GL1200A _ L _ M _ _ i o 03 _ fD1 1 111 50 L _ 1 G 0 _ L jJ L _ fn o _ M _ M _ 1 j i i f E ffi lIm _ r _ _ _ t lr U t w _ lro O J I n d Ii u 0030Z MG9 8400 ...

Page 27: ...GENERAL INFORMATION GL1200A U 15 J co i H r r i _ _ r l L leTl O 0 0 _ 1 1 T _ oll 0 0 _ roo _ 0 M _ EJJ _ I l j OIl 0 I 1 it r r 1 1 J J t Ol I W OO V e c h 1 20 ...

Page 28: ...of its clamp when a weld on clamp is used Note the following when routing cables and wire harnesses CABLE HARNESS ROUTING Do not use wires or harnesses with a broken in sulator Repair by wrapping them with a protec tive tape or replace them Route wire harnesses so they avoid sharp edges or corners and avoid the projected ends of bolts and screws Keep wire harnesses away from the exhaust pipes and ...

Page 29: ...T BRAKE HOSE HONDA GL1200D GL1200A CHOKE CABLE TH ROTTlE CABLES MAIN WIRE HARNESS 1 CRANKCASE 3 BREATHER TUBE rcu 0 b SPARK PLUG WIRES SPEEDOMETER CABLE 1 22 RESERVE TANK BREATHER TUBE CLUTCH HOSE SPARK PLUG WIRES THROTTLE CABLES FRQNT BRAKE HOSE ...

Page 30: ... GL1200D GLI20DA GENERAL INFORMATION IGL1200DI LEFT HANDLEBAR SWITCH WIRE CLUTCH HOSE FRONT BRAKE RIGHT HANDLEBAR HOSE SWITCH WIRE THROTTLE CABLES 00 0 CHOKE CABLE MAIN WIRE HARNESS o WIRE BAND WIRE BAND 1 23 ...

Page 31: ...RONT BRAKE HOSE r i HONDA GL12000 GL1200A CHOKE CABLE CLUTCH HOSES FRONT BRAKE LEFT HANDLEBAR PIPE SWITCH WIRE c c 1 24 REAR SHOCK ABSORBER AlA HOSES MAIN WIRE HARNESS LICENCE PLATE LIGHT WIRE II TAil STOPLIGHT AND TURN SIGNAL WIRES ...

Page 32: ...MODELS FRAME GENERAL INFORMATION MAIN WIRE HARNESS MAIN WIRE HARNESS STARTER MOTOR CABLE i i OVEAFLOWDRAIN Z 1 TUBE CRANKCASE _ BREATHER TUBE i1 BATTERY GROUND l CABLE rCRANKCASEBREATHER e r r DRAIN TUBE STARTER MOTOR CABLE 1 25 ...

Page 33: ...GL1200A IGL1200A SPARK PLUG WIRES MAIN WIRE HARNESS i CRANKCASE BREATHER TUBE d CHOKE CAB LE ANGLE SENSOR WIRE_ T FRONT BRAKE HOSE SPEED SENSOR WIRE RESERVE TANK BREATHER TUBE THROTTLE CABLES FRONT BRAKE HOSE CLUTCH HOSE SPARK PLUG WIRES 1 26 ...

Page 34: ...200A LEFT HANDLEBAR SWITCH WIRE FRONT BRAKE HOSE GENERAL INFORMATION RIGHT HANDLEBAR SWITCH WIRE CHOKE CABLE THROTTLE CABLES MAIN HARNESS LICENCE PLATE LIGHT WIRE MAIN WIRE HARNESS ANTENNA CABLE TURN SIGNAL STOP LIGHT WIRE 1 27 ...

Page 35: ...LUBRICATION LUBRICATION DIAGRAM 2 0 SCAVENGING OIL PUMP HONDA GL1200D GL1200A OIL FilTEA MAIN IL PUMP OIL STRAINER SCREEN ...

Page 36: ...hout removing the engine from the frame To service the scavenging pump it is necessary to remove the engine from the frame SPECIFICATIONS u r nit rnm ITEM STANDARD SERVICE LIMIT Engine oil After disassembly 4 0 liters 4 2 US qt 3 5 Imp qtl capacity After draining 3 2 liters 3 4 US qt 2 8 Imp qt HONDA 4 stroke oil or equi OIL VISCOSITEIES valent API service c1assifi Ir l Recommended engine oil cati...

Page 37: ...em seal Worn valve guide Dilleyel too high Pressure relief valve stuck closed Clogged oil filter gallery or metering orifice Incorrect oil being used Low oil pressure Oil level low Plugged oil filter or screen Pressure relief valve stuck open Oil pump faulty Internal oil leakage Incorrect oil being used 2 2 Oil contamination Oil or filter not changed often enough Worn piston rings Oil emulsificati...

Page 38: ...er cap dipstick and check there are no oil leaks ENGINE OIL FILTER CHANGE NOTE Change engine oil with the engine warm and the motorcycle on its center stand to assure complete and rapid draining Stop the engine Remove the oil filler cap drain plug oil fitter bolt and oil filter cover LUBRICATiON OIL FILLER CAP DIPSTICK 0 MARK MARK OIL FILTER BOLT lIi OIL FILTER COVER After draining the oil complet...

Page 39: ...e engine up to normal operating tempera ture Stop the engine and remove the oil pressure switch Connect an oil pressure gauge to the pressure switch hole using attachment Start the engine and check the oil pressure OiL PRESSURE 100 kPa 1 0 kg cmZ 14 psi at idle speed 520 kPa 5 2 kg cmZ 74 psi at 5 000 min rpm Stop the engine Apply sealant to the pressure switch threads and install TORQUE 10 14 N m...

Page 40: ... the a rings and collars from the pump cover Remove the pump cover from the oil pump by removing the three screws and two bolts LUBRICATION FRONT ENGINE COVER OIL PUMP COVER Remove the inner nd outer rotors from the pump body Remove the dowel pins from the pump body OUTER ROTOR INNER ROTOR DQWE l PI NiSi ilila 2 5 ...

Page 41: ... the pump body SCAVENGING PUMP REMOVAL Remove the rear engine cover Remove the clutch outer Page 8 12 Remove the scavenging pump by removing the three mount bolts Remove the pump cover from the pump by reo moving the three screws 2 6 HONDA GL12000 GL1200A Oil PUMP BODY j SCREWS ...

Page 42: ...me manner TIP CLEARANCE Measure the rotor tip clearance SERVICE LIMIT MAIN SCAVENGE 0 35 mm 0 014 in LUBRICATION 0 BODY CLEARANCE Measure the pump body clearance SERVICE LIMIT MAIN SCAVENGE 0 41 mm 0 016 in END CLEARANCE Measure the end clearance using a straight edge and feeler gauge as shown SERViCE LIMIT MAIN SCAVENGE 0 12 rnm 0 005 in 2 7 ...

Page 43: ... PIN SCAVENGING PUMP INSTALLATION Clean all removed parts thoroughly and dip them in clean engine oil before they can be reassembled Install the dowel pins and gasket on the pump body Install the cover on the pump body aligning the tabs on the drive guide with the grooves in the inner rotor Install and tighten the the three cover screws GASKET DOWEL PINS TABS Coat the O ring and engine case gromme...

Page 44: ... INSTAllATION Clean and dip all removed parts in clean engine oil before they can be rea embled Install the dowel pins and gasket on the engine case Install the pump body on the engine case Insert the washer and dowel pin onto the pump drive shaft LUBRICATION MOUNT BOLTS GASKET WASHER DOWEL PIN i S 1i 0 PUMP BODY 2 9 ...

Page 45: ...r into the outer rotor DOWEL PINS GROOVES Install the oil pump cover and tighten the cover screws and bolts TORQUE 10 12 N m 1 0 1 2 kg m 7 10 ft lb BOLTS at Iujj FRONT ENGINE COVER INSTALLATION Check that the neutral stopper arm is aligned with the neutral cut Qut in the stopper plate properly Check that the longer pin of the gearshift sensor is aligned with the index mark on the sensor body 2 10...

Page 46: ...bolts in a crisscross pattern in 2 3 steps GEARSHIFT FRONT ENGINE COVER SENSOR WIRE GASKET Install the dowel pins and a new gasket on the engine cover Install the radiator and water pump cover and tighten the cOver bolts TORQUE 8 12 N m 0 8 1 2 kg m 6 9 ft lb Fill the engine with the recommended oil up to the proper level Page 2 3 Fill the system with coolant and bleed air from the radiator Page 6...

Page 47: ...ake Lever Pivot Clutch Lever Pivot Speedometer Gearbox Swil lg Arm Pivot Bearings and DU Seals Final Driven Flange BoilS Threadsl Multipurpose Grease Front and Rear Wheel Bearings Rear Wheel Bearing Dust Seal Lips ThrOllle Grip Sliding Surface Canter Stand Pivot SIde Stand Pivol Brake Pedal PiVOt Seal Adju l Lever Pivot Seat Sliding Surfaces Fool Pivol Drive Shalt Universal Joint Molybdenum Disulf...

Page 48: ...3 15 3 16 3 16 3 17 3 17 3 18 3 18 3 20 3 20 3 21 3 22 3 22 Support Ihe mOlOrcycle on the center stand on a leJoel slIrfau before starting any ork When the engine must be running to do some ork make sure the Ofeo is well enliloled Nel n run the engine in a closed area The exhaust contains poisonous carbon mOnoxide gas SPECIFICATIONS Frame Throttle grip free play Final gear oil Brake fluid Clutch f...

Page 49: ...min I rpm HONDA 4 stroke oil or equivalent API Service classification SE or SF The viscosities shown in the chart may be used when the average temperature in your riding area is within the indicated range OIL VISCOSITIES Single grade Engle oil capacity Carburetor vacuum difference TOOLS Vacuu gauge Vacuum gauge adaptor A Vacuum gauge adaptor B 3 2 I d E t 1 7 i F 3 2Q 3 4 US qt 2 8 Imp qtl After d...

Page 50: ...ed performance Alternator voltage low or battery low Ignition system faulty Intake pipe leaks Not enough fuel Valve springs weak or broken Cylinder head gasket blown MAINTENANCE Misfires at idie Dirty air cleaner Spark plugs gapped incorrectly Spark plug caps faulty Ignition cables deteriorated Carburetor problems choke clogged jets high float level etc Mid range performance poor Incorrect spark p...

Page 51: ...RIVE SHAFT JOINT L 3 12 I FINAL DRIVE OIL 1 I R 3 12 BATTERY I MONTH I I I I I I I I 3 13 BRAKE FLUID MONTH I I 1 1 R I I R 3_14 2 YEARS R BRAKE PAD WEAR I I I I 1 I 3 14 BRAKE SYSTEM I 1 I 1 3 15 BRAKE LIGHT SWITCH I 1 1 I 3 16 HEADLIGHT AIM 1 1 1 I 3 16 CLUTCH FLUID MONTH I I I I I R I 1 R 3 17 2YEAR R CLUTCH SYSTEM I I 1 I I 3 17 SIDE STAND I I I 3 18 SUSPENSION I I I I 3 18 AIR PUMP ELEMENT NO...

Page 52: ...ammable and s explosive under certain conditions Do not smoke or allow flames or sparks in your working area Remove the fuel filter bracket and loosen the hose clamps at each end of the filter Pull the fuel lines off the filter and install a new filter with the arrow on the body pointing toward the fuel pump Install the fuel filter bracket on the filter and tighten securely Route the fuel line und...

Page 53: ...ottle grip free play adjustments with the middle cable adjuster after removing the air cleaner cover To make adjustments with either adjuster loosen the lock nut turn the adjuster as reQuired and tighten the lock nut Recheck throttle operation and install all removed parts HONDA GL1200D GL1200A LOCK NUT CARBURETOR CHOKE ADJUSTER CHOKE LEVER LOCK NUT The GOLD WING choke system uses a fuel en richen...

Page 54: ...ions VALVE STROKE 6 7 mm 0 2 0 3 in To adjust loosen the lock nut and turn the adjuster as required Tighten the lock nut MAINTENANCE LOCK NUT ADJUSTER BREATHER TUBE AIR CLEANER Open the top compartment cover and lift out the tool tray Remove the fuse box from the holder Disconnect the breather tube from the air cleaner case Remove the wing nut and air cleaner cover Pull out the air cleaner element...

Page 55: ...tool tray and close the top compartment cover CRANKCASE BREATHER Loosen the drain tube lower clamp Remove the storage tank mounting bolt and remove the storage tank Empty any deposits from the tank and reinstall the storage tank NOTE Service more frequently when riding in rain or at full throttle r j HONDA Gl1200D Gl1200A AIR CLEANER MOUNTING BOLT 3 8 ...

Page 56: ...ire type feeler gauge SPAR K PLUG GAP 0 8 0 9 mm 0 031 0 035 in Adjust by bending the side electrode carefully With the plug washer attached thread each spark plug in by hand to prevent crossthreading Continue tightening by hand until the spark plug bottoms Then tighten the spark plugs another 1 2 turn with a spark plug wrench to compress the plug washer Connect the spark plug caps Install the spa...

Page 57: ...the base Start the engine and fev it up several times Recheck the synchronization and idle speed Install the removed parts CARBURETOR IDLE SPEED NOTE Inspect and adjust idle speed after all other engine adjustments are within specifica tions The engine must be warm for accurate adjustment Ten minutes of stop and go riding is sufficient Warm up the engine shift to NEUTRAL and place the motorcycle o...

Page 58: ...he way A void scalding ne e remol e the radiator cap hen the engine is hot The coolant is under pressure If the reserve tank is empty remove the top com partment and radiator cap Run the engine for 2 3 minutes to allow air to escape Fill the radiator with coolant and install the cap Fill the reserve tank to the UPPER level line and install the cap Install the top compartment RADIATOR CORE Remove t...

Page 59: ...aft and final gear case Section 14 FINAL DRIVE Oil INSPECTION Place the motorcycle on its center stand on level ground Remove the ojl filler cap Check that the oil level is slightly lower than the lower edge of the oil filler cap hole Check for leaks if the level is low Pour fresh re commended oil through the oil filler hole until it reaches the lower edge DRAINING With the motorcycle on its cente...

Page 60: ...attery fluid level for each cell When the fluid level nears the lower level refill with distilled water to the upper Jevel NOTE Add only distilled water Tap water will shorten the service life of the battery MAINTENANCE LOWER LEVEL MARK Replace the battery if sulfation forms or sediments accumulate on the bohom Make sure the battery breather tube is routed as shown by illustration on the battery c...

Page 61: ...r has been turned so that the reservoir is level Do not mix different types offluid as they are not compartible with each other Avoid spilling fluid on painted surfaces and wind screen Place a rag ore the painted surfaces and wind screen whenever the system is serviced Refer to section 15 for brake bleeding procedures BRAKE PAD WEAR FRONT BRAKE PAD INSPECTION Inspect the pads visually from the dir...

Page 62: ...s as a set to assure cren disc pressure BRAKE SYSTEM Inspect the brake hoses metal lines and fittings for deterioration cranks and signs of leakage Tighten any loose fittings Replace hoses metal lines and fittings as required BRAKE PEDAL HEIGHT Adjust brake pedal height so the pedal is 0 5 mm 0 1 5 in above the upper surface of the footpeQ CAUTION Incorrect brake pedal height can cause brake drag ...

Page 63: ...t begins Adjust by holding the switch body and turning the adjusting nut Do not turn the switch body NOTE The front brake light switch does not require adjustment HEDLIGHT AIM NOTE Adjsut the headlight beam as specified by local laws and regulations An improperly adjusted headlight may blind oncoming drivers or it may foil to light the road for a safe distance To adjust the headlight vertically tu...

Page 64: ... e tile cover until tile hand lebar has been turned so that the reservoir is level Do not mix different types of fluid as they are not compartjble with each other Avoid spilling fluid on painted surfaces and wind screen Place a fag over the painted surfaces and wind screen whenever the system is serviced MAINTENANCE ADJUSTING STRE W __ UPPER LEVEL MARK LOWER LEVEL MARK CLUTCH SYSTEM Inspect the cl...

Page 65: ...Make sure the force required to fold up the side stand is within 2 0 3 0 kg 4 4 6 6 Ib when pulling with a spring scale as shown Lubricate the side stand pivot SUSPENSION Do nOl ride 0 ehicle with faulty suspension Loose worn or damaged suspension parts impair i ehicle stobility and control FRONT Check the action of the front forks by compressing them several times Check the entire fork assembly f...

Page 66: ...stand Check the swing arm for damage Move the rear wheel sideways with force to see if the swing arm bearings are worn Replace the bear ings if there is any looseness Check the shock abosrbers for leak or damage Inspect the air hoses for deterioration and cracks Replace parts as required Tighten all nuts and bolts Remove the air vaille cap and inspect the air pres sure Inspect the air pressure by ...

Page 67: ... A fire or explosion could result Soak the element in clean gear oil AE 80 or 90l and squeeze out the excess Reinstall the element in the housing and push the cap onto the housing until it snaps closed WASH IN SOLVENT SQUEEZE OUT SOLVENT THOROUGHLY GEAR OIL SAE80 901 SQUEEZE OUT EXCESS OIL AIR DRIER lGL1200Al Remove the right fairing pocket and pull off the drier cover Inspect the desiccant color ...

Page 68: ... retainer plate and spring seat Clean and dry the sponge filter Install the sponge filter into the drier cover Install the drier cover alJd tighten the screws securely Install the drier and right fairing pocket NUTS BOLTS FASTENERS Check that all chassis nuts and bolts are tightened to their correct torque values Page 1 6 at the intervals shown in the Maintenance Sdledule Page 3 4 Check all coner ...

Page 69: ...t the center of the tires Replace the tires if the tread depth reaches the foHowing limits Minimum tread depth Front 1 5 mm 1 16 in Rear 2 0 mm 3 32 in STEERING HEAD BEARINGS Raise the front wheel off the ground using a jack under the engine While holding the fork sliders check that the front wheel turns freely and smoothly from full left to full right Push and pull on the sliders and check that t...

Page 70: ... HONDA GL1200D GL1200A MEMO ...

Page 71: ...FUEL SYSTEM HONDA GL1200D GLI200A 4 0 ...

Page 72: ...oline from the chambers before removing the carburetors The flolt chambers can be removed without separate each carburetors The carburetors can be removed and disassembled without disturbing the synchronization adjusting screws Always replace used a rings and cotter pins with new ones SPECIFICATIONS Carburetor type VO type Throttle valve bore 32 mm 1 26 in Venturi bore 30mm 1 18in Idle speed 950 1...

Page 73: ...nt blocked Fuel strainer screen clogged Restricted fuel line Intake air leak Restricted or faUlty fuel pump 4 2 HONDA GL1200D GL1200A 07410 0010000 Engine idles roughly stalls or runs poorly Air cleaner clogged Ignition malfunction Carburetors not synchronized Fuel contaminated Intake air leak Idle speed incorrect Rich mixture Lean mixture Low cylinder compression Incorrect pilot screw adjustment ...

Page 74: ...e air cleaner case by removing four screws Remove the element holder from the air chamber Disconnect the vacuum tube from the 3 way joint 3 WAY JOINT FUEL OUTLET LINE Remove the right and left carburetor covers Disconnect the fuel pump outlet line from the fuel pump Disconnect the spark plug caps from the spark plugs and wire clamps Remove the eight intake pipe lo head bolts 4 3 ...

Page 75: ... NOTE Seal the cylinder head inlet ports with tape or a clean cloth the keep dirt and debris from entering the intake ports Place a shop towel over the left cylinder head to prevent the cylinder head cover from damage Move the carburetors and air chamber as an as sembly to the left side and disconnect the throttle cables Loosen the choke cable clamp screw and disconnect the choke cable from the ch...

Page 76: ...for precise alignment CARBURETOR SEPARATION Remove the cotter pin washers and plastic collar from the linkage at No 3 or No 4 carburetor Disconnect the throttle link arm from the carbure tor Remove the cotter pin washers and plastic washers from the choke linkage rod at No 1 or No 4 car buretor starter valve arm Disconnect the choke linkage rod from the starter valve arm FUEL SYSTEM THROTTLE LINK ...

Page 77: ...ge sub rod from starter valve arm Remove the four bolts securing each carburetor to the air chamber Remove the flame traps from the air chamber Remove the carburetors from the air chamber Remove the seal rings and dowel pins from each carburetor 4 6 HONDA GL12000 GL1200A COTTER PIN CHOKE LINKAGE SUB ROD BOLTS SEAL RINGS DOWEL PINS ...

Page 78: ...niza tion adjusting screw CARBURETOR DISASSEMBLY VACUUM CHAMBER REMOVAL Remove the four vacuum chamber cover screws and cover FUEL SYSTEM FUEL JOINT PIPE AIR JOINT PIPE AIR VENT JOINT PIPE VACUUM CHAMBER COVER Remove the compre sion spring diaphragm and vacuum piston Inspect the vacuum piston for wear nicks scratches or other damage Check the diaphragm for deterio ration and tears Make sure the pi...

Page 79: ...on CiJ aoNDA GL1200D GL1200A JET NEEDLE HOLDER Inspect the jet needle for excessive wear at the tip and for bending or other damage FLOAT CHAMBER REMOVAL Remove the float chamber body Pull out the float arm_ pin with a pair of pliers Remove the float and float valve 4 8 VACUUM PISTON JET NEEDLE SPRING F rL OAT FLOAT ARM PIN JET NEEDLE HOLDER FLOAT VALVE ...

Page 80: ...tor body Clean the strainer with clean solvent vlake sure the sealing washer is in good condition FUEL SYSTEM FLOAT VALVE SEAT Remove the main jet main jet holder and slow jet from the carburetor body CAUTION Do IlOt try to remore the leedle jet from the carburetor body nle needle jet is pressed in the carburetor body MAIN JET HOLDER SLOW JET MAIN JET 4 9 ...

Page 81: ...Check the valve spring for weak or damage STARTER VALVE SPRING VALVE SEAT WASHER D RING 0 o SPRING PILOTSCAEW Damage to the pilot screw seQ will occur if the pilot screw is tightened against the seal Remove the pilot screws and inspect them Replace them if they are worn or damaged CAUTION Turn each pilot screw in and carefully count the number of turns before is seats lightly Make a note of this t...

Page 82: ... CENTER COLLAR INSTALLATION Remove the throttle linkage by removing linkage center bolt Remove the linkage as an assembly from the air chamber Remove the cotter pin and washer from the throttle drum and remove the throttle linkage from the throttle drum REMOVAL The main throttle retum spring will unwind when the linkage is removed Note its position for proper reassembly THROTTLE LINKAGE CAUTION Ap...

Page 83: ...crews and return them to their original position as noted during removal CAUTION Damage to the pilot screw seat occurs if the pilot screw is tightened against the seat Perform pilot screw adjustment if new pilot screws are installed page 4 16 NOTE If you replace the pilot screw in one carbure tor you must replace the pilot screws in the other carburetors for proper pilot screw adjustment 4 12 D RI...

Page 84: ...e carburetor pairs No 1 3 and 2 4 FUEL SYSTEM SPRING FUEL JOINT PIPE AIR JOINT PIPE AIR VENT JOINT PIPE Insert the throttle arm of No t or No 2 carburetor between synchronization adjusting screw and arm spring Install the thrust spring between throttle arm pivot of each carburetors Make sure the fuel joint and air joint pipes are securely installed ARM SPRING 4 13 ...

Page 85: ...st touching the valve measure the float valve with the float level gauge Adjust if necessary by bending the float arm care fully FLOAT LEVEL 7 5 mm 0 30 in CARBURETOR INSTALLATION Install the intake pipes on the carburetors but do not tighten the hose clamps until the complete system is installed on the engine Install the cover on the air chamber NOTE Install the cover with FRONT mark facing forwa...

Page 86: ... position FUEL SYSTEM SCREW CHOKE CABLE CHOKE LINKAGE END Install the carburetor air chamber system on the engine from the left side Reconnect the throttle cables while the linkage is accessible before final positioning is made Complete the installation of the carburetor air chamber system in the reverse order of removal Check and adjust the carburetors after installation Carburetor synchronizatio...

Page 87: ...rew 1 2 turn out from the initial setting 6 If the engine speed increases by 50 rpm or more turn each pilot screw out by a continual 1 2 tum until engine speed drops by 50 rpm or less 7 Adjust the idle speed with the throttle stop screw 8 Turn the No 1 carburetor pilot screw in until the engine speed drops 50 rpm 9 Turn the NO 1 carburetor pilot screw 1 tum out from the position obtained in step 8...

Page 88: ...from the frame Remove the rear brake reservoir from the frame FUEL SYSTEM Remove the bolt holding the fuel filter bracket to the fuel tank Turn the fuel valve off and remove fuel valve from the fuel tank Remove the fuel tank mount bolt FUEL VALVE MOUNT BOLT 4 17 ...

Page 89: ... pump relay from the coupler Short the white and black wire terminals at the fuel pump relay coupler with a jamper wire Disconnect the fuel pump out let line at the 3 way joint and hold a graduated beaker under the tube Turn the ignition switch on and let fuel flow into the beaker for 5 seconds then turn the ignition switch off Multiply the amount in the beaker by 12 to determine the fuel pump flo...

Page 90: ...her erid to check that air flows through the outlet tube into the air chamber With the specified amount of vacuum applied to the diaphragm check that no air flows through the outlet tube SPECIFIED VACUUM 420 480 mm 16 5 18 9 in Hg Apply the same procedures to the remaining outlet tube REPLACEMENT FUEL SYSTEM SLOW AIR CUTOFF VALVE VACUUMPUMP Remove the cover spring and diaphragm Use compressed air ...

Page 91: ...1 8 2 5 kg m 13 18 ft lb I _ _ JO 40N m 3 0 4 0 kg m 22 29 ft Ib 55 65 N m 5 S 6 S kg m 40 47 ft lbl 5 0 U HONDA GL1200D GL1200A 55 65 N m b 5 5 6 5 kg m 40 47 ft lb n J I 18 25 N m 1 B 2 S kg m 13 18 ft lb 30 40N m 3 0 4 0 kg m 22 29 ft Ib ...

Page 92: ...stem The lower left frame tube sub frame is removable to facilitate engine removal SPECIF ICATIONS Engine oil capacity Engine oil recommendation Coolant capacity Radiator and engine Engine weight TOROUE VALUES Engine mount bolt nut 12 mm 10mml 8mm Sub frame cap nut Left footpge cap nut Exhaust pipe joint nut Muffler joint bolt Coolant drain plug Engine oil drain plug 4 02 4 2 US qt 3 5 Imp qt afte...

Page 93: ... battery Remove the radiator section 6 Disconnect the spark plug wires from the spark plugs Remove the carburetor section 4 Remove the exhaust pipes and engine guards Disconnect the starter motor cable from the starter motor 5 2 iJ HONDA GL12000 GL1200A EXHAUST PIPE I STARTER MOTOA CABLE ...

Page 94: ...se generator con nectors PULSE GENERATOR ALTERNATOR CONNECTOR CONNECTOR CRANKCASE BREATHER TUBE CLAMPS FAN MOTOR SENSOR CONNECTOR FAN MOTOR WIRE BAND SUB HARNESS SHIFT SENSOR WIRE Disconnect the shift sensor and fan motor sensor connectors Release the shift sensor wire and fan motor sub harness from the wire band and clamp 5 3 ...

Page 95: ...tch slave cylinder from the engine NOTE Squeeze the clutch lever once and keep it in this position by tying it to the handlebar grip to prevent the stave cylinder piston from over stroke caused by fluid gravity Remove the two fro t engine mount bracket bolts 5 4 HONDA GL1200D GL1200A CLUTCH SLAVE CYLINDER ...

Page 96: ... bolt and cap nuts ENGINE REMOVAL INSTALLATION FRONT ENGINE MOUNT BRACKET ENGINE MOUNT BOLTS CAP NUT CAP NUTS Place a floor jack or other adjustable support under the engine NOTE The jack height must be continuously adjust ed so that mounting bolts can be removed and so stress is relieved from other bolts until they are removed Remove the engine mount bolts 5 5 ...

Page 97: ... hose from the hose clamp Adjust the jack and move the engine forward or frame rearward to disengage the output shaft from the universal joint Move the engine out of the frame CAUTION Be careful not to damage tlte brake lines during remOI a 5 6 HONDA GL1200D GL1200A CLUTCH HOSE UNIVERSAL JOINT ...

Page 98: ...haft into the universal joint by moving the engine backward CAUTION Carefully align mounting points with the jack to prevent damage to mounring bolt threads wire hanless Qnd cables Hand tighten mounting bolts and nuts and install parts noted in this order 1 The lett and then the right rear mount bolts 2 The sub frame footpeg and sub frame bolts 3 The forward mount bolt 4 The right and left side mo...

Page 99: ... ft Ib Left side only 2 30 40 N m 3 0 4 0 kg m 22 29 ft Ibl Left side only 3 55 65 N m 5 5 6 5 kg m 40 47 ft Ib 4 55 65 N m 5 S 6 S kg m 40 47 ft Ib 5 18 25 N m 1 8 2 5 kg m 13 18 ft lb 6 30 40 N m 3 0 4 0 kg m 22 29 ft lb 7 30 40 N m 3 0 4 0 kg m 22 29 ft lbl 8 18 25 N m 1 8 2 5 kg m 13 18ft lb 5 8 L Cif HONDA GL1200D GLI200A ...

Page 100: ... rAJ HONDA GLI200D GLI200A MEMO ...

Page 101: ...COOLING SYSTEM r iJ HONDA GL1200D GL1200A 6 0 ...

Page 102: ...ed water 55 ethylene glycol 44 5 C 48 F Coolant capacity After disassembly 2 15 liters 2 3 US qt 1 91mp qt Reserve tank 0 55 liters 0 6 US qt 0 5 Imp qt After draining included reserve tank 2 7 liters 2 9 US qt 2 4 Imp qt Thermostat 8egins to open 80 to 84 C 176 to 183 F Fully open 93 to 97 C 199 to 20S F Valve lift Minimum of 8 mm at 95 C 0 315 in at 203 F Boiling point with 50 50 mixture Upressu...

Page 103: ...fied pres sure for at least six seconds NOTE Before installing the cap on the tester mois ten the sealing surfaces RADIATOR CAP RELIEF PRESSURE 75 105 kPa to 7S l 0S kg cm2 10 7 14 9 psi RADIATOR LEAKAGE TEST Pressurize the radiator engine and hoses and check for leaks CAUTION Excessive pressure can damage the radiator Do not exceed 105 kPa I 05 kg cm1 14 9 psi Repair or replace components if the ...

Page 104: ... Ib COOLING SYSTEM t DRAIN PLUG Fill the system with a 50 50 mixture of distilled water and ethylene glycol Start the engine with the radiator cap off and run until there are no air bubbles in the coolant and the coolant level stabilizes Stop the engine and add coolant up to the proper level if necessary Reinstall the radiator cap Check the level of coolant in the reserve tank and fill to the corr...

Page 105: ...mps Remove the radiator cap from the radiator Disconnect the siphon tube from the radiator Remove the wate pump cover from the front engine cover Remove the water pump colier from the lower hose Remove the two radiator mounting nuts and fairing brackets 6 4 Cif HONDA GL1200D GL1200A HOSE CLAMP HOSE CLAMPS RADIATOR CAP SIPHON TUBE RADIATOR MOUNTING NUTS WATER PUMP COVER ...

Page 106: ...he radiator CAUTION Be careful not ro damage the radiator IllS by radiaror mounting stud DISASSEMBLY Remove the four fan motor mount bracket bolts and the fan and motor FAN MOTOR INSPECTION Disassemble the fan motor from the fan Use a 12V battery to energize the motor and check its operation The motor should run freely COOLING SYSTEM FAN MOTOR FAN 6 5 ...

Page 107: ... is essentially the reverse order of removal NOTE Replace the water pump cover gasket with new one Check the radiator for leaks after installation page 6 2 Fill the system with coolant and bleed air from the radiator page 6 3 Install the removed parts 6 6 HONDA GL12000 GL1200A FAN MOTOR MOUNT FAN MOTOR FAN COOLING SYSTEM TESTER COMMERCIALLY AVAILABLE ...

Page 108: ...t or thermometer touch the pan or false readings will result Technical Data Starts to open I 80 to 84 C 176 to 183 F Full open 93 to 97 e 199 to 20S Fl Valve 11ft 8 mm 0 31 in minimum NOTE Replace the thermostat if the valve stays open at room temperature or if it responds at temperatures other than those specified Valve lift must be checked by applying heat for five minutes WATER PIPE DISASSEMBLY...

Page 109: ...ly sealant to the thread of the coolant tempeature sensor and thermostatic fan motor switch before installation 00 not damage the a rings during installation WATER PIPE JOINT Q RINGS WATER PIPE THERMOSTAT HOUSING WATER PIPE WATER PIPE JOINT a RING I THERMOSTAT COVER COOLANT TEMPERATURE SENSOR 21 25 N m 2 1 2 5 kg m 15 18 ft lbl THERMOSTATIC FAN O MOTOR SWITCH 24 32 N m 2 o 0 6 8 ...

Page 110: ...the three water pump retaining bolts and water pump NOTE Use new sealing washers when installing the water pump COOLING SYSTEM WATER PUMP COVER COOLANT DRAIN PLUG RETAINING BOLTS Inspect the pump for worn bearings loose shaft or damaged impeller Do not try to repair the water pump If it is worn or damaged replace it WATER PUMP DRIVE SHAFT IMPELLAR 6 9 ...

Page 111: ...CYLINDER HEAD VALVE 2l if 25 29N m 2 5 2 9 kg m 18 21 ft Ib 7 0 ji HONDA GL12000 GL1200A 18 22 N m Q 1 8 2 2 k m 13 16 ft lbl 00 oi lf O 8 1 2 kg m 6 9 ft lb ...

Page 112: ...during eassembly which otherwise would allow air to enter the hydraulic tappet adjusters Air in the hydraulic tappet adjuster causes excessive tappet noises Remove the adjuster and bleed air if there is air in any adjuster Use a sounding rod or a stethoscope to diagnose the trouble if the top end is noisy Adjust the hydraulic adjsuter holder with shim if any of the following parts is replaced Cyli...

Page 113: ...6 6 mm Shim selection gauge 07925 3710200 07973 MJOOOOO or 07973 ME90000 07984 5510000 07974 MG90000 Common Valve spring compressor Valve guide remover 6 6 mm 07757 0010000 07742 0010200 TROUBLESHOOTING Engine top end problems can be diagnosed by a compression test or by tracing noises with a sounding rod or stethoscope low compression or uneven compression Valves Sticking hydraulic tappet adjuste...

Page 114: ...IVEN PULLEY CYLINDER HEAD VALVE CRANKSHAFT Identify each belt as left or right and also mark its direction of rotation Mark the crankshaft pulley with tape or felt tip pen to indicate T D C No 1 cylinder PULLYMARK Loosen the tensioner bolts then slip off the right and left belts in that order CAUTION To prevent belt damage do not use sharp lools such as a screwdriver 0 pry ot belrs Do not tum the ...

Page 115: ...ng is evident Inspect the belt tensioners for free movement and smoothness of bearings in rollers CAMSHAFT REMOVAL Install the Pulley Holder then unscrew the cam pulley bolt and remove the driven pulley 7 4 Ciff HONDA GL1200D GL1200A WORN BELT TOOTH Inspect the belt teeth for wear Inspect for jacket separation I PULLEY HOLDER 07925 3710200 DRIVEN PULLEY ...

Page 116: ...R HEAD VALVE CYLINDER HEAD COVER Remove the camshaft end covers from the rear of the cylinder heads Remove the cylinder head covers I DE FORMING CHAMBER COVERS Remove the de foaming chamber covers oil dis tribution plates and a rings from the rocker arm holders 01 L DISTRI BUT N P L lA T E 2 5 t ...

Page 117: ...ylinder head CAMSHAFT INSPECTION Inspect the cam bearing surfaces for scoring scratching or damage caused by insufficient lubri cation Check that the oil passages are clear Bolt the camshaft holder in place and torque the bolts TORQUE 18 22 N m 1 8 2 2 kg m 13 16 ft lb Measure and record the 1 0 of each bearing If the bearing is worn so that the service limit is exceeded replace the cylinder head ...

Page 118: ...en the 0 0 of a cam shaft journal and the 1 0 of its cam bearing the holder and cylinder head is the clearance The clearance may also be checked using plastigauge CYLINDER HEADIVALVE Check each cam lobe s height with a micrometer Replace the cam if the height is less than the service limit SERVICE LIMITS IN 35 6 mm 1 40 in EX 35 6 mm 1 40 in Set each camshah on a stand or Vee blocks Set a dial ind...

Page 119: ...cations Failure to place the shims back to their original locations can cause tappet noises or sticking valve Mark the camshaft holder components during disassembly so they can be installed in their original positions upon reassembly Remove the tappet adjuster from the camshaft holder Remove the adjuster cap from the hole on the inlet side NOTE Only the hydraulic valve adjusters controlling the in...

Page 120: ...arms Remove the center collar from between the right and left rocker arms Remove the shaft collars from the inlet side Remove the intake rocker arms by pressing the rocker arm shaft in Remove the intake rocker arm shaft by screwing in a 5 mm forcing bolt CYLINDER HEADIVALVE CENTER COLLAR ROCKER ARM SHAFT INTAKE ROCKER ARM SHAFT 7 9 ...

Page 121: ...IT IN EX 13 84 mm 0 545 in ROCKER ARM INSPECTION Inspect the rocker arms for wear or damage to the slipper and stem contacting faces Measure the I D of each rocker arm SERVICE LIMIT IN EX 14 05 mm 0 553 in ASSIST SPRING SHAFT INSPECTION Inspect each assist shaft and spring for wear or damage Measure the free length of each assist spring SERVICE LIMIT 16 0 mm a 53 in 7 10 ASSIST SHAFT ASSIST SPRING...

Page 122: ...ght while compressing and extending the adjuster Continue operating the adjuster until there are no air bubbles from the adjuster and it does not make no further action Remove the adjuster and try to compress quickly the adjuster by hand Measure the compression stroke with the dial gauge on the flat place COMPRESSION STROKE 0 0 3 mm 0 0 012 in NOTE Keep the adjuster below the surface of kerosene w...

Page 123: ...nuts and coolant joint pipe bolts Disconnect spark plug wires and remove spark plugs Remove the muffler rear mounting bolts and remove the exhaust system Ci f HONDA GL1200D GL12DOA COOLANT JOINT PIPE EXHAUST PIPE INTAKE PIPES Support the intake pipes with bungee cords Remove the cylinder head bolts then remove the cylinder head 7 12 CYLINDER HEAD BOLT ...

Page 124: ... Remove retainers springs and valves NOTE I Keep valves and related parts in order Clean gasket material from the cylinder head NOTE Gaskets will come off easier if soaked in solvent or sprayed with gasket remover CYLINDER HEAD INSPECTION Clean carbon deposits from the combustion chamber and exhaust ports then check the spark plug holes and valve areas for cracks NOTE Do not damage the valve seats...

Page 125: ...orner to corner Check the cylinders for warpage across the head mating surface with a straight edge and feeler gauge SERViCE LIMIT 0 10 rom O OO4 in NOTE Check for warpage in an X panern from corner to corner VALVE SPRING INSPECTION Measure the valve spring free length SERVICE LIMITS Inner spring 39 0 mm 1 54 in Outer spring 42 5 mm 1 67 in 7 14 HONDA GL12000 GL1200A ...

Page 126: ...o remove carbon deposits Measure and record the I D of each valve guide SERViCE LIMIT 6 64 mm 0 261 in Calculate the valve stem to guide clearanca SERViCE LIMITS Intake 0 08 mm 0 003 in Exhaust 0 10 mm 0 004 in If the stem ta guide clearance exceeds the service limits determine if a new guide would bring the clearance within tolerance If so replace any guides as necessary and ream to fit if cleara...

Page 127: ... Drive in new guides from the rocker arm side of the cylinder head NOTE Cylinder head heat should still be at 100 C 212 F for installation of the new guides Ream the new guides to finished size using a reamer NOTE Use cutting oil on reamer during this pro cedure It is important that the reamer aways be rotated in the cutting direction when it is inserted or removed Clean all cutting residue out of...

Page 128: ... and seat using a rubber hose or other hand lapping tool Remove the valve and inspect the face CAUTION The valves cannot be ground If the I oll e face is rough wom unevenly or confacts rhe seat improperly the ralve must be replaced CYLINDER HEADIVALVE If the seat is too wide too rough or has low spots the seat must be ground VALVE SEAT CUTTERS i FACE STANDARD VALVE SEAT WIDTH 1 4 mm 0 06 in TOOL N...

Page 129: ...5 degree cutter when the valve guide is replaced OLD SEAT WIDTH Use a 32 degree cutter remove 1 4 of the existing valve seat material Use a 60 degree cutter to remove the bottom 1 4 of the old seat Remove the cutter and inspect the area you have just removed 32 Install a 45 degree finish cutter and cut the seat to the proper width VALVE SEAT WIDTH 1 4 mm O OS in 7 18 OLD SEAT WIDTH 1 4 mm 0 06 in ...

Page 130: ...o high on the valve the seat must be lowered uwing a 32 degree flat cutter If the contact area is too low on the valve the seat must be raised using a 60 degree inner cutter Refinish the seat to specifications using a 45 degree finish cutter CYLINDER HEADNALVE CONTACT TOO HIGH C ONTACTTOOLOW OLD SEAT WIDTH After cutting the seat apply lapping compound to the valve face and lap the valve using ligh...

Page 131: ...ems and install valve spring retainers and keepers The spring tightly wound coils should face in toward the cylinder head CAUTION To prevent loss of tel sion do riot compress rhe I oll e spn ng more l11QJl necessary a HONDA GL1200D GL1200A VALVE SEALS SPRING SEATS VALVE SPRING COMPRESSOR 07757 0010000 THESE ENDS TOWAD CYLINDER HEAD Tap the top of each valve with a plastic hammer to seat the keeper...

Page 132: ...ce in the cylinder NOTE Install the orifice with the small diameter end towards the inside Install the dowel pins and a new head gasket NOTE The head gasket is graphite coated and does not require any sealant Install the cylinder head and the head bolts NOTE I GASKET DOWEL PINS 01 L CONTROL ORIFICE O RING Coat the head bolt threads and the underside of the bolt heads with molybdenum disulfide grea...

Page 133: ...and shaft collars in their correct locations by referring to the identification marks made during dis assembly Clean the camshaft holder thoroughly and blow open all holes and passages with a compressed air Coat the all sliding surfaces with molybdenum disulfide grease 7 22 r iff HONDA GL1200D GL1200A ...

Page 134: ...AR Lon ROCKER SH1FT SHAFT ROCKER ARM Install the rocker arms rocker arm shafts and collars in the camshaft holder NOTE Align the cutout in the rocker arm shaft with the tappet adjuster mount opening SHtM SELECTION GAUGE 07947 MG90000 Install the center and side collars with the cutouts aligned with the bolt holes in the camshaft holder 7 23 ...

Page 135: ... on the end of the cam shaft Coat the outer peripheries of the oil seal and end cap with sealant and install the camshaft in the cylinder head Aling the keyway in the camshaft with the upper mating surface of the cylinder head KEY WAY OIL SEAL CAMSHAFT END CAP Install the camshaft holder and tighten the five bolts shown in a crisscross pattern in 2 3 steps TORQUE 18 22 N m 1 8 2 2 kg m 13 16 ft lb...

Page 136: ...oil distribution plate with compressed air Install the oil distri bution plate and tighten the camshaft holder 8 mm bolt and assist shaft spring bolts TORQUE Camshaft holder bolt 18 22 N m 1 8 2 2 kg m 13 16 ft lb Assist shaft spring bolt 8 12 N m 0 8 1 2 kg m 6 7 ft lb OIL DISTRIBUTION PLATE CAMSHAFT HOLDER BOLT 7 25 ...

Page 137: ... both of the pulleys is loose disassemble and inspect pulley keyways for wear GASKET 70 80 N m 7 0 8 0 kg m 51 58 ft Ib RIGHT TIMING BELT COVER BOLT KEY WAYS LEFT Install the woodruff key in the keyway in the cam shaft Install the driven pulley on the camshaft with the key in the camshaft aligned with the keyway in the driven pulley NOTE The right pulley should he installed so that its boss is fac...

Page 138: ...e drive pulley to the original position The T 1 marking on the flywheel should be aligned with the index mark on the engine case Install the right and left timing belt tensioners on the engine case and tighten the bolt just enough to allow smooth movement of the tensioner NOTE To protect the timing belts install the ten sioner springs with the ends facing towards the engine case as shown CAUTION D...

Page 139: ...terclockwise then 30 40 clockwise to bring it to the original position and align the T l mark on the flywheel with the index mark on the engine case Tighten the left tensioner bolts TORQUE 24 28 N m 2 4 2 8 kg m 17 20 ft lb Push the belt lower run midway between the pulleys with 2 kg 4 4 Ib force and make sure that belt slack is 3 5 mm 0 1 0 2 in Rotate the crankshaft clockwise 360 0 and re align ...

Page 140: ...ection Gauge and shim surface of the cam holder by inserting the gauge into the tappet adjuster mount hole NOTE Check that there is no clearance between the rocker arm and cam lobe and rocker arm and valve stem To prevent the incorrect shim selection by valve lifting make sure that the side move ment of the rocker arm during measure ment INTAKE EXHAUST NUMBER OF SHIMS 8 5 9 5 mm 10 5 11 5 mm 0 0 3...

Page 141: ...ters ollce they are filled with oil or kerosene Slide the exhaust valve tappet adjusters into the camshaft holder with the oil holes facing up Install the cap on each intake valve tappet adjust er and slide it into position in the camshaft holder with the cap facing up c i HONDA GL1200D GL1200A EXHAUST TAPPET ADJUSTER t CAP INTAKE TAPPET ADJUSTER Install the shims and stopper plugs TORQUE 23 27 N ...

Page 142: ... outer peripheries of the oil seal and end cap on the ends of the camshaft Install the cylinder head cover Coat the rubber areas of the cover bois with oil and torque the bolts TORQUE 10 14 N m 1 0 1 4 kg m 7 10 ft lbl Install the camshaft end cover Install the timing belt cover Coat the rubber areas of the cover bolts will oil and tighten the bolts TORQUE 10 14 N m 1 0 1 4 kg m 7 10 ft Ib CYLINDE...

Page 143: ...UTCH HONDA GL1200D GL1200A 7 11N m 0 7 1 1 kg m 5 8 ft Ib 8 12 N m 0 8 1 2 kg m 6 9 ft Ib V J I 9 J 8 2N m d if_ 0 8 1 2 kg m 6 9 ft Ib 10 14 N m O 1 4 k m 7 Ofl lb 25 35 N m 2 5 3 5 kg m 18 25 ft Ib 8 0 ...

Page 144: ...5 93 0 627 Piston 0 0 I 15 827 15 854 10 6231 0 6242 15 82 0 623 Clutch slave cylinder Cylinder 1 0 33 600 33 662 1 3228 1 32531 33 68 1 326J Piston 0 0 33 550 33 575 11 3209 1 3218 33 52 1 320 Clutch Spring free height 5 80 0 2281 5 5 1O 22 Disc thickness I 3 45 3 55 0 136 0 140 3 2 0 13 Plate warpage 0 3 0 012 Clutch fluid DOT4 TORQUE VALUES Clutch center lock nut Clutch hose bolt Clutch master ...

Page 145: ...h will not disengage Air bubbles in hydraulic system Low fluid level Hydraulic system leaking Hydraulic system sticking Plates warped 8 2 HONDA GL1200D GL1200A Motorcycle creeps with clutch disengaged Air bubbles in hydraulic system Low fluid level Hydraulic system leaking Hydraulic system sticking Plates warped Excessive lever pressure Hydraulic system sticking Lifter mechanism damaged Clutch ope...

Page 146: ... FILLING NOTE Do not mix different types of fluid since they may not be compatible BLEED VALVE Connect the Brake Bleeder to the bleed valve Pump the brake bleeder and loosen the bleed valve Add fluid when the fluid level in the master cylinder reservoir is low Repeat above procedures until air bubbles do not appear in the bleed hose NOTE If air is entering the bleeder from around the bleed valve t...

Page 147: ...e bleed valve TORQUE 4 7 N m 0 4 0 7 kg m 35 61 in Ib Fill the fluid reservoir to the upper level CLUTCH MASTER CYLINDER DISASSEMBLY Drain clutch fluid from the hydraulic system Remove the rear view mirror and clutch lever Disconnect the clutch switch wires and remove the clutch hose CAUTION A oid spilling clutch fluid on painted surfaces and wind screen Place a rag over he paimed surfaces and win...

Page 148: ...y Check the primary and secondary cups for damage or deterioration MASTER CYLINDER I D INSPECTION PRIMARY CUP df PISTON SECONDARY SPRING CUP CLUTCH Check the master cylinder for scores scratches or nicks Measure the master cylinder 1 0 SERVICE LIMIT 15 93 mm 0 627 in MASTER PISTON O D INSPECTION Measure the master piston D O SERVICE LIMIT 15 82 mm 0 623 inl 8 5 ...

Page 149: ...set Install the snap ring making sure it is seated firmly in the groove Then install the boot and push rod Install the clutch switch if it was removed Place the master cylinder on the handlebar Install the holder and the two mounting bolts Align the split between the master cylinder and holder with the punch mark on the handlebar Tighten the upper bolt first then tighten the lower bolt Install the...

Page 150: ...inder OIL BOLT CLUTCH SLAVE CYLINDER _ If piston removal is hard place a shop towel over the piston to cushion the piston when it is expelled and position the cylinder with the piston down App V compressed air to the fluid inlet to remove the piston Use the air in short spurts Remove the spring from the slave cylinder Remove the oil and piston seals Clean the piston groove with clutch fluid Check ...

Page 151: ...hes Measure the inside diameter of the cylinder bore SERVICE LIMIT 33 68 mm 1 326 in ASSEMBLY Assembly the slave cylinder in the reverse order of disassembly NOTE The all and plston seals must be replaced with new ones whenever they have been removed Apply brake fluid to the piston and piston seal Be certain the piston seal is seated in the piston groove Place the piston in the cylinder with the o...

Page 152: ...SEMBLY Remove the slave cylinder from the clutch cover and remove the lifter rod NOTE Squeeze the clutch lever once and keep it in this position by tying it to the handlebar grip to prevent the slave cylinder piston from over stroke caused by fluid gravity Remove the clutch cover Remove the gasket and dowel pins OIL BOLT LIFTER ROD SLAVE CYLINDER CLUTCH COVER CLUTCH Remove the tifter plate by remo...

Page 153: ...DD LOCK TAB WASHER CLUTCH CENTER HOLDER 07923 4610001 or MODIFIED 07923 4610000 I If use the 07923 4610000 anlage center hole to 39 rnm to provide clearance for the lock nut wrench Straighten the lab of the lock tab washer Remove the clutch center assembly from the clutch outer Remove the clutch center lock nut then remove the lock washers NOTE LOCK NUT WRENCH 26 x 30 mm 07716 0020303 8 10 ...

Page 154: ...han necessary o remove the stopper ing Remove the clutch plates clutch damper plate discs and pressure plate from the clutch center OIL SEAL DRIVER ATTACHMENT 0796S MA 10200 STOPPER RING CLUTCH Measure the height of the clutch spring SERVICE LIMIT 5 5 mm 0 22 in Measure each clutch disc thickness SERVICE LIMIT 3 2 mm 0 13 in Replace any discs that are damaged discolored or thinner than the service...

Page 155: ...e Check the slots in the clutch outer for nicks cuts and indentations made by the friction discs If the surfaces are not smooth or there is evidence of other damage replace the clutch outer CLUTCH OUTER NOTE The clutch outer cannot be removed with the engine in the frame Refer to Section 5 for engine removal Remove the rear engine cover Page 9 31 Remove the spline washer from the clutch outer Pry ...

Page 156: ... order of removal NOTE Install the snap ring with the sharp end facing towards the outside Tighten the oil pump driven sprocket bolt to 7 11 N m 0 7 1 1 kg m 5 8 ft lb torque CLUTCH ASSEMBLY Coat the discs and plates with clean engine oil Install the clutch center plates discs and pressure plate as shown CLUTCH DISC 9 pes STOPPER RING Ii D IAPHRAG RING I fP I o SPRING SEAT PRESSURE PLATE CLUTCH CE...

Page 157: ... bo of the clutch center Install the center lock nut with the taper end facing towards the inside Install the clutch center assembly in the clutch outer Install the lock washer with the marking OUT SIDE facing out Place the diaphragm spring on the clutch center and compress the spring in a press just enough to install the stopper ring To prevent Q loss of tension do not compress the diaphragm spri...

Page 158: ...47 ft lb Bend the tab of the lock tab washer up into the groolle in the lock nut CLUTCH Install the liter plate and tighten the six bolts in a criss cross pattern in 2 3 steps TORQUE 10 14 N m 1 0 1 4 kg m 7 10 ft lb Install the dowel pins and a new gasket GASKET DOWEL PINS 8 15 ...

Page 159: ... TORQUE Bolt 10 14 N m 11 0 1 4 kg m 7 10 ft Ibl Nut 8 12 N m 0 8 1 2 kg m 6 9 ft lbl Install the lifter rod Release the clutch lever from the handlebar grip and push the slave cylinder piston in all the way Install the clutch slave cylinder 8 16 CLUTCH COVER HONDA GL1200D GL1200A ARROW MARK ...

Page 160: ...Q HONDA GL12000 GL1200A MEMO ...

Page 161: ...CH REAR ENGINE COVER 10 14 N m 1 0 1 4 kg m 7 10 ft lb 0 23 27N m 2 3 2 7 k m 17 20 ft lb o J 2l 45 75 N m 4 5 7 5 kg m 33 54 ft Ibl 8 12 N m 0 8 1 2 kg m 6 9 ft Ib 10 14 N m 1 0 1 4 kg m 7 10 ft lbl 9 0 HONDA GL1200D GLI200A ...

Page 162: ...16 0 043 Alternator drive shaft backlash At alternator rotor 0 05 O OO2 TOROUE VALUES Alternator rotor lock nut Alternator drive shaft holder bolt Starter clutch outer torx bolt Alternator cover hole cap Alternator drive shaft bolt 10 mm Stator mount screw Pulse generator rotor bolt Pulse generator case bolt TDOLS Special Lock nut wrench 17 x 27 mm Rotor holder Damper spring compressor Common Atta...

Page 163: ...ternator drive gear backlash Worn or damaged alternator drive gear Abnormal engine noise at low speed Weak alternator drive shaft diaphragm spring Alternator drive shaft friction case binding Starter rotates but engine won t start Faulty starter clutch Broken starter drive chain 9 2 HONDA Gl1200D Gl1200A ...

Page 164: ...e pulse generator rotor Remove the clutch cover NOTE The rear engine cover can be removed without removing the clutch discs and plates Remove the bolts and rear engine cover Remove the gasket and dowel pins ALTERNATOR STARTER CLUTCH REAR ENGINE COVER ___ __ PU L S E G EO N E RATO R ROTO R BOLT DOWEL PINS 9 3 ...

Page 165: ...E Pry off the circlip securing the alternator wire and remove the stator Remove the three bolts and then remove the pulse generator case and spacer CIRCLIP BOLTS OUTPUT SHAFT BEARING Inspect the oil seals and bearings for the output shaft and pulse generator drive shaft Remove the oil seals and bearings from the case and replace with new ones if necessary PULSE GENERATOR DRIVE SHAFT BEARING 9 4 ...

Page 166: ...0600 Pulse generator drive shaft bearing Driver 07749 0010000 Attachment 32 x 35 mm 07746 0010100 Pilot 15 mm 07746 0040300 OIL SEAL Drive in new oil seals OIL SEAL Route the stator wires through the hole in the rear engine case install the grommet so that the groove is seated over the edge of the hole in the engine case Coat the stator mount screw threads with locking agent and tighten the stator...

Page 167: ... necessary to remove the bolt at the end of the shaft This bolt is used to turn the crankshaft when the engine is installed in the frame Do not torque the bolts in excess of 12 N m 1 2 kg m 9 ft Ib to prevent the case from distortion NOTE Place the pulse generator case onto the spacer Install and tighten the pulse generator case bolts TORGUE 8 12 N m 0 8 1 2 kg m 6 9 ft Ibl Hold the alternator rot...

Page 168: ...nt in the clutch outer Check the rollers for wear or damage Check the clutch outer for wear of damage to the roller contacting surfaces Check the plungers for wear springs for loss of tension Check the starter driven sprocket needle bearing for wear or damage If necessary remove the bearing by removing the circlip Check the starter driven sprocket for wear or damage to the roller contacting surfaa...

Page 169: ... TOROUE 23 27 N m 2 3 2 7 kg m 17 20 ft Ibl Assemble the springs with the plungers insert the assemblies into the clutch outer Install the rollers into the clutch outer while press ing the plungers ALTERNATOR DRIVE SHAFT REMOVAL DISASSEMBLY Unscrew the four bolts and remove the alternator drive shaft assembly 9 8 TORX DRIVER BIT T40 07703 0010100 OR EQUIVALENT TOOL r _ __ a STARTER CLUTCH OUTER RQ...

Page 170: ...springs Remove the stell balf case and 10 steel balls NOTE Do not let the steel balls fall out of the ball case during removal Inspeet the steel balls and inside of the steel ball case for evidences of excessive or abnormal wear DAMPER SPRING COMPRESSOR ATTACHMENT 64 37 OOOO COTTERS STEEL BALL CASE C1RCLIP Pry off the circlip and remove the gear stopper and driven gear Inspect the gear stopper for...

Page 171: ...otate the shaft by hand and check for play in the bearing Replace the bearing with a new one if it is noisy or has excessive play Press the shaft with a hydraulic press until the shaft and damper spring case are clear of the shaft holder NOTE The shaft ball bearing must be replaced with a new one whenver the shaft is removed from the case I Replace the bearing with a new one SHAFT HOLDER DAMPER SP...

Page 172: ...GS STEEL BALL CASE COTTERS SP RING SEAT DAMPER SPRINGS J ALTERNATOR DRIVE T DAMPER SPRING CASE DRIVEN GEAR SHAFT HOLDER While holding the shaft with a stand press the damper spring case onto the shaft ATTACHMENT 35 mm 1 0 07746 0030400 DRIVER 07746 0030100 DAMPER SPRING CASE SHAFT HOLDER 9 11 ...

Page 173: ...ix 15 1 mm springs Install the longer springs In the slots next to the index marks on the damper spring case 15 5 mm SPRINGS INDEX MARK OVAL HOLE Install the driven gear with the oval hole in the gear aligned with the index mark on the spring caes Install the damper springs in the driven gear INDEX MARK CIRCLlP Install the gear stopper and circlip GEAR STOPPER 9 12 ...

Page 174: ...t with the round ends facing towards the driven gear Remove the assembly from the press and check that the spring cotters are seated in the shaft groove firmly ALTERNATOR DRIVE SHAFT INSTALLATION Slide the dowel pin into the hole of the engine case install the alternator drive shaft assembly in the engine case Install the four shaft holder bolts and tightening them to the temporary torque TEMPORAR...

Page 175: ...rotor by turning it counterclockwise Check the operation of the one way clutch Place the drive chain on the starter drive and driven sprockets and install the sprocket and rotor onto the shafts CHAIN Install the plain washer on the shaft Apply locking agent to the shaft threads Apply engine oil to the under side of the lock nut Tighten the lock nut to the specified torque TORQUE aD 90 N m 8 0 9 0 ...

Page 176: ...easure the backlash with the alternator rotor in three different positions 120 0 apart All measurements of the backlash should be within 0 010 0 100 mm 0 004 0 040 in NOTE The alternator drive gear will be noisy if the backlash is zero Tighten the holder bolts to the specified torque TORQUE 10 14 N m 11 0 1 4 kg m 7 10 ft lb NOTE Rotate the sprocket stopper into place on the driven sprocket and ti...

Page 177: ...stall the rear engine cover and tighten the bolts in a crisscross pattern in 2 3 steps TORQUE 8 12 N m 0 8 1 2 kg m 6 9 ft lb Install the rotor with the cutout in the rotor aligned with the dowel pin on the rotor shaft Install and tighten the rotor bolt TORQUE 8 12 N m 0 8 1 2 kg m 6 9 ft Ib Inspect the air gap between the pulse generator rotor and pickup AlA GAP 0 40 1 10 mm 0 016 0 043 in Instal...

Page 178: ...Ciif HONDA GL1200D GL1200A MEMO ...

Page 179: ...TRANSMISSION SHIFT LINKAGE 12 16 N m 1 2 1 6 kg rn 9 12 ft lb 10 0 8 mm 24 28 N m 2 4 2 8 kg m 17 20 ft Ib HONDA GL1200D GL1200A 23 27 N m 2 3 2 7 kg m 17 20 ft lb 8 12 N m 0 8 2 kg m 6 9 ft Ib ...

Page 180: ...ng surfaces Wipe off excess sealant thoroughly SPECI FICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT Transmission gear l 0 Cl 31 000 31 025 1 2205 1 2215 31 05 1 222 C2 31 000 31 033 1 2205 1 2218 31 06 1 223 C3 31 000 31 033 1 2205 1 2218 31 06 1 223 M4 25 020 25 041 0 9850 0 9859 25 06 0 987 M5 28 020 28 04111 1031 1 1040 28 06 1 105 Transmission gear bushing 0 0 Cl 30 950 30 975 1 2185 1 2195l...

Page 181: ...t claw bent Shift spindle bolt loose Shift drum stopper bent Shift drum cam grooves damaged 10 2 10 14 N m 1 0 1 4 kg m 7 10 ft lb 24 28 N m 2 4 2 8 kg m 17 20 ft lb 33 37 N m 3 3 3 7 kg m 24 27 ft lb 12 16 N m 1 2 1 6 kg m 9 12 ft lbj 23 27 N m 2 3 2 7 kg m 17 20 ft Ib 14 18 N m 1 4 1 8 kg m 10 13 ft lb 10 14 N m 1 0 1 4 kg m 7 10 ft lb 8 12 N m 0 8 1 2 kg m 6 9 ft lb 8 12 N m 0 8 1 2 kg m 6 9 ft...

Page 182: ...m for excessive or abnormal wear or damage Remove the two 6 rnm bolts and disassemble the shift drum stopper Inspect the stopper plate for excessive or abnormal wear or damage SHIFT ARM SPINDLE Separate the engine cases Page to 9 Remove the gearshift peda1 Straighten the tab of the lock washer and remove the shift arm and spindle from the left engine case by removing the lock bolt TRANSMISSION SHI...

Page 183: ...haft starts to rotate SHIFT ARM SPRING I 0 HONDA GL12000 GLI200A SHIFT RETURN SPRING SHIFT LINKAGE ASSEMBLY SHIFT ARM SPINDLE Reinstall the shift spindle and shift arm in the reverse order of removal Tighten the lock bolt to specified torque TORQUE 23 27 N m 2 3 2 7 kg m 17 20 ft lb Bend the tab of the lock washer up against the side of the lock bolt Install the gearshift pedal on the pedal shaft ...

Page 184: ...drum set center in the shift drum aligning the dowel pin with the dowel hole in the set center TRANSMISSION SHIFT LINKAGE DRUM SET CENTER Install the positive stopper spring and collar and tighten the 6 mm bolt TORQUE 8 12 N m 0 8 1 2 kg m 6 9 ft lb Check operation of the positive stopper 10 5 ...

Page 185: ...set the shift drum in neutral Check that the stopper arm is engaged with the stopper cam plate and the neutral stopper arm is engaged with the drum set center Install the 6 mm nut and tighten TORQUE 8 12 N m O 8 1 2 kg m 6 9 ft lbJ Install the stopper arm and neutral stopper arm on their pivcit bolt Install the roller stopper and shift drum joint aligning the dowel holes with the dowel pin Install...

Page 186: ... Inspect the damper lifter for abnormal wear especially if the assembled spring length is longer than specified Check the shaft splines for damage To disassemble the output shaft compress the spring enough to remove the cotters NOTE The spring compressor attachment can be used without a hydraulic press TRANSMISSION SHIFT LINKAGE OUTPUT SHAFT GEAR DAMPER SPRING COMPRESSOR ATTACHMENT 07964 3710000 t...

Page 187: ...spring Install the output shaft gear in the engine case Install the output shaft from the rear of the engine and push it through the gear Make sure the splines on the gear engage the splines in the damper liter Reinstall the rear engine cover Page 9 16 Reinstall the engine Section 5 10 8 c iiJ HONDA GL1200D GL1200A o DA MPr CAM DAMPER SPRING DAMPER L1FTEA OUTPUT SHAFT GEAR ...

Page 188: ...rn the crankshaft 90 0 further from the above position Remove the starter motor Remove the following parts Right and left cylinder heads Thermostat housing Front engine cover Clutch outer Output shaft Pulse generator drive shaft NOTE The engine case halves can be separated with out removing the alternator drive shah Remove the oil pipe from the engine cases TRANSMISSION SHIFT LINKAGE STARTER MOTOR...

Page 189: ... BOLT O l 10 mm BOLTS 6mmBOLTS t 002 fF 6 mm BOLTS 0 Place the engine with the right engine case down Pull the shift arm away from the shift drum Partial ly separate the case halves and install the case supports Place shop towels under the pistons to prevent them from falling onto the transmission when the left case is removed Lift off the left engine case LEFT ENGINE CASE SHIFT ARM 10 10 ...

Page 190: ...lock washer TRANSMISSION SHIFT LINKAGE Pull the shift fork shaft out of the engine case while taking out the shift forks Remove the shift drum INSPECTION Inspect the shitt fork guide pins for wear or damage Measure the shift fork claw thickness SERViCE LIMIT 6 1 mm 0 24 in Measure the shift fork I D SERVICE LIMITS L and e forks 13 04 mm 0 513 in R fork 13 05 mm O 514 in j I SHIFT FORKS SHIFT FORK ...

Page 191: ...on Inspect the shift drum grooves They should be smooth and free of chips and burrs Measure the shift drum 0 0 at the end SERVICE LIMIT 11 95 mm 0 470 in SHIFT DRUM BEARING SHIFT DRUM TRANSMISSION REMOVAL MAINSHAFT NOTE The mainshaft can be removed without removing the gearshift linkage Remove the mainshaft end cap Remove the primary chain oiler 10 12 MAINSHAFT END CAP PRIMARY CHAIN OllER ...

Page 192: ...aft Pull the ball bearing out of the mainshaft and dis assemble the mainshaft COUNTERSHAFT Remove the shift drum shift fork shaft and shift forks Page lQ l1 Remove the two screws and countershaft bearing cap Lift the shaft and gears out of the case TRANSMISSION SHIFT LINKAGE PRIMARY CHAIN MAINSHAFT BEARING PULLER 07931 4630000 COUNTER SHAFT BEARING CAP 10 13 ...

Page 193: ... 987 in M5 28 06 mm 1 105 in Check the gear bushings for excessive or abnormal wtiar or insufficient lubication Measure the 0 0 of the gear bushings SERVICE LIMITS Cl C2 C3 30 90 mm 1 217 in M5 27 90 mm 1 098 in Calculate the clearance between the gear and gear bushing SERVICE LIMITS Cl 0 15 mm 0 006 in C2 C3 M5 0 16 mm 0 006 in Inspect the mainshaft and countershaft for excessive or abnormal wear...

Page 194: ...HIFT LINKAGE BEARING REMOVER 20 mm 07936 3710600 REMOVER HANDLE 07936 3710100 REMOVER WEIGHT 07741 0010201 Drive a new bearing into the engine case Drive the bearing into a new bearing cap DRIVER 07949 3710001 DRIVER 07749 0010000 P fLf ATTACHMENT 52 x 55 mm 07746 0010400 AND PILOT 20 mm 07746 0040500 ATTACHMENT 42 x 47 mm 07746 0010300 AND PI LOT 17 mm 07746 0040400 10 15 ...

Page 195: ...dle bearings for excessive or abnormal wear and replace with new ones if neces sary BEARING PULLER 07931 463 סס oo PULLER ATTACHMENT 07946 4690200 Pry off the circlip and disassemble the primary driven gear Check the damper rubbers for evidences of deterio ration or other faults C1RCLIP NE DLE BEARING BALL BEARING PRIMARY DRIVEN GEAR HUB o PRIMARY DRIVEN GEAR ASSEMBLY DAMPER RUBBER NEEDLE BEARING ...

Page 196: ...hub onto the driven gear Seat the circlip in the groove of the gear hub with the sharp edge facing towards the outside Install new ball and needle bearings into the hub if they were removed TRANSMISSION SHIFT LINKAGE FACING TO DRIVEN GEAR DAMPER RUBBER HUB CIRCLIP DRIVER DRIVER j 07746 0030100 07 7 4 9 0010000 ATTACHMENT 25 mm 1 0 07746 0030200 ATTACHMENT 32 x 35 mm 07746 0010100 10 17 ...

Page 197: ...n clean engine oil before they can be reassembled NOTE Align the oil holes in the gear bushings with the oil holes in the shafts Install the circlips with the end gap aligned with the shaft spline as shown Note the installation direction OIL HOLES OUTPUT GEAR MAINSHAFT 14Tl M4 GEAR 32Tl M2 M3 GEAR 24T128Tl C3 GEL3ST Th M5 GEAR 35T 10 18 ...

Page 198: ...ment 20 mm 1 0 ATTACHMENT 20 mm 1 0 07746 0020400 REAR BEARING After reassembling the mainshaft measure the assembled length to ensure proper alignment with the case bearing set rings ASSEMBLY LENGTH 177 4 mm 6 9B in TRANSMISSION INSTALLATION COUNTERSHAFT Install the countershaft and gears in the engine case Be sure the oil passage in the bearing cap is clean and push it into position by hand Tigh...

Page 199: ...ngine Engage the claw with the C4 gear and the guide with the shift drum groove Engage the right shift fork with the C4 gear and shift drum as described above Push the shift fork through the right shift fork aligning the lock bolt hole in the shaft with the lock bolt hole in the shift fork SHIFT DRUM SHIFT FORK SHAFT HONDA Gl1200D GlI200A SHIFT FORK MARKS SHIFT FORK MARK Install the lock washer an...

Page 200: ...ough the chain Engage the center shaft fork guide with the shift drum groove with the claw engaged with the M2 M3 gear install the mainshaft in the right engine case TRANSMISSION SHIFT LINKAGE M2 M3 GEAR Align the locating tab of the mainshaft end cap with the case groove and reinstall the end cap Check that the bearing set rings are seated in the bearing grooves securely Install the primary chain...

Page 201: ...on of the tensioner and replace if the spring is weak or broken To remove the tensioner back off the two tensioner mounting bolts NOTE Do not remove the alternator drive shaft assembly Inspect the chain guide for abnormal or excessive wear Also check for signs of damage To remove the chain guide remove the crankshaft and two 6 mm mounting bolts 10 22 OIL STRAINER SCREEN z PRIMARY CHAIN TENSIONER P...

Page 202: ...mbly seQuence is essentially the reverse order of disassembly NOTE Note the tensioner pivot pin direction Engage the guide groove with the case abutment TENSIQNER PIVOT PIN l I PRIMARY CHAIN TENSIQNER TENSIQNER SLIPPER PRIMARY CHAIN GUlDE TENSIQNER BASE 10 23 ...

Page 203: ...e as shown Coat the cylinders pistons and piston rings grooves with oil Lower the case until it rests on the guides Remove the piston bases and guides Apply sealant to the case mating surfaces NOTE Be sure to apply sealant to where the cases are mated Install the dowel pins Make sure that the oil strainer screen is in its correct position PISTON SLIDERS 07955 MG90000 DOWEL PIN Q HONDA GLI200D GL12...

Page 204: ...g m 7 10 ft lb NOTE Tighten all case bolts in a crisscross pattern in 2 3 steps Begin with larger diameter bolts first TRANSMISSION SHIFT LINKAGE o Install the oil pipes and tighten the three oil pipe bolts with the sealing washers NOTE Install the longer bolt on the right engine case Use the bolt with a larger hole on the front of the left engine case and the bolt with small hole on the rear Torq...

Page 205: ...FT LINKAGE Reinstall the following parts Starter motor Pulse generator drive shaft Output shaft Clutch outer Front engine cover Thermostat housing Right and left cylinder heads timing belts 10 26 HONDA GL12000 GL1200A ...

Page 206: ... HONDA GL1200D GL1200A MEMO ...

Page 207: ...CRANKSHAFT PISTON 11 0 CiJ HONDA GL1200D GL1200A 30 34 N m 3 0 3 4 kg m 22 A b ...

Page 208: ...on pins it is necessary to use a special tool m r u SPECIFICATION nI mm ITEM STANDARD SERVICE LIMIT Cylinder compression pressure 1 100 1 500 kPa 1 000 kPa 11 15 kg cm2 156 213 psi 10 kg cm2 142 psi Cylinder Cylinder 1 0 75 500 75 515 2 9724 2 9730 75 60 2 976 Out of round 0 15 0 006 Taper 0 05 0 002 Piston Piston 0 0 at skirt 75 470 75 490 2 9713 2 9720 75 35 2 967 Piston pin hole 1 0 19 010 19 0...

Page 209: ...linder or piston ring High Compression Excessive carbon build ups on piston head or in combustion chambers 11 2 Ciif HONDA GLI200D GL1200A 48 52 N m 4 8 5 2 kg m 35 38 ft lbl 67 73 N m 6 7 7 3 kg m 48 53 ft lb 30 34 N m 3 0 3 4 kg m 22 25 ft lb 07973 MG90000 Excessive Smoke Worn cylinder piston or piston rings Improperly installed piston rings Damaged piston or cylinder Overheating Excessive carbo...

Page 210: ... Kit consists of the following parts Pilot driver Pilot collar Piston base Piston pin guide Remove the left side rods and pistons Mark them to indicate the correct cylinder No 2 and 4 and posi tion on the crankpins Remove the right side rods and pistons Mark them to indicate the correct cylinder No 1 and 3 and position on the crankpins CAUTION Failure to align the piston correctly could result in ...

Page 211: ... is exceeded SERVICE LIMIT 0 05 rnm 10 002 in Clean the piston top and ring grooves Inspect for evidence of pitting or detrioration CAUTION Do not use Q whire brnsh to clean dng groo es and lands Q wire brush can damage these areas Inspect the ring lands for abnormal wear and piston thrust faces for scratches Inspect the pistons for cracks or other damage Inspect the piston ring to ring land clear...

Page 212: ...p second 0 60 mm 0 024 in Oil 1 10 mm 0 043 in If the gap exceeds the service limit measure the cylinder 1 0 Replace the piston ring if the cylinder I D is within specification Measure the piston 0 0 at a point 10 mrn OA in from the bottom and 90 to the piston pin bore SERViCE LIMIT 75 35 mrn 2 967 in CRANKSHAFT PISTON 11 5 ...

Page 213: ...ading to determine the out of round SERVICE LIMIT 0 15 mm 0 006 in Ci J HONDA GL12000 GL1200A The cylinder must be rebored and oversize piston fitted if the service limits are exceeded The following oversize pistons are available 0 25 mm 0 001 in 0 50 mm 0 020 in 0 75 mm 0 030 in 1 00 mm 0 039 in The cylinder must be rebored so that the clearance to an oversize piston is 0 010 0 045 mm lO 0004 0 0...

Page 214: ...main bearing journal Rotate the crankshaft two revolutions and read the unout SERViCE LIMIT 0 05 mm 10 002 in o CRANKSHAFT PISTON WASHp E R _ CIRCLIP CENTER BEARING JOURNAL o o 0 V BLOCKS Measure the crankshaft main bearing journals and crankpins with a mfcrometer for out af round and taper SERVICE LIMITS Taper 0 004 mm 0 0002 in Out at Round 0 008 mm 10 0003 in NOTE The crankshaft cannot be repai...

Page 215: ... 3 steps On the main journal bearings install the main bearings and bearing caps on the correct journals ARROWS 48 52 N m 4 8 5 2 kg m 35 38 ft Ibl 67 73 N m 6 7 7 3 kg m 48 53 ft Ib The arrows on the caps should face to wards the case top Do not rotate the crankshaft during inspection TORQUES Front cap bolt Center and rear cap bolts On the crankpin bearings install the bearing caps and rods on th...

Page 216: ... Cr3J k pin bearing 0 08 mm 0 003 in REAR JOURNAL 0 0 CODE c 0 COD E 0 0 CODE Ita r I I t r r r J D 1 r t 1 I I rO t I I CENTER JOURNAL FRONT JOURNAL o FW Record the corresponding crankshaft main journal 0 0 code number Codes may be 1 2 or 3 MAIN BEARING SELECTION Aecord the engine crankcase bearing support J D codes from the pad on the right side engine case Codes may be I II or Ill NOTE The lett...

Page 217: ...7 0 0788 Yellow 1 994 1 998 0 0785 0 0787 r CAUTION After selecting new bearings reckeck clear alice with plasrigage Incorrect clearance can cause major engine damage CRANKPIN BEARING SELECTION Record each connecting rod 1 0 code number Codes may be 1 2 or 3 11 10 r iJ HONDA GL1200D GLI200A Main Bearing Selection Table Crankcase III Brown Black Blue Bearing II Green Brown Black Support I D Codes I...

Page 218: ...rrect replace ment bearing color Rod Bearing Selection Table n 3 Brown Black Blue 0 no 2 Green Brown Black o 0 n 0 Yellow Green Brown 1 A B C Crankpin 0 0 Codes Bearing Insert Thickness mm in Blue 1 507 1 5 1 0 0593 0 0595 Black 1 503 1 507 0 0592 0 0593 Brown 1 499 1 503 0 0590 0 0592 Green 1 495 1 499 0 0589 0 05901 Yellow 1 491 1 495 0 0587 0 0589 CAUTION After seleettng new bearings recheck cl...

Page 219: ...ATION CiiJ HONDA GL1200D GL1200A CRANKPIN BEARINGS Install the ball bearing and washer on the end of the crankshaft and secure with the eifelip NOTE Seat the eifelip in the shaft groove with the sharp end facing towards the rear of the crankshaft Install the oil seal on the crankshaft Apply sealer to the oil seal and left case mating faces of the right case Apply molybdenum disulfide grease to the...

Page 220: ...e damage Apply molybdenum disulfied grease to the thread and seating surfaces of the bearing cap bolts Tighten the bolts in a crisscross pattern in 2 3 steps Front cap bolt 48 52 N m 4 8 5 2 kg m 35 38 ft lb Center and rear cap bolt 67 73 N m 6 7 7 3 kg m 48 53 ft lb PISTON AND ROD INSTALLATION When replacing a connecting rod be sure to select a new rod according to the table shown below REAR BEAR...

Page 221: ... so that the intake IN mark is facing the opposite direction as the oil hole in the rod Coat the piston pin with clean engine oil Press the new piston pin in to the connecting rod CAUTION FaUue to align the piston cOffee ly could resulr in pistoll damage Check that the pin is installed properly 11 14 HONDA GLI200D GL1200A OIL HOLE IN MARK IN MARK PI TONPIN PISTON PIN DIS ASSEMBlY TOOL SET 07973 MG...

Page 222: ...nto the piston NOTE All rings should be installed with the markings toward the top of the piston After installa tion they should be free to rotate in the piston ring grooves Stagger the piston ring end gaps 120 0 apart Stagger the oil ring and side rail end gaps as shown MARK CRANKSHAFT PISTON 0 TOP RING 0 SECOND RING a OIL RING S i2 Omm OR MORE 11 1 5 ...

Page 223: ...e rod cap bearings Install the No 1 and No 3 rod bearing caps on the correct crankpins CAUTION nle bearing caps must be installed in their correct locations or the bearing oil crearance may not be correct causing engine damage Tighten the nuts in a crisscross pattern in 2 3 steps TORQUE 30 34 N m 3 0 3 4 kg m 22 25 ft lb Install the leh side rod assemblies for cylinders No 2 and 4 in their or igin...

Page 224: ...nnect the spark plug caps and remove the spark plugs Insert the compression gauge Open the throttle all the way and crank the engine with the starter motor NOTE Crank the engine until the gauge reading stops rising The maximum reading is usually reached within 4 7 seconds COMPRESSION PRESSURE 1 100 1 500 kPa 11 15 kg em2 156 213 psi If compression is low che k for the following Improper valve clea...

Page 225: ...m 17 19 ft lbj 13 0 4 0 k mQ 22 29 ft lb _ 30 20 30 N m 18 25 N m 2 0 3 0 kg m t D v 22 29 4 1 8 2 5 kg m ft lbj t 13 18 ft lbj p tJ J1 20 25N m 80 120N m i 12 0 2 5 k m _ 18 0 12 0 k m 14 8 m _ 3 8 87 ft Ibl 13 18 ft Ibl 0 9 1 3 kg m 7 9 ft lbl 55 65 N m 5 5 6 5 kg m 40 47 ft lb 24 29 N m 2 4 2 9 kg m 17 21 ft lb 12 0 ...

Page 226: ... nut Rear axle nut Rear axle pinch bolt Shock absorber lower mount bolt right Shock absorber lower mount bolt left Handlebar holder bolt Steering stem nut Top bridge pinch bolt Steering stem adjustment nut Fork air equalizer set screw Fork equalizer air valve Front fork pinch bolt upper lower 55 65 N m 5 5 6 5 kg m 40 47 ft lb 20 30 N m 2 0 3 0 kg m 14 22 ft Ib 30 40 N m 3 0 4 0 kg m 22 29 ft Ib 2...

Page 227: ...or does not track straight Bent forks Bent frame Forks installed incorrectly Axle installed incorrectly Bent swing arm Wheel installed incorrectly Front wheel wobbling or vibration Loose axle front or rear Loose wheel bearings Loose steering stem nut or bearings Loose lock nut s os swing arm pivot bolt Unbalanced tire and wheel Bent wheel Excessive lateral wheel runout Bent forks Bent swing arm Be...

Page 228: ...ght and left caliper assemblies by removing the caliper bracket mount bolts CAUTION Support the caliper assembly SO that it does lIol hang from the brake hose Do lIot twist the brake hose Remove the axle holders and the front wheel NOTE Do not depress the brake ever or pedal when the wheel is off the motorcycle or it will be difficult to refit the disc bet veen the brake pads DISASSEMBLY Remove th...

Page 229: ...RIM RUNQUT INSPECTION Place the wheel in a truing stand Spin the wheel slowly and measure the runout with a dial indicator gauge SERVICE LIMITS RADIAL RUNOUT AXIAL RUNOUT Replace the wheel if the runouts are exceeded the service limits PLAY 1 I I AXIAL HONDA GL1200D GL1200A AR i PLAY J L J1 RADIAL AXLE INSPECTION Set the axle in V blocks and measure the runout The actual runout is 1 2 of the toral...

Page 230: ...speedometer gear retainer Remoye the bearings and the distance collar from the hub NOTE If the bearings are removed replace them with new bearings during assembly WHEEL STEERING DUST SEAL RETAINER BEARING REMOVER EXPANDER H CRlr_ 07746 0050 Ojii0r BEARING REMOVER COLLET 15 mm 07746 0050400 12 5 ...

Page 231: ...t1 c l e JDI X BEARING IDUST SEAL MOLYBDENUM REATINER DISULFIDE GREASE DRIVER 07749 001000 1 Pack the bearing cavities with grease if new ones are being installed Drive in the right bearing first and press the distance collar into place NOTE Install the bearings with the sealed ends facing out Make sure they are fully seated Install the distance collar and then drive in the left bearing ATTACHMENT...

Page 232: ...dust seal and collar into the hub CAUTION RemOl e all the grellse from Ql Qund the out side ofthe dust seal Install the discs disc bolts and nuts TORQUE 27 33 N m 2 7 3 3 kg m 20 24 ft lb Coat the dust seal lip with molybdenum disulfide grease lubricate the speedometer gear with grease Install the speedometer gear box in the wheel hub aligning the gear box notches with the tangs in the retainer CA...

Page 233: ...and tighten the axle nut TORQUE 55 65 N m 5 5 6 5 kg m 40 47 ft lbl INSTALLATION Position the front wheel between the fork legs and lower the forks onto the axle Position the speedometer gear box so that lug on the gear box is against rear of the stopper lug on left fork leg Install the axle holders with arrow mark facing forward Tighten the axle holder nuts loosely __ ARRO K AXLE HOLDER NUTS 12 8...

Page 234: ...ight brake disc and the right brake caliper bracket with a 0 70 mm 0 028 in feefer gauge If the feeler gauge cannot be inserted easily loosen the right axle holder nuts and move the right fork out until the gauge can be inserted Then retighten the right axle holder nuts CAUTION After installing the wheel apply the brakes several times and recheck the caliper clearance on both sides Failure to prov...

Page 235: ...l while the wheel is off the motorcycle or it will be dif ficult to refit the brake caliper INSPECTION I nspect the wheel as described in front wheel section _ Axle inspection Page 12 4 Wheel bearing inspection Page 12A Wheel rim runout inspection Page 12 4 OISASSEMBLY Remove the brake disc and dust seal from the wheel hub Remove the driven flange from the wheel hub CAUTION Be careful not to damag...

Page 236: ...gs are removed replace them with new bearings during assembly ASSEMBLY r iiJ HONDA GL12000 GL1200A BEARING REMOVER EXPANDER 0f 77 4l 6 0050100 BEARING REMOVER COLLET 20 mm 07746 0050600 FINAL DlRVEN FLANGE C RING O un MOLYBDENUM DISULFIDE GREASE DISTANCE COLLAR 12 12 un DISC BEARING gJ AXLE COLLAR ...

Page 237: ...n the right bearing Lubricate the driven flange pin with molybdenum disulfide grease Install the driven flange to the wheel hub Lubricate the dust seal lip with grease and install the dust seal to the wheel hub Install the brake disc and tighten the bolts TORQUE 27 33 N m 2 7 3 3 kg m 20 24 ft lb REAR WHEEL INSTALLATION Apply molybdenum disulfide grease to the driven flange splines WHEEL STEERING ...

Page 238: ...BRACKET COLLAR AXLE COLLAR SHOCK ABSORBER LOWER MOUNT BOLT i I AXLE NUT SHOCK ABSORBER LOWER MOUNT BOLT Install the rear bumber rear fender left saddlebag and reflex reflector in the reverse order or removal Install and tighten the axle nut while holding the left axle end TORQUE 85 105 N m 8 5 10 5 kg m 61 76 ft Jb TORQUE 20 25 N m 2 0 2 5 kg m 14 18 ft Ib Tighten the axle pinch bolt TORQUE 24 29 ...

Page 239: ... and brake disc assembly in an inspection stand If a stand is not available mount the wheel on its axle and clamp the axle in a vise Spin the wheel allow it to stop and mark the lowest heaviest part of the wheel with chalk Do this two or three times to verify the heaviest area If the wheel is balanced it will not stop consistently in the same position To balance the wheel install wheel weights on ...

Page 240: ...r turn it upside down to prel ent air from entering the brake hose Do not hong the master cylinder by the brake hose Remove the right handlebar switch attaching screws Remove the clutch master cylinder holder Disconnect the choke cable from the choke lever Disconnect the clutch switch wires Remove the left handlebar switch by removing the three screws BRAKE LIGHT SWITCH WIRE LEFT HANDLEBAR SWITCH ...

Page 241: ...ebar on the lower holders with the serrations aligned with the holders and the punch marks aligned with the tops of the holders Install the handlebar holder cover Insert the pin on the bottom half of switch assem bly into the hole in the handlebar Tighten the forward screws first then tighten the rear screws to the same torque Tighten the upper bolt first then tighten the lower bolt TORGUE 10 14 N...

Page 242: ...1200D GL1200A CHOKE LEVE_ R p __ CABLE END Align the gap between the holder and master cylinder with the punch mark on the handlebar Tighten the upper bolt first then the lower bolt Insert the pin on the bottom half of switch assem bly into the hole in the handlebar Tighten the forward screws first then tighten the rear screw Connect the clutch switch wires UPPER BOLT GAP PUNCH MARK PIN HOLDER LOW...

Page 243: ...2 3 Remove the handlebar from the top bridge Remove the front fender and fork brace FORK BRACE WHEEL STEERING FRONT FENDER Remove the meter viser by removing speaker G L1200A or attaching screws Remove the stem under cover by removing the two screws and bolts SCREWS SCREWS 12 19 ...

Page 244: ...e the angle sensor wire and grommet from the stem nut Remove the harness holders from the top bridge Remove the two air equalizer set screws Loosen the fork upper pinch bolts and top bridge pinch bolt Remove the stem nut and washer Remove the top bridge SENSOR WIRE GROMMET LOCK NUT WR ENCH 26 x 30 mm SCREW 07716 0020203 SCREW 12 20 FORK PINCH BOLT TOP BRIDGE PINCH BOLT FORK PINCH BOLT ...

Page 245: ...equalizer IGL1200A Remove the air equalizer and stop rings from the fork tubes STOP RINGS WHEEL STEERING AIR HOSE GL1200A Loosen the fork lower pinch bolts and remove the front forks Straighten the tab of the lock washer and remove the lock nut LOCK NUT TABS 12 21 ...

Page 246: ... and replace if necessary BOTTOM BEARING REPLACEMENT NOTE Always replace the bearing and race as a set Remove the bonom bearing with a hammer and a drift NOTE Install the adjustment nut on the top end of the steering stem to prevent damage to the threads The bearing and dust seal will be damaged during removal and will require replace ment 12 22 CiiJ HONDA GL1200D GL1200A STEERING ADJUSTMENT NUT R...

Page 247: ... 37010500 Always remove the top race before driving out the bottom race BEARING RACE REPLACEMENT Inspect the top and bottom races and replace if worn or damaged Drive out the top face and then the bottom race NOTE Install a new bottom race ATTACHMENT 07946 3710701 NOTE The bottom race has a larger 1 0 than the top race Be sure to install the races in their proper places Drive the races in squarely...

Page 248: ...first Then use attachment 07746 0010300 or old race to install the top race untit it seats NOTE Drive the races in squarely until they are fully seated INSTALLATION Pack all bearing cavities with grease IS TOP RACE I SMALL INNER DIAMETER IJ LOCK NUT LOCK WASHEA STEERING C DJUSTMENT NUT jjijUffi BEARING _ f f I OUTER RACE BEARING Q OUTER RACE DUST SEAL GREASE HOLDER STEERING TEM_ 12 24 ...

Page 249: ... cornering instability and excessiJ e noise dllring braking wjfl be experienced Turn the steering stem lock ta Iock five times to seat the bearings Repeat the bearing tightening and steering stem turning sequence twice more Install the steering adjustment nut Tighten the steering adjustment nut to the specified torque TOROUE 14 16 N m 1 4 1 6 kg m 10 12 ft lbJ Insert the steering stem into the ste...

Page 250: ...o the a rings in the air equalizer Install the stop rings and air equalizer tube onto the fork tubes Tighten the steering stem nut TORGUE 80 120 N m 8 0 12 0 kg m 58 87 ft lb Then loosen the lower fork pinch bolts and place the fork tube up into the fork bridge until the stop ring seats Tighten the upper fork pinch bolts TORQUE 9 13 N m 0 9 1 3 kg m 7 9 ft Ibl Apply engine oil to the thread of the...

Page 251: ... 4 5 5 lb for right and left turns If the readings do not fall within the limits lower the front wheelan the ground and adjust the bear ing adjustment nut Install the harness holder on the top bridge Instal the angle sensor and grommet into the stem pipe Connect the angle sensor to the sensor wire at bottom of steering stem Install the angle sensor to the steering stem Install the sensor cover and...

Page 252: ... 58 87 h lb rt 24 30 N m 2 4 3 0 kg m 17 22 ft lbl 2 18 20 N m j ro 11 8 2 0 kg m 13 14 ft Ib 80 120 N m 8 0 12 0 kg m 58 87 fHb 13 0 CfiJ lHONDA GL1200D GL1200A 30 40 N m f3 0 4 0 kg m 22 29 ft lb 24 30N m lil 2 4 3 0 kg m 17 22 ft lbl ...

Page 253: ...fter draining 323 em 10 92 US oz 11 34 Imp oz Front fork oil ATF Front fork tube runout 0 20 0 008 Rear shock absorber refill capacity 259 5 cm 8 77 US oz 9 11 Imp ozl Rear shock absorber oil ATF TOROUE VALUES Front fork pinch bolt upper lower Front fork bottom socket bolt Front fork cap bolt Air valve Air hose joint 8 mm 10 mm Air hose connector Air pressure sensor Rear shock absorber upper mount...

Page 254: ...oft suspension Weak spring Insufficient air pressure Weak rear damper Insufficient fluid weight 13 2 HONDA GL1200D GL1200A 07947 KF00100 07947 KA50100 07914 3230001 07917 3230000 or equivalent tool commercially available 07947 3710101 07908 4690001 07917 3710000 07936 8890101 07746 0010200 07749 0010000 Hard suspension Incorrect fluid weight Too much air pressure Clogged fork hydraulic passage Ben...

Page 255: ...ch bolts Remove the stop rings from the front fork tubes and remove the front forks SUSPENSION FRONT FENDER UPPER PINCH BOLT LOWER PINCH BOLTS STOP RING DISASSEMBLY Hold the fork tube in a vise with sofr jaws and remove the fork cap bolt CAUTION Do not damage or bend the sliding surface Use care when loosening the bolt or the spring will pop OUI FOR K CAP BOLT 13 3 ...

Page 256: ...se with soft jaws and remove the hex bolt CAUTION Excessh e vise pressure can damage the fork slider HONDA GL1200D GL1200A HOLLOW SET WRENCH 6 mm ro O 9 17 3230000 OR EQUIVALENT NOTE Temporarily install the spring and fork bolt if difficulty is encountered in removing the hex bolt Remove the dust seal foam seal plastic washer and circlip 13 4 ...

Page 257: ... OIL SEAL BACK UP RING CIRCLIP Do not remove the fork tube bushings unless they are necessary to replace them with new ones Remove the circlip oil lock valve spring and spring seat from the piston Remove the piston and re bound spring from the fork tube Remove the oil lock piece from the slider INSPECTION FRONT FORK SPRING FREE LENGTH Measure the fork spring free length SERVICE LIMITS Spring A 162...

Page 258: ...STON REBOUND SPRING S FORK TUBE FORK SLIDER FORK TUBE Set the fork tube in V blocks and read the runout SERViCE LIMIT 0 2 mm 0 01 in BACK UP RING CHECK POINTS 1 0 COPPER SURFACES BUSHING Check the back up ring replace it if there is any dis tortion at the check points shown BUSHING BACK UP RING Visually inspect the slider and fork tube bushings Replace the bushings if there is excessive scoring or...

Page 259: ...em Place the steel ball and spring in a parts rack so they are not lost Remove the boot set ring and remove the boots and pivot collar Remove the screw washer spring and steel ball from the anti dive case Remove the orifice by removing the set pin SUSPENSION ANTI DIVE CASE BOOT PIVOT COLLAR SOCKET BOLTS STEEL BALL SPRING n 1 WASHER SCREW SET PIN ORIFICE 13 7 ...

Page 260: ...NOTE Apply a locking agent to the threads of the screws and socket bolts before assembly Apply ATF to the piston and piston Q ring Apply Hi Temperature silicone grease to the pivot bolt collar Install the pivot bolt collar boot set ring as shown PIVOT COllAR 1 SET RING BOOT Tighten the socket bolts to the specified torque TORGUE 6 9 N m 0 6 0 9 kg m 4 3 6 5 ft lbl NOTE Apply a locking agent to the...

Page 261: ...NG Q l FDRK TUBE Q JID QD O o c j Q 0 ANTI DIVE CASE FDRKTUBE BUSHINGS OIL LOCK PIECE fJ IJ FORK SLIDER CIRCLIP Install a new bushing on the fork tube if necessary Place the rebound spring and piston into the fork tube Install the spring seat spring and oil lock valve onto the piston and secure them with the circlip Place the oil lock piece on the end of the piston and insert the fork tube into th...

Page 262: ...e back up ring and an old bushing or equivalent tool on top Drive the bushing into place with the seal driver Remove the old bushing Check the groove and top edge of the fork tube for burrs or scratches Wrap the fork tube groove and top edge with vinyl tape to prevent damage to the oil seal lip during installation Install the back up ring Coat a new oil seal with ATF and install it with the seal m...

Page 263: ... lower spring into the fork tube with the small diameter end must face toward the bottom Install the spring seat and upper spring with narrow coils toward the bottom Install and torque the fork cap bott TORGUE 15 30 N m 1 5 3 0 kg m 11 22 ft lb CAUTION Be careful IIot to cross thread the fork cap bolts LOWER iK SPRING DOWN FORK CAP BOLT INSTALLATION Place the fork tubes into the steering stem Tigh...

Page 264: ...inch bolts and place the fork tube up into the fork bridge until the stop ring seats Install the fork brace and front fender NOTE Install the fork brace with F mark facing forward Do not torque the fork brace bolts before installing the front wheel Install the front wheel Page 12 8 Fill the fork tubes with air Section 3 With the front brake applied pump the forks up and down several times then tig...

Page 265: ...ridge onto the forks Page 12 26 Check for air leakage after assembly SUSPENSION a RINGS O RINGS REAR SHOCK ABSORBER REMOVAL Place the motorcycle on its center stand Remove the side cover and seat Remove the travel trunk and saddlebags Disconnect the air hose and elbow from the 3 way joint G11200A Remove the 3 way joint from the frame Remove the air hoses from the hose clamp CLAMP AIR HOSES 13 13 ...

Page 266: ... or the fluid will run out the air hose Remove the lower shock absorber mounting bolt and remove the shock absorber OIL SEAL REPLACEMENT Disconnect the air hose from the 3 way joint Remove the air valve from the 3 way joint GL 1200DJ Remove the outlet air valve from the air outlet hose on right side of fairing GL1200A Remove Ihe boot AIR VALVE AIR HOSE BACK UP PLATE Remove the circlip and back up ...

Page 267: ... t 7 _ i _ _ a AIR VALVE Press the oil seal out by compressing the chock ab sorber Wrap a shop towel around the shock absorber Leave the shock absorber for another 10 minutes to let any remaining ATF drain out Remove the shop towel from the shock absorber Do not tilt the shock absorber or ATF will flow out of the damper case Let the shock stand for 5 minutes to allow air to escape Install the air ...

Page 268: ... CAUTION Be careful lot to damage the oil seal during imtallation OIL SEAL HONDA GL1200D GL1200A Drive the oil seal in with the fork seal driver Install the back up plate and eirelip CAUTION Be sure the circlip is seated in the groove all the way around Remove the air valve from the air hose Install the boot 13 16 GUIDE BUSHING FORK SEAL DRIVER 07947 3710101 BACK UP PLATE CIRCLIP ...

Page 269: ... Right lower mount bolt 20 25 N m 2 0 2 5 kg m 14 18 ft Ib Left lower mount bolt 65 75 N m 6 5 7 5 kg m 47 54 ft lb Connect the air hose to the 3 way joint TORQUE 15 20 N m 1 5 2 0 kg m 11 14 ft lb Route the air hoses through the clamp on the rear fender SUSPENSION UPPER MOUNT NUT _ SHOCK LOWER SHOCK ABSORBER ABSORBER CLAMP Install the 3 way joint into the frame Loosely install the elbow to the 3 ...

Page 270: ...8 4690001 SUSPENSION SWING ARM REMOVAL Remove the rear wheel Page 12 9 Remove the final gear case Page 14 3 Remove the brake hose from the hose clamp Remove the swing arm pivot lock nut Remove the exhaust muffler 13 18 fAJ HONDA GLI200D GL1200A ...

Page 271: ...pivot bearings in pairs PIVOT BEARING REPLACEMENT Inspect the tapered roller bearings and races for damage or wear NOTE Disconnect the universal joint from the final shaft Refer to page 14 4 for universal joint inspection Remove the right and left pivot bolts RACE Remove the outer races with the bearing remover RACE Remove the grease holder BEARING REMOVER 07936 8890101 13 19 ...

Page 272: ... GREASE HOLDER l UNIVERSAL BEARING II JOINT DUST SEAL Jrl W MOLYBOENUM DISULFIDE GREASE BOOT DUSTSEAL BEARING GREASE HOLDER Install the grease holder Drive the new bearing races squarely into the swing arm J D R VER 07949 0010000 ATIACHMENT 37 x 40 mm 07746 0010200 SWING ARM ...

Page 273: ...NSTALLATION Install the universal joint into the swing arm Install the swing arm Apply grease to the tip of the right and left pivot bolts and loosely install them NOTE Make sure that the end of the pivot bolts are inserted into the bearing inner races SUSPENSION BEARING PIVOT BOLT 13 21 ...

Page 274: ...13 14 ft Ibl Move the swing arm up and down several times to seat the bearings with the pivot bolt then retighten the pivot bolt to the specified torque LEFT PIVOT BOLT SOCKET BIT 10 mm 07917 3710000 Install the pivot lock nut on the pivot bolt Hold the pivot bolt and tighten the pivot lock nut to a torque wrench reading of 75 105 N m P 5 10 5 kg m 54 76 ft Ib NOTE Because the lock nut wrench incr...

Page 275: ...ake hose to the hose damp Install the final drive gear case Page 14 17 Install the rear wheel Page 12 13 CLAMP ON BOARO AIR SUSPENSION SYSTEM GL1200Al FORK TUBE EQUALIZER PRESSURE SENSOR 3 WAY JOINT SOLENOID VALVE 4 WAY JOINT REAR SHOCK ABSORBERS 13 23 ...

Page 276: ...el Remove the outlet air hose by removing the lock nut Remove the selector valve by removing two screws _ HONDA GLI200D GL1200A I 6 mm NUT REAR SUSPENSION AIR HOSE SCREWS Remove the right fairing pocket Pull the air pump drier assembly and sensor joint out from the fairing Disconnect the air hose from the sensor joint 13 24 PUMP DRIER AIR HOSE SENSOR JOINT ...

Page 277: ...he screws then disassemble the drier as shown if necessary Check the color of the desiccant It should be blue If not bake the desiccant until it is blue or replace if necessary Check the packings for dirt or moisture and replace if necessary Clean the inside of the body and the cover openings with compressed air PACKING DESICCANT SCREWS SPRING SPRING SEAT 13 25 ...

Page 278: ...he air pump I I I I I I I I I AIR PRESSURE SENSOR Measure the resistance between the sensor coupler Black Brown and Green terminals SPECifiED RESISTANCE 0 7 1 3 kQ Measure the resistances between the Black Brown and Light Blue terminals and Light Blue and Green terminals of the sensor by applYing pressures from oto 4 kg cm 2 0 57 psi gradually The resistance between the Black Brown and Light Blue ...

Page 279: ...en the selector is pressed on REAR The rear suspension air hose joint should be open to the main pipe yellow band Apply the same procedures to the front suspension air hose joint MAIN PIPE 9 i FRONT SUSPENSION AIR HOSE JOINT SOLENOID VALVE Check the valve for leakage by applying vacuum to the discharge tube of the sensor joint The valve is normal if there is no vacuum in the discharge tube when a ...

Page 280: ... OUTLET BUTTON INCREASE BUTTON Check the switches for continuity with switch depressed I ncrease button Black Brown to Green with button depressed No continuity with button released Decrease button BlacklYeliow to Green with button depressed No continuity with button released DECREASE BUTTON Air outlet bunon Light green Black to Light green Black with button depressed No continuity with button rel...

Page 281: ...sembly sequence is disassembly essentially the reverse of 15 20 N 1 5 2 0 kg m 11 14 ft Ibl SUSPENSION HAND TIGHTEN 12 16 N m Y 1 2 1 6 kg m 0 9 12 ft lbj 8 8 12N m t J 08 1 2 kg m _ _ Q 6 9ft lbl _ kg m ri I N_ 3 5 f 4 0_H m t fi l H OlD 13 29 ...

Page 282: ...N m 0 4 0 7 kg m 3 5 ft lb Connect the selector valve and 4 way joint with air tubes NOTE Connect the main air tube to the sensor joint TORQUE 4 7 N m 10 4 0 7 kg m 3 5 ft lb Install the air pressure sensor on the sensor joint TORQUE 8 12 N m 0 8 1 2 kg m 6 9 ft lb NOTE I Do not bend the plastic tubes ellcessively I Do not overtighten the pressure sensor Connect the air drier hose to the sensor io...

Page 283: ...se and selector valve Connect the selector valve wires to the wire harness Install the switch panel onto the control switches 6 mm NUT Install the 6 mm nut onto the stud of the 4 way joint Tighten the nut securely Connect the front and rear suspension air hoses to the 4 way joint Tighten the hose joint nuts TORQUE 8 12 N m 0 8 1 2 kg m 6 9 ft Ibl 1l I _ III A EAR SUSPENSION AIR HOSE FRONT SUSPENSI...

Page 284: ...Check the operation and air leakage after installa tion Install the right fairing pocket AIR PUMP RELAY GL1200A Remove the air pump relay from the relay bracket Disconnect the relay from the coupler Connect a fully charged 12V battery and an ohm meter to the relay terminals as shown r7J HONDA GL1200D GL1200A AIR PUMP DRIER AIR PUMP RELAY The relay is normal if there is continuity when voltage is a...

Page 285: ... HONDA GL1200D GL1200A MEMO ...

Page 286: ...0 14 N m 1 0 1 4 kg m 7 1 0 ft Ib 14 0 100 120 N m 10 0 12 0 kg m 72 87 ft lb HONDA GL1200D GL1200A 23 28 N m 2 3 2 8 kg m 17 20 ft lbl 45 50 N m 4 5 5 0 kg m 33 36 ft lb lej 100 120 N m 10 0 12 0 kg m 72 87 ft lbj ...

Page 287: ...CI FICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT Final gear oil Capacity 170 em 5 7 US Ol 6 0 Imp oz Recommended oil Hypoid gear oil SAE 80 API GL 5 Gear backlash 0 08 0 18 lO OO3 0 007l 0 30 0 012 Gear assembly preload 0 2 0 4 N m 2 4 kg em 1 7 3 5 in lb TORQUE VALUES Pinion bearing retainer Pinion joint nut Gear case cover bolt 10 mm Bmm Final drive gear case attaching nut Final drive gear ca...

Page 288: ...7 mm Bearing puller TROUBLESHOOTING 07924 9690100 07924 ME40000 07910 ME80000 07931 4630300 07934 MG7020Q 07965 3710300 07931 M E4QOOO 07746 0030100 07746 0030300 07746 0010100 07746 0040500 07746 00 10400 07749 001 0000 07746 0010300 07631 0010000 Excessive noise Worn or scored ring gear shaft and driven flange Scored driven flange and wheel hub Worn or scroed drive pinion and splines Worn pinion...

Page 289: ... ing the axle Place the shock mount between the jaws for stability Separate the drive shaft from the gear case by gently revolving the shaft in a circular motion while tug ging slightly DISASSEMBLY Remove the circlip spring seat and spring from the drive shaft Remove the oil seal and stop ring from the drive shaft NOTE Replace the oil seal with a new one if it is removed Inspect the drive shaft sp...

Page 290: ...bearings Rotate the shaft and joint in oppo site directions If there is any evidence of side play the universal joint must be replaced Lubricate the splines with molybdenum disulfide grease UNIVERSAL JOINT FINAL DRIVE GEAR RING GEAR REMOVAL Remove the distance collar Remove the dust guard plate bolt and the dust guard plate by turning it clockwise MOLYBDENUM DISULFIDE GREASE DISTANCE COLLAR DUST G...

Page 291: ...er Remove the ring gear from he final drive case RING GEAR BEARING REMOVAL Remove the a ring guide by tapping it from the opposite side FINAL DRIVE GEAR CASE COVER RING GEAR D RING GUIDE Remove the ring gear bearing and gear adjusting spacer BEARING PULLER ATTACHMENT 07934 MG70200 RING GEAR BEARING COMMERCIALLY AVAILABlE BEARING PULLER 14 5 ...

Page 292: ...seal PINION GEAR REMOVAL Install the pinion joint holder and pinion joint holder attachment onto the pinion joint and remove the pinion shah nut Remove the tools Remove the pinion joint Remove the retainer lock tab 14 6 I LOCK TAB PINION JOINT HON DA GLI200D GL1200A OIL SEAL PINION JOINT HOLDER 07924 ME40000 ...

Page 293: ...inion assembly PINION BEARING REMOVAL Pull the bearing outer and inner races off the shaft with the bearing puller Pull the other inner race off with the same tool Remove the pinion adjustment spacer FINAL DRIVE PINION REATINER WRENCH __ O 7910 ME80000 _ PINION JOINT HOLDER 07924 ME40000 PINION JOINT HOLDER ATTACHMENT 07924 9690100 BEARING PULLER 07631 0010000 ___L _ co PINION BEARING 14 7 ...

Page 294: ... case to BOoe 176 FI Tap the gear case with a plastic hammer and remove the ring gear and pinion bearings CAUTION AIWQ s lVear g o es ren Mlldling the gear case after it has been heated Remove the ring gear haft oil seal Drive a new oil seal into the case using the special tools 14 8 Oil SEAL PINION REATINER C RING a HONDA GL1200D GL1200A DRIVER 07749 0010000 ATTACHMENT 52 x 55 mm 07746 0010400 PI...

Page 295: ...d air PINION GEAR ASSEMBLY Install the original pinion gear spacer NOTE When the gear set pinion bearing and or gear case has been replaced use a 1 5 mm 0 06 in thick spacer FINAL DRIVE DRIVER BEARING RACE INSERT 07749 0010000 ATIACHMENT Q7931 4630300 ATTACHMENT 32 x 35 mm 07748 0010100 AND PILOT 20 mm 07746 0040500 BREATHER HOLE BREATHER HOLE PINION SPACER PINION BEARING 14 9 ...

Page 296: ... threads on the pinion retainer Screw in the pinion retainer to press the pinion bearing into place then tighten it to the specified torque TORQUE 100 120 N m 10 0 12 0 kg m 72 87 ft Ib RING GEAR ASSEMBLY Install the original spacer onto the ring gear NOTE If the gear set pinion bearing ring gear bear ing and or gear case is replaced install a 2 0 mm thick spacer Place the ring gear bearing over t...

Page 297: ...nd drive the D ring guide onto the ring gear shaft Place a new ring gear bearing on the ring gear shaft Press the new bearing onto the shaft with hydraulic press Install the ring gear into the gear case cover Measure the clearance between the ring gear and the ring gear stop pin with a feeler gauge CLEARANCE 0 30 0 60 mm 0 012 0 024 in I I I STOP PIN ATTACHMENT 42 x 47 mm 07746 0010300 GEAR CASE C...

Page 298: ... STOP PIN STOP PIN SHIM Clean all sealing material off the mating surface of the gear case and cover NOTE Keep dust and dirt out of the gear case Be careful not to damage the mating sur faces Apply liquid sealant to the mating surface of the gear case cover GEAR TOOTH CONTACT PATTERN CHECK Apply a thin coat of Prussian Blue to the pinion gear teeth for a gear tooth contact pattern check Place the ...

Page 299: ...ps TOROUE 23 28 N m 2 3 2 8 kg m 17 20 ft lbl Then tighten the 10 mm bolts TORQUE 45 50 N m 14 5 5 0 kg m 33 36 ft lbl Remove the oil filler cap from the final gear case Rotate the ring gear several times in both directions of rotation Check the gear tooth contact pattern through the oil filler hole The panern is indicated by the Prussian Blue applied to the pinion before assembly Contact is norma...

Page 300: ...R A 1 32 mm 0 0520 in B 1 38 mm 0 0543 in c 1 44 rnm 0 0567 in 0 1 50 rnm 10 0591 in Standard E 1 56 mm 0 0614 in F 1 62 mm 0 0638 in G 1 68 mm 0 0661 in BACKLASH INSPECTION Remove the oil filler cap Set the final gear assembly into a jig or stand to hold it steady Set a horizontal type dial indicator on the ring gear through the oil filler hole Temporarily install the pinion ioint onto the pinion...

Page 301: ...mall replace the ring gear spacer with a thinner one Backlash is changed by about 0 06 0 07 mm 0 002 0 003 in when thickness of the spacer is changed by 0 10 mm 0 004 in RING GEAR SPACER A 1 82 mm 0 072 in 8 1 88 mm 0 074 in C 1 94 mm 0 076 in 0 2 00 mm 0 079 in Standard E 2 06 mm 0 081 in F 2 12 mm 0 084 in G 2 18 mm 0 086 in H 2 24 mm 0 088 in I 2 30 mm 0 091 in Remove the pinion joint from the ...

Page 302: ...m 10 0 12 0 kg m 72 87 ft lb Remove the tools Make sure that the gear assembly rotates smoothly without binding by turning the pinion joint GEAR ASSEMBLY PRELOAD 0 2 0 4 N m 2 4 kg em 1 7 3 5 in lb Install the dust guard plate and torque the bolt Install the distance collar 14 16 HONDA GL1200D GL1200A PINION JOINT HOLDER 07924 M E40QOQ 01 If h e At PINION JONT HOLDER ATTACHMENT 07924 9690100 DUST ...

Page 303: ...pline grooves NOTE Make sure that the stop ring is seated properly by pulling on the drive shaft lightly Be careful not to damage the drive shaft oil seal PINION JOINT DRIVE SHAFT Attach the gear case onto the swing arm loosely NOTE To ease axle installation do not tighten the gear case nuts until after the axle is installed Install the rear wheel and tighten bolts and nut page 12 13 Then tighten ...

Page 304: ...bolt is tightened L Remove the oil filler cap and pour the specified amount of recommended oi RECOMMENDED OIL Hypoid gear oil SAE 80 API GL S OIL CAPACITY 170 cm3 5 7 US OZ 6 0 Imp oz 14 18 OIL FILLER CiJ HONDA GL1200D GL1200A f OIL DRAIN PLUG ...

Page 305: ... HONDA GL1200D GL1200A MEMO ...

Page 306: ... 24 ft lbl 25 35 N m 2 5 3 5 kg m 18 22 ft lb 30 40 N m 3 0 4 0 kg m 22 29 ft lb 24 29 N m 2 4 2 9 kg m 17 21 ft Ib 15 20 N m 1 5 2 0 kg m 11 14ft lb 16 18 N m 1 6 1 8 kg m 12 13 ft lbl 25 35 N m 2 5 3 5 kg m 18 22 ft lb I I 18 25 N m 1 8 2 5 kg m 13 18 ft lbl 15 0 ...

Page 307: ...torcycle Replace the sealing washers whenever the brake hose bolt is removed SPECI FICAT10NS Unit mm in ITEM STANDARD SERVICE LIMIT G type 15 870 15 913 0 6248 0 6265 15 925 0 6270 Cylinder 1 0 Except G type 12 700 12 743 0 5000 0 5017 12 755 0 5022 Front brake master cylinder G type 15 827 15 854 0 6231 0 6242 15 815 0 6226 Piston 0 0 Except G type 12 684 12 657 0 4994 0 4983 12 645 0 4978 Right ...

Page 308: ... Sticking piSlon s Incorrect rear brake pedal adjustment Caliper side slide pin sticking Caliper installed incorrectly Disc or wheel misaligned 15 2 HONDA GL1200D GL1200A 25 35 N m 2 5 3 5 kg m 18 25 ft lb 16 18 N m 1 6 1 8 kg m 12 13 ft lb 30 40 N m 3 0 4 0 kg m 22 29 ft Ib 20 25 N m 2 0 2 5 kg m 14 18 ft Ib 25 30 N m 2 5 3 0 kg m 18 22 ft Ibl 20 25 N m 2 0 2 5 kg m 14 18 ft Ib 27 33 N m 2_7 3 3 ...

Page 309: ...hen filling the reservoir A void spilling fluid on painted surfaces and wind screen Place a rag over the painted surfaces and wind screen whenever the system is serviced Remove the reservoir cover and diaphragm with the fluid reservoir parallel to the ground Connect a bleed hose to the bleed valve Loosen the caliper bleed valve and pump the brake lever or pedal Stop pumping the lever or pedal when...

Page 310: ... To fill the foot operated brake system with brake fluid fill the rear brake caliper first then fill the right front brake caliper Except G type Repeat the above procedures until air bubbles do not appear in the plastic hose NOTE If air is entering the bleeder from around the bleed valve threads Seal the threads with teflon tape Close the bleed valve and operate the brake lever or pedal If it feel...

Page 311: ...ighten the bleed valve TORQUE 4 7 N m 40 70 kg em 35 61 in lb Filllhe fluid reservoir to the upper level mark Reinstall the diaphragm and master cylinder cover A contominated brake disc or pod reduces stopping power Discard contaminated pads and clean a contaminated disc ith a high quality brake degreasing agent BRAKE PAD DISC PAD REPLACEMENT Remove the left saddlebag before rear brake caliper rem...

Page 312: ...the caliper as shown Install the new pads in the caliper Install the pad pins one pad pin first then install the other pin by pushing the pads against the caliper to depress the pad spring PAD SPRING BRAKE PADS Place the pad pin retainer over the pad pins Push the retainer down to secure the pins Install the pad pin retainer bolt 15 6 BOLT PAD PIN RETAINER ...

Page 313: ...ioned between the pads making sure not to damage the pads Apply Hi Temperature silicone grease to the caliper pivot bolt and insert the pivot bolt into the pivot bolt hole Install the caliper bolt and tighten the caliper pivot and caliper bolts to specified torCl e TORQUE Caliper pivot bolt 25 30 N m 2 5 3 0 kg m 18 22 ft lb Caliper bolt and bracket lower mount bolt 20 25 N m 2 0 2 5 kg m 14 18 ft...

Page 314: ...ASSEMBLY HONDA Gl12000 Gl1200A Drain brake fluid from the hydraulic system Disconnect the brake light switch wires Remove the brake lever and rear view mirror from the master cylinder Disconnect the brake hose BRAKE HOSE OIL BOLT MASTER CYLINDER CAUTION Avoid spilling brake fluid 011 painted surfaces or wind screen Place Q rag over the painted surfaces and wind screen whenever the brake system is ...

Page 315: ...r cylinder piston and spring Remove the brake light switch from the master cylinder body if necessary Clean the inside of the master cylinder and reservoir with brake fluid INSPECTION MASTER CYLINDER Check for scores scratches nicks or other damage Measure the master piston bore 1 0 SERVICE LIMITS Except G type 12 755 rnm 0 5022 in G type 15 925 mm 0 6270 in 15 9 ...

Page 316: ...o tum inside out Be certain the circlip is seated finnly in the groove BOOT I RCLIP MASTER CYLINDER P1STON DDT4 fI PRIMARY 0 CUP l SP RING J1S J MASTER CYLINDER BODY Install the circlip and boot UP MARK LUG PUNCH MARK MASTER C Y L N DER HOLDER OILBOLT InstaU the brake lever Install the oil hose with the oil boh and its two sealing washers TORQUE 25 35 N m 2 5 3 5 kg m 18 25 ft lb PlaCl the master ...

Page 317: ...ke fluid from the brake line Page 15 3 Remove the cotter pin and clevis pin Disconnect the brake rod clevis from the brake arm Place a drip pan under the brake line Disconnect the reservoir hose from the reservoir Remove the two master cylinder bolts HYDRAULIC BRAKES LEFT PASSENGER FOOT LEST BRAKE PAD CLEVIS CLEVIS PIN MASTER CYLINDER BOLTS 15 11 ...

Page 318: ...tter from entering the inside as it will affecr the perfomumce of the control valve except G type The pressure control valve cannot be dis assembled Do not attempt to disassemble the pressure control valve except G type Remove the dust cover from the master cylinder Remove the circlip and pull the rod out of the master cylinder body CAUTION Beware that the piston rod will pop out when removing the...

Page 319: ... CYLINDER Check the master cylinder bore for scores scratches or nicks Measure the inside diameter of the master cylinder bore SERVICE LIMITS Except G type 15 925 mm 0 6270 in G type 14 055 mm 0 5533 in MASTER CYLINDER PISTON Inspect the piston for scores scratches or other faults Check the primary and secondary cups for damage or deterioration Measure the master piston 0 0 as shown SERVICE LIMITS...

Page 320: ...the master cylinder piston NOTE Handle the master cylinder piston cups and spring as a set CAUTION When installing the cups do not allow the lips to tum inside out Be certain the circlip is seated firmly in the groo e HONDA GL1200D GL1200A r N PRIMARY CUP _ MASTER CYLINDER DOT 4 VPISTON PUSH ROO CI RCLIP CLEVIS Install the circlip and dust cover 15 14 _ C RCLI P Ai r f DUST COVEA ...

Page 321: ... HOS Eiiiii JOINT NUTS Install the master cylinder and tighten the bolts TORQUE 24 29 N m 2 4 2 9 kg m 17 21 ft lbl Connect the reservoir hose to the reservoir and tighten the hose band securely RESERVOj lOR_ RESERVOIR HOSE BOLTS Connect the brake rod clevis to the brake arm with the clevis pin and a new cotter pin Adjust the brake pedal height page 2 181 Tighten the lock nut TORQUE 15 20 N m 1 5 ...

Page 322: ...fool rest and righten the bolts GL1200A TORQUE 10 mm Bolt 30 40 N m 3 0 4 0 kg m 22 29 ft fbl 8 mm Bart 18 25 N m 1 8 2 5 kg m 13 18 ft lbJ Avoid spilling brake fluid on painted surfaces and wind screen BRAKE CALIPERS Place a dean container under the caliper and dis connect the brake hose from the caliper REMOVAL DISASSEMBLY Remove the brake pads and pad spring Remove the caliper slide collar and ...

Page 323: ...cratches or other damage and replace if necessary HYDRAULIC BRAKES PISTON SEALS Push the piston and dust seals in lift them out and discard them Clean the piston and dust seal grooves with brake fluid CAUTION Be careful lot to dOl7U1ge the piston sliding surfaces when removing the seals PISTON INSPECTION Check the pistons for scoring scratches or other faults Measure the piston diameter with a mic...

Page 324: ... N m 2 5 3 5 kg m 18 25 ft Ib Caliper bracket lower mount bolt 20 25 N m 2 0 2 5 kg m 14 18 ft Ib Install the pad spring and pads INSTALLATION ASSEMBLY Coat the outer side of the slide collar with Hi Temperature silicone grease Install the pistons with the dished ends toward the pads The piston and dust seals must be replaced with new ones whenver they are removed Coat the seals with silicone grea...

Page 325: ...er bracket onto the fork leg Install the pivot boot and pad spring Loosely install the upper and lower mount bolt then torque the upper mount bolt TORQUE 30 40 N m 3 0 4 0 kg m 22 29 ft Ibl Install the caliper assembly onto the caliper bracket Page 15 7 CAUTION Note the caliper bracket bridge installation direction Face the m lrk B toward the inside and install the lower mount bolt through the hol...

Page 326: ... brake arm Remove the brake arm INSTALLATION Remove the cotter pin and clevis pin Disconnect the brake rod clevis from the brake arm Install the brake pedal return spring and stop light spring as shown Apply grease to the brake pedal shaft Install the brake pedal aligning the punch marks as shown Tighten the brake pedal bolt TORGUE 18 25 N m 1 8 2 5 kg m 13 1Sft lb BOLT BRAKE PEDAL 15 20 ...

Page 327: ...etal line Remove the air cleaner case and ignition coil Disconnect the metal line from the rear master cylinder Disconnect the metal line from the front brake hose Remove the metal line HOSE JOINT BRACKET METAL LINE HYDRAULIC BRAKES HOSE CUP 8 METAL LINE JOINT NUT INSTALLATION Connect the metal line to the brake hose Tighten the joint nut to the specified torque TORQUE 16 18 N m 1 6 1 8 kg m 12 13...

Page 328: ...twist the metal lines during installation Secure the lines with clamps as shown Check each line to be certain that it does not contact or interfere with any moving or sliding parts After installation check that there are no fluid leaks HOSE CLAMPS CLAMP 16 18 N m 1 6 1 8 kg m 12 13 ft lb 16 18 N m CLIP loG 1 8 kg m 12 13 ft lb 15 22 ...

Page 329: ... HONDA GL1200D GL12DOA MEMO 15 23 ...

Page 330: ...BATTERY CHARGING SYSTEM IGNITION SWITCH AEGULATQR RECTIFI ER BATTERY IGNITION SWITCH REGULATOR RECTIFIER ALTERNATOR 16 0 r iJ HONDA GL1200D GL1200A BATTERY rlllllllill L MAIN FUSE STARTER RELAY SWITCH ...

Page 331: ...c F Need charging 1 200 Charging rate 2 0 amperes max Alternator capacity 14V 360W 5 000 min rpm Regulator rectifier I Ty Transistorized non adjustable I Regulated voltage 13 15V Charging start rpm 1 000 1 200 min rpm At idle I 11 OAfAbove 12V Charging current At 3 000 min t rpm 0 8Af14 15V At 5 000 min t rpm 0 8A114 15V TROUBLESHOOTING No power key turned on Dead battery low fluid level Low speci...

Page 332: ...em the battery must be fully charged and in good condition Perform the following inspections and tests before attempting to troubleshoot charging system problems SEPCIFIC GRAVITY o 12J o w I 211 1216 The specific gravity must be checked with a hydro meter Test each cell by drawing electrolyte into the hydrometer Fully Charged 1 280 at 20 C 168 F Normal Reading 1 260 at 20 C 68 F Needs Charging 1 2...

Page 333: ...es Q t ly Venti ale when charging in on enclosed area Turn power ON OFF at the charger not 01 the battery terminals The batrery contains sulphuric acid amid contact With skin eyes or clothing Alwuys shield eyes when working with baller _ CAUTION ROllte the breather lIIbe as shown all the battery coutiol label BATTERY CHARGING SYSTEM CAUTION I I 1S SII Iflil limn HI UTtEn ItI1THI nil t LI I SEIT TH...

Page 334: ...tely after starting The needle of the ammeter should be swung widely toward the positive range of the dial then returned to DA Check the charging outputs at the speeds shown right Gradually raise the engine speed from the idle to find the speed at which the output is OA CHARGING START 1 000 1 200 min 1 rpm NOTE Measure the current after the fan motor has come to a complete stop If the ammeter show...

Page 335: ...ere is continuity between the leads and ground VOLTAGE REGULATOR RECTIFIER Remove the seat and top compartment Disconnect the regulator rectifier couplers Check for continuity between the leads with an ohmmeter BATTERY CHARGING SYSTEM REGULATOA R ECTI F IER COUPLER REDIWHITE NORMAL DIRECTION CONTINUITY 5 40 fll probe e prove I YElLOW GREEN AEDI NHITE YEllOW REVERSE DIRECTION NO CONTINUITY Over 6 0...

Page 336: ......

Page 337: ...SWITCH ENGINE STOP SWITCH IGNITIONI 23i e COILS SPARK PLUGS GEARSHAFT SENSOR BATTERY PULSE GENERATOR TACHOMETER SUB FUSE 15A I BATTERY MAIN FUSE I GNITION ICONTROL UNIT L O PULSE GENERATOR I L f f b b SPARK PLUGS GEARSHIFT SENSOR IGNITION COILS 17 0 ...

Page 338: ...smission is in 1st through 3rd gears When the transmission is shifted into 4th or 5th over drive gears a gearshift sensor signals the ignition control unit to electronically very ignition timing according to carburetor vacuum SPECIFICATIONS Recommended spark plugs For cold climate Standard For extended Blow 5 C 41 F high speed riding NGK DPR7EA 9 DPR8EA 9 DPR9EA 9 ND X22EPR U9 X24EPR U9 X27EPR U9 ...

Page 339: ...e stop switch Between spark unit and ignition coil Between ignition coil and plug Ben leen spark unit and pulse generator Faulty ignition coil Faulty ignition switch Faulty ignition control unit Faulty pulse generator Engine starts but runs poorly Ignition primary circuit Faulty ignition coil loose or bare wire Intermittent short circuit Secondary circuit Faulty plug Faulty high tension cord Timin...

Page 340: ...nect the primary wires from the ignition coils Disconnect the three coupler from the coupler holder and remove the turn signal relay from the ignition coil bracket Remove the ignition coils and cable guide by remov ing two bolts Remove the spark plug wires from the ignition coil PRIMARY COIL INSPECTION Check the resistance between the terminals with an ohmmeter as shown RESiSTANCE 2 4 3 0 n IGNITI...

Page 341: ...ps Measure the secondary coil resistance RESISTANCE 12 6 15 4 K l TRANSISTORIZED IGNITION SYSTEM PULSE GENERATOR INSPECTION Remove the left side cover and disconnect the pulse generator coupler Measure the coil resistance between white yellow and yellow lead No 1 2 cylinders or white blue and blue lead No 3 4 cylinders RESISTANCE 1 1 1 3 Kf at ZO C 68 F 17 4 HONDA GL12000 GL1200A RESISTOR ...

Page 342: ...ve the pulse generator mounting screws and pulse generators Install the new pulse generators Inspect the air gap between the pulse generator rotor and pickup AIR GAP 0 40 1 10 mm 0 016 0 043 in Install the pulse generator cover Install the swing arm page 13 21 IGNITION SYSTEM PULSE GENERATOR COVER PULSE GENERATORS 17 5 ...

Page 343: ...y reference mark At 950 100 min rpm The F mark should be aligned with the index mark At 1 500 1 750 min rpm Ignition timing should start to advance At 2 800 3 200 min l rpm Ignition timing should cease to advance HONDA GL1200D GLI2DOA F MARK MARK FLYWHEEL HERE No 1 No 2 CYLINDER F MARK No 3 No 4 CYLINDER F MARK Connect a stroboscopic timing light to the No 3 or No 4 cylinder spark plug wires Check...

Page 344: ...nsor coupler to the ground Start the engine and let it run at 2 800 3 200 min rpm Apply vacuum to the vacuum tube and check the reference mark movement The advance starts at 36 44 rnm 1 4 1 7 in Hg applied The advance ceases at 63 77 mm 2 5 3 0 in Hg applied If ignition timing is not correct check all individual ignition system components except the ignition control unit If the individual componen...

Page 345: ...on coils shift sensor and wiring are good and the ignition timing is not within specification replace the ignition control unit with new one and recheck the ignition timing See page 19 11 for shift sensor inspection 17 8 r iJ HONDA GL1200D GL1200A IGNITION CONTROL UNIT ...

Page 346: ... HONDA GL1200D GL1200A MEMO ...

Page 347: ...L1200A BATTERY CLUTCH DIODE TARTE R BUTTON STARTER RELAY SWITCH STARTER MOTOR STARTER RELAY SWITCH I NEUTRAL INDICATOR GREEN CLUTCH SWITCH GREEN DIODE GREEN RED RELAY COIL STARTER BUTTO N __ U 8 O IGNITION SWITCH FUSE 30A BATTERY 18 0 ...

Page 348: ...ngaged until the starter button is released SPECIFICATIONS ITEM STANDARD SERVICE LIMIT Starter motor Brush spring tension 560 6809 19 8 24 0 ezl 440 9 15 5 ezl Brush length 12 13 mm 0 47 0 51 in 7 5 mm 0 30 in TROUBLESHOOTING Starter motor will not turn Dead battery Faulty ignition switch Faulty starter switch Faulty neutral switch Faulty starter relay switch Loose or disconnected wire or cable Cl...

Page 349: ...tarter mounting bolts and pull the motor out of the engine case Inspect the O rings for damage or deterioration BRUSH INSPECTION Remove the starter motor case screws Inspect the brushes and measure brush length Measure brush spring tension with a spring scale SERVICE LIMITS Brush length Brush spring tension COMMUTATOR INSPECTION Remove the starter motor case NOTE Record the location and number of ...

Page 350: ...shaft Replace the starter motor if armature coils are open or shorted to the armature shaft FIELD COIL INSPECTION Check for continuity from the cable terminal to the motor case and from the cable terminal to the brush wire Replace the starter motor if the field coil is not continuous or if it is shorted to the motor case CARBLE TERMINAL STARTER SYSTEM COMMUTATORr __ COMMUTATOR BARS BRUSH WIRE I ST...

Page 351: ...EL PIN GROOVE Install the starter motor case align the index marks on the case with the index marks on the cover Apply engine oil to the new O riog Install the starter motor into the engine case sliding the drive splines into the splines of the drive sprocket then install the mounting bolts Install the rear engine cover Reconnect the batlery cables at both ends With the engine stop switch off test...

Page 352: ...n The switch is normal if there is continuity CLUTCH SWITCH DIODE INSPECTION Remove the clutch switch diode from the wire harness Check for continuity with an ohmmeter NOTE The test chart is for a positive ground ohm meter The test results will be reversed if a a ground ohmmeter is used NORMAL DIRECTION CONTINUITY B probe terminal e probe terminal REVERSE DIRECTION NO CONTINUITY o probe I terminal...

Page 353: ...MEMO HONDA GL1200DoGL1200A ...

Page 354: ...released before disconnecting and must be aligned when reconnecting The following color codes are indicated throughout this section and on the wiring diagram Bu Blue BI Black Sr Brown G Green Gr Grey Lb Light Blue Lg Light Green o Orange P Pink A Red W White Y Yellow To isolate an electrical failure check the continuity of the electrical path through the part A continuity check can usually be made...

Page 355: ... covers from the fairing Remove the windshield trim mount bolts Remove the windshield trim by lifting it with screw driver NOTE Protect the headlight with shop towel to prevent damaging the headlight lens Remove the headlight garnish Remove the headlight mounting bolts Remove the headlight garnish bracket and trim holder HONDA GL1200D GL1200A REAR VIEW MIRROR ATTACHING BOLTS WINDSHIELD TRIM TRIM H...

Page 356: ... and position light wires and remove the headlight SCREWS BEAM ADJUSTING CABLE INSTALLATION Connect the headlight coupler position light wire and beam adjusting cable to the headlight Install the headlight trim holder bracket and garnish bracket Install the headlight garnish Latch the windshiled trim into position by pushing it down on top MOUNTING BOLT LATCH 1 19 3 ...

Page 357: ...adlight beam if necessary HONDA GL1200D GL1200A REAR VIEW MIRROR BOLTS INSTRUMENTS REMOVAL Flemove the headlight from the faring Remove the spark covers speakers and meter visor GL1200A METER VISOR l SPEAKERS GL1200A Disconnect the instrument coupler from the wire harness Remove the four nuts from the instrument mount studs Remove the radio bracket from the instruments GL12QOA Disconnect the speed...

Page 358: ...bracket from the instrument case Remove the tripmeter knob GL 12000 Remove the instrument glass and instrument panel by removing four screws Remove the meters from the instrument case LIGHTS SWITCHES INSTRUMENTS BRACKET SCREWS L C D UNIT L DDA _f I I J I ODOMETER 19 5 ...

Page 359: ...IINSTALLATION The assembly and installation sequences are reverse order of disassembly and removal GL1200AI INSTRUMENT PANEL G L1200DI INSTRUMENT GALSS INSTRUMENT PANEL 19 6 CASE J L C D UNIT TACHOMETER CASE HONDA GL1200D GL1200A BRACKET ...

Page 360: ...u touch the bulb with your bare hands clean it with Q cloth moistened with alcohol to prevent its early failure Install the headlight in the reverse order of removal Page 19 3 FRONT TURN SIGNALS Remove the turn signal lens by removing screws Remove the bulbs from the base plates The installation sequence is the reverse order of remova1 CAUTION Be careful not 0 overtighten the eru mount ing screws ...

Page 361: ...move the two cap nuts Turn the butb socket counterclockwise and remove the socket from the housing Remove the bulb by turning it counterclockwise GL1200A Remove the under cover by removing three screws 19 8 HONDA GL12000 G11200A SOCKET TAIL BRAKE LIGHT BULB U TYPE ONlY UNDER COVER SCREWS ...

Page 362: ...counterclockwise Remove the bulb by turning it counterclockwise METERIINDICATOR BULB Remove the instruments Page 19 4 Remove the socket from the meter case Remove the bulb from the socket by pulling the bulb LIGHTS SW ITCHES I NSTRUMENTS SOCKETS BULB INSTRUMENTS BULB 19 9 ...

Page 363: ...e normaly r iff HONDA GL1200D GL1200A SWITCH WIRE GROUND Apply a liquid sealant to the switch threads Install and tighten the switch TORQUE 10 14 N m 1 0 1 4 kg m 7 10 ft Ib CAUTION Be CtJreful not to overtighten the switch to prevent damaging the threads of the engine cover Connect the switch wire to the switch Install the rubber cover onto the switch Oil PRESSURE SWITCH SWITCH WIRE REAR BRAKE LI...

Page 364: ...4 RIW 5 0 0 G D HANDLEBAR SWITCHES The handlebar cluster switches lights turn signals horn etc must be replaced as assemblies Continuity tests for the cOmponents of the handle bar cluster switches follow Continuity should exist between the color coded wires on each chart HEADLIGHT HI LOW SWITCH LIGHTS SWITCHES INSTRUMENTS TURN SIGNAL SWITCH HORN BUTTON HI MIDDLE N LO BulW to Bu BuIW to W to Bu BuI...

Page 365: ...r to 0 SrlW to lblW HORN BUTTON WIG to Lg with button depressed No cintinuity with button released HAZZARD SWITCH OFF No continuity ON Pto LhtoO 19 12 r iff HONDA GL1200D GL1200A W R l TLI PR Pl R N L Color code G lb 0 B N1 lbNl ONi BAT3 I Ho i i Color code wiG I l W R N OFF ON Color code P lb 0 ...

Page 366: ...L P 0 H 0 C Color Sr Bu 8 1W SI A 80IW d STARTER BUTTON Bl to YfR with button depressed No continuity with button released ENGINE STOP SWITCH RUN 81 to BIIW OFF No continuity LIGHTS SWITCHES INSTRUMENTS ENGINE STOP SWITCH EADltGHT SWITCH BAT2 ST FREE PUSH Color code 81 VIR BAT2 IG OFF RUN Color code 81 811W 19 13 ...

Page 367: ... are no colors on the switch Check continuity of the terminals on the ignition switch in each position LOCK OFF No continuity ACe R to Lg SI ON R to BI to le SI to Bu O Srtw to Bf P A to 19 et to ef IGNITION SWITCH DISASSEMBLY Insert the key and position it Up position 19 14 HONDA GL1200D GL1200A IGNITION SWITCH II BOLTS BAT IG ACC FAN P TL1 TL2 LOCK OFF ACC ON p Color code R BI Lg SI ButO Be Berw...

Page 368: ... WIRE CLAMP CONTACT BASE Check continuity of the clutch lever safety S vitch with the dutd l released and applied and replace if necessary CLUTCH APPLIED CONTINUITY CLUTCH RELEASED NO CONTINUITY REMOVAL Unplug the wires and remove the clutch lever and cable Remove the switch NOTE The switch case has a small protrusion that must point toward the handlebar when installation CLUTCH SWITCH TERMINALS 1...

Page 369: ...to the thermometer readings as the oil heats GL1200D 120 C 24SoF TEMP SENSOR INSPECTION Suspend the sensor in oil and measure the resistance through the sensor as the oil heats up GL1200D G Br SENSOR GL1200A OIL JM J t SENSOR HONDA GL1200D GLI200A THERMO SENSOR WIRE 60 C 85 C 110 0 e t20 C Temperature 140 F 185 F 230 F 24S F Resistance 140n 44 n 20n 16 n Do not let the unit or thermometer touch th...

Page 370: ... wires to the fuel level sensor Turn the ignition on and inspect the fuel gauge operation by moving the float arm Float at bottom Gauge should read empty Float at top Gauge should read full NOTE I Do not bend the float arm FLOAT Reinstall the fuel level sensor Check the resistance at top of travel first then move the float arm to the bottom position SENSOR INSPECTION Check the resistance of the fu...

Page 371: ...ot light when the ignition switch is turned ON with disconnected the coupler from the fuel level sensor If the warning light comes on check for a short circuit in the wire harness or coupler Replace the sensor if nothing wrong is indicated THERMOSTATIC SWITCH If the fan motors do not start inspect the coolant level page 3 11 before switch inspection Fill the cooling system with recommended coolant...

Page 372: ...BRAKE AND TAIL LIGHT SENSOR SYSTEM INSPECTION Turn the ignition switch ON The tail light warning light should light for a few seconds and go out If the warning light does not light check the warning light bulb filament or wiring for an open or short circuit If there is no problem in the bulb or wiring replace the brake and tail light sensor with a new one If the warning light does not go out after...

Page 373: ...2000 GL1200A 12V BATTERY The relay is normal if there is continuity when vohage is applied r 1 OHMMETER FUEL PUMP RELAY Remove the top compartment and ignition coils Remove the fuel pump relay from the mount bracket Check for a burnt sub fuse Check the relay coupler for improper contact and looseness Measure the voltage between the relay black wire and abody ground The battery voltage should reqis...

Page 374: ...r biue yellow wire If there is continuity replae the fule pump relay lf there is no continuity replace the wire harness SELF CANCELLING TURN SIGNAL SYSTEM INSPECTION Test ride the motorcycle to check the turn signal cancelling system operation If the system is faulty proceed as follows NOTE Before going into detailed inspections first check that the sub fuse is not blown Also check that all wires ...

Page 375: ...tment Disconnect the brown control unit coupler Cii HONDA GL12000 GL1200A STEEFjING STEM ANG LE SENSOR BROWN COUPLER BROWN 9P COUPLER Turn the ignition switch to ON and push the turn _ signal switch to the LEFT position Connect the Blue Black and BrownlWhite terminals in the wire harness side connector with a jumper wire If the switch returns to neutral cancels it is normal Check the switch in the...

Page 376: ...BROWN 9P COUPLER Turn the ignition switch to ON OIW BulW Measure the voltage between the Green and Blue White and Green and OrangelWhite terminals with the tUfn signal switch in each position Position BulIN to G O W to G RIGHT OV Minimum lOV NEUTRAL Minimum 10V Minimum lOV LEFT Minimum 10V OV ANGLE SENSOR HARNESS Disconnect the angle sensor coupler 3P white located inside of the fairing Check the ...

Page 377: ...suddenly ANGLE SENSOR SUB WIRE HARNESS Remove the angle sensor from the steering stem Check the continuity end to end for each wire Between same colors Continuity Between different colors No continuity BIIY w GIW 3 BIIY CONTROL UNIT REPLACEMENT Replace the control unit with a new one if the turn signal switch is still not cancelled automatically Remove the air cleaner case and air cleaner element ...

Page 378: ...d Battery voltage should be indicated SPEED SENSOR INSPECTION LIGHTS SWITCHES INSTRUMENTS Dj connec the speed sensor from the speedometer gearbox Connect a voltmeter across the Green Black and Black Yellow terminals of the sensor white 3 P coupler Turn the ignition switch to ON The sensor is normal if the voltmeter needle swings from 0 to about 5V slowly eight times when the sensor drive shaft is ...

Page 379: ... pump Check the pressure sensor if the pressures applied to the sensor do nOI agree with the pressures indi cated on the pressure gauge Page 13 26 Check the wire for loose or poor connection if the sensor IS normal Replace the L C D unit with a new onl if necessary GEAR POSITION INDICATOR Disconnect the black G p coupler from the meter turn on the ignition switch Check lor correct indication in ea...

Page 380: ...r from the meter unit and check for continuity between the terminals in each switch position E U type only I Color code YIG V SI Yffl GIB RIY RIG Lg Y BulBI BUTTON TRIP 1 C 0 TRIP 10 D TRIP 100 TRIP 0 D a SET C 0 DIG TACH mph km h 0 LIGHTS SWITCHES INSTRUMENTS BLACK 9P COUPLER 19 27 ...

Page 381: ...MEMO HONDA GL1200DoGL1200A ...

Page 382: ... when performing the following services Rear wheel removal and installation Rear suspension removal and installation Rear fender removal and installation Rear brake caliper repair After removing the fairing wrap it around with a blanket or shop towel to prevent damage to it Avoid contact with chemicals brake and clutch fluid gasoline thinner or other solvents Use two people when removing and insta...

Page 383: ... mounting socket bolts Pull the seat adjust lever Move the seat toward the rear of the motorcycle and remove the seat HONDA GL1200D GL1200A SEAT MOUNTING SOCKET BOLT SEAT 1 i0 mM 0 SEAT ADJUST LEVER RemOlle the right fairing pocket lid covers and left fairing pocket 20 2 LEFT FAIRING POCKET COVERS ...

Page 384: ...ain wire harness coupler Remove the coupler holder mounting screws Replease the wire band securing the wire harness to the fairing bracket Disconnect the antenna wire terminals from the wire harness terminals inside the fairing Remove the wires from the fairing GL1200A Remove the coupler holder mounting screws Release the wire band securing the wire harness to the fairing bracket WIRE BAND 20 3 ...

Page 385: ...iring lower covers by removmg screws and collars Remove the fairing inner cover by removing the screw and collar Remove the right and left horns from the fairing bracket Remove the right and left socket bolts 20 4 r iiJ HONDA GL1200D GL1200A ...

Page 386: ...e the two center bracket mount bolts Remove the fairing ACCESSORIES BOLTS FAIRING BRACKET REMOVAL Remove the fairing bracket from the fairing by remove the two socket bolts two flange bolts and four nuts FAIRING BRACKET FLANGE BOLTS NUTS SOCKET BOLTS 20 5 ...

Page 387: ...NDA GL1200D GL12DOA FAIRING ASSEMBLY Except U type 8 12 N m 7 _IOj 87m 6 9 ft lbl r 8 12 N m 0 8 1 2 kg m 6 9 ft lbl lB 25N m 1 8 2 5kg m 13 18ft lb 8 12N m O 8 1 2 kg m 6 9 ft lb 7 11N m 0 7 1 1 kg m 5 8 ft lb 20 6 ...

Page 388: ...ew the two screws anaching the saddlebags to the rear fender Remove the four saddlebag mount bolts Release the tail brake light switch wires and rear turn signal wires from the wire clamps on the saddlebag bracket Disconnect the wire coupler and remove the saddlebags ACCESSOR IES SCREWS BOLTS COUPLER 20 7 ...

Page 389: ...avel trunk by removing the four mount bolts SAOOLEBAGITRAVEL TRUNKITRUNK BRACKET REMOVAL Remove the rear fender and mud guard Remove the rear bumper Remove the passenger foot rest brackets GL 1200A Remove the saddlebag travel tfunk bracket bolts and remove the bracket 20 8 r iJ HONDA GL1200D GL1200A TRUNK LID REAR BUMPER TRAVEL TRUNK BRACKET ...

Page 390: ...D GL1200A ACCESSORIES INSTALLATION 24 30 N m 2 4 3 0 kg m 17 22ft lb 8 12 N m 0 8 1 2 kg m 6 9 ft lb 8 12 N m _ _ 0 8 1 2 kg m 6 9 ft lb U I 24 30 N m 2 4 3 0 kg m 17 22 ft lb 30 40 N m 3 0 4 0 kg m 22 29 ft lb 20 9 ...

Page 391: ...ACCESSOR IES CiiJ HONDA r GL1200D GL1200A v AUDIO SYSTEM GL1200A POWER AMPLIFIER SPEAKERS AUTO VOLUME TONE CONTROLLER I ANTENNA RADIO CASSETTE DECK ANTENNA CABLE 20 10 ...

Page 392: ...ler panel from the fairing Remove the controller from the panel by removing the mount nut and screws FUSE REPLACEMENT The fuses from the motorcycle s audio system and accessories are located inside the left fairing pockt Back up power supply 7 5A Radio cassette deck 20A CAUTION lv henver Q use is blown be sure to isolate the cause and take co ective measure before installing a new olle CONTROLLER ...

Page 393: ...E OLLER iR g o ANTENNA RADIO CASSETTE DECK W Sl I I SPEEDDM AUTQVOLU ITONECONTR G Lg BI POWER AMPLl RiB BulBI Yi Y B j MUT ARCH JGtB L g SWITCH LEFT SPEAKER RIGHT PE FUSE 20A FUSE 7 5A BrlW Lg BI V R IGNITION SWITCH MAIN FUSE 30A BATTERY I 20 12 ...

Page 394: ... not require adjustment and help the engine to run quieter by keeping valve clearance at zero at all engine temperatures and engine speeds up to redline The tappets are continuously supplied with air bled oil from the de foaming chamber in the rocker arm holder where oil passes through ROCKER ARM ROCKER ARM SHAFT DE FOAMING CHAMBER HYDRAULIC TAPPET 21 1 ...

Page 395: ...nother notch in the shaft Together they make the eccentric rocker arm shaft revolve to help maintain zero valve clearance INTAKE ROCKER ARM SHAFT INTAKE ROCKER ARM t HYDRAULIC TAPPET ADJUSTER EXHAUST ROCKER ARM INTAKE VALVE j EXHAUST VALVE _ HYDRAULIC TAPPET ADJUSTER ROCKER ARM SHAFT ASSIST SHAFT If I PLUNGER 21 2 OIL INLET HOLE CHECK BALL CAGE HIGH PRESSURE CHAMBER BODY k f 1 CHECK VALVE PLUNGER ...

Page 396: ...against the plunger At the same time the rocker arm is pushing against the tappet plunger This causes a very small amount of oil to leak out of the high pressure chamber bet ween the plunger and body This allows the plunger to absorb the shock from the effects of the cam lobe reaching maximum lift After the cam lobe passes maximum lift the engine valve springs force the engine valve to close and t...

Page 397: ...MEMO HONDA GLI200D GL1200A v ...

Page 398: ...tank cap vent hole WEAK OR NOSPARK __ 1 Faulty spark plugs 2 Fouled spark plugs 3 Faulty ign tion control unit 4 Broken or shorted high tension wires 5 Opened or shorted in ignition circuit 6 Broken or shorted ignition coil III Faulty ignition switch 8 Faulty pulse generator LOW COMPRESSION 1 Low battery charge 2 Improper valve clearance Faulty hydraulic tappet J Valve stuck open 4 WOrn cyl nder a...

Page 399: ...L Oil level too low I TOO LOW III 7 T t cylinder cOffipre lion Vallie stuck open 121 Worn cylinder and piston rings NORMAL Leaking head gasket l Improper vallie limin Faulty hydraulic tappet Check carburetor for clogging CLOGGED Ill Carburetor not serviced frequently enough NOT CLOGGED I Remove park plug FOULED OR DISCOLORED Plug not erviced frequently enough NOT FOULED OR DISCOLORED Spark plug wi...

Page 400: ...rator 111 Fuel tank empty 121 Clogged fuel line or fuel filter 131 Clogged fuel tank cap ent hole Sticking float al e lSI Faulty fuel pump 161 Faulty fuel pump relay Clean INCORRECT Camdri e pulley not in5talled properly CLOGGED _ INCORRECT _ WEAK Faulty spring FUEL FLOW RESTRICTED 1 Check ignition timing and tappet noise CORRECT t 2 Disconol fuel line al earburetor FUEL FLOWS FREELY I 3 Remo e ca...

Page 401: ...Faulty hydraulic tappet CORRECT j 131 Air in hydraulic tappet Worn or nicking hydraulic tappet 151 Improper hydraulic tappet imtallation 5 Oisassemble camshaft holder and check INCORRECT 111 Worn or damaged rocker arm or parIS shaft 121 Worn valve stem 131 Broken or weak assist spring 1 1 Sticking assist shaft 151 Use of improper shim 161 Improper installation 171 Worn camshaft LOW CYLINDER COMPRE...

Page 402: ... HONDA GL1200D GL1200A MEMO ...

Page 403: ...ns some warnings and cautions against some specific service methods which could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe Please understand that those warnings could not cover all conceivable ways in which service whether or not recommended by Honda might be 4pne or of the possibly hazardous consequences of each conceivable way not could Honda investi...

Page 404: ... HONDA GL1200D GLI200A LJ7 7 v A I A Lr L I IV I d 11c K 1 41 ill r l llu j h 1 _ _J 1 i _ m 1D3 cE L It 03 _ _ _ 0 _ 0030Z MG9 8300 oj _ oJ o 0 o L I c 1 If m 0 L fl ...

Page 405: ...GENERAL INFORMATION Gl1200A E F ED SW I w i L 1 111111111 I Ij _ g l _ 111 u d J l sl li J t er l _ _ _ _ _ 1 fJ i r _ _ I illl OJ I t c _ n _ i N rrrc _ _ 1 1 Ir dr O UO TO n _ 0 01 _ C h 00 1 _ 1 18 ...

Page 406: ...GENERAL INFORMATION 1 L 1 _ _ 8 SO 0030Z MG9 9700 cF t 1IJ l B j _ _ 1 19 I ...

Page 407: ... HONDA GL1200D GLI200A ro _ 10 Ow i N M r 1 0 i __ 3 i 4 Tr f _ H 0 ro J _ I 1 0 to _ _ TT 0 MM _ 1 K N __ _ J t l I M 1 j i T 1t U _ _ _ 01 wT M ro L __ L _ j c c_ _ _ tl H G11200A SO ...

Page 408: ...CiiJ HONDA Gl1200D GlI200A _ _ II _ _ _ 03 _ _ _ t K 5 i u 0030Z MG9 8400 ID iI _ 1m __ 0 _ _ __ _ _ Y oro _ _ IC K e i m I JoT toO _ to l W ft i 1 0 _ l E5 L 0GU 0_ _f _ I ...

Page 409: ...GENERAL INFORMATION GL1200A U 9 I _ _ _ _ _ _ _ T O iI _ 1 _ IOU K I _ _ _ _ _ _ __ _ _ _ _ _ _ _ _ _ _ _ Eb I 1 20 ...

Page 410: ...GENERAL INFORMATIO i i ao ti mI Ill w oJ L __ wj 1 t r ITr l rf r C C _ 411 N _ _ w 1 03 sw 0030Z MG9 7000 e M1 1UJ 11 11 L w _ t w 1 1 15 I ...

Page 411: ... E F ED SW _r _ al H T l C lI 0 2 J l t _ O k IT 40 _ Ji 0 00 to 0 5onrr _ I TUn 10 Md _ l 1 J III I L ecJ l F _ or 1 0 Q u l W I I 2 1_ roc _ JOIl J 0 I a 0 0 III TU s l r _ k OUIO i _ Qo In T n n r S a In o _ O ON Iv I c 11 0 Ie I ...

Page 412: ...GENERAL INFORMATION _ _ C8 c _ r i n Ql I NL I LQJ _ to _ 0 ____ II C _ _ _ w _ i SA 0030Z MG9 7600 _ tt _ _ roo _ o _ _ r 110 _ _ Ilr 1 1 17 I ...

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Page 414: ... HONDl GL1200D GLI2 _ i _ _ co 0 N _ rrrD3 o e rr u J _ SO 0030Z MG9 9600 IAn h M _ l RMO rot _ ...

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