MPD 10739 05 MCA SUI.fm

Transcription

2005 GL1800/A
SET-UP
INSTRUCTIONS
Set-up and pre-delivery service
must be performed by an authorized
Honda motorcycle dealer.
©2004 American Honda Motor Co., Inc. - All Rights Reserved
MPD 10739 (0409)
Issued: September 2004
IMPORTANCE OF PROPER SET-UP AND PRE-DELIVERY SERVICE
FOR YOUR CUSTOMER'S SAFETY
Proper set-up and pre-delivery service are essential to rider safety and the reliability of the
machine. Any error or oversight made by the technician assembling and servicing a new machine
can result in faulty operation, damage to the machine, or injury to the rider.
WARNING
Improper set-up or pre-delivery service can
create an unsafe condition that can cause
your customer to be seriously hurt or killed.
Follow the procedures and precautions in
this manual and the service manual carefully.
FOR YOUR SAFETY
Some of the most important safety precautions are given below. However, we cannot warn you of
every conceivable hazard that can arise in performing set-up and pre-delivery service. Only you
can decide whether or not you should perform a given task.
WARNING
Failure to properly follow instructions and
precautions can cause you to be seriously
hurt or killed.
Follow the procedures and precautions in this
manual carefully.
IMPORTANT SAFETY PRECAUTIONS
Make sure you have a clear understanding of all basic shop safety practices and that you are
wearing appropriate clothing and safety equipment. When performing the set-up or pre-delivery
service, be especially careful of the following:
• Read the instructions before you begin, and make sure you have the tools and skills required to
perform the tasks safely.
• To prevent the machine from falling on you, park it on a firm, level surface, using the proper
stand(s) to provide firm support.
Make sure the engine is off before you begin any servicing procedures. This will help eliminate
several potential hazards:
• Carbon monoxide poisoning from engine exhaust—be sure there is adequate ventilation
whenever you run the engine.
• Burns from hot parts—let the engine and exhaust system cool before touching.
• Injury from moving parts—do not run the engine unless the instruction tells you to do so.
Even then, keep your hands, fingers, and clothing away.
To reduce the possibility of a fire or explosion, be careful when working around gasoline or
batteries. Use only a nonflammable solvent, not gasoline, to clean parts. Keep all cigarettes,
sparks and flames away from the battery and all fuel-related parts.
i
2005 GL1800/A
How To Use This Manual
Follow the complete sequence of steps as shown. Do not short-cut any steps. The sequence has
been established to ensure the unit is properly assembled.
The individual steps are composed of three components:
• Sub-heading—The large sub-headings are a brief description of the step. They are intended
to be used by the experienced technician, one who only needs a brief reminder of the
set-up sequence.
• Descriptive text—The descriptive text explains in detail what is to be done during that step.
This explanation is intended as a guide for the technician needing additional information.
• Photographs/Line art—The photographs or line art support both the sub-headings and the
detailed text.
Indicates the Set-up section
Indicates the Pre-delivery section
Modifications and Accessories
Modifications that you may have made, or should make in the future, to any Honda product, shall
be deemed by our company to have been performed at your sole risk and responsibility, and
without our company's or the manufacturer's approval, or consent, implied or expressed. We
further disclaim any and all liability, obligation, or responsibility for any defects of modified parts
or of the modified product, and for any claims, demands, or causes of action for damage to
property or for personal injuries resulting from the modification of said Honda product.
Revised Pages
PAGE
ii
REVISED
Torque Table
ITEM
Seat bolts
Final drive oil check cap
SIZE
8 mm
8 mm
TORQUE
27 N·m (2.7 kgf·m, 20 lbf·ft)
19 N·m (2.0 kgf·m, 14 lbf·ft)
1. Remove the carton cover.
Pull the zip tab to separate the carton cover
from the crate base. Use short pulls (4 to 5
inches) parallel to the floor.
2. Check for damage.
Check the unit for damage.
If you find damage, follow the instructions on
the Delivery and Damage Claims Guidelines
wall chart (Reorder No. S0477) before
proceeding further.
ZIP TAB
3. Remove the loose parts.
Turn the carton cover over and remove the
windshield box from the inside top of the
carton cover.
Remove the loose parts bags from the left
saddlebag, the electrolyte from the tail trunk,
and the mirrors from the right saddlebag.
Keep the Owner’s Manual and the You and
Your Motorcycle Riding Tips & Practice Guide
booklet separate and hand-deliver to the
customer at the time of delivery.
CROSS
SUPPORT
SEAT
BACKREST
REAR
CHOCK
4. Remove the motorcycle from the
crate frame.
Remove the seat and rear backrest.
Remove the wood screws and the lower
cross support.
Remove the screws and the rear wheel chock.
Support the motorcycle and release
the tie-downs.
Roll the motorcycle backward, off the
crate frame.
TIE DOWNS
(Both sides)
TIE DOWNS
(Both sides)
1
2005 GL1800/A
5. Loose Parts Information.
Unpack the remaining loose parts and check them against the parts list and this illustration.
1.
15.
8.
7.
11.
2.
6.
3.
4.
12.
9.
13.
16.
5.
14.
10.
17.
DESCRIPTION
QTY
PART NUMBER
STEP
1.
Mirror, R assembly
1
88110-MCA-A00
8
2.
Mirror, L assembly
1
88120-MCA-A00
8
Note: Add color code to end of mirror part number.
Yellow: ZG, Red: ZM, White: ZQ, Silver: ZR, Blue: ZT, Gray: ZU
3.
Holder, shield, A
1
64547-MCA-000
7
4.
Holder, shield, B
1
64548-MCA-000
7
5.
Windshield
1
64100-MCA-A20
7
6.
Owner's Manual*
1
31MCA640
3
7.
Stay, cowl, R
1
64257-MCA-000
8
8.
Stay, cowl, L
1
64267-MCA-000
8
9.
Tips & Practice Guide**
1
*G0045
3
Flame red
1
77200-MCA-A20ZB
6
All other colors
1
77200-MCA-A20ZA
6
11.
Rubber, seat
4
77215-MCA-000
6
12.
Collar, seat
4
90504-MCA-000
6
13.
Grip, passenger, R
1
84150-MCA-000ZA
6
14.
Grip, passenger, L
1
84155-MCA-000ZA
6
15.
Backrest
Flame red
1
77500-MCA-A20ZB
6
All other colors
1
77500-MCA-A20ZA
6
10.
Seat
(Continued on next page)
*If missing, order from Helm Inc. **If missing, order from Resolve Corp. (formerly DDS)
2
5. Loose Parts Information (cont.).
DESCRIPTION
QTY
PART NUMBER
STEP
16.
Electrolyte
1
------------------------------
11
17.
Plate, shield
2
64116-MN5-000
7
18.
Attaching parts (not shown):
Bolt, socket 8 x 70 mm
4
96600-08070-17
6
Screw, pan. hd. 6 x 8 mm
1
93500-06080-0H
7
Screw, special 5 x 12 mm
2
90104-964-000
8
Screw, self tap 5 x 16 mm
2
93903-25380
6
Screw/washer 5 x 20 mm
6
93891-05020-08
8
Screw, pan.hd. 6 x 11 mm
2
90106-KY2-701
7
Screw, special 6 x 12 mm
2
90103-HC4-770
7
Washer, plain 5 mm
2
94103-05700
6
Washer, nylon 8 mm
2
90507-921-0004
7
Missing Parts or Shipping Damage
Identify missing parts by referring to the “Loose Parts Information” section. Order the parts
using normal parts ordering procedures. Claims for missing loose parts or those damaged
during transit should be submitted to American Honda, not the carrier. After completing
repairs, submit a Transportation Claim via iN. For complete details, please refer to the
Warranty Policy and Procedures Manual.
3
2005 GL1800/A
6. Attach the seat, passenger grips, and
back rest.
SEAT
GROMMET
Insert the collars into the seat mounting
grommets with the larger diameter flange
opposite the flange on the grommet. Do this
for all four grommets.
COLLAR
Insert a seat grommet into each of the
mounting holes in the seat. Be sure the
portion of the grommet without the flange is
positioned toward the seat base.
Remove the protective plastic from the seat
and position the seat on the motorcycle by
slipping the front prong under the frame stay
and the two upper tabs into the slots in the
upper shelter.
Before attaching the seat, thread the seat
mounting bolts into the frame to be sure
the threads are clean. If the bolts do not
thread in easily, clear the threaded hole with
an 8 mm x 1.25 thread tap.
Attach the passenger grips and the seat to the
motorcycle using two 8 x 70 mm socket bolts
on each side. Torque the bolts.
Torque: 28 N·m (2.7 kgf·m, 20 lbf·ft)
PASSENGER
GRIP
8 x 70 mm
SOCKET BOLT
(2 each side)
Slide the backrest retainers into the trunk lid
slots and open the trunk lid.
5 x 16 mm SELF
TAPPING SCREWS
Attach the backrest to the trunk lid using two
5 x 16 mm self-tapping screws and washers.
BACKREST RETAINERS
4
7. Install the windshield.
Remove a bolt, washer, and grommet from
each side of the garnish. Carefully pull the
garnish studs (four places) from their
grommets and remove the garnish.
Loosen the 5 mm cross-recess screw and
rotate the air vent cover to access the small
head windshield holder mounting bolt.
Remove the small head 6 mm windshield
holder bolt.
BOLT, WASHER,
and GROMMET
GARNISH
6 mm
BOLT
5 mm
SCREW
AIR VENT
COVER
Remove the two 6 mm nuts (one each side)
attaching the windshield holder to the
windshield locking mechanism and remove
the holder.
WINDSHIELD
LOCKING
MECHANISM
6 mm NUT
(EACH SIDE)
5
2005 GL1800/A
7. Install the windshield (cont.).
6 x 8 mm
SCREW
Assemble the center adjustment plate and
backup plate onto the windshield using a
6 x 8 mm screw.
BACK UP
PLATE
ADJUSTMENT
PLATE
Set the windshield in place on the fairing
and begin the installation by installing the
two 6 x 11 mm special screws in the center
adjustment plate.
SPECIAL
SCREWS
Place an 8 mm nylon washer on both
6 x 12 mm special screws. Install the outer
adjustment plates and attach them using
the special screws and washers.
ADJUSTMENT
PLATE and
6 x12 mm
SPECIAL SCREWS
6
7. Install the windshield (cont.).
Be sure that the windshield holder locator tab
is hooked over the fairing tab.
HOLDER
LOCATOR
FAIRING
TAB
Attach the windshield holder with the small
head 6 mm bolt and two 6 mm nuts (one on
each side).
6 mm
BOLT
6 mm NUT
(EACH SIDE)
Tighten the bolt and nuts.
Rotate the air vent cover so that it is parallel to
the bottom edge of the fairing and tighten
the screw.
Reinstall the garnish by carefully pressing the
lower mounting studs into their grommets (a
little soapy water will help).
Attach the garnish using the two bolts,
washers and grommets removed at the
beginning of the installation.
GROMMET
STUDS
COLLARS
BOLTS
GROMMET
WINDSHIELD
GARNISH
7
2005 GL1800/A
8. Install the mirrors.
Installation of the mirrors includes installing a
stay for the inner cowling on both sides. The
right-hand stay is marked with an “R”.
Mount each stay on top of the mirror mount.
COWL STAY
MIRROR
MIRROR
BOOT
Loosely install the mirror assembly (on both
sides) using a 5 x 20 mm screw/washer in the
top mounting hole.
5 X 20 mm
SCREWS
Set a cowl stay (be sure of the correct side)
on the top of the lower mirror mounts and
attach the mirrors using two 5 x 20 mm
screws and washers.
TURN SIGNAL
CONNECTORS
5 X 20 mm
SCREW
Attach the inner cowling to the cowl stay
using a 5 x 12 mm special bolt (both sides).
Connect the turn signal connectors
(on both sides).
Repeat the procedure for the opposite side
and tighten all six screws.
Lubricate the mirror boot tabs with soapy
water and press them into place (two at the
top and three at the bottom) in the garnish.
9. Install the auxillary input patch cord.
LEFT FAIRING POCKET
A length of wire is enclosed with the
Owner’s Manual pouch. This wire is a
patch cord that owners can use to attach a
personal stereo (CD player, MP3 player, etc.)
to the motorcycle.
Remove the left hand fairing pocket to reveal
the wiring boot where the headset DIN
connector is plugged. Contained within the
boot is a white three-pin connector to be used
with the patch cord. Run the wire through the
bottom of the fairing pocket with the enclosed
grommet; the cord can then be plugged into
the headset outlet of the personal stereo. This
allows the personal stereo to be played
through the motorcycle’s external speakers or
optional headsets.
8
TRIM CLIPS
10. Check that the cables, hoses, and wire harnesses are properly routed.
POSITION
LIGHT RELAY
LEFT FRONT
SPEAKER WIRE
To meter (16P
Black and 20P
Black connectors)
TURN SIGNAL/
RUNNING LIGHT
RIGHT FRONT
SPEAKER WIRE
To turn signal
relay (in meter) 3P
connector
TURN SIGNAL/
RUNNING LIGHT
AMBIENT AIR
TEMPERATURE SENSOR
HIGH BEAM HEADLIGHT
CONNECTOR
CONNECTORS:
Rider headset
HIGH BEAM
HEADLIGHT
CONNECTOR
Auxilary input
Optional for
accessory socket
LEFT PANEL
SWITCH
LOW BEAM
HEADLIGHT
CONNECTORS
HEADLIGHT
ADJUSTING
MOTOR
HEADLIGHT
ADJUSTING
MOTOR
BANK
ANGLE
SENSOR
FRONT
BRAKE
LINES
REAR
BRAKE
LINES
RADIATOR
HOSE (LH)
RADIATOR
HOSE
FRONT
ABS
MODULATOR
REAR ABS
MODULATOR
9
2005 GL1800/A
10. Check that the cables, hoses, and wire harnesses are properly
routed (cont.).
RH
LH
SWITCH
HARNESS
BRAKE
HOSE
CLUTCH
HOSE
CLUTCH
SWITCH
WIRE
THROTTLE
CABLES
THROTTLE ADJUSTER
FUEL
LEVER
SENSOR
FUEL LINE
(SUPPLY)
SWITCH
HARNESS
FUEL LINE
(RETURN)
FUEL PUMP
NEGATIVE (-)
CABLE &
TERMINAL
10
BATTERY STAY BOLT
POSITIVE (+)
CABLE &
TERMINAL
BATTERY
BOLT
11. Service the battery.
LEFT
SIDE
COVER
Service and install the battery in the
motorcycle only if the unit has been sold or
will be used as a demonstrator.
Remove the battery from the motorcycle
before filling it with electrolyte. Spilled
electrolyte can damage frame and body parts.
Remove the left side cover.
Remove the push-pin by pulling the stem out.
Remove the protective cover.
BATTERY
HOLDER BOLT
BATTERY
HOLDER
Before removing the battery holder bolt, place
a folded shop towel over the frame rail below
the battery holder to prevent any contact
between it and the frame.
Remove the battery holder bolt. Lower the
battery stay onto the shop towel and remove
the battery.
Service the battery according to Service
Letter #48 and the instructions on the
electrolyte container.
Slide the battery terminal nuts into the battery
terminals. Set the battery in the battery
compartment. Connect the positive (+) battery
cable to the positive (+) battery terminal and
the negative (-) battery cable to the negative
(-) battery terminal using the terminal bolts.
PROTECTIVE
COVER
PUSH PIN
Tighten the bolts securely, coat the terminals
with dielectric grease, and pull the red cover
over the positive terminal.
Raise the battery holder into position and
attach it using the 6 mm bolt previously
removed. Tighten the bolt securely.
Hook the battery cover in place and secure it
with the push-pin.
Make sure the positive (+) battery cable is not
resting on any metal parts. Prolonged wear
could cut through the insulation and cause a
short circuit. Replace the protective cover and
secure it with the push-pin.
Using soapy water to lubricate the rubber
grommets, carefully replace the side cover.
11
2005 GL1800/A
12. Check the fluid level in the front and
rear brake reservoirs.
LOWER LEVEL MARK
Turn the handlebar so that the front brake
reservoir is level and check the fluid level.
COVER
Remove the right engine cowl to access the
rear brake reservoir and check the fluid level.
CAP
Keep the engine cowl off until the completion
of step 15.
If the level is below the lower level mark,
remove the cover and diaphragm or cap. Add
Pro Honda DOT 4 or equivalent brake fluid
from a sealed container.
LOWER
LEVEL
MARK
Reinstall the diaphragm and cover or cap.
Tighten the screws securely.
Operate the brake lever and pedal. If the free
play is excessive and the reservoir is filled to
the correct level, bleed the brake system.
Handle brake fluid with care as it can damage
painted surfaces and plastic components.
This type of hydraulic disc brake requires no
free play adjustment.
13. Check the clutch master cylinder.
Turn the handlebar so that the clutch reservoir
is level. Check the fluid level.
COVER
Operate the hand lever. If the free play is
excessive, bleed the system.
If the fluid level is low, remove the
reservoir cap and diaphragm by removing
the two screws.
LOWER
LEVEL
MARK
Add Pro Honda DOT 4 or equivalent brake
fluid from a sealed container to bring the level
up to the upper level mark. Install the
diaphragm, cover, and screws.
This type of hydraulic system requires no free
play adjustment.
12
14. Check the throttle free play.
Check the throttle cables for damage.
Operate the throttle. Confirm that it moves
smoothly and returns from any open to the
fully closed position, automatically, in all
steering positions.
3-6 mm
(1/8 - 1/4 in.)
LOCK NUT
ADJUSTER
Confirm the throttle grip free play.
Throttle grip free play:
3 - 6 mm (1/8 - 1/4 in.)
Free play adjustments are made at the throttle
grip adjuster by loosening the lower lock nut
and turning the adjuster. Tighten the lock nut
after making the adjustment.
15. Check the oil level.
Before starting the engine, remove the antirust compound by washing the engine and
exhaust system with mild detergent and
water. Rinse with clean water.
Place the motorcycle on its centerstand on a
firm, level surface. Remove the right engine
side cover.
LOWER LEVEL MARK
Remove the oil filler cap/dipstick and wipe
it clean. Insert the dipstick until it seats, but do
not screw it in. Remove the dipstick and check
the oil level. If the level is low, add oil as
needed to bring the level above the lower
level mark.
• Oil recommendation: Pro Honda HP4 or
GN4 (without molybdenum additives)
4-stroke oil or equivalent.
• Viscosity: SAE 10W-40
• API Classification: SG or higher. Do not
use oils labeled as energy conserving
on the circular API service label
• JASO T 903 standard: MA
• Crankcase capacity: 3.6 liters
(3.8 U.S. quarts)
Replace the oil filler cap/dipstick.
13
2005 GL1800/A
15. Check the oil level (cont.).
Start the engine and let it idle for 3 - 5
minutes. Make sure the low oil pressure
indicator goes off. If the indicator remains on,
stop the engine and troubleshoot the cause.
Stop the engine and wait 2 - 3 minutes.
Recheck the oil level using the above
procedure and, if necessary, add the
recommended oil until it reaches the upper
level mark.
Reinstall the right engine cover removed in
step 12.
16. Check the coolant level.
Remove the left engine cover and the
coolant reserve tank cap/dipstick. Check
the coolant level.
RIGHT FAIRING POCKET
TRIM CLIPS
If required, add Pro Honda coolant (premixed) or a 1:1 mixture of anti-freeze and
distilled water to restore the level to the upper
level mark.
If it is necessary to add coolant to the radiator,
unlock the right hand fairing pocket using the
ignition key.
Unlock the four pocket retainer clips by
pressing the center pin in with a small
screwdriver. Carefully remove and save the
four clips.
OPENER
CABLE
IGNITION KEY
RADIATOR CAP
Lift the pocket out of the fairing and remove
the latch cable by pulling the cable housing
down and out of its anchor tab.
Do not spill coolant on any painted or plastic
surfaces, as it may damage the finish.
14
17. Check the final drive gearbox
oil level.
OIL LEVEL
CHECK CAP
Support the motorcycle on its centerstand on
a firm, level surface.
Remove the oil level check cap from the final
reduction gear box. Check the oil level. It
should be flush with the lower edge of the oil
filler hole. If the level is low, add the
recommended oil until it reaches the lower
edge of the opening.
LOWER
EDGE
Recommended oil: Pro Honda Shaft
Drive Oil or equivalent Hypoid gear
oil (SAE 80).
Install and torque the oil check cap.
Torque: 19 N·m (2.0 kgf·m, 14 lbf·ft)
18. Clean the brake discs and
the motorcycle.
Clean the anti-rust coating off all three brake
discs with Pro Honda Brake Cleaner or
equivalent and a clean shop towel.
19. Initialize the ECM.
The GL 1800 uses an electronically controlled
IAC (Intake Air Control Valve) to minimize
idle fluctuations normally caused by air
temperature and load variations.
Idle Speed: 700 ± 50 rpm
In order for the IAC to operate properly,
the ECM (Engine Control Module) must
be initialized.
Start the engine and let it warm up to normal
operating temperature.
Once normal temperature is achieved, allow
the engine to idle, without touching the
throttle, for at least 90 seconds. If the throttle
is operated during this time, the ECU will not
initialize properly and the process will need to
be repeated. Idle speed should stabilize at
700 ± 50 rpm.
15
2005 GL1800/A
20. Check the tire pressure.
Front: 36 psi
Rear: 41 psi
21. Complete the Set-up/Pre-Delivery
Checklist.
Complete an On-Road Motorcycle Set-up/
Pre-delivery Checklist (Reorder No. S0299) by
checking the boxes confirming that the steps
were done.
16
ACC
TERMINAL
–
+
22
23
24
25
26
27
11
12
13
14
15
16
1
2
3
4
SPEED LIMITER
FUSE 70 A
MAIN FUSE B
100 A
21
10
19
8
20
18
7
9
17
6
5
FUSE BOX
27 HORN TURN FUSE
13 ABS MAIN FUSE
14 Not used
26 HEAD LO FUSE
23 RVS SHIFT FUSE
HEAD RLY FUSE
9
12 RVS FUSE B
22 BATTERY FUSE
ST. KILL FUSE
8
25 Not used
21 AUDIO/ACC FUSE
FAN FUSE
7
11 RVS FUSE A
20 SUSP LEVEL FUSE
ACC. TERM. FUSE
6
24 HEAD HI FUSE
19 IGN CRUISE FUSE
TAIL FUSE
5
10 RVS START FUSE
18 STOP LIGHT FUSE
17 FI IGN FUSE
ABS MTR FR FUSE
3
ABS MTR RR FUSE
16 Not used
MAIN FUSE A
2
4
15 Not used
Not used
1
Fuse Box
17
2005 GL1800/A
Fuse Box - Wire Routing
FUSE BOX
Y
Y
SPEED LIMITER RELAY
W
ALTERNATOR
SPD LIMIT FUSE 70 A
MAIN FUSE B 100 A
+
–
BATTERY
W/Y
TAIL LIGHT RELAY
Bl
FI/IGNITION RELAY
W/R
STOP LIGHT RELAY
5 15 A
17 20 A
STARTER RELAY
SWITCH A
18 15 A
Y
IGNITION CRUISE RELAY
Br
SUSPENSION LEVEL MAIN RELAY
Lg
ACCESSORY RELAY
R/Y
TRUNK LOCK CONTROL SYSTEM
AUDIO SYSTEM
COMBINATION METER (BACK-UP)
R/Bl
REVERSE SHIFT RELAY 1
19 15 A
20 15 A
21 15 A
22 20 A
23 15 A
W/Bu
HEADLIGHT HI RELAY
W/Y
HEADLIGHT LO RELAY
Bl/W
HORN/TURN RELAY
R/Bu
ABS MOTOR DRIVER (FVBM)
R/G
ABS MOTOR DRIVER (RVBM)
24 10 A
26 15 A
27 15 A
3 30 A
4 30 A
2 30 A
R
W
Bl
IGNITION SYSTEM
8 10 A
Br/R
HEAD ADJUSTER RELAY
STARTER/REVERSE SWITCH
Br
STARTER/REVERSE SYSTEM
R/Bu
ABS CONTROL UNIT (MAIN)
Bl/Bu
FAN CONTROL RELAY
Lg/Bl
ACCESSORY RELAY
Bl
HORN TURN RELAY
TAIL RELAY
9 10 A
10 5 A
13 5 A
Bu/O
7 20 A
Bu/O
Lg/Bl
Bl
R
Lg/Bl
Bu/O
Lg/Bl
Bl
R
4P W
LOCK
OFF
ON
ACC
IGNITION SWITCH
18
Suspension Level Control
19
2005 GL1800/A
ABS
20
No. 1 FUEL
INJECTOR
2P Bl
2P Bl
Br
R/Y
P/Bl
Lg
P/Bu
R/Bl
P
Br
COOLANT TEMPERATURE GAUGE
COMBINATION METER
CRUISE/REVERSE CONTROL UNIT
FUEL LEVEL SENSOR
MALFUNCTION INDICATOR LAMP
(MIL)
2P Bl
2P Bl
2P Bl
P/Bu
Br
No. 2 FUEL
INJECTOR
Br
R/Y
2P Bl
No. 3 FUEL
INJECTOR
R/Bl
Br
Br
P/Bl
No. 4 FUEL
INJECTOR
3P Bu
W/Bl
Gr
W/Bu
Br
R/Y
R/Bl
Lg
P/Bu
R/Bl
P/W
Br
Lg
G/O
Y/R
8P
MINI
Gr
Lg
O/G
Bl/Y
Y/R
Lg/Y
G/R
G
Lb
Lg
O/G
Bl/Y
Y/R
Lg/Y
G/R
G
Lb
2P W
Bl/Y
G
Lb
6P
MINI
Gr
ECT SENSOR
3P
3P Gr
IDLE AIR
CONTROL
VALVE
CAM PULSE
GENERATOR
2P Bl
2P Bl
IGNITION PULSE
GENERATOR
2P R
[MINI]
22P Gr
Bl/Y
6P Bl
VEHICLE
SPEED SENSOR
Br
Bu/R
W/R
3P W
[MINI]
S
S
G
G/R
Bl/Y
O/G
W
Gr
INJ1
INJ3
INJ5
INJ2
INJ4
INJ6
P/Bu
R/Bl
P/W
R/Y
R/Bl
Lg
Y
W/Y
TP SENSOR
No. 5 FUEL
INJECTOR
P
Br
Br
Lg
No. 6 FUEL
INJECTOR
Gr
4P
Gr
4P
Bl/Y
O/G
3P Bl
BARO SENSOR
22P Bl
Bl
W
W/Bu
Bl/Y
PAIR CONTROL
SOLENOID
VALVE
Gr
Lg
Bl/O
Lg/Bl
Y/Bu
Bu
Br/W
G
W/Bl
PCP
IMOV
O2-1
PB
TA
KNOCK 1
VSP
Y
W/Y
Y/Bl
G/R
Lg/Bl
Y/R
Y
Bl/Y
Bl/R
Lg/Y
Gr/Bu
R/Bu
W/Bl
ENGINE CONTROL MODULE
G/R
Gr/Bu
MINI
2
OD
N
GEAR POSITION SWITCH
3
4
Lg/R
6P
Bl
RELAY BOX
FUEL PUMP RELAY
Br
Br/Bl
IAT SENSOR
Bl/Y
Bl/Y
G/R
Lg/Y
Y/R
G
G
S STAND
GP2
TACHO
CYLP
THL
O2-2
PA
TW
KNOCK 2
IMOID
SCS
NLSW
GP3
RXD-TXD
Br
G
W/Bl
G/Bl
G/R
Y/Bu
W/Y
Gr
G/Bl
G/R
Y/Bu
W
Gr
G/Bl
G/R
Y/Bu
W/Y
G
G
Lb
O/G
Br/Bl
3P Gr
W
IGPLS1&2
IGPLS5&6
PG1
SG
IMOAU
PCS
IDC
ACGF
HTCNTL 1
WARN
IGP
IGPLS3&4
PCM
PG2
LG
RACV
EX-AI
FLR
FANR
HTCNTL2
IMMO IND
VCC
Y/R
Bl/Y
W/R
R/W
G/O
Bl/Y
W/R
R/W
G/O
Lg/R
MAP SENSOR
Br
G
2P
FUEL LEVEL
SENSOR
FUEL PUMP
REVESE REGULATOR ASSEMBLY,
OVERDRIVE INDICATOR
G/O
Br
G
G
Gr
REVERSE REGULATOR ASSEMBLY,
REVERSE REGULATOR ASSEMBLY
REVERSE REGULATOR ASSEMBLY
TAIL LIGHT RELAY
ALTERNATOR
LEFT KNOCK SENSOR
RIGHT KNOCK SENSOR
EVAP PURGE
CONTROL
SOLENOID
VALVE
LEFT O 2 SENSOR
REVERSE REGULATOR ASSEMBLY,
Br
G
G
Gr
1P Bl
1P Bl
SERVICE CHECK
CONNECTOR
3P Bl [MINI]
2P Bl
W
W
Gr
Bl
RIGHT O 2 SENSOR
Lg/R
5P Gr
4P Bl
4P W
W
W
Gr
Bl
FI/IGNITION RELAY
R/W
Bu/R
W/R
Br/W
Bl
Bu
R/Bu
Br
G
Y/Bl
Bl/Y
W
Bl/Y
G/R
Bl/O
W
Bl/Y
G/R
Bl/R
4. FUEL PUMP RELAY
4
RELAY BOX
Fuel System
21
G/W
CRUISE/REVERSE CONTROL UNIT,
CLUTCH SWITCH
Bl/W
Y/Bl
SIDE STAND INDICATOR
STARTER/REVERSE SWITCH
Y/G
Bl/Y
COMBINATION METER
FUEL SYSTEM
G
ENGNE STOP SWITCH
OFF
RUN
OFF
18P
MINI
G
G
3P
G
BANK
ANGLE
SENSOR
R/W
R/W
W
W
Bl/W
W
Bl/W
Bl/Lg
SPARK
PLUGS
IGNITION
COILS
G
G
#6
#5
Y/R
Bl/Y
G
4P Bl
#3
Y/Bu
Bl/Y
G
#4
4P Bl
#1
Y/W
Bl/Y
G
#2
4P Bl
22P
Gr
PCP
SSTAND
TACHO
NLSW
2P
IGNITION PULSE
GENERATOR
[MINI]
R
Y
G/W
Y/G
Bu/R
Y
W/Y
Y
W/Y
22P
Bl
I GPLS1&2
I GPLS5&6
ACGF
I GP
I GPLS3&4
PCM
FANR
Bl
LEFT FAN MOTOR
Bl
RIGHT FAN MOTOR
Y/W
Y/R
Bl
Bl/Y
Y/Bu
W/Y
Br/R
FAN CONTROL
RELAY
G
Bu
Bl
Bu
2P Bl
G
Bu
Bu
Br/R
Bl
2P W
Bl/Bu
Bl/Bu
Bu
RELAY BOX
FI IGN RELAY
15
ALTERNATOR
P
B
E
IC
REGULATOR
IG
3. FAN CONTROL RELAY
15. FI IGN RELAY
Bl/Y
Bl/Y
R/W
22
Bl
F
(L)
FR
4P
3
3P G
[MINI]
SIDE STAND SWITCH
RELAY BOX
G
G/W
Y/Bl
G
G/W
Y/Bl
ENGINE CONTROL MODULE
MAIN FUSE B
W
8 FUSE
Bl/Y
W
REVERSE REGULATOR
ASSEMBLY
7 FUSE
Bu/R
17 FUSE
Bl
Bl/Bu
2005 GL1800/A
Cooling/Charging/Ignition System
W
Bl/W
Bl
Starter/Reverse System
23
2005 GL1800/A
Lighting System
24
Turn Signal Lights/Horn
25
2005 GL1800/A
DIGITAL
AMBIENT AIR
ACCESSORY RELAY
Combination Meter
26
ACC/Trunk Lock System
27
2005 GL1800/A
VEHICLE
Cruise Control System
28

MPD 10739 05 MCA SUI.fm

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