Honda GL 1000 Manuals

Honda GL 1000 Manuals

Manuals and User Guides for Honda GL 1000. We have 1 Honda GL 1000 manual available for free PDF download: Shop Manual

Honda GL 1000 Shop Manual

Honda GL 1000 Shop Manual (327 pages)

Brand: Honda | Category: Motorcycle | Size: 35.75 MB

Table of Contents

Table of Contents
1
Service Information
2
Vehicle Serial Numbers
3
NPS Part Numbers
4
Metric Conversions
5
Service Planninggeneral Service Precautions
6
Working Practice
6
O-Rings
7
Service Parts
7
Circlips
8
Dust Seals
8
Oil Seals
8
Mechanic's Hand Tools
9
Tools and Materials
9
Shop Tools
10
Heavy Shop Tools
11
Precision Inspection Tools
11
Special Assembly/Disassembly Tools
12
Special Repair Tools
15
General Specifications
16
Lubricants
16
Acceleration and Passing Ability
17
Dimensions
17
Engine
18
Vehicle Stopping Distance
18
Troubleshooting
19
Maintenance Operations
20
- Maintenance Schedule
  21
- Torque Specifications
  22
- Lubricants and Coolant
  24
Tune-Up
25
- Service Information
  26
- Air Filter Maintenance
  31
- Crankcase Breather
  32
- Valve Adjustment
  33
- Valve Clearance Adjustment
  33
- Compression Test
  35
- Spark Plug Maintenance
  36
- Contact Breaker Points
  37
- Static Ignition Timing
  38
- Dynamic Ignition Timing
  40
- Choke/Throttle/Idle Speed
  41
- Carburetor Synchronization
  42
Engine Removal & Installation
44
- Removal
  47
- Exhaust System Removal
  48
- Electrical System Disconnections
  49
- Radiator Removal
  49
- Starter Cable Removal
  49
- Spark Plug Wire Removal
  50
- Wiring Harness Uncoupling
  50
- Air Cleaner Case Removal
  51
- Choke Cable Removal
  51
- Fuel Pump Outlet Hose Removal
  52
- Throttle Cable Removal
  52
- Clutch Cable Removal
  53
- Driveshaft Snap Ring
  53
- Fan Shroud Removal
  53
- Engine Removal
  54
- Sub-Frame Tube Removal
  54
- Engine Installation
  55
- Installation
  55
- Snap Ring Installation
  55
- Installation and Connection of Parts Removed
  56
- Throttle Free-Play Adjustment
  56
- Engine Top End Repair
  58
Engine Top End Repair
60
- Timing Belt Removal
  64
- Belt Inspection
  65
- Camshaft and Rocker Arm Removal
  66
- Left Hand Head
  67
- Camshaft Bearing Clearance
  68
- Cylinder Head Removal
  69
- Cylinder Head Disassembly
  71
- Valve and Guide Inspection
  72
- Valve Guide Replacement
  73
- Valve Seat Inspection and Grinding
  74
- Cylinder Head Assembly
  75
- Cylinder Head Installation
  76
- Engine Lower End Repair
  81
Engine Lower End Repair
85
- Kick Starter Inspection
  85
- Engine Case Removal
  87
- Piston and Rod Removal
  88
- Piston Pin Installation
  90
- Piston Pin Removal and Installation
  90
- Piston Inspection
  91
- Cylinder Inspection
  92
- Piston Ring Installation
  93
- Crankshaft Removal and Inspection
  94
- Bearing Inspection
  96
- Bearing Selection
  98
- Engine Assembly
  100
- Screw and Bolt Sizes
  103
- Lubrication System
  104
- Engine Oil Level
  109
- Engine Oil Cgange
  110
- Engine Oil Filter Change
  110
Lubrication System
110
- Oil Pressure Check
  111
- Oil Pumps
  111
- Oil Pump Inspection
  112
- Oil Pressure
  114
- Oil Pressure Warning Switch
  114
- Oil Strainer
  114
- Oil Contamination
  115
Cooling System
116
- Coolant Level Check
  121
- Flushing & Coolant Replacement
  121
- System Testing & Inspection
  123
- Radiator and Fan
  125
- Fan Motor Testing
  126
- Radiator Core Inspection
  126
- Water Pump
  127
- Thermostat
  128
- Fuel System
  129
- Carburetor Circuit Diagrams
  133
- Fuel Filter Replacement
  139
- Fuel Line Inspection
  139
- Fuel Pump
  140
- Carburetor and Air Chamber
  141
- Air Cutoff Valve Removal and Disassembly
  148
- Air Cutoff Valve
  149
- Float Level
  149
Fuel System
149
- Idle Drop Adjustment Procedure
  150
- High Altitude Adjustment
  151
- Idle Mixture Adjustment
  151
- Clutch
  152
- Free-Play Adjustment
  156
- Clutch Repairs
  157
- Engine Flushing Procedure
  160
- Outer Drum Inspection
  160
- Outer Drum, Chain, and Sprocket Removal
  161
- Plate and Disc Installation
  163
- Transmission
  165
Clutch
167
Transmission
167
- Gear Shift Mechanism
  169
- Crankcase Disassembly
  171
- Shift Shaft
  172
- Transmission Disassembly
  173
- Shift Drum and Fork Inspection
  174
- Mainshaft Removal
  175
- Countershaft Removal
  176
- Primary Drive Gear Removal
  177
- Output Shaft
  178
- Output Shaft Removal
  178
- Output Shaft Disassembly
  179
- Transmission Reassembly
  179
- Countershaft Installation
  180
- Shift Drum Installation
  180
- Mainshaft Installation
  181
- Shift Fork and Shaft Installation
  181
- Crankcase Reassembly
  182
- Front Cover Installation
  183
- Case Screw and Bolt Sizes
  184
Final Drive
185
- Drive Hub
  189
- Drive Hub Removal
  189
- Case Bearing Removal
  194
- Hub Assembly
  195
- Pinion Preload Inspection
  196
- Drive Shaft
  198
- Installation of Drive System
  201
- Drive Shaft Joint Lubrication
  204
- Final Drive Oil Level
  204
- Maintenance
  204
- Final Drive Maintenance
  205
- Final Drive Oil Change
  205
- Frame and Suspension
  206
Frame and Suspension
208
- Suspension Inspection
  211
- Service Operations
  212
- Front Fork Disassembly
  213
- Front Fork
  214
- Handle Bar Replacement
  217
- Fork Bridge Removal
  218
- 1975-1977 Stem Removal
  220
- 1975-1977 Bearing Replacement
  221
- Bearing Replacement
  222
- 1978-1979 Stem Removal
  223
- 1978-1979 Bearing Replacement
  224
- Rear Suspension
  226
- Rear Wheel Removal
  227
- Swing Arm Inspection
  228
- Fuel Tank Removal
  231
- Main Stand Removal
  233
- Frame Inspection
  234
- Side Stand Inspection and Replacement
  234
- Brakes and Wheel Assemblies
  235
- Front Brake System
  239
Brakes and Wheel Assemblies
240
- Brake Fluid Level
  241
- Brake Fluid Replacement
  242
- Brake Bleeding
  243
- Front Pad Replacement
  244
- Front Caliper Inspection
  246
- Front Caliper Assembly
  247
- Front Master Cylinder Disassembly
  248
- Front Master Cylinder Inspection
  249
- Front Master Cylinder Assembly
  250
- Rear Brake System
  251
- Rear Brake Pad Replacement
  252
- Rear Caliper Removal
  253
- Rear Caliper Disassembly
  254
- Rear Caliper Inspection
  255
- Rear Caliper Assembly
  256
- Master Cylinder Disassembly
  257
- Master Cylinder Removal
  257
- Master Cylinder Assembly
  258
- Master Cylinder Inspection
  258
- Wheel Inspection
  260
- Wheel Balancing
  262
- Front Wheel Disassembly
  264
- Axle Inspection
  266
- Disc Inspection
  266
- Front Wheel Assembly
  267
- Rear Wheel Assembly
  268
- Speedometer Drive
  269
- Tires
  269
- Electrical Starter
  271
Electric Starter
273
- Starter Motor
  275
- Commutator Inspection
  276
- Starter Relay
  278
Ignition
279
- Ballast Resistor
  283
- Ignition Coils
  283
- Capacitor
  284
- Spark Advance Mechanism
  284
- Lights, Switches, and Instruments
  285
- Switches
  293
- Handlebar Switches
  294
- Clutch Switch
  295
- Ignition Switch
  295
- Diodes
  296
- Thermostatic Fan Switch
  296
- Instruments
  297
- Temperature Gauge Function Test
  298
- Temperature Sensor Resistance Test
  298
- Fuel Gauge and Sensor
  299
- Fuel Gauge Function Test
  299
- Voltmeter (1978-1979)
  300
- Accessory Terminal Box
  301
- TEMP/FUEL/VOLT Meter Panel ('78,'79)
  301
- Instrument Panel Lights
  302
- Turn Signal
  302
- Turn Signal Flasher and Buzzer
  302
- Headlight Aim
  303
- Headlight and Tail Light
  303
- Headlight Bulb Replacement
  303
Lights, Switches, and Instruments
303
- Reverse Lighting System
  304
- Input Voltage to Switching Unit
  306
- Output Voltage at the Resistor
  306
- Output Voltage at the Switching Unit
  306
- Resistor Continuity Test
  307
- Horn, Fuses, and Wiring
  308
- Junction Box Connectors
  310
- 1975-1977 Wiring Diagram
  311
- Wiring Diagram 1978, 1979
  312
- Battery & Charging System
  313
- Battery
  317
- Battery Removal
  317
- Testing Specific Gravity
  317
- Battery Charging
  318
- Charging Output Test
  318
- Charging System
  318
- AC Generator Continuity Test
  319
- Silicon Rectifier Test
  319
- Regulator Performance Test
  320
- AC Generator Removal
  321
- Generator Drive Inspection
  323
- Starter Clutch Inspection
  323

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