GL1100 Hondaline Fairing Install

HONDALINE
'82
Public8tions No.
AppIteation
HP 144 8104
FAIRING
HONDALINE
GL 1100
Hie
luue Caw
APRIL 1981
PARTS LIST
Index
I Q'..,
Put Neme
;
N,.
Index
I,
,,
,
Fairing mount
Bolt, flange, 8 )( 80 mm
Fairing inner co,er, Right
Fairing inner cover,left
Screw, 6 x 12 mm
5
Wnher, plain, 6 mm
6
Inner co,er set rubber A
7
Inner eo'er set rubber B
8
Fairing inner cover seal
Nut, flange, 8 mm
Nut, flange, 6 mm
([1
Fairing set collar A
@
Screw, 6 x 16 mm
Collars
(ji
Nut, cap, 6 mm
(16
Washer,Iock,6 mm
17
Front cover
18
Bolt, flange, 6 x 14 mm
19
Screw,6 x 20 mm
Connector holder
<lI
.1
Bolt, flange, 8 x 20 mm
~cket,illftrtia _i9tt
~
Band, Right inertNi wei!t't
i
5
~
~
6
~
2
4
2
~
,
I
8
4
4
4
4
4
<i$
<is
Put Neme
N,.
~
,
,
3
4
2
2
2
1
•
a'ty
,
,
,,,
Band, Left inertia weight
Fairing set collar B
Lower biring bracket, Right
lower fairing bracket, Left
Bah flange, 6 x 22 mm
Lower bracket, Right
Lower bracket, Left
Inertia weight
Washer, lock, 8 mm
Nut,8 mm
Caution label
Horn, low
Bolt, flange, 6)( 12 mm
Sub wire harness C
Horn, High
"u" boh
Bracket
Sub wire harness F
Meter'isor
Wnher, plain, 4 mm
WiIIS"r, lock, 4 mm
Bolt, hex, 4 x 35 mm
Wire band B1
Wire band
2
1
4
2
2
2
,
,,
2
2
,
2
1
2
2
2
,
2
Fi9. 1
"
n
\,
J.1.32
~3~5.
U'~
.31
J6
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HONDA MOTOR CO., LTD. 1981 ·All Riihu A_fWd
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1 of 9
08154-46333-95 Printed in J..-,
11) Remove the radiator upper cover @.
12) Remove the radiator lower cover ©.
13) Remove and discard the right and leh
radiator covers @and ®.
TOOLS REQUIREO
• 8,10.12.14 BOO 19mm
combination wrenches
• #2 Screwdri.,er (+11-)
• 6mm socket
•
Torque wrench
•
Ratchet
,
Fi,.2
PRECAUTIONS
•
•
Proper torque of the attaching hardware is
essential.
Be sure to tighten all bolts, nuts and other
fasteners to their specified torques.
Standard torque values:
Torque val,,"
Item
N~
6 mm bolt and nut
10
8 mm bolt and nut_ I- 2~_
10 mm boh and nu!_
8 mm screw
6 mm flange bolt
and nut
8 mm flange bolt
¥ld nut
Ikll-n>l
1.~ _
2.~ _
3~_
0
3.5
0.0
12
1.2
25
2.5
~bs'-
8
W~
1
I.
0
-
PREPARATION FOR FAIRING
INSTALLATION
Refer to the G l1100 Owner's Manual, Shop
Manual and Parts List for detailed procedures
of the following:
11 Remove the seat.
2) Remove the shelter assembly.
3) Disconnect the battery ground cable from
the negative battery terminal.
4) Remove and discard the right and left
front reflex reflectors.
5) Remove the headlight and retain only the
headlight unit and bulb.
6) Disconnect the wire harness connectors
inside the headlight case.
7) Remove and discard the front turn signals.
8) Remove and discard the headlight case.
9) Remove and discard the lower fork bridge
cover. (Retain the screws.)
10) Remove the radiator grill ®.
CAUTION:
Do not damage the radiator
fins.
2 of 9
.....
,
2{;
-
14) Remove and discard the horn assemblies.
15) Remove the right and left front fork
covers as follows:
a. Remove the two 4 mm pan head
screws and nuts holding each front
fork cover.
b. Remove the front fork covers from
the fork pipes by prying between the
gap in each cover with the end of a
screwdriver.
c. Remove the cushions from the front
fork pipes. Discard the front fork
covers and cushions.
NOTE,
Avoid damaging the wire harnesses by
the screwdriver when removing the
front fork covers.
Fig. 3
VIEW X
FRONT FORK
COVER
I
P!'=='......
SCREWDRIVER I-I
VIEW X
~
I
FAIRING MOUNT INSTALLATION
1) Install the turn signal buzzer on the left
inertia weight band.
2) Position the inertia weight brackets @
and bands @ and @ on the front forks
and install using an 8 x 20 mm flange bolt
® for each.
NOTE: Position the bands@and ® so
that the flange ® is down
against the surface @ (shadowed) of the lower fork bridge.
Fig. 4
TURN SIGNAL BUZZER
"'----<x
Fig_ 5
@
Fig. 5-'
TO'
LOWER FORK BRIDGE
the ignition switch wires as
follows:
a. Disconnect the ignition switch connector.
b. Connect the sub wire harness F @
connector to the ignition switch connector.
RIGHT/LEFT TURN SIGNAL
WIRE HARNESSES
HEAOLIGHT
UNIT
THROTTLE
CABLES
RIGHT HANDLEBAR
SWITCH WIRES
®
Fig. 4-1
®.
NOTE:
• Check that the connectors are connected securely.
• Re-check the routing before going to
the next step.
• Neatly arrange the wires inside the
connector holder ® before installing
the cover.
LEFT FRONT FORK
3) Re-route
install the connector holder @ using two
8 x 20mm flange bolts @.
NOTE: Tighten the flange bolts to the
specified torque.
5) Connect all wires to wire harness colorto-color inside the connector holder
place the wire connectors as shown and
secure the wires with a wire band ®.
Note that connect the light blue/white
and brown wire of the sub wire harness F
@ to the light blue/white wire of the
right turn signal.
LEFT HANDLEBAR
SWITCH WIRES
IGNITION
SWITCH
~
CLUTCH
CABLE
~
CHOKE CABLE
/
SUB WIRE
HARNESS F
SUB WIRE
~C""3>4ii
F@
FAIRI~
CONNECTOR
............... IGNITtON SWITCH
WIRE HARNESS
4) Route the wire harnesses through the
upper and lower holes of the wire harness
connector holder ® as shown. Insert the
lugs on the connector holder ® into holes
in the inertia weight brackets @ and
Fig. 6
SUB WIRE HARNESS F@
(IGNITION SWITCHI
LEFT HANDLEBAR
SWITCH WIRES
,~~~~~~~
HANDLEBAR
RIGHT
SWITCH WIRE
"irt-="',
'J
SUB WIRE
HARNESS F@
(FAIRING
,CONNECTORI
I
INSTRUMENT
WIRES
,
WIRE BAN
WIRE HARNESS
TURN SIGNAL BUZZER WIRE
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6) Secure the sub wire harness F @with the
wire bands @ and @ furnished with the
fairing. (The band @ is longer than the
band @ )
b.
Install the meter visor ,g, using the
two 4 x 35 mm bolts .~ , 4 mm plam
washers 4~ and 4 mm lock washers@
and reinstall the two 6 mm nuts l.8J
and lock washers @(Fig. 81.
Fig. 7
"
.,
"
'
O __ FAIRING
CONNECTOR
7) Install the inertia weight 31 on the
brackets ~ using two 8 mm nuts 33 and
lock washers 32.
CAUTION:
Do not pinch the wires between the weight and connector holder.
Tighten the nuts to the specified torque.
8) Reinstall the radiator lo......er cover CI.
(Refer to Fig. 2)
9) Reinstall the radiator upper cover Band
wire harness guard.
10) Install the radiator grill ':g;_
11) Remove and retain the two 6 mm nuts
and lock washers attaching the instru·
ments to the bracket.
12) Remove and discard the two 4 mm screws
attaching the cover to the back of the
indicator light panel.
13) Install the meter visor ~ as follows:
a.
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Remove the two 6 mm nuts @ , 6
mm lock washers @ and 4 x 20 mm
pan head screws © from the back of
the meter and discard only the 4 x 20
mm pan head screws © (Fig. 8).
14) Position the fairing bracket I on the
frame and install as follows:
a. Install the fairing mount taking care
not to damage the wires, cables, and
wire harnesses.
b. Insert the 8 x 80 mm flange bolt 2
through the mount and loosely install
the 8 mm flange nut 10 .
c. Attach the mount to the down tubes
using a "U" bolt 39 , a bracket 40 and
two 6 mm flange nuts lion each side.
Do not tighten at this time.
d.
Route the cables and wire harness
through the mount to the left and
right of the steering head as shown:
Left side: Throttle cables, choke
cables and wire harness.
Right side: Tachometer cable and
clutch cable.
NOTE: Tighten the bolts and nuts to the
specified torques, being cartain
that the cables and wires are not
pinched between the mount and
frame.
19) Connect the sub wire harness C ® to the
high and low horns ~ and @.
NOTE: The sub wire harness C ® is
rotlted behind the mount.
Fig. 10
Fig. 9
"
Fig. 11
.,
'0
11
15) Install the horns ~~ and ~using a 6 x 12
mm flange bolt 36 for each.
NOTE: Tighten the bolts to the specified
torque.
16) Position the right and left lower fairing
brackets ~ and <ft on the fairing mount
I and loosely install using four 6 x 14
mm flange bolts (Jjl.
17) Install the right and left fairing inner
covers ([ and @ using three 6 mm plain
washers ® and 6 x 12m m screws @ for
each cover. Tighten the screws @to the
specified torque.
Install inner cover set rubber A-S (jj ®
and fairing inner cover seal@.
18) Install the front cover @using the screws
retained in step 9 in PREPAR ING FOR
FAIRING INSTALLATION.
FRONT FORKS
FAIRING AND WINDSHIELD
1) Install the headlight on the fairing.
a. Remove the headlight mount assembly ® from the fairing.
b. Remove the two 3 x 12 mm screws
from the mount assembly ® and
install the headlight unit as shown.
Connect the socket to the headlight.
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c.
Install the headlight assembly on the
fairing.
b.
F.... 12
Engage the hooks in the holes in the
lower fairing sections © and @ ;
install the fairing sections using two
snort collars @ @. two 6 x 16 mm
screws 1 at the top and a long collar
@ 3 and a 6 x 20 mm screw @ at
the bottom for each section.
Fit. 13
FAIRING
2) Install the fairing on the fairing bracket
CD as follows:
a. Position the right and left fairing nut
plates ® and ® on the fairing align·
ing holes in the fairing with the holes
in the mount 1 . Install 6 mm flange
nuts on the studs from underneath
and tighten securely.
b. Attach the fairing to the lower fairing
brackets @and rit using four collars
® . 6 mm lock washers @ . 6 mm cap
nuts @ and 6 x 22 mm flange bolts
@.
NOTE: Tighten all bolts and nuts to the
specified torques.
c. Tighten the lower fairing bracket
flange bolts Qj.. to the specified
torque.
3) Install the right and left lower fairing sec·
tions.
a. Install the right and left lower brackets
.iJ
and ~O.
4) Reinstall the shelter.
5) Reinstall the seat.
6) Retighten all bolts and nuts.
7) Connect the sub wire harness F to the
wire harness connector inside the lower
left of the fairing; place the boot over the
connector.
8) Reconnect the battery ground cable to
the battery negative terminal.
9) Fill the front forks to the recommended
air pressure.
NOTE:
•
•
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Refer to the Owner's Manual 11.0-1.5
kg/cm 1 114-21 psi)).
Check for leaks by applying soapy
water around the valve and valve joint.
10jlnstall the windshield as follows:
a. Remove the six bolts <AI • windshield
trim @collars © and special nuts @.
b. Install the windshield on the fairing as
shown in Fig. 14. Remove the handlebar mirrors and install the fairing
mirrors using the two bolts @ and
four bolts furnished with mirrors.
Press grommets into the holes left by
the handlebar mirrors.
F'" 14
WINDSHIELD
NYLON /
WASHER
E
•
D
c
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