gl1000

L1SERVICEINFORMATIONI2MAINTENANCEOPER.ATIONS3TUNE-UP[4ENGINEREMOVAL&INSTALLATION11I5ENGINETOPENDREPAIRII6ENGINELOWERENDREPAIRII7LUBRICATIONSYSTEMI[8COOLINGSYSTEMI9FUELSYSTEMI:10CLUTCH[11TRANSMISSION[12FINALDRIVE[13FRAMEANDSUSPENSION[14BRAKESANDWHEELASSEMBLIES15ELECTRICSTARTER16IGNITIONI17LIGHTS,SWITCHES,ANDINSTRUMENTS=tI~BATTERYANDCHARGINGSYSTEMTHISBOOK,.,..,...,1'1,,,,,,Sr)E:!clalinformationformoreefficientandconvenientGL·1000SHOPMANUAL1978AmerIcanHondaMotorCo.,Inc.U.S.A.7·78Thismanualcontainsinf()rmaticlnforseveralmodelyears,Youmaynoticesomeminorappearancedifferencesfromyourmo·torl~vclle.TABLEOFCONTENTSTheGL1000Manualisdividedinto18,('tin.,,,TofindthevehicleonthispageandusetheindexattheofthepagestolocatethatsectiontheEachincludesthegoldwingdocs.com'SERVICEINFORMATIONVEHICLESERIALNUMBERS1-2NPSPARTNUMBERS1..3METRICCONVERSIONS1-4WORKINGPRACTICE1..5SERVICEPARTS1..6TOOLSANDMATERIALS1..8GENERALSPECIFICATIONS1..17GL·1000SHOPMANUAL11916AmericanHondaMotorCo.,PrintedinU.S.A.IIgoldwingdocs.comVEHICLESERIALNUMBERSThenumberissideoftheserialnumberis1,rn,~orlonofthesideofthecrankcase.Thefinaldriveserialnumberislocatedontheleftsideofthefinaldrivecase,neartheCARBURETORIDENTIFICATIONNUMBER1...2L·l000SHOPMANUAL1978AmericanHondaMotorCoInc.Printedin7·78goldwingdocs.comStandardNumbersSERVICEINFORMATIONNPSPARTNUMBERSrAnr,,:,pntThefollowingx42HexBolt1\llpThrii-jofManufacture....UU'ofthreadNominalDiameterundertheheadTreatment921'V-VVI.J....'.V£..120-042oZWHEELSEALFunctionDetailNumberNumber(wherefirstClassification91251-3;,p'ecI.ClINumbersLEFTSIDECOVERColorCode83700-371-305ZAZAGL-1000SHOPMANUAL13@1976AmericanHondaMotorCo.,Inc....PrintedinU.S.A.7-78goldwingdocs.comMETRICONVERSIONSnrIlTl'\,,.,'ttlrt'lofmeasurementinthismanualisthemetric(:\J:1,e:m'U.S.customaryunitswillfitisnecessarytoconvertfrommetrictoEnglisheqlJlVl3lerlts,usethefollowingconversionfactors:GIVENMULTIPLYBY25.400.62141TOOBTAIN(ft-IblUUUllUl(in-lb)ilnl1r::IIY1meter(kg-mlKii()grelm-(:en1:imE~ter(kg-em)Inches(in)Meter(m)Mile(milinch(psi)ilnrlr::lrYl/~;ncentimeter(kg-cm2)FahrAnihAit(FO)Cel'1ltigr'ade(CO)Gallon(gal)(qt)(I)3.785(I)1L-l000SHOPMANUAL1976AmericanHondaMotorCoInc,in4Miles/hour(mph)Kilometer/hour(km/hr)goldwingdocs.comWORKINGPRACTICESERVICEINFORMATIONWORKINGPRACTICESERVICEPLANNINGPrr~n.rplanningwillserviceontheGL1000.Duetothehotcoolantinthe.thismotorcyclemaycooldownperiodthanHondaverifyinganycustomercomplaintsonthethetechnicianshouldthecoolIftheisinforaandserviceascalledforinthemaintenanceschedulefor6000mileintervals,operationsshouldbetodrainthehotandremovethevalvecoversallowingthehotairtoescape.Useofafanasusedforothermodelswillonlyslightlyduetotheengineandlayoutintheframe.Whiletheisdrawtheandfromstockandlayoutthe''''''IU''....R,f,..,...n,f('\lrrn;nnmaintenanceontheGL1000,technicianshouldbecomefamiliarwiththetoolslistedinthissection.Newtoolsrequiredtomaintainthisareinboldfacetypeandthesespecialtoolsaremanyoperations.Ifcustomerco!mplal!ntsareontheworkandarerefertothesectionsthismanuaLGENERALSERVICEPRECAUTIONS:1.replaceandcotterpinswithnewones.Whenassemblingmakesurethesealsaremstalleacorrectlysnapareseatedintotheirgrooves.2.Whentighteningnutsandbolts,startwiththelarger,orcenteronesthemtothespecifiedtorqueaCrl:ss..c:rossn:::ltt,rnUsegenuineHondaandrecommendedlubricants.4.Useallwhererequired.5.Whenandfinaldrivecomponentsaredisassembledandinspected,coatthematingsurfaceswithlubricanttocorrosion.6.(,,,,,,mn,nn,,,,n't~usetheproperGL-l000SHOPMANUAL©1976AmericanHondaMotorCo.,Inc.PrintedinU,S,A.7-781-5goldwingdocs.comx45x2.4x3.030.8x20.8x296.5x2x442.5x223x2x1.718x327x26x2.217.0x2.58x1.940x2.615x2.5xx2x2.415x2.589x4.517.0x2.529x33.5x330.8x3.221.9x2.312.5x2.21x115.5x1.421.9x2.3IDxW6.5x1.5mmoilorifice(1perside)4.1x1.5mmoilorifice(1perside)(4)(1)(1)(1)(2)(1)(1)(1)(1)(1)(1)(1)(1)(1)(1)(1)(1)(1)(1)(1)(1)(1)(1)(4)(1)(2)(0)(1)(1)(1)AdjusterFilterRearDowelDowelIManifoldTankNutMasterWheelFinalAssemblyAlternatorWiresOilPump1\lt:LIUdlSwitchOilFillerPlug~t~\1nn,PumpFrontCoverWaterLOCATIONWaterlinesI:\flinrl'rHeadAs!,emlblvO-RINGSSERVICEPARTS1-6.GL-1000SHOPMANUAL1976AmericanHondaMotorCo.,1ne.7·78goldwingdocs.comSERVICEINFORMATIONSERVICEPARTSTYPEOIA(QUANTITY)Internalmm(2)External28mm(1)25mm(5)Externalmm(2)40mm(1)ClutchGeneratorTransmissionDriveLOCATIONc+,,~+....,.,,,.......ClutchIPSCIRLOCATION1.0.x0.0.xW.OILSEALSw\...­IHandCylinderHeadLeftHandCylinderHeadTac:horneterDriveOilPumpScavengePumpCaseLeftForkDriveAssembly27xx9x43x94.8x14x5.410x25x711x15x314x24x525x54x7x54x718x29x714x28x735x55x8x48x1132x67x8x52x870x90x8LOCATIONLD.x0.0.xW.IDUSTSEALSwI~IWheelWheelSwingArm22xx830x45x9.5x46x10.5GL-1000SHOPMANUAL171976AmericanHondaMotorCo.,Inc.-PrintedinU.S.A.7-78goldwingdocs.comTOOLSANDMATERIALSNOTEToolnumberswhosesecondwith-371in07900-37101aretoolsnewlyfortheGl1000.Toolsfromseriesotherthan-371aretoolspreviouslyde1~ell)p€ldforothermodels.MECHANIC'SHANDTOOLSThel\II,/'htllni/':Handcanbeobtainedlocally.TOOLNAMEANDDESCRIPTIONTirePressureGaugeAllenWrenchSet6-1Omm7mmSocketWrench19mmSocketWrench22mmS