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2001 HONDA GL1800/ A Radio Muting Improvement

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Filed Under (Honda) by admin on 29-01-2011

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1. Place the faulty radio in the same box in which the exchange radio was sent. THE FAULTY RADIO (CORE) MUST BE RETURNED IN THE SAME BOX IN WHICH THE EXCHANGE RADIO WAS SHIPPED. These boxes are identified by the label shown below which is printed on the inside of the lid. 2. Fill out the pre-printed FedEx airbill that came in the box with the exchange radio. The airbill should have the following address preprinted on it: AHM Remanufactured Parts c/o NK Parts Industries Inc./West 2640 Campbell Rd. Sidney, OH 45365-8836 • Do not use an ordinary FedEx airbill. The pre- addressed airbill has a special account number on it for the exchange program. If you need more airbills, call the Radio Order Desk toll free, not your assigned Parts Center . • Write your dealer number and the warranty claim number in the area shown in the sample airbill ffix the FedEx Airbill to the outside of the box. Radios sent in a box not bearing the correct FedEx airbill will not be accepted for reimbursement under this program. 4. Enclose a copy of the HONDANET for Windows warranty claim in the box. If the claim form is incomplete or not in the box, the faulty radio will be returned to your dealership. 5. Ship the faulty radio to the preprinted address on the airbill. NOTE: Do not ship the faulty radio to the manufacturer or the Warranty Parts Inspection (WPI) Center. 6. For your records, on the repair order include the following: • warranty claim number • original part number • FedEx airbill number When the faulty radio is received, a core credit will be posted to your dealership’s Balance Forward Account. The credit can be identified by the claim number + “CORE” (e.g., 12345/CORE). REMEMBER: A copy of the HONDANET for Windows warranty claim must be included in the box. RETURNING THE FAULTY RADIO The faulty radio must be returned within 20 days of

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2001-2002 GL1800/ A CB Radio Replacement/ REPAIR PROCEDURE

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Filed Under (Honda) by admin on 29-01-2011

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For authorization, call the CB Exchange Radio Order Desk toll free: (888) 997-7278 . The CB Exchange Radio Order Desk hours are Monday thru Friday, 8:30am – 8:00pm EST. BEFORE STARTING ANY REPAIR ON THE CB RADIO, YOU MUST FIRST CALL THE ORDER DESK FOR AUTHORIZATION. Part Number: 08E95-MCA-101RM Honda Code: 7066319 3. After calling the CB Radio Order Desk, an exchange transceiver will be shipped overnight (freight prepaid). 4. Replace the faulty CB Transceiver with the exchange unit (see REPAIR PROCEDURE ). . Remove the seat (see the GL1800 Service Manual, page 2-4). 2. Remove the right rear side cover (page 2-4). 3. Remove the right-hand fairing molding (page 2-8). 4. Remove the right hand top shelter setting bolts and mounting nut (page 2-9). It is not necessary to remove the left-hand fairing molding, shelter bolts, or shelter. 5. Disconnect the 14P CD coupler under the rear seat. Remove and set aside the CD Changer (if equipped). (Continued on page 2) Some customers may experience weak radio transmissions and/or the need to use abnormally high squelch settings for reception on the Hondaline CB Radio. To correct this condition, the CB Transceiver unit must be replaced as described in this Service Bulletin. Do not order a CB kit from parts stock. Follow the ordering procedures in this Service Bulletin. AFFECTED MOTORCYCLES 2001 – 2002 GL1800/A ORDERING AND REPLACING THE CB TRANSCEIVER 1. Before calling the CB Exchange Radio Order Desk, have the following information ready: • VIN • Failure Information (i.e., symptom) • Warranty Status 2. For authorization, call the CB Exchange Radio Order Desk toll free: (888) 997-7278 . The CB

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HONDA GL1100 AM/FM RADIO INSTALLATION MANUAL/ WIRING DIAGRAM

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Filed Under (Honda) by admin on 22-04-2011

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INSTALLATION ■ Outline Procedures This section gives general information needed for mounting the individual radio components on and in the fairing. A) Fairing 1) Install radio on fairing before mounting fairing on motorcycle. (Remove fairing from your motorcycle when already mounted). 2) Remove fairing parts. 3) Drill unit mount holes. 4) Install six wire clips. 5) Install windshield on fairing before install- ing speakers. 6) Install radio indicator I on indicator panel II , then install indicator panel on fairing. 7) Install speakers III. 8) Install nutplate IV. 9) Install Power Amplifier in fairing. 10) Install radio funer VI. 11) Install the radio controller VII. 12) Install controller base panel VIII 13) Install radio switch sub-wire. 14) Connect adapter harness and wires inside fairing by working through left turn signal lens hole. B) Motorcycle frame and handlebar 1) Remove travel trunk and seat. Unscrew four shelter bolts (M6, one on each side at front and rear) to route antenna feeder. 2) Install antenna mount and antenna IX. 3) Route antenna feeder along the frame tube. 4) Install radio switch X on left handlebar lever bracket and route the wires. 3 of 11 Page 4 C) Fairing instllation 1) Install fairing on motorcycle. 2) Connect motorcycle wire harness 9-P coupler to fairing wire 9-P coupler. 3) Connect radio switch wire to switch sub- wire.4) Connect antenna feeder. 5) Confirm that radio operates properly. Reinstall parts removed in step 2 or (A) and in step 1 of (B). REWORKING ■ Remove Fairing and Fairing Parts (Fig.10) 1) Install radio on fairing before mounting fairing on motorcycle. (Remove fairing from your motorcycle when already mounted). 2) Remove right and left fairing pockets, right and left turn signal lenses, right and left nutplates, left hole cover and indi- cator base panel from fairing. (Fig.10) Fig. 10 LEI-1 NU I PLATE 4 of 11■ Reworking on Fairing — Speaker mounting holes- 1) Remove 18 mm grommet. 2) Lightly roll template so that it will follow contour of fairing snugly. 3) Position template on fairing with its upper and outer edges aligned with those offairing as indicated by arrows. 4) Attach template to fairing using adhesive tape where shown. 5) Punch mark centers of four holes with a
drift and hammer. 6) Drill 6 mm holes through marked centers. To obtain a more balanced response with richer, deeper bases, drill two 50 mm holes in the fairing so as to link the speaker box with the inside of the fairing. Fig. 11-1
—Power amplifier mounting holes- 7) Drill two 5.5 mm holes through concaves in fairing. Fig. 11-2 RIGHT HAND SHOWN, LEFT SIMILAR ADHESIVE TAPE

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MECHANIC CERTIFICATION REQUIREMENTS MDOS Form: Repair Facility Manual

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Filed Under (Tips and Review) by admin on 18-11-2010

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Chapter 7: Mechanic Certification Requirements Page 4 7-2.2 Heavy-duty Truck Certification Categories. The Heavy-duty Truck Repair categories requiring mechanic certification to repair vehicles over 10,000 pounds G.V.W. are: a) Engine Repair, Gasoline; b) Engine Repair, Diesel; c) Drive Trains; d) Brakes and Braking Systems; e) Suspension and Steering Systems; f) Electrical Systems; g) Collision-Related Mechanical Repair. 7-2.3 Other On-road Vehicle Certification Categories. Repair categories for other on-road vehicles that require mechanic certification to perform repairs are: a) Motorcycle; b) Recreational Trailer. Automobile and Light Truck Certification Categories. The repair categories requiring mechanic certification to repair vehicles under 10,000 pounds gross vehicle weight (G.V.W.) are: a) Engine Repair; b) Engine Tune-up/Performance; c) Front End, Suspension and Steering Systems; d) Brakes and Braking Systems; e) Automatic Transmission; f) Manual Transmission, Front and Rear Drive Axles; g) Electrical Systems; h) Heating and Air Conditioning; i) Collision-Related Mechanical Repair; j) Unitized Body Structural Repair; k) Pre-1973 Vehicle Repair

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HARLEY DAVIDSON FLHT ADVANCED AUDIO AM/FM/CD RADIO KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 09-02-2011

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INSTALLATION Remove Existing Equipment To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 1. Refer to the Service Manual and follow the instructions given to remove the maxi-fuse. 2. Remove outer fairing and windshield. Refer to OUTER FAIRING/WINDSHIELD REMOVAL in Service Manual. 3 2 1 is 00397 1. Socket head screw (4) 2. Radio support bracket (2) 3. Radio Figure 1. AM/ FM Radio Installation 3. See Figure 1. Using a long shank ball end socket (Snap- on® FABL6E or equivalent), remove the four socket head screws (1) to release the storage box from the left and right radio support brackets (2). Use the oblong holes in the fairing brackets to access the screws. Install Radio 1. Pull the storage box forward to remove the box from the opening in the inner fairing. Discard the storage box. 2. Position the radio (3) between the radio support brackets and push it into the opening in the inner fairing. 3. Align the threaded inserts in the sides of the radio with the oblong holes in the left and right radio support brackets. 4. Starting at the rear, install the four socket head screws previously removed. Alternately tighten the screws to 35- 45 in-lbs (4.0-5.1 Nm). 5. Plug the 23-place radio socket housing [27A] (part of the interconnect harness already installed on the vehicle) into the back of the radio. 6. Remove three T25 TORX® screws that hold the speaker opening cover on one end of the fairing. Discard the cover and screws. Install Speakers 1. See Figure 3. If the speaker (3) and adapter (4) are not assembled, or are assembled incorrectly, orient the speaker on the adapter and grille assembly so the speaker spade contacts are toward the side of the adapter with the widest edge. Snap the speaker into the adapter using finger pressure only.

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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.

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2007 FJ Cruiser POOR SOUND QUALITY FROM SATELLITE RADIO REPAIR

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Filed Under (Toyota Manuals) by admin on 28-10-2011

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some customers may experience poor sound quality from the Toyota XM or SIRIUS satellite radio accessory option (sound quality is normal in AM, FM, and CD mode). A revised radio has been developed to remedy this condition. 2007 model year FJ Cruiser vehicles equipped with the upgraded radio and the port or dealer-installed Toyota satellite radio kit (XM or SIRIUS). PREVIOUS PART NUMBERCURRENT PART NUMBER PART NAME QTY 86120-35380 Same Radio Receiver

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2006 Honda GL1800 AirbagCB Radio Squeal REPAIR PROCEDURE

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Filed Under (Honda) by admin on 08-04-2011

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To remedy this problem, a ferrite core harness kit is now available for installation. 2006 GL1800 VIIIA (Airbagmodels) with optional CBRadio. Install a ferrite harness core kit according to the installation instructions that are packaged with the kit. ÒÑÌÛæ • The kit includes both a rider and a passenger harness; it’s necessary to install both harnesses to eliminate the squealing noise. • Passengers must route the headset cord as shown. If routed otherwise, it will be too close to the motorcycle’s antenna, which can create an interference. Subharness installation can be confirmed by removing the left-side fairing pocket, and check- ingtoseeifthe harness is already installed. Ferrite CoreHarness Kit (1 required) P/N: 08E95-MCA-100WA H/C: 8607665 ÒÑÌÛæCallTechLineat (800) 421-1900 to order parts. Due to the limited number of affected units and parts availability, ordering will be controlled until May 31,2007. Normal warranty claim submission require- mentsapply. Submit one claim per VIN. Template: GL19 Flat RateTime: 0.3 hours

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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HONDA GL1800 CB RADIO KIT INSTALLATION And REMOVAL

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Filed Under (Honda) by admin on 20-11-2011

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These instructions are for installation of the CB radio. For operation of the CB radio, refer to the Owner’s Manual and FCC Rule Book furnished with the CB radio. • Install the antenna which is sold separately between the installation of the rear trunk and the routing of the wire harness. • It is not necessary to drill four 7 mm holes and install the plate when you are also installing the CD changer. 1. Refer to the Service Manual to remove the right and left side covers and disconnect the negative terminal from the battery

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