Table Of Contents - Honda Gold Wing GL1200D Shop Manual

Table of Contents

Contents2
General Information3
General Safety3
Service Rules3
Model Identification4
Frame Serial Number4
Engine Serial Number5
Final Drive Serial Number5
Specifications6
Service Data11
Carburetor13
Frame13
Cable & Harness Routing28
Lubrication Service Information36
Lubrication Specifications36
Lubrication Troubleshooting37
Lubrication Torque Values37
Lubrication Tools37
Oil Level Too Low37
Engine Oil Level38
Engine Oil & Filter Change38
Oil Pressure Inspection39
Front Engine Cover Removal39
Main Oil Pump Removal40
Scavenging Pump Removal41
Oil Pump Inspection42
Tip Clearance42
Body Clearance42
End Clearance42
Scavenging Pump Installation43
Relief Valve Inspection43
Main Pump Installation44
Front Engine Cover Installation45
Strainer Screen Cleaning47
Lubrication Points47
Maintenance48
Engine Will Not Crank50
Engine Cranks But Will Not Start50
Engine Cranks But Will Not Start-Cold Weather50
Engine Cranks But Will Not Start-Engine Hot50
Maintenance Schedule51
Fuel Lines52
Fuel Filter52
Throttle Operation53
Carburetor Choke53
Air Cleaner54
Crankcase Breather55
Spark Plugs56
Recommended Spark Plugs56
Carburetor Synchronization56
Carburetor Idle Speed57
Radiator Coolant58
Radiator Core58
Cooling System Hoses & Connections59
Drive Shaft Joint59
Final Drive Oil59
Battery60
Brake Fluid61
Brake Pad Wear61
Front Brake Pad Inspection61
Brake System62
Rear Brake Pad Inspection62
Brake Pedal Height62
Bra Ke Light Switch63
Hedlight Aim63
Clutch Fluid64
Clutch System64
Side Stand65
Suspension65
Air Pump Element67
Air Drier67
Nuts, Bolts, Fasteners68
Wheels69
Steering Head Bearings69
Recommended Tires And Pressures69
Fuel System72
Fuel System Service Information72
Fuel System Specifications72
Fuel System Torque Values72
Fuel System Troubleshooting73
Fuel System Tool73
Engine Cranks But Won't Start73
After Buring During Deceleration73
Carburetor Removal74
Carburetor Separation76
Carburetor Disassembly78
Vacuum Chamber Removal78
Float Chamber Removal79
Throttle Linkage82
Carburetor Assembly83
Pilot Screw Installation83
Carburetor Installation85
Float Level Inspection85
Pilot Screw Adjustment87
Idle Drop Procedure87
Fuel Tank87
Fuel Pump89
Slow Air Cutoff Valve90
Engine Removal/Installation92
Engine Removal/Installation Service Information92
Engine Removal/Installation Specifications92
Engine Removal/Installation Torque Values92
Engine Removal93
Engine Installation98
Cooling System101
Cooling System Service Information102
Cooling System Troubleshooting102
Cooling System Specifications102
Cooling System Torque Values102
Cooling System Inspection103
Coolant103
Radiator Cap103
Radiator Leakage Test103
Coolant Replacement104
Radiator Removal105
Radiator Disassembly106
Radiator Fan Motor Inspection106
Radiator Assembly107
Radiator Installation107
Thermostat Removal108
Water Pipe Disassembly108
Cooling System Installation109
Water Pump110
Cylinder Head/Valve111
Cylinder Head/Valve Service Information112
Cylinder Head/Valve Specifications112
Cylinder Head/Valve Troubleshooting113
Cylinder Head/Valve Tools113
Cylinder Head/Valve Torque Values113
Timing Belt Removal114
Camshaft Removal115
Belt Inspection115
Camshaft Inspection117
Camshaft Holder Disassembly119
Rocker Arm Shaft Inspection121
Rocker Arm Inspection121
Assist Spring/Shaft Inspection121
Hydraulic Tappet Adjuster Inspection122
Cylinder Head Removal123
Cylinder Head Disassembly124
Cylinder Head Inspection124
Valve Spring Inspection125
Valve, Valve Guide Inspection126
Valve Guide Replacement127
Valve Seat Inspection/Refacing128
Valve Seat Cutters128
Cylinder Head Assembly131
Camshaft Holder Assembly/Installatlon133
Hydraulic Tappet Adjuster Shim Selection140
Clutch143
Clutch Service Information144
Clutch Specifications144
Clutch Torque Values144
Clutch Tools144
Clutch Troubleshooting145
Clutch Lever Soft Or Spongy145
Clutch Lever Too Hard145
Clutch Slips145
Clutch Fluid Replacement/Air Bleeding146
Clutch Fluid Draining146
Clutch Fluid Filling146
Air Bleeding147
Clutch Master Cylinder147
Master Cylinder I.d. Inspection148
Master Piston O.d. Inspection148
Clutch Assembly149
Clutch Slave Cylinder150
Piston O.d. Inspection151
Cylinder I.d. Inspection151
Clutch Disassembly152
Clutch Outer155
Alternator/Starter Clutch/Rear Engine Cover161
Alternator/Starter Clutch/Rear Engine Cover Service Information162
Alternator/Starter Clutch/Rear Engine Cover Specification162
Alternator/Starter Clutch/Rear Engine Cover Torque Values162
Alternator/Starter Clutch/Rear Engine Cover Tools162
Alternator/Starter Clutch/Rear Engine Cover Troubleshooting163
Abnormal Engine Noise (Gear Noise)163
Abnormal Engine Noise At Low Speed163
Starter Rotates, But Engine Won't Start163
Rear Engine Cover Removal164
Rear Engine Cover Disassembly165
Rear Engine Cover Assembly166
Alternator Rotor/Starter Clutch167
Alternator Drive Shaft Removal/Disassembly169
Alternator Drive Shaft Installation174
Rear Engine Cover Installation177
Transmission/Shift Linkage179
Transmission/Shift Linkage Service Information180
Transmission/Shift Linkage Specifications180
Transmission/Shift Linkage Torque Values181
Transmission/Shift Linkage Troubleshooting181
Transmission/Shift Linkage Tools181
Gearshift Linkage Disassembly182
Shift Drum Linkage182
Shift Arm/Spindle182
Shift Linkage Assembly183
Output Shaft185
Engine Case Separation188
Shift Fork/Shift Drum190
Transmission Removal191
Mainshaft191
Transmission Inspection193
Primary Driven Gear195
Transmission Assembly197
Transmission Installation198
Countershaft198
Primary Chain Tensidner/Guide201
Engine Case Assembly203
Crankshaft/Piston207
Crankshaft/Piston Service Information208
Crankshaft/Piston Specification208
Crankshaft/Piston Troubleshooting209
Crankshaft/Piston Torque Values209
Crankshaft/Piston Tools209
Excessive Noise209
Piston/Connecting Roo Removal210
Side Clearance Inspection210
Piston/Ring/Rod Inspection211
Cylinder Inspection213
Crankshaft Removal213
Crankshaft Inspection214
Crankshaft Bearing215
Oil Clearance Inspection215
Crankpin Bearing Selection217
Bearing Installation219
Crankshaft Installation219
Piston And Rod Installation220
Cylinder Compression224
Wheel/Steering225
Wheel/Steering Service Information226
Wheel/Steering Specifications226
Wheel/Steering Torque Values226
Wheel/Steering Troubleshooting227
Wheel/Steering Tools227
Hard Steering227
Steers To One Side Or Does Not Track Straight227
Front Wheel228
Wheel Bearing Inspection229
Wheel Rim Runout Inspection229
Axle Inspection229
Wheel Balancing239
Handlebars240
Bearing Race Replacement247
Suspension Service Information253
Suspension Torque Values253
Suspension Troubleshooting254
Suspension Tools254
Wobble Or Vibration254
Soft Suspension254
Front Fork255
Rear Shock Absorber265
Oil Seal Replacement266
Pivot Bearing Replacement271
Swing Arm Assembly272
Swing Arm Installation273
On-Board Air Suspension System275
Final Drive286
Final Drive Service Information287
Final Drive Specifications287
Final Drive Torque Values287
Final Drive Troubleshooting288
Final Drive Tools288
Oil Leak288
Final Drive Removal289
Drive Shaft289
Universal Joint290
Final Drive Gear290
Ring Gear Removal290
Ring Gear Bearing Removal291
Case Cover Oil Seal Replacement292
Pinion Gear Removal292
Pinion Bearing Removal293
Pinion Retainer Oil Seal Replacement294
Case Bearing And Oil Seal Replacement294
Breather Hole Cleaning295
Pinion Gear Assembly295
Ring Gear Assembly296
Gear Tooth Contact Pattern Check298
Backlash Inspection300
Pinion Joint Installation301
Final Drive Installation303
Hydraulic Brakes306
Hydraulic Brakes Service Information307
Hydraulic Brakes Specifications307
Hydraulic Brakes Troubleshooting308
Hydraulic Brakes Torque Values308
Hydraulic Brakes Tool308
Brake Lever Soft Or Spongy308
Brake Fluid Replacement/Air Bleeding309
Brake Fluid Draining309
Brake Fluid Filling310
Brake Pad/Disc311
Front Master Cylinder314
Brake Disc Thickness314
Brake Disc Warpage314
Master Cylinder Piston316
Rear Master Cylinder317
Hydraulic Brakes Inspection319
Brake Calipers322
Metal Brake Lines327
Battery/Charging System330
Battery/Charging System Service Information331
Battery/Charging System Troubleshooting331
Battery/Charging System Specifications331
No Power - Key Turned On331
Specific Gravity332
Battery Voltage332
Battery Charging System333
Battery Charging333
Leakage Inspection333
Charging System Inspection334
Charging Output Specifications334
Alternator335
Voltage Regulator/Rectifier335
Stator Coil Inspection335
Ignition System337
Ignition System Service Information338
Ignition System Specifications338
Ignition System Troubleshooting339
Engine Cranks But Wilt Not Start339
No Spark At Plug339
Engine Starts But Runs Poorly339
Ignition Coil340
Primary Coil Inspection340
Transistorized Ignition System341
Pulse Generator Inspection341
Pulse Generator Replacement342
Ignition Timing Inspection343
Electrical Aovance System343
Vacuum Advance System344
Ignition Control Unit345
Starter System347
Starter System Service Information348
Starter System Troubleshooting348
Starter System Specifications348
Starter Motor Will Not Turn348
Starter Motor349
Commutator Inspection349
Field Coil Inspection350
Starter Motor Reduction Gear Inspection350
Starter Relay Switch352
Clutch Switch Diode352
Lights/Switches/Instruments354
Lights/Switches/Instruments Service Information354
Lights/Switches/Instruments Tools354
Headlight355
Instruments357
Bulb Replacement360
Front Turn Signals360
Rear Turn Signal/Brake Light361
Oil Pressure Warning Switch363
Brake Switches363
Gearshift Sensor364
Handlebar Switches364
Turn Signal Switch365
Horn Button365
Hazzard Switch365
Headlight Switch366
Starter Button366
Engine Stop Switch366
Ignition Switch367
Ignition Switch Disassembly367
Clutch Switch368
Temperature Gauge369
Sensor Inspection369
Fuel Gauge370
Low Fuel Warning Light371
Thermostatic Switch371
Brake And Tail Light Sensor372
Brake Light Relay373
Fuel Pump Relay373
Self Cancelling Turn Signal System374
Ang Le Sensor375
Solenoid Wire Harness376
Main Turn Signal Wiring Harness376
Angle Sensor Harness376
Angle Sensor Resistance377
Angle Sensor Sub·wire Harness377
Control Unit Replacement377
L.c.d. Meter378
Input Voltage Inspection378
Speed Sensor Inspection378
Tachometer379
Air Pressure Gauge379
Gear Position Indicator379
L.c.d. Meter Control Buttons380
Accessories382
Fairing383
Seat And Top Compartment Removal383
Fairing Assembly387
Saddlebag/Travel Trunk388
Audio System (Gl1200A)391
Power Amplifier392
Auto Volume/Tone Controller392
Fuse Replacement392
Technical Featurers394
Hydraulic Valve Adjuster System394
Troubleshooting398
Engine Does Not Start Or Is Hard To Start398
Engine Lacks Power399
Poor Performance At Low And Idle Speeds400
Poor Performance At High Speed400
Poor Handling400