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Honda GL1100 KA 1980 User Manual

Honda GL1100 KA 1980
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Honda GL1100 KA 1980 Specifications

General IconGeneral
Year1980
ManufacturerHonda
ModelGL1100 KA
CategoryTouring
Displacement1085 cc
Compression Ratio9.2:1
IgnitionElectronic
Transmission5-speed
Final DriveShaft
Front SuspensionTelescopic fork
Fuel Capacity19 liters
Rear SuspensionDual shocks, adjustable preload
Dry Weight272 kg
Bore x Stroke75 x 61.4 mm
Rear BrakeSingle disc

Summary

Acknowledgements

About this manual

Introduction to the Honda GL1100 Gold Wing

Model dimensions and weights

Technical specifications for the motorcycle's size and mass.

Ordering Spare Parts

Safety First!

Asbestos

Warning regarding asbestos in components.

Fire

Precautions related to fire hazards during maintenance.

Fumes

Caution about toxic fumes from cleaning solvents.

Ignition HT Voltage

Warning about high voltage from the ignition system.

Routine Maintenance

Tyres

Checking and maintaining tyre pressure and condition.

Battery

Checking and maintaining battery electrolyte level.

Engine Oil

Checking and changing engine oil.

Coolant

Checking and topping up coolant levels.

Electrical system

Brake pad wear

Checking the brake pads for wear.

Clutch adjustment

Adjusting the clutch cable and lever.

Carburettor adjustment - Idle speed

Adjusting the idle speed of the carburettors.

Engine oil and filter renewal

Sparking plugs

Checking and cleaning sparking plugs.

Valve clearance adjustment

Carburettor adjustment - synchronisation

Synchronising the carburettors.

Steering head bearings

Suspension

Checking and adjusting suspension units.

Front brake caliper: examination and refitting

Front fork wear

Checking front fork wear.

Brake fluid

Quick glance maintenance adjustments and capacities

Recommended lubricants

Conversion factors

Working conditions and tools

Chapter 1 Engine, clutch and gearbox

General description

General description of the engine, clutch, and gearbox.

Preparation for engine/gearbox removal

Steps to prepare the motorcycle for component removal.

Engine/gearbox unit: removal from the frame

Procedure for removing the engine and gearbox assembly.

Engine oil and filter renewal

Procedure for renewing engine oil and filter.

Engine specifications

Valve clearances

Specifications for valve clearances.

Pistons and rings specifications

Big-end bearings

Specifications for big-end bearings.

Gearbox specifications

Specifications for the gearbox.

Torque wrench settings

Operations with engine/gearbox removed from the frame

Procedures for engine and gearbox when removed.

Engine/gearbox unit: removing the clutch

Engine/gearbox unit: removing the final drive shaft

Procedure for removing the final drive shaft.

Disassembling the engine/gearbox: removing the carburettors

Disassembling the engine/gearbox unit: removing the timing covers

Disassembling the engine/gearbox unit: removing the CDI pulser generator assembly

Disassembling the engine/gearbox unit: refitting the oil pumps

Disassembling the engine/gearbox unit: refitting the main bearing shells

Disassembling the engine/gearbox unit: refitting the oil pumps

Bearing selection

Connecting rods: examination and renovation

Procedure for examining and renovating connecting rods.

Cylinder head

Rocker arms/spindle support

Removing and fitting rocker arm/spindle support.

Camshaft

Examining and fitting the camshaft.

Camshaft, rocker arms and rocker spindles: examination and renovation

Bearing selection

Guidance on selecting bearings based on code number.

Clutch assembly: examination and renovation

Gearbox components and primary shaft

Primary driven gear assembly: examination and renovation

Final drive output shaft: examination and renovation

Procedure for examining and renovating the final drive output shaft.

Starter rotor assembly and starter clutch assembly

Journal ball bearings: examination, removal and fitting

Engine/gearbox unit assembly: refitting the oil pumps

Engine/gearbox unit assembly: refitting the oil pumps

Engine/gearbox unit assembly: refitting the oil pumps

Engine/gearbox unit assembly: refitting the oil pumps

Engine/gearbox unit assembly: refitting the oil pumps

Engine/gearbox unit assembly: refitting the oil pumps

Engine/gearbox unit assembly: refitting the oil pumps

Engine/gearbox unit assembly: refitting the oil pumps

Reassembling the engine/gearbox unit: refitting the oil pumps

Reassembling the engine/gearbox unit: refitting the oil pumps

Reassembling the engine/gearbox unit: refitting the oil pumps

Reassembling the engine/gearbox unit: refitting the oil pumps

Reassembling the engine/gearbox unit: refitting the oil pumps

Clutch plates: fitting

Final drive output shaft oil seal

Reassembling the engine/gearbox unit : refitting the valve drive assembly and timing the valves

Reassembling the engine/gearbox unit : refitting the cylinder head cover

Reassembling the engine/gearbox unit : refitting the fuel pump

Reassembling the engine/gearbox unit : refitting the thermostat assembly

Procedure for refitting the thermostat assembly.

Reassembling the engine/gearbox unit: refitting the oil pumps

Reassembling the engine/gearbox unit: refitting the oil pumps

Chapter 2 Cooling system

General description

General description of the cooling system.

Cooling system: draining

Procedure for draining the cooling system.

Cooling system: flushing

Procedure for flushing the cooling system.

Coolant

Specifications for the coolant.

Thermostat: removal, testing and refitting

Water pump: removal, renovation and refitting

Procedure for removing, renovating, and refitting the water pump.

Radiator: removal, examination and refitting

Procedure for removing, examining, and refitting the radiator.

Radiator pressure cap: testing

Fault diagnosis: cooling system

Chapter 3 Fuel system and lubrication

General description

General description of the fuel system.

Fuel tank: removal and refitting

Procedure for removing and refitting the fuel tank.

Fuel filter: removal and renewal

Procedure for removing and renewing the fuel filter.

Carburettors: dismantling, examination and reassembly

Procedure for dismantling, examining, and reassembling carburettors.

Torque wrench settings

Fuel filter: removal and renewal

Fuel pump: removal, examination and refitting

Procedure for removing, examining, and refitting the fuel pump.

Carburettors: removal from the machine

Carburettors: dismantling, examination and reassembly

Procedure for dismantling, examining, and reassembling carburettors.

Carburettors: dismantling, examination and reassembly

Accelerator pump: examination and adjustment

Carburettors: idle speed adjustment

Carburettors: pilot screw adjustment

Carburettors: synchronisation

Synchronising the carburettors.

Float level: checking

Air filter: renewal

Replacing the air filter element.

Exhaust system: removal and refitting

Procedure for removing and refitting the exhaust system.

Fuel filter: renewal

Brake fluid

Checking and topping up brake fluid.

Cooling system

Checking the cooling system.

Oil pumps: removal, examination and refitting

Oil filter: renewing the element

Procedure for renewing the oil filter element.

Chapter 4 Ignition system

General description

General description of the ignition system.

Testing the electrical system: general

General procedure for testing the electrical system.

Battery: examination and maintenance

Procedure for examining and maintaining the battery.

Fuses: location

Location of the fuses.

Ignition system

Ignition timing

Adjusting ignition timing.

Pulser coils: testing

Testing the pulser coils.

Ignition coils: location and testing

Ignition amplifier (spark unit): testing

Vacuum advance unit: testing

Chapter 5 Frame and forks

General description

General description of the frame and forks.

Front forks: dismantling, examination and refitting

Procedure for dismantling, examining, and refitting front forks.

Rear suspension units: removal, examination and refitting

Procedure for removing, examining, and refitting rear suspension units.

Wheels

Details on wheels.

Torque wrench settings

Front fork lubrication

Chapter 6 Wheels, brakes and tyres

Tyre specifications

Specifications for tyres.

Front brake caliper: examination and overhaul

Procedure for examining and overhauling the front brake caliper.

Rear brake caliper: examination and overhaul

Procedure for examining and overhauling the rear brake caliper.

Front wheel bearings: removal, examination and fitting

Procedure for removing, examining, and fitting front wheel bearings.

Rear wheel bearings: removal, examination and fitting

Bleeding the front brake hydraulic system

Cush drive assembly: examination

Final drive system: examination and renovation

Procedure for examining and renovating the final drive system.

Fault diagnosis: wheels, brakes and tyres

Chapter 7 Electrical system

General description

General description of the electrical system.

Alternator: general

General description and testing of the alternator.

Testing the electrical system: general

General procedure for testing the electrical system.

Fuses: location

Location of the fuses.

Battery: examination and maintenance

Starter motor: removal, examination and refitting

Ignition switch: removal, testing and fitting

Procedure for removing, testing, and fitting the ignition switch.

Pulser coils: testing

Ignition amplifier (spark unit): testing

Headlamp: adjusting beam height - Interstate models

Headlamp: bulb renewal

Procedure for replacing the headlamp bulb.

Direction indicator bulbs

Tail/stop lamp bulbs

Checking and replacing tail/stop lamp bulbs.

Direction indicator relay: location and testing

Locating and testing the direction indicator relay.

Instrument illumination lamps

Horn assembly

Removing and refitting the horn assembly.

Temperature gauge and sensor: testing

Fault diagnosis: electrical system

Troubleshooting common electrical system faults.

English/American terminology

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