Honda Goldwing GL1200L 1985 Manual Download

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Summary of Contents for Goldwing GL1200L 1985

Page 1: ...to know what the vehicle needs to in condition and within EPA established standards The first scheduled eS lecially imrlnrtAnt since it COlnpl lnSistels the break in In sections 10 1 Service Information follows i nr t r t be sure to read those few lines before you pro1cedlure to avoid any difficulty once you re in the middle of a In most cases a reference draw will be in Service Information values...

Page 2: ...General Information Service Safety 1 2 Important Safety Notice 1 2 Model Identification 1 3 Emission Control Systems 1 4 Metric Conversions 1 7 H ...

Page 3: ... near the battery especially while it IMPORTANT SAFETY NOTICE Detailed of standard and service are not included It is imrlnl 1 lnf to note that this manual contains some some service methods which could cause PERSONAL INJURY to service or could a vehicle or render it unsafe Please under stand that those could not cover all conceivable ways in which whether or not recommended be or of the hazardous...

Page 4: ...Model Identification 1 1 GL1200L Umlted GOLD WING LIMITED EDITION 1 3 ...

Page 5: ...o Ltd utilizes a se or1ldalry air and hv iro arIJorIS sv tern as well as other SYI telms to reduce carbon monoxide Exti8U St Emission Control System Secondary Air Supply System The exhaust emission control SYistem consists of a air supply which introduces filtered air Into the exhaust gases in the exhaust Fresh air is drawn into the exhaust port whenever there is a negative pressure in the exhaust...

Page 6: ...l vapor from the fuel tank is routed into a charcoal canister where it is adsorbed and stored while the engine is stclpp ed When the motorcycle is running and the purge control diaphragm valve is open fuel vapor in the charcoal canister is drawn into the 1II11 No to the emission control SVlstem are necessary however periodic inspection of the hoses and canister is recommended 1 5 ...

Page 7: ... or rendered any person AMONG THOSE ACTS PRESUMED TO CONS rlTi TAMPERING ARE THE ACTS LISTED BELOW 1 Removal or the muffler baffles header or any other component which conducts exhaust gases 2 Removal or of any part of the intake sYl tern 3 Lack of proper maintenance 4 any of the or of the exhaust or intake system with parts other than those the manufacturer Emission Control Information Label The ...

Page 8: ...m Sq centimeter kg cm2 Fahrenheit F 1 Cenltigra le C 0 Foot ft Ib Newton meters N m Feet ft Inches in Meter m Millimeter mm Miie mi Kilometer kml 0 723 1 383 3 281 0 03937 0 3048 25 40 0 6214 1 609 14 22 0 0703 x 1 32 1 8 0 2642 1 0568 0 9463 3 785 0 061 16 39 2 205 0 03527 28 3495 0 6214 1 609 Kilometer hour Miles hour mph 0 Fahrenheit Liter Il Liter I Quart Gallon Meter Millimeter Feet Inches Ki...

Page 9: ...Specifications General 2 2 eFt l I It 11 III iii It iI ill iii tI 11 iii 11 e 11 01 2 3 Electrical 2 4 Standards Service Limits 2 5 Torque Values 2 8 ...

Page 10: ...ression ratio Valve train Oil capacity At disassembly After draining Lubrication system Cooling system capacity Cylinder compression Engine weight Intake valve Opens Closes Exhaust valve Opens Closes Valve clearance Idle speed Double cradle Telescopic 140 mm 5 5 in 0 10 0 14 psi SWing arm 105 mm 4 1 in 20 6 5 28 92 psi 30190 1667H 2 25 32 psi 50190 15 74H 225 32 psi Double disc 952 cm2 148 sq in S...

Page 11: ...w SoC 41 F ND X22EPR U9 For extended high NGK DPR9EA 9 speed riding ND X27EPR U9 Spark plug gap 0 8 0 9 mm O 031 Q 035 in Firing order 1 3 2 4 Fuses 7 5A lOA 15A and aDA main fusel 2 4 2 7 psi 2 0 2 4 psi 55 1 85 Ohms 20 C 68 Fj 3 58 4 02V 2 85 350V 2 16 2A5V 1 2HAOV 4 75 5 25V 4 75 5 25V 4 6 K Ohms OA75 0 495V 29 1 36 3 Ohms OA 0 9 mm 0 016 0 035In 30 36 Ohms 58 82 mm 0 023 0 024In 2 3 K Ohms 0 2...

Page 12: ... 1073 12V 4W 12V 2 cp SAE No 57 12V 2 cp SAE No 57 12V 2 cp SAE No 57 12V 2 cp SAE No 57 12V 2 cp SAE No 571 12V 2 cp SAE No 57 12V 20A 1 280 12 13V 1 260111 12V i 200 below 12V 2A max 3 OOO rpm 490W 5 OOO rpm Transistorized 14 15V 1 000 1 200 rpm Starter motor Electrical Brush Brush Oil pressure switch continuity pressure Fan motor switch No continuity temperature Continuity temperature Temperatu...

Page 13: ...0 25 021 IU O U ou 27 000 27 021 0 050 0 087 lvV V IJ VV l 1 0 030 0 067 35 6 1 40 24 91 26 91 059 25 05 0 986 27 05 1 065 0 14 0 006 0 14 0 006 Cylinder Piston Crankshaft I Cylinder compression Cylinder Inside Diameter Out aI round Taper Warpage across lop of cylinders Cylinder Pislon 0 0 at skirt Pislon lo cylinder clearance 11 15 156 213 psI 75 500 75515 2 9724 2 9730 75 470 75 490 2 9713 2 972...

Page 14: ...25 06 0 987 28 06 1 105 30 90 1 217 27 90 1 098 0 15 0 006 0 16 0 006 0 16 0 006 0 15 0 006 100 3 9 Min 0 010 U JUU41 Max 0 1 31000 31 025 1 2205 1 2215 31 000 31 033 2205 1 2218 25 020 25 041 IU Cl U U l lIOO 1 28 020 28 041 1031 1 1 30 950 30 975 12185 1 2195 27 959 27980 1 1007 1 1016 0 025 0 075 0 025 0 083 0 040 0 082 0 040 0 082 0 0016 0 0032 1774 6 98 84 5 110 9 0 05 0 002 12 966 12 984 0 5...

Page 15: ...SAE 80 APi GL 5 7 US 130cc US 0 08 0 18 0 003 0_007 0 3 0 01 Difference at 3 points O 0 0004 Frnal gear assembly preload Rrng gear to case stopper clearance 2 0 4 0 kg em 1 7 3 5 in lh 0 3 06 O 01 0 02 Front brake master Rear brake disc 12 755 0 5022 12 645 0 4978 25 460 32 090 25 310 v oa 31 940 9 0 0 35 0 3 0 01 15 925 15 815 32 090 1 31 940 1 6 0 0 3 5 4 5 6 0 21 0 22 15 870 15 913 V O O Ij O O...

Page 16: ...0 35 25 NOTE 1 2 8 26 19 24 6 12 9 Crankshaft cap bolt 1 2 mm 4 12 70 51 NOTE 1 10 2 10 50 36 NOTE 1 rod cap nut 8 9 32 23 NOTE 3 Gearshift arm lock bolt 1 8 26 19 fork lock bolt 1 7 16 12 Oil filter bolt 1 12 30 22 Oil drain 1 14 38 27 Alternator drive shaft holder bolt 5 6 12 9 Oil pressure switch 1 12 9 NOTE 4 Starter clutch outer torx bolt 3 8 25 18 NOTE 2 Coolant sensor 1 23 17 NOTE 4 fan mot...

Page 17: ...8 25 18 Front brake disc bolt 5 8 30 22 Front brake bracket 2 10 35 25 2 8 23 16 Brake bolt 3 12 28 20 Brake bolt 3 8 23 17 Brake hose oil bolt 4 10 30 22 Brake metal line 6 10 17 12 Front brake master holder bolt 2 6 12 9 Rear brake disc nut 5 8 30 22 Rear brake master bolt 2 8 27 19 Rear brake rod lock nut 1 8 18 13 Rear axle nut 1 18 95 70 Rear shock absorber mount nut 2 10 35 25 Rear shock abs...

Page 18: ... mount bolt 2 10 40 29 Muffler bolt 4 8 22 16 Center stand bolt 2 8 18 13 Side stand lock nut 1 10 22 16 Rear brake bolt 1 8 22 16 Gearshift 1 6 10 7 Rear fender bolt 2 8 14 10 Seat bolt 2 8 22 16 Standard Torque Values Item 5 mm bolt and nut 6 mm bolt and nut 8 mm bolt and nut 10 mm bolt and nut 1 2 mm bolt and nut o Torque Values 5 N m 4 10 N m 7 ft lbl 22 N m 16 35 N m 55 N m ft lbl Item 5 mm s...

Page 19: ...Maintenance Maintenance Schedule 3 2 Fuel Filter 3 3 Air Cleaner 3 4 Throttle Valve Synchronization 3 5 Cruise Valve Element 3 6 ...

Page 20: ...NECESSARY R ncrLI U w Q 1 0 zr c o W r Z 1 be serviced an authorized Honda dealer unless Ihe owner has proper tools and service data and is mechanically inclined interest Of we recommend these items be serviced only by an authorized Honda dealer If page reference is nollisled consull the GL12001 A Service Manual NOTES fre l H nllv when riding dusly areas rreau ntIY when riding rain or al fulllhrot...

Page 21: ...lve and Inniti n switch OFF BANJO BOLT line and to drain the lines SOI 8vina out bolts to disconnect the fuel lines and remove the filter from Remove the Loosen the 6 mm its bracket a towel Loosen the fuel line and filter and to Install the new filter in the filter bracket Connect the fuel lines the bolts BANJO BOLT SEALING WASHERS the fuel line with bolt switch ON to check for fuel line leaks Tur...

Page 22: ...e r t sensor COIJpll lf and the breather hose from the air cleaner cover Remove the air cleaner cover Remove and discard the air cleaner element Install in the reverse order of removal and attach the AIR CU NERC fEA Install the new element with the breather hose arclmrnet the rear Install the air cleaner cover with breather hose NOTE Be careful not to darna le the COlJpIE r terminals installation ...

Page 23: ...d are not Differences in vacuum reStOlrlCS between these is due to car UUlliU 11 J on the throttle valve VINYL TUBE THROTTLE VALVE remove the air cleaner case to the T1 senSOL Connect a and let it idle dirt from drawn into the air chamber hose to spray f1AI hlllrAf 1 nliAl llrlA into the in thrt il h the wire screen NOTES Decarbonize the throttle valve with the vacuum the lowest last the throttle ...

Page 24: ...k the air Inlet hole or hose dur Ing or the cruise control will not side covers and top cornp81rtment Remove the Remove the element cover Remove and discard the cruise valve element Install the new element and assemble the order of removal 3 6 in reverse ...

Page 25: ...Engine Removal Installation Removal 4 2 Installation 4 6 ...

Page 26: ... access to the electrical COljplE rs remove the NOTE Drain the removed Install the drain Disconnect the Disconnect the starter cable at the starter Remove the crankcase breather tank Disconnect the alternator cOlupllSf Remove the fuel pump and bracket bolt Remove the foot peg and U JIJUH the fuel pump with str or wire ...

Page 27: ...sensor wire 4P l iYIUUII 2P and red sub hamess Release the wires from the wire band Disconnect the Ns sensor wire Disconnect the Disconnect the oil pressure sensor Disconnect the Tw sensor Releaele the wires from the wire bands Release the shift sensor Ns sensor and fan motor wires from the wire bands and wire l ili lmlJiJ ...

Page 28: ...the clutch lever in and tie it to the handlebar This overextension of the slave cylinder Remove the two bolts from the top of the front mount bracket Re mo ve the two bolts from the bracket front Remove the fan shroud and the front braickE t Remove left engine mount bolt a nd the cap then remove the sutlfrslme ...

Page 29: ...the right Remove the Place a floor belt cover for added clearance removal or other adjusitable ll lnrlnrt under the mount bolts Release the clutch hose from the hose Remove the trislnOllllar side mount bracket from each With the aid of another person to the while you raise the boss Ollt of the frame tabs cont d 4 5 ...

Page 30: ...me while shaft with the universal Lubricate the shaft with a IIIVI UlJ fJ NLGI no 2 grease with 40 M J additive CAUTION Be careful not to damage the brake lines en gmie removal Move the install mo unltinQ bolts and nuts Hand mounting points with the to to mount lng bolt threads wire harnesses and cables in this order 1 The left and then the rear mount bolts 2 The and bolts 3 The forward mount bolt...

Page 31: ... relieve stress from re m inirln bolts or other adjustable under the mount bolts Remove the right Place a floor Release the clutch hose from the hose clamp Remove the trlslnglular side mount bracket from each With the aid of another person to the l 1l d I I the while you raise the right rear boss out of the frame tabs 4 5 ...

Page 32: ...Remove the and Quenee shown 1 60 N m 2 35 N m 3 60 N m 4 60 N m 5 22 N m 16 6 35 N m 7 35 N m 8 22 N m 16 the Mnllntlr n bolts in the se Left side only Left side 4 7 ...

Page 33: ...Frame Suspension Handlebar Replacement 5 2 Front Fork Illustration 5 3 Rear Shock Illustration 5 3 ...

Page 34: ...emove the handlebar switch Release the handlebar cover two screws Remove the two 6 mm bolts and four handlebar mount bolts Remove the set Installation and handlebar Install the handlebar in the reverse order of removal Torque Handlebar mount bolt 10 mm 35 N m 26 ft lb Handlebar locating bolt 6 mm 10 N m 7 5 2 ...

Page 35: ...0L has an extra and an oil se ar ltor between the upper and lower fork nrin UPPER SPRING PISTON RINQ OIL SEPARATOR ________ LOWER SPRING Rear Shock Illustration The Gl1 200L has a check valve at each rear shock absorber CHECK VALVE 5 3 ...

Page 36: ...Brakes Front Master Cylinder 6 2 ...

Page 37: ...clina to the base manual Iiatlt cruisle cancel switch from the looserling the screw Installation the gap between the holder and the master cylinder with the arrow on the handlebar Install the brake cancel switch by ali ilninlQ the switch with the master hole the screw AI I ifAlv ...

Page 38: ...Ignition Service Information 7 2 Troubleshooting 7 4 I t T gnl Ion imlng 7 5 Ignition Coil 7 6 Spark Unit 7 7 Spark Unit Resister 7 8 III 1 11 ...

Page 39: ...nsor inslpe tio n Be sure the is ch lrQE d before trolJbh shoolting the outputs at pins insert the tester them open Be careful not to short out from behind the coupler pins to avoid bending or prying a vVIUIJ OI or connector Turn the switch OFF Positive and neClatl e sides are so marked Do not remove from the llnl r l ECU Coupler Pin Numbers FUSE RELAY BOX T1 SENSOR OR Gt SENSOR 7 2 ...

Page 40: ...liindl9r of residual Olc lir r inkinn 2 or 3 seconds with the switch and fuel valve OFF 1 0 does not start or is hard to I _ J No Spark at One Plug 1 _ plug No Pall No Spark at All Plugs SPARK TEST Remove and 1 1 _ Go to eFI check for at each cvlindl9f Troubleshooting Fuel indicator does not light page 10 7 PLUG CAPS AND LEADS Measure resistance between caps of Abnormal 1 FaUlty cap Faulty lead Fa...

Page 41: ...G Check from W with Y tube wire to ECU vUU 7 and from G with Bu tube W tube wire to 8 Continuity Ilf Volts 1 circuit between unit and coli nl i Yl J terminal Poor contact at No Continuity 1 circuit Poor contact at IGNITiON COil Ins ect page Abnormal 1 1 Faulty ignition coiL Normal CAMSHAFT ANGLE SENSORS Ins ect Gr GI sensors page 1 Normal Abnormal 1 FaUlty Gr GI sensors Faulty ECU ...

Page 42: ... 1 or No 2 wire Start the engine and let it idle tdle 1000 t 100 rpm The is correct if the F1 mark the inspe cticm cap center index mark at idle advance is correct if when the the F1 mark moves up and dj iappel rs with is AT IDLE SPEED 1 000 100 RPM AT INCREASED ENGINE SPEED Oth install mark Connect the light to the No 3 or No 4 cylinder wire and the the F2 If the is check the PBR PBL and Tw senso...

Page 43: ...ove both Remove the air cleaner case aS lemlbly Remove the two bolts and the throttle cable Pull the coil toward the air cleaner Remove the coil screws and disconnect the ter minal wires Remove the coil NOTE When the the and Y Bu wires go to the left coil 1 The BIIW and BulY wires go to the coil Coll has no effect on perfor mance Inspection See the base manual for coil inSipe tion 1 6 ...

Page 44: ...nd the black 13P Y lead on the rear fender If there is no continuity the wir harness has an open Check for nit between the vVU IJI 1 BI W l and G terminats vOlilag B check for between the r ollOli r W terminal on the fuse box and the unit BI W terminal If there is no cOintirmitv the harness has an open and unit between the COlJph r Y If there Is no check for continuity between COIJpIE r G terminal...

Page 45: ...the bolt and spark unit Remove the unit VUljJ Remove the case Ignition Spark Unit cont d Removal Installation install a new resister If r i fJ l nr p is outside these Re istianc G 2 9 3 2 ohms Spark Unit Resister Inspection Disconnect the coupler and measure resistance between the white and black wire terminals 7 8 ...

Page 46: ...truments Service Information 8 2 Troubleshooting 8 3 Turn Signal Cornering Lights 8 11 Front Brake Light Switch 8 12 Oil Pressure Warning Switch 8 12 Oil Pressure Sensor 8 13 Tall light Relay 8 13 Handlebar Switches 8 14 ...

Page 47: ...Lights Switchesllnstruments Se ice Infor ation Refer to the base manual for disa 3selilblyliassembly procedures ...

Page 48: ... wire shorted Battery Voltage 11 5 to 13 5 n u n D TO COUPLER Turn ON Measure between terminal of meter 13P white vVIUIJ t and G terminal of meter 13P black cOIJpIE r BIIBr oVolts POWER TO FUSE RELAY BOX Measure between BI Br terminal of box gp black COljplE r and terminal Battery Voltage Open circuit between main wire harness or fairing wire harness Poor contact at right coupler oVolts Battery Vo...

Page 49: ...ween G and R leads of adElptE r About 5 V o Volts Abnormal Voltage About 5 V Open or short circuit in Sl Sr or G BI wire between meter and sensor Poor contact at meter or left oVolts Faulty meter SENSOR SIGNAL Measure voltage be tween W and leads of inspEll ticm adclptElr VOlt i08 should be 0 7 1 3V oVolts SIGNAL WIRE TO METER Check for con tinuity between BuN terminal of meter white 20P coupler a...

Page 50: ...E r for loose contact If coupler is meter is SENSOR WIRE Disconnect meter white 20P coupler Check for continuity between sensor wire and body Short circuit in sub hal ness main harness or sub harness Continuity Normal from un IUIIU METER Ground sensor wire t rrnir I turn switch ON Check that ten1pelrature rises one every 15 seconds Also check that ten1p13lrature decreases one selJm ent every 15 se...

Page 51: ...check for continuity between BllBr and BIIY terminals of harness side coupler and sensor black 3P coupler Battery SENSOR SIGNAL Measure voltaae between BIIY and GIBI terminals of meter white 13P Rotate front wheel 3 5 and Low should appear Normal 8 6 Abnormal Continuity Short circuit in harness Normal sensor Check for poor contact at meter cOIJpll lr If it is OK meter is faulty No Continuity Fault...

Page 52: ...ness Poor contact at left Check for poor contact a t ETC unit If coupler is OK ETC unit circuit board is W Iih lr Temperature Fuel Gauge Will Not Shift to au Temperature Pressure Gauge METER Short Lb W terminal of meter white 20P to GIS terminal of meter white 13P Meter is normal if shifts Display Shifts Display Does Not Shift Check for poor contact at meter If it is meter is r L Display Does ETC ...

Page 53: ...te 13P Meter is normal if it resets Meter Ir Resets ETC UNIT WIRING Disconnect meter No white nlinl r and ECU white 17P Continuity Check for continuity between RIG terminals of both I Normal 8 8 Check for poor contact at meter coupler If coupler is OK meter is faulty or short circuit In wire harness Poor contact at left fairing coupler Check for poor contact at ETC unit If coupler is OK trouble is...

Page 54: ...ircuit in fll t i1 I I box Battery Voltage oVolts Fuse Fuse OK Blown FUSE RELAY BOX Measure voltage between 81 Lb banded and G terminals of fuse relay box black 21 P coupler under i iti m Open circuit in wire harness 12V O W G OV lb W G R Switch SIGNAL TO RELAY With left handlebar switch measure voltaoe between Lb W or O W terminals of switch GOIJpllBrS under rubber cover next to left I JV I t t R...

Page 55: ...Normal Abnormal oVolts Poor contact at left handlebar L handlebar switch switch coupler Short circuit in wire harness Lb W or O W wire WIRING Measure voltacle between Br Bu terminal of switch red 9P vV UIJI 1 and oVolts Battery Voltage circuit in wire harness WIRINGfFUSEfRELAV BOX Measure valtacle between Sr Bu terminal of fus e rE lav box black 9P and oVolts 8 10 Battery Voltage Open circuit in w...

Page 56: ...11 0 11 I G I V rl II G BI L be j IGNiTION SWITCH COlOR GI PIG I V I Wi ll igc 81 i I I I I I I i I G R w G l ii Ill LbIW LllIW t I R Y r 0 i E i Tf 01 1 i R Y R Iy 0 Lb WBI e 0 J 2 WIG I 1 Y2 I IJt C l u w v A _ TION LIGHTS ruSES f f fh C i 3 s c en i ca sI m I CDI No I lABlEL 1 I STOP HORN TURN 3 I TAILLIGHT ISA 15A No LAlla 6 L LIGHT 7 R CORNERING LIGHT ...

Page 57: ...s on the switch side UU I Il lever released No COll ltlrlUiity Lever puilled COlntilmlily Check nrH n IIT J at the switch terminals and retllee e the switch if is abnormal NOTE Make sure the switch wire doesn t contact the cable after installation Oil Pressure Warning Switch T_ _ _ 12 N m The oil pressure switch is behind the charcoal canister on the California model 8 12 ...

Page 58: ...oval Installation sealant to the switch threads Install and the switch 12 N m Connect the sensor COIJpIE r and air vent tube Install the air cleaner cover The is to the left of the radiator cap Remove the from the bracket and off the rubber cover screwdriver nAI1rA the catch on the cOIJPIE r with a the out Tail light Relay Inspection Remove the shelter Check for no cDrltin uitv between terminals 1...

Page 59: ...t between the color coded wires Lights Switches Instruments Handlebar Switches Turn Signal Switch Remove the left side and shelter InS lect at the black and brown 9P behind the rubber cover inner side of COUPltlf on the Ofltinlilitv between the color coded wires Starter Button 8 14 ...

Page 60: ...Accessories Fairing Lower Covers 9 2 ...

Page 61: ...s and collars to release the lower cover Accessories Fairing lower Covers Removal Remove the air ventilator from the Hold the lower cover while the r nr nPI inn then remove the cover Relea le the inner cover the screws 9 2 ...

Page 62: ...oting 10 7 Fuel Pressure Inspection 10 20 Fuel Injectors 10 20 Pressure PS Sensors 10 22 Throttle lith Sensor 10 24 Crankshaft Angle NS Sensor 10 27 Camshaft Angle GR GL Sensors10 28 Air Temperature T1 Sensor 10 29 Coolant Temperature TW Sensor 10 30 Fuel Pump 10 31 CFI Electronic Control Unit ECU 10 33 Air Valve 10 34 Air Chamber 10 34 ...

Page 63: ... washers stlnsert the tester from behind the to avoid berldirlg or them open Be careful not to short out a or connector Tum the switch OFF Positive and neClstilfe marked Do not remove grommets from the cOlJpIE rs Coupler Pin NUlmbers CFI MAIN RIElAY BOX T1 SENSOR FUEL INJECTORS 1 ...

Page 64: ...ake pipe pressure and send signals to micro computer To detecl coolant temperature and send signals to micro computer To detect intake air temperature and send signals to micro computer To detect variations crankshaft speed and to send signals to the micro computer Micro computer controls ignition liming and fuel injection volume accurately Function To detect opening of throttle and send signals t...

Page 65: ... li W R W R I P G Q 8 W R J f W R W RELAY 4 ij S 8F SES I Bu I P THROTTLE SENSOR R W f G FUEL INJECTORS MAIN FUSE 30A t Y I W I STARTER i I V L P SENSORS OTORR f Bu W I Bu G V R G R f Y W Bu R B BI START P G BI W Y BI W Bu Gp G I VBu G_ _ I G_ Ub BAT T SENSOR Mik u J 1 Gw t i H I G W Q d 3 FUEL PUMP Girl T SENSOR iI J _ W BoW Bo SPARK UNITS FUEL PUMP 1 2 3 J R 8 b 1111 G GL GR SPARK PLUGS GR GL SE...

Page 66: ...Z HJ3 y tJ T1 sensor 0 0 10 29 en TW sensor 0 1Q 30 R o i_ _f _ _ _ t t Wire connectors 0 0 0 IV O Tubing 0 0 0 0 ECU unil g o 0 0 0 0 Throllie valve synchronization Ir 0 0 0 10 33 3 5 10 27 o o o o o o a 0 000 o 0 o o o o a o o o o o Insulator fuel s e tled Worn Spark plugs Spark plug wire a1 nCOjl til unit 0 0 0 e c lo r s o o I o 1 0 7 7 Q Battery 0 0 0 7 2 1 1 1 1 ZGRIGL sensors 0 0 0 0 0 2 Ns...

Page 67: ... lind ignilion liming PBR sensor oulput is used When paR sensor is faulty NE Oth map is used for controlling fuel injection lind ignition liming NE Pa map is used for controlling fuel and igni tion timing When PI sensors are also fuel dis charge duration and ignition timing are both fixed 1 1 is fixed to 760 mm 30 in Hg Tl is fixed to 25 C 77 F Tw is fixed to 85 C 185 0 F Fuel injection and igniti...

Page 68: ...arna led RIBI or G wires instrument Eeu Check ECU COtmll r for loose contact POWER TO EeU Measure ECU between ECU terminals 1 and 2 POWJ j t TO RELAY BOX Measure it between W and G terminals of box 1P black No Good III Poor contact III Good ECU III Poor contact at black 13P vu1UIJ on rear fender III W wire between this UIU and ECU 1 and 1 No Good A Battery Good RElAY Check CFl main see page 10 31 ...

Page 69: ... or short circuit in harness Voltage WIRING Measure between terminal 2 of base and ground Voltage oVolts Broken or loose subfuse 9 or 30A fuse Open or short circuit in wire harness Wwire or short circuit in fuse relay box W R Poor contact at couplers SENSOR sensor Dalma Jed W R wire in tuse rE lay box N_o_G o O d Faulty fuel pump shut off sensor Damaged fuel pump shut off sensor wire or poor conta...

Page 70: ...pump Clear Increase Blocked as necessary Measure fuel pump output page 10 31 low FUEL FitTER Reolace recheck fuel pump Low Abnormal fuel pressure only at idle High fuel pressure engine OFF RETURN LINE Check fuel return line for 1 n l l or block81ge Normal Normal Normal Abnormal Faulty pressure regulator Blocked filter Faulty fuel pump Faulty pressure regulator Repair as necessary cont d 10 9 ...

Page 71: ...lirle cranking or 3 seconds the stop switch and fuel valve OFF FAULTY PARTS In n t system or parts LED s OFF LED s ON ECU Normal with known No Spark Go to IGNITION SYSTEM TROUBLESHOOTING page Pump Go to FUEL PRESSURE TROUBLESHOOTING see page 1 Pump Won t 41 fuel pump OK Does Not Operate and check for FUEL PUMP Check that FUEL PUMP o Sn lte1s for about 3 seconds after switch is turned ON POWER TO C...

Page 72: ...k and ECU Poor contact at 13P black or ECU Measure between and SrlSf terminal of 13P black vV UIJIt1 on rear fender 1C tt f V llt I 11 should be indicated for 1 5 seconds after switch is turned ON Battery Vol ta le oVolts 1 circuit in wire harness oVolts 1 circuit in wire harness VIR Poor contact at 13P black nllnlj r rear fender Disconnect ECU l JIl lPI1tll between terminals 30 I l l tt vl llfpmA...

Page 73: ... Abnormal I _ _ Go to IGNITION TROUBLESHOOTING see page this chart Normal Check LED s on ECU with and spark In5 trll f PB sensors Check the following items before Fouled or CIOggEld air cleaner Tire pressures Abnormal or incorrectly adjusted throttle sensor THROTTLE SENSOR Measure output nitl lt l of throttle sensor page 1 rFUEiLP mE _ _ Go to FUEL PRESSURE TROUBLESHOOTING page 1 ECU Try with a kn...

Page 74: ...wires Abnormal Abnormal t Io Abnormal t Go to FUEL PRESSURE TROUBLESHOOTING page 10 9 Abnormal 1 Faulty or incorr ectly adjusted throttle sensor Normal Normal In n t throttle Measure fuel pressure lnspe ot each PB sensor HOSES napsl t PB sensor hoses for Blocked L JI Incorrect vacuum applied to PB sensor Clear WIRING Check each sensor and ECU for poor contact at connectors or broken wires Abnormal...

Page 75: ... Ns Oth n IL Normal Normal ECU Try with a known ECU Abnormal 1 Follow proce iurElS on page 10 18 1 Go to FUEL PRIE UI IF TROUBLESHOOTING page 1 Abnormal 1 lI Poor contact at cOIJph r or short circuit In harness PB sensor Abnormal Abnormal 1 Normal Normal Normal Check fuel pressure Check PB sensor hoses for WIRING Check each sensor for poor contact at or broken wire page blockl lge with vacuum pump...

Page 76: ...ire Poor contact at connector or short circuit in harness Incorrect throttle valve adjusitmEmt Follow pr c idures on page 10 18 Too lean a mixture due to seicorldary air leak After Adjustment Loose or Broken Connector or Wire Abnormal leaking Not Synchronized After Adjustment THROTTlE VALVES Ins ect vr1 hlf 1i lti 1in of throttle valves Q fI n i7 tin nifvacuums CVllnaers and AIR LEAKS Check for in...

Page 77: ...ir valve page 10 65 10051 AIR VALVE Pinch air hoses between air valve and air air valve and reed valves Recheck idle Idle should decrease oVolts Abnormal circuit in wire harness air valve Air valve To air chamber Not Decreased Idle Speed Decreases air valvs COOLING Check water hoses between air valve and thermostat housing There should be no Clear Blocked Coolant cannot reach air valve AIR LEAKS C...

Page 78: ... Too rich a fuel mixture due to incorrect pressure to PB sensors Faulty ini tl lr or wires See Blocked Loose or Broken Abnormal Abnormal Abnormal Clear Normal Normal following sensors Check fuel pressure WIRING Check each sensor for poor contact at connectors or for a broken wire SENSORS P8 sensor TW sensor Check P8 sensor hoses for blc ck Eig with a vacuum pump page 10 18 Not Loose or Broken _ EC...

Page 79: ...hose Correct Check and ini tt r or wires Blocked AIR JETS Ins eCl vacuum air at each intake for blolcklage see page 1 Incorrect pressure Correct Go to FUEL Correct Abnormal Abnormal Go to FUEL PRESSURE I PB sensor THROTTlE VALVES vI1 rll I I ti n of throttle valves Connect vacuum pump as shown Start and check PB sensor hoses for blockalge Vacuum gauge should indicate intake manifold vacuum 1 8 ...

Page 80: ... rv air at intake system 1 Excessive carbon built up on throttle valves CARBON Clean the t rottle valves with carburetor cleaner page recheck Abnormal pressure to each PrE ssure should hold Normal Pressure Bleeds 1 reed valve or at reed valve case Pressure Holds 1 throttle connection 10 19 ...

Page 81: ...Jllne stol ped 2 4 2 7 kg em psi Idle 2 0 2 4 kg em psI If pressure is not within the fuel pressure re lul8ltor NOTE Install a new aluminum washer when you recon nect the fuel line Fuel Injectors Operation Inspection With the turn the ignition switch ON and open the throttle You should hear the injector click LED Inspection The LED s wifl indicate trouble by banks Discon nect the one at a time and...

Page 82: ... of removal a thin coat of clean oil to the O ring and the in take face Use dowel bolts to install the Selection SHIM SELECTION TABLE Unit mm ln Brown Green Yellow Shim not used Blue No color code Fuel ini ct r Fuel riol vo Fuel iniE cb r Throttle Intake NOTE Injectors must be adjusted with shims when any of the are rep aced Shim the affected injector Determine the ini h color code Measure the dis...

Page 83: ...minals and any of the other ECU ter minals Check the sensor nlln r for loose or terminals contacted Ina tutJ OlJltPllJt Voltage Inspection ttl Itl 9 843 ttl ALTITUDE Hg i i f 100 tli r GOO r j i v 500 we 2U L r m 2 00 m 3 000 m 4 OllO m UNCORRECTED ATMOSPHERIC PRESSURE YS TEMPiALTITUDE Pl mm this for Reading to measurements which pressure and 2 95 V x for atnlosph ric EXAMPLE Voltmeter readifllo b...

Page 84: ...nnect the inspel tic1n 8liaolter between the PB Sensor INSPECTION ADAPTER PS SENSOR COUPLERS TEST JAt 1II IU OUTPUT VOLTAGE mm Hg kPa kg cm2 psi 100 13 73 0 14 1 93 285 3 50V 300 40 21 5 83 216 245V 66 69 068 9 67 1 140V The PB sensor is OK if the unl to r l Irl inn Q fall within the limits shown below Turn the I 1l U lI II measure the and green leads Disconnect vacuum tube from the PBsensor Turn ...

Page 85: ... vacuum hose for deterioration Throttle tilth Sensor Inspection Connect the inSI Elction adliptf lr between the ECU and throttle sensor and measure the voltage page 10 1 t nr tin lihl between the white adapter lead and c olmll r terminal With the sensor disconnected for no COlnti 1uitv between the 11 ECU CQIJpI1 lf terminal and Sensor Resistance Inspection INSPECTION ADAPTER Check the sensor coupl...

Page 86: ...e is nnrltinli iitv No 1 2 ECU COljplE r to rm ol stall a new ECU vnltJ mll between the voltaole is OK in switch measure the voltage and green adapter leads while grsldUially opemirlQ the throttle ReIClla e the sensor it the vnltaolA does not rise smoot hly as the throttle is opEmed Loosen the idle adjlustml ntscrewand insert a 2 9 mm 1 gauge between the throttle arm and throttle screw Set the tes...

Page 87: ...the throttle and wire screen new break bolt Break the head off the hole the marked the break a9mm NOTE Do break the heads off the bolts until after ad the sensor Install a new sensor on the throttle head bolts Install the throttle on the Insert the 2 9 mm gauge between the throttle valve arm and screw Turn the sensor until the output valteels is 0 475 0 495 Start the and recheck the If the is turn...

Page 88: ... ECU terminal and other terminals Check the sensor f I r for poor contact at the ter minals Reisis tanlce Inspection Remove the call from the frame page Remove the Ns sensor white 2P from the holder Measure the resistance between the and white vV UI J 1 1 terminals Resistance 291 363 ohms Check for no f tir Iit l between each of the two ter minals and Install a new Ns sensor if the resistance is o...

Page 89: ... and the No 24 terminal With the sensor coupler check for no can between the No 7 and No 8 ECU ter minals and ground or other terminals Check the sensor I VUl lt minals for poor contact at the ter Coil Resistance Inspection Remove the fairing Remove the GR GL white 4P sensor from the holder Measure the GL sensor coil resistance between the W with Y tube and Y terminal Measure the NR sensor coil be...

Page 90: ...EN Disconnect the from the sensor and measure voltl icle between the terminals should be 4 75 5 25 V with the switch ON Air Temperature T1 Sensor LED Inspection if there is no check the harness for an open circuit Check for continuity between the sensor ne gative terminal and the No 3 ECU terminal bet ween the terminal and the NO 1 a ECU ter minal With the sensor check for no con between the No 10...

Page 91: ...emperature TW Sensor TW SENSOR WIRE WIRE HARNESS SIDE With the Sensor check for no can between the No 28 ECU terminal and each of the other terminals and indicates a short circuit If the above test results indicate no measure resistance between the terminals on the sensor side Resistance should range between 1 and 3 K ohms with the cold If resistance indicates no nntil il check the sensor sub harn...

Page 92: ... and check the coolant level THERMOSTAT HOUSING OFF Disconnect the fuel line from the renlov ino the nut Fn 1 1IA the transmission with the clutch lever out and the starter button so the starter motor will not work but the fuel pump Opl rat es Measure the amount fuel dischl med Pump Fuel pump C8i Scity 630 cc 3 oZ Jfminule minimum Turn the left fuel 1AIIVAI V Remove the from the fUE elr elEIV box ...

Page 93: ...ing loosen the fuel hose nut Slowly then disconnect the hose foo tpeig bracket bolt and the fuel Removal Installation Disconnect the fuel pump white 2P f nllnll r the rear fender Remove the pump located on Disconnect the fuel lines from the pump Remove the mounting bracket Install in the reverse order of removal COVER Torque values Fuel hose banjo nut 28 N m 20 tt lb Footpeg bracket bolt 60 N m 43...

Page 94: ... Press out ECU and disconnect the from the ECU NOTES not pry the open or bend the terminals and dirt away from the terminals attlAmiol to disassemble the ECU Slide the ECU into its case and install the dust cover CAUTION If the dust cover is not installed the ECU may be by water or dust and install the ltin and Attach the ECU r ollnl to the ECU until the lock I nln A Position the ECU under the tra...

Page 95: ...tall them in their locations injE hC rs with shims whenever you install cap throttle Chamber Disconnect the heater COlJPIE3r from the air valve Remove the two air valve bolts and remove the valve Remove the two mounting bolts and the air valve cover NOTES Turn the Remove the fuel filter from the left mount bracket FUEL FILTER BANJO BOLT Remove the air cleaner element Remove the four screws and the...

Page 96: ...wel around the fuel line and Loosen the fuel hose nut then disconnect the hose Remove the i i t cap bolts and caps tor to out dirt Remove the intake cover bracket Disconnect the crankcase breather tube each and the in Disconnect the vilin IAr heads and air tubes from the case holders Disconnect the cruise control throttle and throttle sensor IjUIJj Ilt 1 t i cancel switch 10 35 ...

Page 97: ...es with with the air remove the left fuel nPIIVl V Pull the air chamber out to the throttle cables and disconnect the NOTE See the base manual for service of the se c orldary air reed and the purge control valve Remove the nrilnl lI V reed valve set Disconnect the air hoses from the hOlusina Remove the reed valve covers Install new reeds and valves if the seat rubber is cracked or or if there is c...

Page 98: ...n solvent washers PURGE CONTROL VALVE CALIFORNIA ONLY PRESSURE REGULATOR THROTTLE CABLE HOLDER QRIP CANCEL SWITCH Install air chamber cover with the front mark forward Connect the throttle link the throttle arm install the washer and a new cotter pin FRONT MARK AIR CHAMBER COVER 10 37 ...

Page 99: ...E ANTI AFTERBURN VALVE REED VALVE REED VALVE AIR HOSES AIR JOINT HOSE UPPER FIB PORT VACUUM HOSES AIR VALVE OUTLET AIR HOSE SECONDARY AIR SUPPLY HOSES SECONDARY AIR SUPPLY TUBES UPPER FIB PORT REED VALVE AIR HOSES 10 38 VALVE OUTLET AiR HOSE SECONDARY AIR SUPPLY HOSES PURGE AIR REED VALVE SUPPLY HOSE REED VALVE AIR HOSE ...

Page 100: ...the air chamber into oil to the pressure fuel rl lh Connect the air outlet and inlet hoses to the air chamber Connect the vacuum hoses to the pressure re lul13ltor a thin coat of clean O lU Vi C r lnas and install the NOTE Check that the hose and are not on and disconnected On California connect the purge air hose to the purge control valve Connect the air heads and to the holders on the have been...

Page 101: ...ake throttle Install the throttle bolts between the head and cover bracket and the vacuum hose to the intake Connect leads Connect the fuel line to the left fuel and the nut Tnl nUIll 22 N m 16 Connect the throttle sensor and cruise control throttle cancel switch Install the air cleaner case and air cleaner Instal the fuel filter on the left mount bracket In stall all removed in the reverse order ...

Page 102: ...Electronic Travel Computer Service Informati on 11 2 Troubleshooting 11 4 Removal 11 12 Disassembly 11 12 Assembly 11 4 ...

Page 103: ...rldirlg or prying nT Tln OIT i or c r M n a vnitl lnA or resistance Make sure all related COIJpl erS or wires are connected Dlscorlne ctinlg a I ll nls r or connector Turn the nnlnnn switch OFF Positive and ne latl e sides are so marked CFI CflIJISE HEIGHT CONT 15 0 PARKING 10A RADIO CASSETTE DECK FUSE RELAY BOX I I T C UNIT AUDIO CONTROLLER CONNECTORS 11 ...

Page 104: ...11 3 ...

Page 105: ... wire harness Continuity Poor contact at fuse terminal WIRING Remove 7 5 A fuse from fuse holder Check for between the fuse wire and R of ETC unit 17P cOIJpIE r R 7P WHITE black COlJpIElr Open circuit between fuse and ETC unit Loose or poor contact at left Short circuit between fuse and ETC unit Blown Fuse Battery Voltage Voltage OK oVolts oVolts 13P WHiTE COUPLER POWER TO FUSE Measure between 7 5...

Page 106: ...IGNITION SWITCH Check ignition switch for base manual box cOIJpIE r in harness between ignlitic n switch and fuse terminal Poor contact at nnitir n sWitch vV I1J1 1 or fug s oVolts No Continuity No Continuity 1 circuit between fuse terminal and ETC unit Poor contact at box WIRING Check for between sub fuse terminal and terminals unit white 17P POWER TO FUSE Remove fuse IRJtl DIO IFI ASHIFRI and me...

Page 107: ... voltaoe bet NeEln Wand G BI of 17P white COljpIE r oVolts the fuel indicator The fuel t indicator should come on for about 3 seconds when the is switched ON SPEEDOMETER ODOMETER Check sPI leclorrletE rand odometer functions Normal Abnormal Go to FUEL circuit in wire SYSTEM INDICATOR harness DOES NOT LIGHT next Abnormal SENSOR SIGNAL Measure between BIIY terminal of the instrument 20P and G SI ter...

Page 108: ...nal of instrument 13P white l UIUpl t l 1 I Volts I circuit between instrument and switch I Poor contact at 13P white AUTO VOLUME Check auto volume function OK Not OK ETC unit with known ETC SENSOR SIGNAL Measure valteo between W 131 and G Bl terminals of ETC unit 17P white with ON Volt meter should indicate from o to about 9V when the front wheel is rotated Not OK OK Not OK SENSOR SIGNAL Measure ...

Page 109: ...SOR SIGNAL Measure voltage between WIBu and GISI terminals of the fuel level sensor terminals Volt meter should indicate than 7V No No less than 10 Liters I Refill tank More than 10 liters Battery Voltage Yes FUEL GAUGE Check fuel gauge LCD more than 3 Se lm ints lOW FUEL INDICATOR Check low fuel indicator Indicator should go off about 3 seconds after is switched ON FUEL QUANTITY Check amount of f...

Page 110: ...circuit in wire harness Correct illo Faulty ETC unit FUEL LEVEL Check amount of fuel in fuel tank Below 5 Liters 1 3 gal Fill tank with more than 5 liters 1 3 gal with ignition switch OFF Recheck display with ignition switch ON More than 5 liters 1 3 gal Abnormal Normal COUPLER Check fuel level sensor iUUVlt 1 for poor contact Then check fuel sensor page 18 24 in base Normal Abnormal 1 Poor contac...

Page 111: ...IRING Check for between Qroluna and G SI terminal of the sensor Ohmmeter should indicate no Check ETC unit 17P white for loose contact Abnormal with a known L Ioo Poor contact at17P cOIJplf r SIGNAl ETC Disconnect white 3P cOIJpll r resistor the rear fender Check fuel c0I18ump tion function with switch ON CQI Isump1tlon 11 should increase for every 50 Yes Go to AVERAGE SPEED AND TRIP FUNCTIONS DO ...

Page 112: ... U and G terminal of 17P white Normal IGNITION SWITCH Check switch page 18 22 in base mAn ll COUPLERS Check contact at ETC 17P and switch or short circuit in wire harness Abnormal p Off ACC ON Lock OV 12V 12V OV ov ov ov OV 12V Normal BULB Check socket for poor contact Check for burned out meter ht Normal ETC unit 11 11 ...

Page 113: ...cOlupiers and connectors from the E T C unit the COimp artlnel1t cover SCREWS COVER SCREWS Unscrew the six cover screws Disassembly CAUTION water and dirt away from the board and other Press the wire down into the cover Remove the cover Remove the illumination bulbs counterclockwise turning the sockets 11 2 ...

Page 114: ... the six cOIJpll r from the Disconnect the black LCD indicator cOIJpIE r from the nrilntl 1 11 board Release the LCD indicator from the case seven screws rI 111f iinn the Remove the screws radio controller and fader Remove the screws which secure the nrilnt 11 boards Remove the water shield and buttons from the case NOTE Record the button colors and note the location of paper insulators as are rem...

Page 115: ...Electronic Travel Computer Assembly Assemble in the reverse order of diS lssE mlJily KNOBS WATER SHIELD lCD DISPLAY DlSPlAY gElIl ITlCn BOARD COMPUTER PRINTED BOARD 11 4 ...

Page 116: ...Leveling Rear Suspension AI A Information 12 2 Troubleshooting 12 4 Pump 12 11 Control Switch 12 17 Dls1trn nJtor 12 18 t rE SS Ure Relief Valve 12 23 SWSDEtnsion Computer 1 Helgnt SAI IIc nr 1 ...

Page 117: ...ying or measuring a voltaole or resistance Make sure all related couplers or wires are connected Disiconn4ecting a CmjplE r or connector Turn the marked switch OFF Positive and ne Jatlve sides are so Fuses Relay Box AIR PUMP CFI MAIN RELAY Parts Location CONTROL SWITCHES SHOCK AB OR BER VI nVIU VAlVESI AIR DiSTRIBUTOR RELIEF AIR HOSE SUSPENSION COMPUTER AIR DRIER 12 2 ...

Page 118: ...NITION lOA 9 Cfl CIlUISEJiEIGHTCONTl 1M 10 AiR PUMP lOA 7 PARKING lOA AIR PUMP DRIER 9 I b l ll l_TO FRONT FORKS tils _TO REAR SHOCKS HEiGHT CONTROL SYSTEM SUSPENSION COMPUTER 11 G y 11 1 Lt R H H 19 W t 14 p W t I HI il3 iH t 17 S R t t 1 20 Briy 5 8118 1 71 Lb HI 2 16 3 4 12 3 ...

Page 119: ...ck 20P for poor contact Normal lCD DISPLAY Ins ect BRAKELIGHT Check brakeliight with switch ON Go to SYSTEM DOES NOT OPER Il TE WITH E DISPLAYED 1 Go to SYSTEM DOES NOT OPERATE r I Auto Level WITH EEE DISPLAYED 1 Does Not Flash switch Normal harness Short circuit in front brake switch Incorrect rear brake BRAKE SIGNAL Measure between nel latl re terminal and GN SII nAI irm C OmlJutlsr 20P cOljpl r...

Page 120: ... of computer Less than 2 should be indlicaled less than 1 2 Volts Abnormal I sensor page 1 circuit in wire harness Abnormal Poor contact al 24P or at switch cOluolier switches of Normal Abnormal Check 20P M 1 for poor contact Normal sUlspEmsion computer 12 5 ...

Page 121: ... V with switch ON LCD counler GIBl Paper clip Below 3 0 Volts LCD DISPLAY Disconnect LCD COljplt r vOltAClP to side as show three bars Dis Dlavunil coupler Normal COUPLER Reconnect LCD 6P water CO Jpll r and recheck E Indicated COUPLER Check sus peI1sic n Ci mIJutl r 20P for poor contact If is secure install a known computer 12 6 Above 3 0 Volts LCD Abnormal EEE Indicated I l Faulty LCD display E ...

Page 122: ...RING Disconnect suspension com utE r and solenoid valve 4P Check Br R and Br Y wires for r nntir1111 h between RHC unit and solenoid valve Aii nlaY of wire harness Between same Between different colors Normal SOLENOID VALVI Connect C 1l n n i n Measure resistance at 4P of solenoid valves with L UIJplit l1 disconnected Br R G Br Y G Br W G Normal B Abnormal Abnormal Abnorm I Poor contact at termina...

Page 123: ... Lb and G of 3P red with connected There should be below 0 3 when switch ON oVolts No Air Flow No Normal II Blocked or pinlch ld air relief hose Blocked relief on air distributor Poor contact at JUIU II computer II circuit in sub wire harness n n inn computer inspe t the air to On Board Air base manu l l Abnormal pressure sensor Normal RELIEF VALVE Check air orEISSlure relief valve page Normal c 1...

Page 124: ... I t Measure Jit r A betvveEIn t rm nt ll wire harness R ttpirv f It n should be COUPLER Check 6P for poor IJnll lr is secure install new I Volts STEM OPERATION Check sv tem operation iii circuit in subharness Does Not COUPLER Check 24P f jnl lf contact If is secure go to SYSTEM DOES NOT OPERATE page 1 12 9 ...

Page 125: ... button not AUTO lEVEL is not indicated COMPUTER WIRING Remove grommet trom LCD 6P llr r_ nrn r t I JUU Measure vol1tagE s GiSI without disicormeictirig IJUIJ O 1 should be above 3 V Check W Sf WIV wires between this and There should be between same colors Volts SUSiPeinsic O computer COMPUTER Check voltage between W SI and G SI wires while pushing the INf RI A F or button Voltage should decrease ...

Page 126: ...nq air outlet button with at Go SYSTEM DOES NOT OPERATE HOSES Check air pump inlet and pump to distributor air hoses for blockage or pinc hina sh owrs increase but system doesn t respond No Air Flow HOSES Disconnect front and rear air hoses under Check if air flows out Trm each air hose air pump Normal SOLENOID VALVES Check solenoid valve opeirati m see page 12 19 to 12 20 Air Flows Reconnect air ...

Page 127: ......

Page 128: ...ION PrE SSlure will decrease NOTES is below 10 V TROUBLE CODES Check LCD r E or EEE Displayed Go to SYSTEM DOES NOT OPERATE 1 Normal SWITCH Disconnect n cornpllter 20P Check IncreaselDecrease switch for page 12 1 Normal Abnormal 1 circuit in main or harness Poor contact at switch I r switch sub wire 24P or Abnormal be switch ON and neutral SUSPENSION COMPUTER Reconnect 20P Measure between Y W and ...

Page 129: ...9 V DEC ON at FRONT or REAR Br W G above 9 V Normal SOLENOID VALVE Check solenoid valves for battery to solenoid valve tf mTlin ll Click Heard Abnormal Click Not sus oelnsil n computer solenoid valve SENSOR Check air pressure sensor base mSI luall Normal RELIEF VALVE Check pressure relief valve of air distributor for blockclge page 1 Normal Check solenoid valve page 12 1 12 14 Abnormal Abnormal No...

Page 130: ...rease or loss after pressure check su pE nsion air pressure is at maximum 1 0 14 and 6 5 kU If ml 92 psi rear PRESSURE CHECK lever will reduce pressure to as low as 0 6 kg cm front and kn rr rear This is normal opisratiol1 NOTE less Than 4 Seconds CHECK VALVE Disconnect air pump hose that goes to air distributor at air pump Check for air flow this hose in DECREASE Air Flows Faulty distributor chec...

Page 131: ...oil levels when there has been excessive oil leal age Clean the air hoses and air distributor before the sv nern SEPARATORS Check front fork separators for dannage Normal CHIEC K V MLVll ii In Ol t rear shock darnacle or blo ckage Normal 1 6 Abnormal oil se ar ltor di sasseI11blle and clean Abnormal 1 Incorrect check valve OpElratlion 1 Incorrect oil level ...

Page 132: ...ls 1 and 2 If there install a new Remove the air pump fuslem lay box SELECT SWITCH INCREASE DECREASE SELECT SWITCH WIG Remove the Disconnect the 20P from the and check for between the terminals Indicated If tests indicate no r tin ih check for a loose switch COlJpIE r or COIJpIE r and for an open or short circuit in the wire harness or sub harness SWITCH Suspension Control Switch 1 7 ...

Page 133: ...lief hose from the wire band NOTE Use a wrench to the hose from t r inn while the hose joint nut Remove hoses slowly to allow pressure to bleed from air lines l tf l I ln inn air hoses from inner cover Disconnect the front and rear the air di trirll Itl l Remove the Remove the air distributor Remove the vent hose from the front of the air distributor NOTE The hose contains a steel ball seat and Be...

Page 134: ... valli ellS If pressure remains even when the solenoid valve is clean the air passage in the air distributor RA nAR the above for the rear side nluinn h tif volitaCle between the Br Y and G terminals of the valve C o upl el vacuum to the air distributor relief port If vacuum does not remain remove the solenoid valve and re la e the rubber seat at the of the rod While vacuum apply between the Br W ...

Page 135: ...se Check the rubber seat at the end of each valve rod Rel la e d am 3 OEfd or deteriorated seats RELIEF SOlENIOD VALVE CONTROL NEEDLE Remove the pressure relief valve and air valve AIR DISTRIBUTOR Check that the air valve moves Check the for darna le or deterioration O RINGS Disassemble the pressure relief valve Check the air passages for obstructions for darna le or deterioration Check the Blow o...

Page 136: ...o all Make sure the rubber solenoid valve seats are in Check each valve for proper S611tina the as Indicated SENSOR BRACKET RELIEF HOSE RELIEF SOLENOiD VALVE white mark AIR VALVE PRESSURE RELIEF VALVE BODY PISTON PLUG 55N m 141 ft lb AIR PRE SSIJRE SENSOR SUSPENSION SOLENOID VALVE red mark 55N m 41 ft lb 12 21 ...

Page 137: ...air hoses to the air distributor hole onto the 5 56 or eqlJivstlenit NOTE Be careful not to the air relief hose If the hose is blocked or resltri tel l the RHC reacts as if the pressure sensor is and shuts the down Position the hose chemical lubricant tion the hose Route the air relief hose Route the relief hose n lIlflll the forward NOTE Do not intE3rclhanioe front and rear air hose tions Use a w...

Page 138: ...cornp ments as necessary TOf ue 55 N m Install new If does disassemble the relief valve and check the pisi ons rubber seat and for wear or dannage must be VIII JlJltll case the cornpartment and NOTE To remove removed Remove the cornpllter from the case Remove the Disconnect the 20P black cOlJplE r Suspension Computer Remove the two bolts and case lid Install in the reverse order of removal and awa...

Page 139: ...ve the H Win the gap between the frame and fuel tank With the switch ON measure between the sensor terminals in each of the three po iticlns harness check the wire harness for an open sensor wire to the at the HI and below 1 2V at the LO level INDEX MARKS If the COtJpIE r is circuit Reconnect Measure the between terminals of the sensor cOlJplE r ON If there is no check the black 13P cOIJpIE ron th...

Page 140: ... wire and connect the sensor vVUIJ Connect the sensor arm to the t n rod the 8 mm bolt 21 N m 15 SENSOR ARM J INDEX MARK bolts bolts in the reverse order of removaL the adjustino rod Turn the rod to the end of the sensor arm with the sensor case index mark Loosen the adjiusl ing rod TOI Ql lie 12 N m Install SUI lPClrt the mellol cycle on its center stand 12 25 ...

Page 141: ...ng 13 4 Cruise Valve Relay 13 13 Cruise Actuator 13 13 Vacuum Hose 13 14 One Way Valve 13 15 Cruise Control Valve 13 15 Cruise Cancel Switches 13 16 Cruise Control Switches 13 18 Junction Box 13 19 Throttle Operation 13 21 Throttle Cable Adjustment 13 22 ...

Page 142: ...LJitv or me aslurirlg a voltaole or resistance Make sure all related IJV IJ O Ii or wires are connected Discormectirlo vVUI or connector Turn the switch OFF Positive and ne lati e sides are so marked STOP HORN IGNITION C F I CRUISE CORNERING TURN SIGNAl REGULATOR HEIGHT CONTROL STOP LIGHT 15A 10 A 10 A 10 A Location FRONT BRAKE CANCEL SWITCH REAR BRAKE CANCEl SWITCH 13 2 ...

Page 143: ...13 3 ...

Page 144: ...e cruise indicator comes on for a few then goes off Normal Abnormal Go to CRUISE INDICATOR LIGHT DOES NOT COME ON WHEN IGNITION SWITCH IS TURNED ON troubleshooting see page 1 Check cruise indicator with switch ON for function Not lit Check auto levellFIQ sluspiem3ion for No C Go to page 13 6 Abnormal Normal Go to DOES NOT DISPLAY troubleshooting page 1 Short wires between Bu O and G terminals of i...

Page 145: ...re connected Continuity CANCEL SWITCHES With and cruise switches check if there is unl t r between BrlR and G terminals of ECU v JIUIJII lI POWER TO RELAY With switch and cruise switch ON check that there is between G BI and G terminals of ECU COlJplElf oVolts oVolts RELAY Check Cruise Valve Relay page 13 1 Normal Faulty Battery RELAY Check for between the cruise valve terminals There should be no...

Page 146: ...rom page 13 4 WIRING Check Bu O wire for between instrument 13P and ECU 13 6 No Yes Continuity No Blown circuit circuit in con meter nected 13P circuit of white W wire in 1 o Volts lIo cruise set switch circuit in harness or poor contact at cOLJplE r ...

Page 147: ...NDICATOR Is indication of gear nn itir n indicator normal CLUTCH SWITCH With innitinrdrr switch measure between G Bu and G terminals of ECU I V1UIJI t l voltacle should appear when clutch in Normal handlebar switch Poor contact at switch CUIUPlel lit circuit in wire harness circuit or short in wire between sensor and ECU coupler Poor contact at C O Jpl r Abnormal Abnormal SWITCHES switches GEARSHI...

Page 148: ... contact at coupler vacuum circuit Abnormal sensor V n speed sensor see base manual Abnormal Abnormal G Voltacl6 should f hl nOle from about 9V to less than 1V when front wheel is rotated HOSES Check vacuum hoses for dalna 18 or clogging SPEED SENSOR With switch ON and cruise switch measure between BIIY and G terminals of ECU coupler Normal Abnormal Abnormal actuator or cable cruise control valve ...

Page 149: ...I iUIUfJ1 oVolts WIRING Measure voltage between Bl Br terminal of indicator light check relay iViUIJIt l and battery terminal Battery Voltage oVolts Battery Voltage WIRING Short wires between Bu O and G Bu R and G terminals of indicator light check The cruise indicator should come ON Normal RELAY COUPLER Check indicator check for poor contact Normal indicator check circuit in wire Open circuit in ...

Page 150: ...me switch Cruise control should resume I _A_b_ _o_r_ma_I l Go to Cruise Control Does Not Function at All page 1 Normal POWER TO ECU With irmitinn switch and cruise switch and switch in measure W Bu and G terminals of ECU COIJplE lr oVolts Start engine Won t Start Go to Fuel Indicator Does Not of CFI page 10 7 Starts cruise switch resume switch Poor contact at handlebar should appear when resume sw...

Page 151: ...th a known good ECU CONTROL VALVE control valve unit Short or open circuit in wire harness Poor contact at cOlupller sensor Abnormal SENSOR SIGNAL With switch measure between and G terminals ECU COI lDIl3r should from about 9V to less than llt rnAh j when front wheel BIIY j Cruise Control is Cancelled Accidently Abnormal CANCEL SWITCHES Check rear brake and throttle cancel switches 1 Iml rooer swi...

Page 152: ...nn rAj inn HOSES Check vacuum hoses for Abnormal or Normal CABLES Check throttle cables and Abnormal jUllvllUI box for smooth movement by turning throttle grip Normal ACTUATOR Check actuator Abnormal page 13 1 Normal CONTROL VALVE Check cruise Abnormal control valve unit page 13 1 Normal RELAV Check cruise valve Abnormal page 13 1 Normal vacuum circuit Stiff throttle cat le ln ag e Stuck or actuat...

Page 153: ... and 2 If install a new Remove the cruise valve from the Cruise Actuator Remove Discorlne ct the vacuum from the and con nect a vacuum pump to the actuator Apply vacuum install a new actuator If the throttle does not rotate with vacuum applied check the fnll nwiinn Throttle Op eraition Junction box of drum and Actuator cable Throttle cables If vacuum does not remain cont d 13 13 ...

Page 154: ...le nut and disconnect the cable from the box careful not to Pull the vacuum hose off the actuator IJUli I iLUI the Cruise Control ruise ctu8tor ont Removal If vacuum does not remain check the vacuum hose for deterioration or loose connection Vacuum Hose Inspection Connect a vacuum pump to the hose and vacuum Disconnect the vacuum hose from the intake of the No 13 14 ...

Page 155: ...OLD HOLD BriBI BrlW RELIEVE RELIEVE G BrlW HOLD HOLD Sr Br W HOLD HOLD Br BI G Br W RELIEVE RELIEVE BriBI Sr Br W RELIEVE RELIEVE Sr G Br W HOLD HOLD 8ri81 Sr G Br W DECREASE RELIEVE Control VaIve If unable to obtain sp lci1ied U install a new valve While malint alninq vacuum the terminals shown in the table on the Test each of terminals with the actuator hose open and then blocked with a hose Avo...

Page 156: ...k for r r tinlilih between the BI Bu and G W wire terminals EXCHANGE BLACK liP COUPLER behind the right Brake lever released Cnnth llliirv Brake lever in Disconnect the black 4P handlebar If unable to obtain the above results check for continuity at the switch terminal If switch continuity is normal check the sub harness for If is ab flUrl install a new switch Remove the screw and disconnect the w...

Page 157: ...at the 2P COl lolElr cruise control unit Throttle closed Further return No f nfi u ii left of the Disconnect the left throttle link arm from the throttle arm ADJUSTING SOLT the bolt 2 1 3 rotations and Back off the lock nut NOTE Rel J ac e the switch if L UIHIi UIlV or no fails to shift Connect an ohmmeter to the switch wires and turn the adjusting bolt until shifts to no l UIIUllluny To remove th...

Page 158: ...tinlllh NOTE Reillac e the switch if or no vVIHlII UIlJ fails to shift rod and muffler remove the exhaust Loosen the lock nut on the master cVliind 9r To The switch is normal if h lt1rpnJ voltaoe is preiserlt with the cruise control and switches ON Cruise Control Switches Cruise Switch NOTE Do not confuse this wire with the BIIY sen sor wire Remove the cruise control unit dust cover Measure voltao...

Page 159: ... between the terminals The is normal if resume switch switches ON Measure voltaOie between the of the controlCOljplE r nction Box Remove cable drum from the cable ends Remove the cover from the box box from its Remove the and washer Remove the mount bolts and bracket Remove actuator cable and loosen the throttle cable lock nuts Disconnect the lower throttle cable throttle cable then the upper Remo...

Page 160: ...the drum shaft In out Be sure groove Install the washer and a new stall the with the the is seated all the way around the Connect the throttle cables to the box Coat the faces of the cable drum and drum shaft with grease NOTE install the cable drum with the the inside Connect the cables to the cable drum with the stopp r c ontaciting the control arm Insert the ends of the throttle cables into the ...

Page 161: ...r nn dannage the throttle cables Rel lac e Check for smooth throttle full in all l tAArirll 1 p4 sit ions If throttle opl3raltion is not smooth check the inner cable condition them if are or kinked Atiill c tmA nt l with the loosen the lock nut turn the i tUj U llC11 as re and the lock nut Recheck throttle oDE ratjon and install all removed 13 21 ...

Page 162: ...the locI nut the actuator mount nuts CONTROL ARM loosen the upper throttle cable aUj t A llt l to allow the upper throttle cable in Tum the lower throttle cable to the index mark on the cable drum with the arrow mark on the case T h the throttle cable 1Uj U l 1 lock nut the upper cable lock nut throttle free and check opl ra1tion of the throttle and cancel switch Recheck alio nment of the index an...

Page 163: ...Index Index 14 2 ...

Page 164: ...1 4 4 6 4 2 9 2 8 12 5 3 6 2 3 3 10 20 10 20 10 31 10 28 5 2 8 14 12 24 7 6 7 1 7 5 7 3 8 1 3 2 1 7 Sensors Sensor Sensor Handlebar Switches Sensor Coil Maintenance SCl1eClule Crankshaft Cruise Actuator Cruise Cancel Switches Cruise Control Cruise Control Trc ub les hootillg Cruise Control Valve Cruise Junction Box Cruise Switches Cruise Vacuum Hose Cruise Valve Element Cruise Valve E T C Assemtll...

Page 165: ... 1 I 0 it 9 I I L C J 1 JJ J ill RFM lOrMJ ER VSW We 25 C II t IQoA l gO RII s q N W 1 NO I COOl i s r L I eo _ L Gil G I I _ M Py II 1 tIRs U Gt l lioo 11 n HC lIP COo l M AlS lLUY Ih TQfl rlA C II OOTI L OiOMETE 3 B rim 12 1 ollQV I CC 13 oJECTiON SI IAL I 0 0 I 1 _ I 0 0 0 0 co oP BY Gl1200lllMITED WIRING DIAGRAM r J llJ F illl Cot Bdll G L9 Bk l 1 2 l rJ u l _ _ J O JQ JO I ee oIoroI 0 010 0 C...

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Summary of Contents for Goldwing GL1200L 1985

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Honda Goldwing GL1200L 1985, Manual

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Summary of Contents for Goldwing GL1200L 1985

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