Honda GL1500 Service Manual - PDF DOWNLOAD

Honda GL1500 Service Manual - PDF DOWNLOAD

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Honda GL1500 Service Manual - PDF DOWNLOAD

Language :English
Pages :761
Downloadable : Yes
File Type : PDF

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Honda GL1500 Service Manual - PDF DOWNLOAD

About this Publication

The GL 1500 Service Manual and Electrical Troubleshooting Manual are combined in this single reference source. This manual features a seven-ring binder for easy use.

Service Manual

• The GL 1500 Service Manual includes all three i 994 models: Aspencade, SE, and Interstate. Most service procedures are based on the GL 1500 Aspencade model.
• In those instances where service information for the SE and/or Interstate model differs, the text identifies the applicable model or models by the following codes: A (Aspencade), SE (SE), and I (Interstate).
• The GL 1500 Service Manual is divided into twenty sections. The first (index) page of each section is marked with a black symbol tab identical to the tab seen on this page.
• The section symbol also appears at the top of each right-hand page of the section as a reference aid. Section index pages list the contents of each section and give specific page references. Except for the Specifications and General Information sections, "Service Information" follows each index; be sure to read those few lines before you start any procedure to avoid any difficulty once you're in the middle of a job. In most cases a torque reference drawing will appear in Service Information.
• Torque values are given in the metric standard newton-meters (N-m) and also in footpounds (ft-lb.) (See page 1-9 for a specific explanation of the use of metric equivalents.) A system troubleshooting list follows the torque reference drawing, and then the service procedures begin.
• Wiring information is found in the appropriate section. Refer to the circuit diagrams in Sections 4, 5, 12, 16, 17, 18, 19, 20. Sections 1-3 of this manual apply to the whole motorcycle, while sections 4-20 describe parts of the GL 1500 grouped according to location. Refer to the Maintenance Schedule (Section 3) to know when service is needed to keep the vehicle in peak operating condition and within EPA-established emissions standards.
• The first scheduled maintenance is especially important since it helps compensate for the initial wear that occurs during the break-in period. Electrical Troubleshooting Manual (ETM) The ETM is located after section 20 of the Service Manual. It includes information for all three models, noting variations between the models.
• The manual divides the GL 1500's electrical systems into individual sections which include circuit schematics. Three handy reference sections appear at the rear of the ETM: Component Location Photographs, Component Location Index (which gives the number of the photograph in which the component appears), and Component Index (which lists all pages referring to the component).
• All information, illustrations, directions and specifications included in this publication are based on the latest product information available at the time of approval for printing.
• Honda Motor Co., Ltd. reserves the right to make changes at any time without notice and without incurring any obligation whatever. No part of this publication may be reproduced without written permission.

TABLE OF CONTENTS:

Honda GL1500 Service Manual - PDF DOWNLOAD

GENERAL INFORMATION 1
INDEX 564
SPECIFICATIONS 14
General 15
Standards & Service Limits 17
Torque Values 21
MAINTENANCE 24
Troubleshooting 30
Maintenance Schedule 35
Engine Oil 36
Final Drive Oil 38
Fuel Line & Throttle Operation 39
Carburator 40
Air Cleaner 41
Crankcase Breather & Spark Plugs 42
Carb Synchronization 43
Compression 44
Coolant 45
Cooling System 46
Pulse Secondary Air Injection (PAIR) 47
Battery 48
Brakes 49
Brake and Headlights 51
Clutch 52
Reverse Gear 53
Sidestand & Suspension 54
Air Pump Element 56
Air Dryer 57
Cruise Valve Element 58
Wheels & Tires 59
Steering Head Bearings 60
FUEL SYSTEM 61
Troubleshooting 69
Fuel Tank 75
Auto Fuel Valve 76
Fuel Filter 77
Air Cleaner Housing 78
Carburators 79
Intake Manifold 97
Pilot Screw Adjustment 99
Fuel Pump 100
Fuel Reserve & Sensor 103
Engine Control Module 106
Air Intake Shot Air (IASA) System 107
Carb Air Jet (CAJ) Control System 110
Intake Air Temp (IAT) System 113
Pulse Secondary Air Injection (PAIR) System 115
Cruise Control 121
COOLING SYSTEM 139
Troubleshooting 143
Inspection & Testing 145
Coolant Replacement 146
Radiator 147
Cooling Fan & Reserve Tank 149
Stat, Water Lines, & Valves 151
Water Pump 153
Temperature Sensor/Gauge 155
Fan Motor Switch 156
ENGINE REMOVAL/INSTALLATION 157
Removal 157
Installation 162
CYLINDER HEAD/EXHAUST SYSTEM 164
Troubleshooting 166
Timing Belt - Removal 167
Camshaft - Removal 169
Camshaft Holder - Disassembly 171
Cylinder Head Removal 173
Cylinder Head Disassembly 174
Cylinder Head Assembly & Installation 180
Timing Belt - Installattion 185
Valve Adjusters 189
Exhaust & Mufflers 191
CRANKSHAFT/PISTON 197
Troubleshooting 201
Front Engine Cover - Removal 202
Rear Case Cover - Removal 203
Scavenging Pump 206
Oil Pump & Strainer 210
Pistons - Removal 213
Crankpin Bearing 217
Pistons - Installation 220
Crankshaft - Removal 223
Main Journal Bearings 224
Front Engine Cover - Install 228
Rear Case Cover - Install 229
CLUTCH 232
Troubleshooting 235
Clutch Fluid Replacement & Bleeding 236
Clutch Master Cylinder 239
Clutch Slave Cylinder 240
Clutch 241
TRANSMISSION 250
Troubleshooting 254
Gearshift Linkage 255
Crankcase Separation 258
Transmission - Disassembly 259
Transmission Inspection 261
Transmission - Assembly 263
Crankcase Assembly 267
Primary Drive & Driven Gears 271
Output Shaft 274
FINAL DRIVE 280
Troubleshooting 282
Gearcase Removal & Drive Shaft 283
Universal Joint 284
Gearcase - Disassembly 285
Gearcase - Assembly 293
Gearcase - Installation 296
FRAME/SUSPENSION 297
Troubleshooting 302
Fork Legs 307
Shock Absorbers 316
Swingarm 322
On-Board Air Compressor System 327
Handlebars 333
Steering Stem 338
FAIRING/BODY COMPONENTS 343
Windshield 345
Fairing 348
Trunk & Saddlebags 356
Front Fender 360
Rear Fender 361
Passenger Footrests 362
BRAKES 365
Troubleshooting 368
Brake Fluid Replacement & Bleeding 369
Brakepad Replacement 371
Brake Disc Inspection 375
Front Master Cylinder 376
Rear Master Cylinder 378
Front Brake Caliper 383
Rear Brake Caliper 385
Brake Pedal 387
Metal Brake Line 388
WHEELS/TIRES 391
Troubleshooting 394
Front Wheel 395
Rear Wheel 400
Wheel Balancing 410
IGNITION SYSTEM 411
Troubleshooting 415
Engine Control Module 418
Ignition Coil 419
Ignition Pulse Generator 421
Gear Position Switch 424
Side Stand Switch 425
Engine Coolant Temp Sensor 426
Ignition Timing 428
CHARGING SYSTEM 431
Troubleshooting 435
Battery 437
Charging System Output 439
Alternator & Regulator/Rectifier 440
Alternator Drive & Driven Gears 449
STARTER/REVERSE 454
Troubleshooting 458
Starter/Reverse Motor 466
Starter Clutch 475
Fuel Pump Shut-Off (Bank Angle) Sensor 478
Starter Relay Switches 479
Reverse Relay Switch & Relay Box 480
Diode Assembly & Reverse Switch 481
Starter Reverse Switch 482
Clutch Switch & Reverse System 483
Reverse Control Unit 492
Starter Relay Regulator 494
Reverse Resistor Assembly 495
Power Control Relay 496
Speed Limiter Relay 497
Reverse Lever Switch 497
LIGHTS/SWITCHES/INSTRUMENTS 506
Troubleshooting 512
Headlight/Position Light 519
Turn Signals/Brake Lights 520
License/Accessory Light 522
Instruments 523
Ignition Switch 527
Left Handlebar Switches 529
Brake Light Switches 530
Oil Pressure Switch 530
Relay Box 531
Parking Diode 531
Self-Cancelling Turn Signal System 532
Hazard Relay 535
Horn 535
Spoiler Light 536
Corniering Lights 537
AUDIO SYSTEM 538
Troubleshooting 545
Speakers 554
Muting/Search Switch 554
CB Switch/Fader Control 555
Antenna 556
Radio & Cassette Deck 557
CB Transceiver 561
ELECTRICAL TROUBLESHOOTING MANUAL 566
How to Use this manual 567
Fuse info:ASP & SE 582
Power Distribution:ASP & SE 586
Ground Distribution 596
Engine Control System 608
Starting System 622
Charging System 634
Radiator Fans 636
Reverse System 638
Cruise Control System 648
Horn:ASP & SE 662
Clock 664
Automatic Level Control 666
Low Fuel & Oil Warning System 668
Indicators 670
Instrument Panel A 674
Speed Sensor Circuit 676
Instrument Panel B 678
Headlights 680
Marker Lights 684
Cornering Lights 687
Handlebar Switch Illumination 689
Turn Signal,Hazard & Position Lights 690
Tail,Parking and Licence Lights 696
Brake Lights 700
Trunk Light 702
Accessory Lights 703
Spoiler Brake/Taillight 704
Radio & Cassette 706
Component Location Index 736
Component Location Pictures 744
Component Index 756

S.M 18/3/2025