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Honda Goldwing GL1800 Solid Rear Axle Trike Conversion Installation Manual

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Filed Under (Honda) by admin on 16-02-2011

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Specifications Overall Width: 57.75″ Overall Length: 108″ Overall Length w/EZ-Steer 109.5 Wheel Base: 71″ Extended 4.5″ At Rear Axel Wheel Base w/EZ Steer 72.5″ Load Capacity: 500 Lb Tire Size: 205 / 70 / R15 Wheel Size (15″) Offset +35 mm 15x7JJ 4×4.5 Tire Pressure 20 PSI Suspension: “Zero-Flex” Internal Swing Arm utilizing 3 shocks, OEM shock absorber plus 2 coil over shock absorbers. Rear Differential: Champion Lightweight rear axle / differential assembly. Gear Ratio 2.93:1 gear ratio Brakes: Original front plus 2 high performance disc brakes at rear. Storage Capacity: 6.75 cubic feet. 3 full-face helmets and additional storage. Trike Conversion Installation Kit Honda Goldwing GL1800 Champion Trikes Page 7 of 28 Revision 10 4 Removal of Original Parts Most tasks necessary in this guide can be accomplished with the vehicle on its center stand. Secure the center stand to one of the forward crash bars with a ratchet strap to keep vehicle from rolling forward and off the center stand. Be sure that the vehicle is laterally stable as well. Remove the following from the vehicle. See OEM manual for detailed instructions. Items to be retained for return of deposit or re-installation after modification shall be duly noted. • Seat (to be re-installed without modification) • Left and right side covers (to be re-installed without modification) • Battery and battery box (to be re-installed without modification) • Left and right saddle bags • Remove taillight and locking assemblies from saddlebags (to be returned for refund of deposit) • Trunk (to be re-installed without modification) • Left and right passenger foot rests (to be re-installed without modification) • Left and right foot rest under covers (to be modified and re-installed) • Left and right rear crash bars • Saddle bag trunk stay (to be modified and re-installed) • Left and right mufflers (Mufflers only, do not remove decorative covers) • Rear wheel • Left and right pivot bolt covers (to be re-installed without modification) • Reverse resistor (to be relocated) • Swing Arm – Note : Carry out brake system modifications (Section 5) prior to removing Swing Arm. • Note : Upper bolt of mono shock can be removed without removing the fuel tank. • Note : Do not remove actuator hose from actuator pump or shock absorber. Dismounting shock actuator pump will allow more movement of shock absorber when removing swing arm.Trike Conversion Installation Kit Honda Goldwing GL1800 Champion Trikes Page 8 of 28 Revision 10 5 Brake System Modification Note : Modification to the vehicle brake system should be carried out prior to removal of the swing arm. From the manufacturer, your Honda Gold Wing brake system utilizes both front and rear brakes when the foot brake is applied. In order to insure safe operation of your Gold Wing when converted to a Champion Sidecars Trike, the brake system must be modified to isolate the front and rear brake systems from each other. Once modification is complete, four of the six pistons in the front calipers operate only when the hand brake lever is applied. The rear brakes operate only when the foot brake pedal is applied. The diagrams below outline the difference between the GL1800 OEM brake system and the system as modified by the Champion Sidecars Trike Conversion Kit.

2001 – 2002 GL1800/ GL1800A Rear Tire Inspection

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Filed Under (Honda) by admin on 27-11-2010

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1. Inspect the motorcycle for a punch mark as described in Identification on page 2. If a punch mark is present no further action is necessary, return the unit to the customer. 2. Qualify the unit/customer as follows: •Is the tire on the motorcycle the original factory installed tire? •Is the air pressure loss more than three psi per month? Note: Refer to page 145 in the Owner’s Manual. “Even tires that are in good condition may lose one to two psi per month if not checked and adjusted regularly” . If the GL1800 meets the above qualifications, proceed with the repair procedure. 3. Place the motorcycle on a lift and secure it on the centerstand. 4. Remove the rear wheel as described on page 14-9 of the Service Manual. 5. Starting at the valve stem/balance mark area, carefully remove the rear tire from the wheel. Be sure to use plenty of commercially available tire lubricant on the inside and outside of both beads. 6. Carefully inspect the entire circumference of both tire beads. Inspect both the inside and outside of the bead for any distortion or injuries. See examples of injuries below. 2001 – 2002 GL1800/GL1800A Rear Tire Inspection GL1800 #6 OCTOBER 2001 MTB 9430 (0109) CUSTOMER INFORMATION: The information in this bulletin is intended for use only by skilled technicians who have the proper tools, equipment, and training to correctly and safely maintain your Honda. These procedures should not be attempted by “do-ityourselfers,” and you should not assume this bulletin applies to your Honda, or that your Honda has the condition described. To determine whether this information applies, contact an authorized Honda dealer. Service Bulletin American Honda Motor Co., Inc. 2001-2002 GL1800/GL1800A Rear Tire Inspection 0110 GL1800 #6*GL1800 #6*0110*2001-2002 GL1800/GL1800A Rear Tire Inspection*GL1800/GL1800A, Rear Tire Inspection, Bead, Tread*Motorcycle*1800 2 of 4 ©2001 American Honda Motor Co., Inc. – All Rights Reserved GL1800 #6 OCTOBER 2001 Inside BeadInjury Outside BeadInjury Outside BeadInjury 7. Carefully inspect the entire circumference of both tire beads. Inspect both the inside and outside of the bead for any distortion or injuries. See examples of injuries below. 8. If there is no evidence of bead damage, re-install the tire on the rim. Be sure to use plenty of commercially available tire lubricant on the inside and outside of both beads. Be sure to align the balance dot with the valve stem. Inflate the tire to 41 psi. Install the wheel assembly on the motorcycle and proceed to the Identification and then to the Warranty section. 9. If any damage or injury is present replace the tire and valve stem. Be sure to use plenty of commercially available tire lubricant on the inside and outside of both beads. Balance the new tire as necessary

Honda Goldwing GL1800 Independent Rear Suspension Installation Manual

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Filed Under (Honda) by admin on 16-02-2011

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Removal of Original Parts Most tasks necessary in this guide can be accomplished with the vehicle on its center stand. Secure the center stand to one of the forward crash bars with a ratchet strap to keep vehicle from rolling forward and off the center stand. Be sure that the vehicle is laterally stable as well. Remove the following from the vehicle. See OEM manual for detailed instructions. Items to be retained for return of deposit or re-installation after modification shall be duly noted. □ Seat (to be re-installed without modification) □ Left and right side covers (to be re-installed without modification) □ Battery and battery box (to be re-installed without modification) □ Left and right saddle bags □ Remove taillight and locking assemblies from saddlebags (to be returned for refund of deposit) □ Trunk (to be re-installed without modification) □ Left and right passenger foot rests (to be re-installed without modification) □ Left and right foot rest under covers (to be modified and re-installed) □ Left and right rear crash bars □ Saddle bag trunk stay (to be modified and re-installed) □ Left and right mufflers (Mufflers only, do not remove decorative covers) . Retain OEM muffler rubber mounting bushings and flanged spacers for re-installation of the mufflers. □ Rear wheel □ Left and right pivot bolt covers (to be re-installed without modification) □ Reverse resistor (to be relocated) □ Swing Arm and Driveshaft IMPORTANT : Carry out brake system modifications (See Section 5) prior to removing Swing Arm. Evacuating all the brake fluid from the system will prevent brake fluid spills when the OEM swing arm is removed. Note : Upper bolt of mono shock can be removed without removing the fuel tank. □ Rear Shock and Hydraulics. Unscrew angle sensor from OEM shock and secure to frame with cable tie. □ Shock arm and shock link Note : You may need to cut out the bolt that attaches the shock link to the frame Brake System Modification Note : Modification to the vehicle brake system should be carried out prior to removal of the swing arm . 5.1 Explanation of OEM brake system and changes From the manufacturer, your Honda Gold Wing brake system utilizes both front and rear brakes when the foot brake is applied. In order to insure safe operation of your Gold Wing when converted to a Champion Trike, the brake system must be modified to isolate the front and rear brake systems from each other. Once modification is complete, four of the six pistons in the front calipers operate only when the hand brake lever is applied. The rear brakes operate only when the foot brake pedal is applied. The diagrams below outline the difference between the GL1800 OEM brake system and the system as modified by the Champion Trike Conversion Kit.

2003 SUZUKI SV 650 COOLING AND LUBRICATION SYSTEM SERVICE MANUAL

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Filed Under (Suzuki) by admin on 26-02-2011

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COOLING CIRCUIT INSPECTION Before removing the radiator and draining the engine coolant, inspect the cooling circuit for tightness. • * Remove the cowling. (SV650S) (C-7–7-6) • * Loosen the radiator cap stop screw 10 . (SV650) • * Remove the radiator cap O2 and connect the radiator tester to the filler. A WARNING Do not remove the radiator cap when the engine is hot. • * Give a pressure of about 120 kPa (1 .2 kgf/cm2,17.0 psi) and see if the system holds this pressure for 10 seconds . • * If the pressure should fall during this 10-second interval, it means that there is a leaking point in the system . In such a case, inspect the entire system and replace the leaking component or part. A WARNING When removing the radiator cap tester, put a rag on the filler to prevent spouting of engine coolant. CAUTION Do not allow the pressure to exceed specified pressure, or the radiator can be damaged. COOLING AND LUBRICATION SYSTEM 6-3 6-4COOLING AND LUBRICATION SYSTEM RADIATOR REMOVAL • * Remove the cowling. (SV650S) ( r- 7-7-6) • * Drain engine coolant. (r– 72-20) • * Disconnect the right and left radiator hoses from the radiator. • * Disconnect the siphon hose from the radiator. • * Disconnect the horn lead wires. rI .rr • * Remove the radiator lower mounting bolt. • * Disconnect the cooling fan motor and its thermo-switch lead wire coupler 10. • * Remove the radiator by upper mounting bolt. • * Remove the cooling fan. • * Disconnect the cooling fan thermo-switch. • * Remove the cooling fan thermo-switch. • * Remove the horn. CAUTION When removing the horn, hold the nut by spanner to prevent the horn bracket distortion. COOLING AND LUBRICATION SYSTEM 6-5 INSTALLATION • * Install the cooling fan and horn. 0 Cooling fan/horn mounting bolt: 8 N .m (0.8 kgf-m, 6 .0 Ib-ft) • * Install the cooling fan thermo-switch. ( l”76-9) • * Install the siphon hose to the radiator. • * Install the radiator in the reverse order of removal. • * Route the radiator hoses properly. (=9-22) 9-22) • * Install the drain plug with a new sealing washer and pour engine coolant. (=2-20) • * Bleed air from the cooling circuit. (r– 72-21) • * Install the cowling. (SV650S)

2002-2003 Honda GL1800/ A Frame Weld REPAIR PROCEDURE OVERVIEW

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Filed Under (Honda) by admin on 14-12-2010

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If your inspection identifies a crack or cracks in or on either Left or Right lower crossmember frame welds, STOP – call your DSM or TechLine for further instructions. • If your inspection reveals no cracks, proceed to REPAIR PROCEDURE. NOTE: Verification of repair can also be found in the Dealer Responsibility Report and on the Honda Interactive Network (iN). If you have any questions about verification, please contact TechLine before proceeding. IMPORTANT: For complete Dealer and Welder Repair procedures, refer to the following items: • 2002-2003 GL1800/A Frame Weld Safety Recall Dealer Booklet (S0510) • Frame Weld Inspection Chart (S0513) You MUST provide your TIG welder with the following items: • 2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual (S0511) • Welding Template Box (S0512) All of the above items were shipped to you with this Service Bulletin. If you need additional copies of the Dealer Booklet , Welding Manual , Welding Template Box , or Frame Weld Inspection Chart , you may order them at no cost from DDS at (440) 572-0725. For your reference, a brief repair procedure overview is provided below. Disassembly Overview You will be removing the following components from the vehicle as instructed in the Dealer Booklet : • Handlebar weights • Rear view mirrors • Swingarm pivot covers • Rider foot pegs • Seat • Side covers/Engine side covers • Fairing pockets • Fairing molding • Meter panel • Top shelter • Battery • Fuel tank • Main wiring harness ground • Front lower fairing • Front exhaust pipe protector • Muffler/exhaust pipe • Antenna Whip(s) • Coolant reserve tank • Center stand NOTE: You will need to remove any accessories that may contact the ground during the Welding and Re-assembly procedures. IMPORTANT: You MUST cover the following with RED duct tape for welder identification pur- poses: • Negative (-) and positive (+) battery cables • Fuel return hose end • Fuel feed hose end • Main wiring harness ground • Alternator • Exhaust ports Welding Overview A qualified TIG welder will weld the frame following the procedures in the 2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual . Re-assembly Overview You will be inspecting the new TIG welds, painting the frame, and re-assembling the vehicle as detailed in the Dealer Booklet and Frame Weld Inspection Chart (S0513)

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