HONDA GL1800-ABS GOLDWING 2001-2005 Service Manual & Parts

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SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols.

Replace the part(s) with new one(s) before assembly.

Use recommended engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1).

Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent). Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or equivalent). Example: Molykote® BR-2 Plus manufactured by Dow Corning, U.S.A. Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or equivalent). Example: Molykote® G-n Paste manufactured by Dow Corning, U.S.A. Honda Moly 60 (U.S.A. only) Rocol ASP manufactured by Rocol Limited, U.K. Rocol Paste manufactured by Sumico Lubricant, Japan Use silicone grease.

Apply a locking agent. Use a medium strength locking agent unless otherwise specified.

Use sealant.

Use DOT 3 or DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified.

Use fork or suspension fluid.

1. GENERAL INFORMATION
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SERVICE RULES ············································ 1-2 MODEL IDENTIFICATION······························ 1-2 GENERAL SPECIFICATIONS························· 1-4

BRAKE SYSTEM SPECIFICATIONS·············1-10 BATTERY/CHARGING SYSTEM SPECIFICATIONS··········································1-10 IGNITION SYSTEM SPECIFICATIONS ········1-11

LUBRICATION SYSTEM SPECIFICATIONS · 1-6 FUEL SYSTEM (Programmed Fuel Injection) SPECIFICATIONS··········································· 1-6 COOLING SYSTEM SPECIFICATIONS ········· 1-6 CYLINDER HEAD/VALVE SPECIFICATIONS··········································· 1-7 CLUTCH SPECIFICATIONS ··························· 1-7 GEARSHIFT LINKAGE/TRANSMISSION SPECIFICATIONS··········································· 1-8 CYLINDER/PISTON/CRANKSHAFT SPECIFICATIONS··········································· 1-8 FINAL DRIVE SPECIFICATIONS···················· 1-9 FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS··········································· 1-9 REAR WHEEL/SUSPENSION SPECIFICATIONS··········································· 1-9 STARTER/REVERSE SYSTEM SPECIFICATIONS··········································1-11 LIGHTS/METERS/SWITCHES SPECIFICATIONS··········································1-11 CRUISE CONTROL SYSTEM SPECIFICATIONS··········································1-11 STANDARD TORQUE VALUES ················
···1-12 ENGINE & FRAME TORQUE VALUES ········1-12 LUBRICATION & SEAL POINTS ··················1-19 CABLE & HARNESS ROUTING ···················1-23 EMISSION CONTROL SYSTEMS ················1-69 EMISSION CONTROL INFORMATION LABELS ·························································1-72

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GENERAL INFORMATION

SERVICE RULES
GENERAL INFORMATION

1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that don't meet HONDA's design specifications may cause damage to the motorcycle. 2. Use the special tools designed for this product to avoid damage and incorrect assembly. 3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts, and screws are not interchangeable with English fasteners. 4. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling. 5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified. 6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. 7. After reassembly, check all parts for proper installation and operation. 8. Route all electrical wires as shown in the Cable & Harness Routing (page 1-23).

MODEL IDENTIFICATION
This manual covers 2 types of GL1800 models: · GL1800 ­ no ABS · GL1800A ­ equipped with ABS Be sure to refer to the procedure for the appropriate version of the GL1800.

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