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Honda GL 1000 User Manual

Honda GL 1000
326 pages
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L1
SERVICE INFORMATION
I
2
MAINTENANCE OPER.ATIONS
3
TUNE-UP
[
4
ENGINE REMOVAL & INSTALLATION
11
I
5
ENGINETOP END REPAIR
I
I
6
ENGINE LOWER END REPAIR
I
I
7 LUBRICATION SYSTEM
I
[
8
COOLING SYSTEM
I
9 FUEL SYSTEM
I:
10 CLUTCH
[
11
TRANSMISSION
[
12 FINAL DRIVE
[
13
FRAME AND SUSPENSION
[
14 BRAKES AND WHEEL ASSEMBLIES
15
ELECTRIC STARTER
16 IGNITION
I
17 LIGHTS, SWITCHES, AND INSTRUMENTS
=tI
~BATTERY
AND CHARGING SYSTEM
THIS
BOOK
,.,
..
,...",1'1,,,,,,
Sr)E:!clal
information
for
more
efficient
and convenient
GL·1000
SHOP
MANUAL
1978
AmerIcan
Honda
Motor
Co.,
Inc.
U.S.A.
7·78
This manual contains inf()rmaticln
for
several model years,
You
may
notice
some
minor
appearance
differences
from
your
mo·torl~vclle.
TABLE
OF
CONTENTS
The GL
1000
Manual
is
divided
into
18
"",('tin.",,,
To
find
the
vehicle
on
this
page
and
use
the index
at
the
of
the
pages
to
locate
that
section
the
Each includes the

Table of Contents

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Honda GL 1000 Specifications

General IconGeneral
Compression Ratio9.2:1
Transmission5-speed
Final DriveShaft
Front SuspensionTelescopic fork
Rear SuspensionSwingarm with dual shocks
Front BrakeDual disc
Rear BrakeSingle disc
Front Tire3.50-19
Rear Tire4.50-17
Dry Weight265 kg (584 lbs)
Fuel Capacity19 liters (5.0 US gallons)
Bore x Stroke72.0 mm x 61.4 mm
Fuel System4 Keihin carburetors

Summary

1 SERVICE INFORMATION

Vehicle Serial Numbers

Locates the frame and engine serial numbers stamped on the motorcycle.

NPS Part Numbers

Explains the structure and meaning of Honda NPS part numbers.

Metric Conversions

Provides conversion factors between metric and U.S. customary units.

Working Practice

Offers general guidelines for performing maintenance and service.

Service Parts

Lists various O-rings used in the motorcycle for replacement.

Tools and Materials

Details essential hand tools and shop tools required for maintenance.

2 MAINTENANCE OPERATIONS

Maintenance Schedule

Outlines scheduled maintenance intervals and required service items.

Torque Specifications

Lists specific torque values for various engine and drive hub fasteners.

Lubricants and Coolant

Specifies recommended lubricants and coolant types and capacities.

3 TUNE-UP

Service Information

Provides general specifications for tune-up procedures.

Troubleshooting

Guides users through diagnosing common engine tune-up issues.

Air Filter Maintenance

Details the procedure for inspecting and cleaning the air filter element.

Valve Adjustment

Explains how to check and adjust valve tappet clearances.

Compression Test

Describes the process for testing engine cylinder compression.

Carburetor Synchronization

Provides steps for synchronizing the motorcycle's carburetors.

4 ENGINE REMOVAL & INSTALLATION

Service Information

Lists specifications and working practices for engine removal/installation.

Removal

Details the step-by-step process for safely removing the engine.

Electrical System Disconnections

Explains how to disconnect electrical components before engine removal.

Installation

Guides the user through the correct procedure for reinstalling the engine.

5 ENGINE TOP END REPAIR

Service Information

Provides specifications for engine top-end components.

Troubleshooting

Helps diagnose common low compression or excessive noise issues.

Timing Belt Removal

Details the procedure for removing the engine timing belt covers.

Camshaft and Rocker Arm Removal

Explains how to remove camshafts and rocker arms.

Cylinder Head Removal

Guides the user through the process of removing the cylinder head.

Valve and Guide Inspection

Describes how to inspect valves and guides for wear and damage.

Cylinder Head Assembly

Details the steps for assembling the cylinder head components.

6 ENGINE LOWER END REPAIR

Service Information

Provides specifications for engine lower-end components.

Kick Starter Mechanism Inspection

Explains how to inspect the kick starter ratchet and pinion teeth.

Engine Case Removal

Details the procedure for removing the engine crankcase halves.

Piston Inspection

Guides the user on inspecting piston rings and the piston dome.

Crankshaft Removal and Inspection

Explains how to remove and inspect the crankshaft for wear.

Bearing Selection

Provides a guide for selecting replacement bearings based on size codes.

7 LUBRICATION SYSTEM

Service Information

Lists specifications for engine oil capacity, type, and viscosity.

Troubleshooting

Helps diagnose common lubrication system issues like low oil pressure.

Engine Oil Level

Details how to check and maintain the engine oil level.

Engine Oil Change

Provides steps for changing the engine oil and oil filter.

Oil Pump Inspection

Explains how to inspect the oil pump for damage and measure clearances.

Oil Contamination

Guides in identifying and addressing oil contamination issues.

8 COOLING SYSTEM

Service Information

Provides specifications for the cooling system, including coolant type.

Troubleshooting

Helps diagnose common cooling system problems like overheating.

Coolant Level Check

Details the procedure for checking and adjusting coolant levels.

Flushing & Coolant Replacement

Explains how to flush and replace the cooling system's coolant.

System Testing & Inspection

Guides on testing the cooling system for pressure and leaks.

Radiator & Fan

Describes inspection and removal procedures for the radiator and fan.

9 FUEL SYSTEM

Service Information

Lists specifications for fuel tank capacity and carburetor details.

Troubleshooting

Helps diagnose issues with engine starting, idling, and fuel delivery.

Carburetor Circuit Diagrams

Illustrates internal fuel flow paths within the carburetors.

Fuel Filter Replacement

Details the procedure for replacing the fuel filter.

Fuel Pump

Explains how to test and remove the fuel pump.

Carburetor and Air Chamber

Guides disassembly and reassembly of carburetors and air chamber.

10 CLUTCH

Service Information

Lists specifications for clutch type, lubrication, and torque values.

Troubleshooting

Helps diagnose common clutch operation problems.

Free-Play Adjustment

Details how to adjust the clutch lever and cable free play.

Clutch Repairs

Guides the user through clutch component removal and inspection.

11 TRANSMISSION

Service Information

Provides specifications for transmission shafts, gears, and backlash.

Troubleshooting

Helps diagnose issues with shifting gears and transmission jumps.

Gear Shift Mechanism

Explains the operation and inspection of the gear shift mechanism.

Crankcase Disassembly

Details the procedure for disassembling the transmission crankcase.

Transmission Disassembly

Guides the user through disassembling transmission shafts and gears.

Transmission Reassembly

Provides steps for reassembling the transmission shafts and gears.

12 FINAL DRIVE

Service Information

Lists specifications for hypoid gear oil, ring and pinion backlash.

Troubleshooting

Helps diagnose issues with rear wheel rotation and oil leaks.

Drive Hub

Details the procedure for removing and disassembling the drive hub.

Seal Removal

Guides on removing and installing seals in the final drive.

Hub Assembly

Details the steps for assembling the final drive hub components.

Backlash Check

Explains how to check and adjust ring gear and pinion backlash.

Maintenance

Provides procedures for drive shaft lubrication and final drive oil change.

13 FRAME AND SUSPENSION

Service Information

Lists specifications for front and rear suspension components.

Troubleshooting

Helps diagnose issues with wheel wobble, steering, and suspension.

Suspension Inspection

Guides on inspecting front and rear suspension components.

Front Fork

Details disassembly, inspection, and assembly of the front fork.

Handle Bar Replacement

Explains how to remove and replace handlebar components.

1975-1977 Stem Removal

Details stem removal for 1975-1977 models.

1975-1977 Bearing Replacement

Guides bearing replacement for 1975-1977 steering head.

1978-1979 Stem Removal

Details stem removal for 1978-1979 models.

1978-1979 Bearing Replacement

Guides bearing replacement for 1978-1979 steering head.

Rear Suspension

Describes inspection and removal of the rear shock absorbers.

Swing Arm Inspection

Explains how to inspect the swing arm and its bearings.

Fuel Tank Removal

Details the procedure for removing the motorcycle's fuel tank.

Main Stand Removal

Guides the user through removing the main stand.

Frame Inspection

Instructs on inspecting the frame for cracks or damage.

14 BRAKES AND WHEEL ASSEMBLIES

Service Information

Lists specifications for brakes and wheel assemblies.

Troubleshooting

Helps diagnose common brake and wheel assembly issues.

Brake Fluid Level

Details how to check the brake fluid level in reservoirs.

Brake Fluid Replacement/Bleeding

Explains the process for replacing and bleeding brake fluid.

Front Pad Replacement

Guides the user through replacing the front brake pads.

Front Caliper Inspection

Details how to inspect the front brake caliper for wear.

Front Master Cylinder Disassembly

Explains how to disassemble the front master brake cylinder.

Rear Brake Pad Replacement

Details the procedure for replacing the rear brake pads.

Rear Caliper Assembly

Guides the user through assembling the rear brake caliper.

Master Cylinder Assembly

Explains how to assemble the master brake cylinder components.

Wheel Inspection

Guides on inspecting wheels, spokes, and runout.

Wheel Balancing

Details the process for balancing motorcycle wheels.

Front Wheel Disassembly

Explains how to disassemble the front wheel assembly.

Speedometer Drive

Provides information on the speedometer drive unit.

Tires

Lists tire sizes and brands for different model years.

15 ELECTRIC STARTER

Service Information

Lists specifications for the electric starter motor and relay.

Troubleshooting

Helps diagnose issues with the starter motor not turning or running slowly.

Starter Motor

Details the removal, inspection, and installation of the starter motor.

Starter Relay

Explains how to remove, inspect, and test the starter relay.

16 IGNITION

Service Information

Provides specifications for ignition coils, ballast resistor, and plugs.

Troubleshooting

Helps diagnose issues with engine starting, running, or backfires.

Ignition Coils

Details how to test ignition coils and the ballast resistor.

Spark Advance Mechanism

Explains inspection of the spark advance mechanism.

17 LIGHTS, SWITCHES, AND INSTRUMENTS

Service Information

Lists specifications for bulbs, fuses, and sensor resistances.

Troubleshooting

Helps diagnose issues with lights, switches, and instruments.

Switches

Details testing procedures for various motorcycle switches.

Instruments

Explains testing for voltage regulator, fuel gauge, and voltmeter.

Headlight and Tail Light

Guides on replacing bulbs and adjusting headlight aim.

Reserve Lighting System

Describes the reserve lighting system components and testing.

Horn, Fuses, and Wiring

Covers horn testing, fuse replacement, and wiring checks.

1975-1977 Wiring Diagram

Provides the electrical wiring diagram for 1975-1977 models.

1978-1979 Wiring Diagram

Provides the electrical wiring diagram for 1978-1979 models.

18 BATTERY & CHARGING SYSTEM

Service Information

Lists specifications for the battery, AC generator, and regulator.

Troubleshooting

Helps diagnose issues with battery charging and power output.

Battery

Details battery testing, removal, and charging procedures.

Charging System

Explains how to test the charging system output.

AC Generator Removal

Guides the user through removing the AC generator.

Generator Drive Inspection

Details how to inspect the starter clutch and generator drive components.

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