GL1800 SECONDARY

GL1800 #23
REVISED: DECEMBER 11, 2015
Service Bulletin
American Honda Motor Co., Inc.
SAFETY RECALL
2001-2015 GL1800/A, GL1800B/BD SECONDARY MASTER CYLINDER REPLACEMENT
(This bulletin supersedes GL1800 #20 and GL1800 #22.)
Honda is launching a Safety Recall of 20122015 GL1800/A and 2013-2015 GL1800B/BD
motorcycles, and is implementing a recall
remedy for 2001-2010 and 2012 GL1800/A
motorcycles already subject to Safety Recall
“JG6”. Honda has determined that under conditions where the brake fluid is subject to prolonged aging due to a lack of maintenance
(i.e., the brake fluid is not replaced for a long
period of time despite the published maintenance schedule of replacement every 12,000
miles or two years, whichever comes first),
deposits may form within the brake fluid. If
sufficient deposits are formed, they can result
in a malfunction of the secondary master cylinder, which may cause the rear brake to drag.
A redesigned secondary master cylinder with
new internal valving is now available to correct this condition; in addition, Honda has
updated its brake fluid replacement service
procedure to better ensure that all old brake
fluid is removed from the system.
Safety Consequence
A dragging rear brake increases the risk of a
crash and may generate enough heat to cause
the rear brake to catch fire.
CUSTOMER NOTIFICATION
During the month of November 2015, Honda
will mail a letter to all owners of affected
motorcycles informing them that their motor-
cycle is being recalled for a safety related
defect, or that a remedy is now available for
the previously identified safety defect. The
customer will be made aware of the safety risk
and advised to have a Honda dealer replace
the secondary master cylinder.
For your reference, copies of the applicable
Customer Letters are reproduced on Pages 3
and 4 of this Service Bulletin.
AFFECTED UNITS
2001-2015 GL1800/A
All units and types within the above model
year range.
2013-2015 GL1800B/BD “F6B”
All units within the above model year range.
DEALER INVENTORY
Do not sell any un-repaired units.
According to federal law, any affected units in
your new inventory cannot be sold or leased
until they are repaired with a replacement
secondary master cylinder parts kit, and
Honda policy prohibits the sale of new or
used unrepaired units.
To search for applicable recalls on a specific
unit, refer to Unit Information on iN.
To manage your affected inventory, use eResponsibility Report on iN.
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©2015 American Honda Motor Co., Inc. – All Rights Reserved
MTB 15624 (1510)
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-it yourselfers," 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.
GL1800 #23
REVISED: DECEMBER 11, 2015
REPAIR VERIFICATION
Before you begin the repair procedure, check
if the repair has been performed on the unit.
the REPAIR PROCEDURE and make sure to
also consult the trike conversion manufacturer’s instructions for brake fluid filling/
bleeding.
• If there is a punch mark:
- No further action is necessary
• If there is no punch mark:
- You must proceed with the REPAIR PROCEDURE section of this Service Bulletin.
Remove the right engine side cover.
CLAIM INFORMATION
This Safety Recall will be in effect indefinitely,
regardless of the date of vehicle purchase.
Normal warranty claim submission requirements apply. After completing the Service
Bulletin repair procedure, submit one warranty claim per unit with the following information:
NEW
WARRANTY CLAIM TEMPLATES
2001-2010 GL1800/A
Template: JV6A
Flat Rate Time: 2.2 hrs.
Trike Conversion Template: JV6W
Flat Rate Time: 2.7 hrs.
NEW
Look for a punch mark on the rear master cylinder lower mounting tab as shown.
2012-2015 GL1800
Template: JV6B
Flat Rate Time: 2.2 hrs.
Trike Conversion Template: JV6X
Flat Rate Time: 2.7 hrs.
PUNCH MARK
NEW
2013-2014 GL1800B/BD
Template: JV6C
Flat Rate Time: 2.2 hrs.
Trike Conversion Template: JV6Y
Flat Rate Time: 2.7 hrs.
NEW
REPAIR PROCEDURE
2015 GL1800B/BD
Template: JV6D
Flat Rate Time: 2.2 hrs.
Trike Conversion Template: JV6Z
Flat Rate Time: 2.7 hrs.
NEW
The REPAIR and IDENTIFICATION procedures
are located at the end of this bulletin.
TRIKE CONVERSIONS or MODIFIED
BRAKES:
If the vehicle’s secondary master cylinder
(SMC) is removed, or the SMC has no brake
fluid flow or connections, this recall does not
apply. Note these facts on the R.O. and return
the vehicle to the customer.
If the SMC is functional, or modified but still
has brake fluid flow, follow all instructions in
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©2015 American Honda Motor Co., Inc. – All Rights Reserved
GL1800 #23
REVISED: DECEMBER 11, 2015
PARTS INFORMATION
NEW
REQUIRED PARTS
Parts are available on open order.
Application
Part No. (Qty.)
Pro Honda DOT 4 Brake Fluid
08203-0004 (6)*
GL1800/A - All model years
‘15 GL1800B/BD
(Cruise control equipped)
06454-MCA-306 (1)
‘13-’14 GL1800B/BD
(Without cruise control)
06454-MJG-306 (1)
Kit Contents (Qty.)
Secondary master cylinder (1)
Rear master cylinder sub-assy. (1)
Washer, oil bolt (7)
Pin, split 2.0 mm (1)
Nut, hex cap 10 mm (2)
* Trike conversions typically require 8 bottles of Pro
Honda DOT 4 brake fluid.
©2015 American Honda Motor Co., Inc. – All Rights Reserved
3 of 6
GL1800 #23
REVISED: DECEMBER 11, 2015
TEXT OF CUSTOMER LETTER
2001-2012 GL1800/A
December 2015
NHTSA Recall 15V-700
IMPORTANT SAFETY RECALL
This notice applies to your vehicle.
Dear GL1800 Owner:
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.
What is the reason for this notice?
Honda has decided that a defect which relates to motor vehicle safety exists in certain 2001-2012 model
year Honda GL1800 motorcycles. In September 2014 you received notice from Honda that the secondary
master cylinder repair, identified in 2011 as part of NHTSA recall 11V-567, was not sufficient in
preventing the rear brake from dragging and that a remedy to correct the safety defect identified in 11V567 was not yet available. This letter is to inform you a remedy is now available for your motorcycle.
As previously stated in NHTSA recalls 11V-567 and 14V-472, there is a possibility the secondary
master cylinder may cause the rear brake to drag. Unexpected braking increases the risk of a crash
and riding the motorcycle with the rear brake dragging may generate enough heat to cause the rear
brake to catch fire.
What should you do?
Call any authorized Honda motorcycle dealer and make an appointment to have your motorcycle’s
secondary master cylinder and rear brake master cylinder replaced at no cost to you.
While parts are available to conduct secondary master cylinder replacements at the time of this notice,
there is a possibility that parts may be unavailable at the time you call.
You can continue to ride your motorcycle if you carefully inspect it before and after each ride. Please
read and follow the accompanying instructions regarding steps you can take to inspect your motorcycle
for this issue.
Once you make an appointment for your vehicle, be advised that the repair may take approximately 2.7
hours; however, please ask your dealer for the specific time your vehicle will need to be at the
dealership.
*After the recall is completed, continuing to adhere to your motorcycle’s brake fluid maintenance schedule is
essential to the performance of your motorcycle and your safety. As stated in your Owner’s Manual, brake fluid
should be inspected every 4,000 miles and replaced every 2 years or 12,000 miles, whichever comes first. To ensure
the performance of the braking system, Honda strongly recommends having your motorcycle serviced by an
authorized Honda motorcycle dealer using only Pro Honda DOT 4 Brake Fluid.
For assistance with locating a Honda motorcycle dealer, you may call Honda Motorcycle Customer
Support at:
1-866-784-1870 or use the ‘‘find a dealer’’ option on www.powersports.honda.com
Who to contact if you experience a problem?
You may write to or call:
American Honda Motor Co., Inc.
Motorcycle Customer Support
Mail Stop 100-4C-7B
1919 Torrance Blvd.
Torrance, CA 90501-2746
1-866-784-1870
If you believe that American Honda or the dealer has failed or is unable to remedy the safety defect in
your vehicle, without charge, within a reasonable period of time (60 days from the date you first contact
the dealer for a repair appointment), you may submit a complaint to:
Administrator
National Highway Traffic Safety Administration
1200 New Jersey Ave., SE
Washington, DC 20590
Or call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153], or go to:
http:// www.safercar.gov
What to do if you feel this notice is in error.
Registration records indicate that you are the current owner of a 2001-2012 GL1800 affected by this
recall. If this is not the case, or the name/address information is not correct, please fill out and return the
enclosed, postage-paid Information Change Card. We will then update our records.
What if you already had your vehicle repaired for this issue?
If you previously paid to have the secondary master cylinder replaced, you may be eligible for
reimbursement. Refer to the attached Instructions for Reimbursement for the eligibility requirements
and the reimbursement procedure.
Lessor Information:
Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this
notice to the lessee within 10 days.
We apologize for any inconvenience this campaign may cause you.
Sincerely,
American Honda Motor Co., Inc.
Motorcycle Division
Campaign #JV6P / Service Bulletin: GL1800#23
MTB 15624 (1510)
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©2015 American Honda Motor Co., Inc. – All Rights Reserved
GL1800 #23
REVISED: DECEMBER 11, 2015
TEXT OF CUSTOMER LETTER
2012-2015 GL1800, GL1800B
December 2015
NHTSA Recall 15V-700
IMPORTANT SAFETY RECALL
This notice applies to your vehicle.
Dear GL1800 Owner:
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.
What is the reason for this notice?
Honda has decided that a defect which relates to motor vehicle safety exists in certain 2012-2015 model
year Honda GL1800/GL1800B motorcycles. There is a possibility the secondary master cylinder may
cause the rear brake to drag. Unexpected braking increases the risk of a crash and riding the motorcycle
with the rear brake dragging may generate enough heat to cause the rear brake to catch fire.
What should you do?
Call any authorized Honda motorcycle dealer and make an appointment to have your motorcycle’s
secondary master cylinder and rear brake master cylinder replaced at no cost to you.
While parts are available to conduct secondary master cylinder replacements at the time of this notice,
there is a possibility that parts may be unavailable at the time you call.
You can continue to ride your motorcycle if you carefully inspect it before and after each ride. Please
read and follow the accompanying instructions regarding steps you can take to inspect your motorcycle
for this issue.
Once you make an appointment for your vehicle, be advised that the repair may take approximately 2.7
hours; however, please ask your dealer for the specific time your vehicle will need to be at the
dealership.
*After your recall is completed, continuing to adhere to your motorcycle’s brake fluid maintenance schedule is
essential to the performance of your motorcycle and your safety. As stated in your Owner’s Manual, brake fluid
should be inspected every 4,000 miles and replaced every 2 years or 12,000 miles, whichever comes first. To ensure
the performance of the braking system, Honda strongly recommends having your motorcycle serviced by an
authorized Honda motorcycle dealer using only Pro Honda DOT 4 Brake Fluid.
For assistance with locating a Honda motorcycle dealer, you may call Honda Motorcycle Customer
Support at:
1-866-784-1870 or use the ‘‘find a dealer’’ option on www.powersports.honda.com
Who to contact if you experience a problem?
You may write to or call:
American Honda Motor Co., Inc.
Motorcycle Customer Support
Mail Stop 100-4C-7B
1919 Torrance Blvd.
If you believe that American Honda or the dealer has failed or is unable to remedy the safety defect in
Torrance, CA 90501-2746.
your vehicle, without charge, within a reasonable period of time (60 days from the date you first contact
1-866-784-1870
the dealer for a repair appointment), you may submit a complaint to:
Administrator
National Highway Traffic Safety Administration
1200 New Jersey Ave., SE
Washington, DC 20590
Or call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153], or go to:
http:// www.safercar.gov
What to do if you feel this notice is in error.
Registration records indicate that you are the current owner of a 2012-2015 GL1800/GL1800B involved in
this campaign. If this is not the case, or the name/address information is not correct, please fill out and
return the enclosed, postage-paid Information Change Card. We will then update our records.
What if you already had your vehicle repaired for this issue?
If you previously paid to have the secondary master cylinder replaced, you may be eligible for
reimbursement. Refer to the attached Instructions for Reimbursement for the eligibility requirements
and the reimbursement procedure.
Lessor Information:
Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this
notice to the lessee within 10 days.
We apologize for any inconvenience this campaign may cause you.
Sincerely,
American Honda Motor Co., Inc.
Motorcycle Division
Campaign #JV6N / Service Bulletin: GL1800#23
MTB 15624 (1510)
©2015 American Honda Motor Co., Inc. – All Rights Reserved
5 of 6
GL1800 #23
REVISED: DECEMBER 11, 2015
TEXT OF CUSTOMER LETTER
Request for Reimbursement
2001-2015 GL1800/A, GL1800B/BD:
Secondary Master Cylinder Replacement
Use this form only if you have previously paid for this repair. If you meet the
following qualifications, American Honda Motor Co., Inc. will reimburse you for the cost
of the secondary master cylinder replacement. No reimbursement will be made for
other costs or repairs.
1. The vehicle must be an affected Honda motorcycle identified in the Honda Service
Bulletin, GL1800 #23.
2. The repair must have been required due to the failure that is the subject of this recall.
Unrelated repairs will not be reimbursed.
3. The previous secondary master cylinder repair must have occurred before
December 11, 2015.
4. You must have a repair bill showing itemized parts and labor costs, the model, year,
VIN, name, address and phone number of the repair shop, and the date of the repair.
There must be verification of payment, such as a copy of a cancelled check, cash
receipt, or paid invoice.
5. To qualify for reimbursement, it is not necessary that you still own the affected Honda
motorcycle, but you must have been the owner when the secondary master
cylinder was replaced. Only the owner at the time of the repair may request
reimbursement. Do not request reimbursement for the expenses of any other owner.
IF YOU QUALIFY FOR REIMBURSEMENT:
Fill in the blanks; please print clearly.
Name: _______________________________________________________________________________
Street Address: _______________________________________________________________________
City: _________________________________ State: _________ Zip Code: ______________________
Telephone: __________________________ E-mail: _________________________________________
Vehicle Identification Number (VIN): __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
Total Amount Requested: ______________________________________________________________
Mail this form together with a copy of your repair bill and verification of payment to:
American Honda Motor Co., Inc.
Customer Support, M/S 100-4C-7B
1919 Torrance Blvd.
Torrance, CA 90501-2746
Please allow 6–8 weeks for reimbursement processing.
This form is provided for dealer information and customer photocopies if needed.
MTB 15624 (1510)
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©2015 American Honda Motor Co., Inc. – All Rights Reserved
GL1800 #23 - REPAIR PROCEDURE
Service Bulletin
American Honda Motor Co., Inc.
SAFETY RECALL
OVERVIEW·················································· 2
PEDAL BRAKE LINE FLUID FLUSHING ···· 9
PEDAL BRAKE LINE FLUID DRAINING ····· 2
PEDAL BRAKE LINE FLUID FILLING ······· 12
REPLACE THE REAR MASTER CYLINDER 4
PEDAL BRAKE LINE AIR BLEEDING ······· 14
REMOVE THE FRONT WHEEL··················· 7
CHECK THE REPAIR ································· 14
REMOVE THE SECONDARY MASTER
CYLINDER ··················································· 8
IDENTIFICATION ······································ 14
’01-’10 GL1800/A
’12-’15 GL1800
GL1800B/BD
©2015 American Honda Motor Co., Inc. – All Rights Reserved
MTB 15624 (1510)
1
GL1800 #23 - REPAIR PROCEDURE
OVERVIEW
GL1800 #23 - REPAIR PROCEDURE
OBJECTIVE
This repair procedure, when properly executed, will eliminate contaminants from the pedal brake system prior
to the installation of the secondary master cylinder (SMC) parts kit.
The procedure differs significantly from the Service Manual brake filling/bleeding sequence, as it includes a
fluid flushing procedure and the installation of a new rear master cylinder (to ensure all contaminants are
removed from the pedal brake line) before the final fluid filling and bleeding. Carefully review the complete
procedure before starting. AHM will issue Service Manual revision pages to update the Service Manual with the
new brake fluid replacement procedure.
Use only Pro Honda DOT 4 brake fluid from sealed containers to ensure the quality of the repair
procedure.
PARTS, SUPPLIES, AND TOOLS
REQUIRED
NEW
In addition to common hand tools, the brake fluid replacement procedure requires the following parts, supplies
and tool:
– Use only Pro Honda DOT 4 brake fluid (P/N 08203-0004):
Motorcycle: 6 bottles per repair, Trike: 8 bottles per repair
– Master cylinder kit, second/rear (For model application, see the PARTS INFORMATION section of this
bulletin.)
P/N 06454-MCA-306 (1) or
P/N 06454-MJG-306 (1)
– Applicable Service Manual
– Commercially available brake bleeder
NEW
TRIKE CONVERSIONS or MODIFIED
BRAKES
If the vehicle’s secondary master cylinder (SMC) is removed, or the SMC has no brake fluid flow or
connections, this recall does not apply. Note these facts on the R.O. return the vehicle to the customer.
If the SMC is functional, or modified but still has brake fluid flow, follow all instructions within this repair
procedure and make sure to also consult the trike conversion manufacturer’s instructions for brake fluid filling/
bleeding.
PEDAL BRAKE LINE FLUID DRAINING
Spilling fluid can damage painted, plastic or rubber
parts. Place a shop towel over these parts whenever
the system is serviced.
• Do not mix different types of fluid. They are not compatible.
• Do not allow foreign material to enter the system when filling the reservoir.
PEDAL BRAKE LINE FLUID DRAINING
RIGHT FRONT CALIPER
SECONDARY
MASTER CYLINDER
DELAY
VALVE
ANTI-DIVE
PLUNGER
PCV
LEFT FRONT
CALIPER
2
REAR MASTER CYLINDER
REAR
CALIPER
GL1800 #23 - REPAIR PROCEDURE
Refer to the Service Manual and remove the following:
[2]
– right engine side cover
– front fender A, both fender covers, and front fender
B
– rear fender A
Support the motorcycle on its centerstand or a lift.
Remove the bolt [1] and rear master cylinder reservoir.
Remove the rear master cylinder reservoir cap [2], set
plate [3], and diaphragm [4].
Temporarily install the reservoir and tighten the bolt.
[1]
Connect a commercially available brake bleeder [1] to
the bleed valve of the pedal brake line as shown.
Loosen the bleed valve and activate the brake bleeder
until no more fluid flows out of the bleed valve.
Close the bleed valve.
Perform the fluid draining procedure at each remaining
valve of the pedal brake line in the following order:
1.
2.
3.
4.
[3]/[4]
[1]
Right front caliper:
Rear caliper:
right front caliper, lower: [1]
rear caliper, lower: [2]
anti-dive plunger: [3]
rear caliper, upper: [4]
[1]
[2]
Rear caliper:
Anti-dive plunger:
[4]
[3]
3
GL1800 #23 - REPAIR PROCEDURE
REPLACE THE REAR MASTER
CYLINDER
REMOVAL
Remove the two screws and brake light/cruise cancel
switch (’13 – ’14 GL1800B: brake light switch) assembly
[1] from the master cylinder.
[1]
Remove the two bolts [2] and right footpeg [3].
[4]
[2]
Remove the pinch bolt [4] and brake pedal [5].
When removing the
hose and oil bolt,
cover the ends of
the hoses to
prevent
contamination.
Remove the reservoir hose [1] from the master cylinder
[2].
[5]
[3]
[4]
[3]
Disconnect the brake hose by removing the oil bolt [3]
and sealing washers [4].
[2]
[2]
[1]
Unhook the spring end to remove the return spring [1]
from the frame and pivot arm [2].
[4]
[3]
Release the drive shaft joint boot [3] from the engine.
Remove the master cylinder mounting bolts [4].
Remove the pedal pivot arm from the frame while
pushing the water hose aside, then remove the master
cylinder/pivot arm assembly [5].
[5]
[2]
4
[1]
GL1800 #23 - REPAIR PROCEDURE
Remove the following from the master cylinder:
[1]
– split pin [1]
– joint pin [2]
– pivot arm [3]
[3]
[2]
CLEAN THE RESERVOIR
AND OIL BOLT
Use a wire brush if
necessary to clean
the oil bolt threads.
Thoroughly clean the reservoir [1], hose [2], and oil bolt
[3] with WATER only. DO NOT USE BRAKE
CLEANER!
[3]
[1]
Blow all components dry with compressed air.
[2]
INSTALLATION
MASTER CYLINDER
OIL BOLT
SEALING WASHERS
PIVOT ARM
BRAKE LIGHT/CRUISE CANCEL
SWITCH ASSEMBLY
RETURN SPRING
RIGHT FOOTPEG
BRAKE PEDAL
5
GL1800 #23 - REPAIR PROCEDURE
Install the pivot arm [1] into the new master cylinder
push rod joint with the joint pin [2] and a new split pin
[3].
[3]
[1]
Apply grease to the pivot shaft groove of the pivot arm
[1].
[2]
[2]
[3]
[4]
Place the master cylinder/pivot arm assembly [2] into
the frame while pushing the water hose and driveshaft
joint boot aside, then insert the pivot arm into the pivot
hole, being careful not to damage its splines.
Install the master cylinder onto the frame and tighten
the mounting bolts [3].
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
Install the joint boot [4] onto the engine.
Install the return spring [5] into the pivot arm and onto
the frame stopper pin in the direction shown.
[1]
Install the reservoir hose [1] onto the joint.
[5]
[3]
[2]
Connect the brake hose to the master cylinder with the
oil bolt [2] and new sealing washers [3], and tighten the
oil bolt.
TORQUE: 34 N·m (3.5 kgf·m, 25 lbf·ft)
[1]
Install the brake pedal [1] by aligning the slit with the
punch mark on the pivot arm.
[2]
Install the pinch bolt [2] and tighten it.
TORQUE: 27 N·m (2.8 kgf·m, 20 lbf·ft)
Align
[1]
6
GL1800 #23 - REPAIR PROCEDURE
Install the footpeg [1] and tighten the bolts [2].
[2]
TORQUE: 27 N·m (2.8 kgf·m, 20 lbf·ft)
[1]
Apply locking agent to the threads of the switch holder
screws.
Install the brake light/cruise cancel switch (’13 – ’14
GL1800B: brake light switch) assembly [1] with the
screws.
Adjust the switch position so that the brake light comes
on when pushing the brake pedal slightly and the push
rod moves 0.7 – 1.7 mm.
Tighten the switch holder screws.
[1]
TORQUE: 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)
REMOVE THE FRONT WHEEL
Refer to the Service Manual, remove the front wheel.
7
GL1800 #23 - REPAIR PROCEDURE
REMOVE THE SECONDARY MASTER
CYLINDER
REMOVAL
Remove the following:
When removing the
oil bolt, cover the
joints of the hoses
to prevent
contamination.
Airbag models:
[1]
– oil bolt (upper side) and sealing washers [1]
– upper side brake hose(s) [2]
– brake hose joint attaching bolt [3]
Non-airbag
models:
[1]
[4]
Loosen the oil bolt (front side).
Remove the following:
–
–
–
–
mounting bolts [4]
oil bolt (front side) and sealing washers [5]
front side brake hose [6]
secondary master cylinder [7] (discard)
[2]
[3]
[4]
[3]
[2]
[5]
[7]
[6]
PLUG THE BRAKE HOSES
Use a wire brush if
necessary to clean
the oil bolt threads.
Install the washers (reuse), oil bolts [1], and provided
cap nuts [2] to the brake hoses as shown.
Tighten the cap nuts securely.
[1]
[2]
8
GL1800 #23 - REPAIR PROCEDURE
TEMPORARILY REINSTALL THE
FRONT WHEEL
Temporarily reinstall the front wheel and hand tighten
the axle nut [1].
Temporarily reinstall the brake calipers and hand
tighten the bolts [2].
[2]
[1]
NEW
PEDAL BRAKE LINE FLUID FLUSHING
TRIKE CONVERSIONS
Follow all instructions within this procedure and make sure to also consult the trike conversion manufacturer’s
instructions for brake fluid draining/flushing.
FLUID FLUSHING
• Use only Pro Honda DOT 4 brake fluid from
sealed containers to ensure the quality of the
repair procedure.
[1]
• It is not a problem if the fluid flowing out of the bleed
valve contains air bubbles because the lines will be
bled in later steps (AIR BLEEDING).
Fill the reservoir [1] with only Pro Honda DOT 4 brake
fluid from a sealed container.
Operate the brake pedal [2] several times until the
brake fluid level in the reservoir goes down.
[2]
Connect a commercially available brake bleeder to the
upper side bleed valve [1] of the left front caliper.
Activate the brake bleeder and loosen the bleed valve.
• Check the reservoir fluid level often while filling the
brake to prevent air from being pumped into the
system. If air is entering the bleeder from around the
bleed valve threads, seal the threads with Teflon
tape.
If an automatic refill system is not used, add brake fluid
when the fluid level in the reservoir is low.
[1]
Repeat above procedure until a sufficient amount of
clean fluid flows out of the bleed valve.
Close the bleed valve.
• When using a brake bleeding tool, follow the
manufacturer’s operating instructions.
9
GL1800 #23 - REPAIR PROCEDURE
Perform the flushing procedure at each bleed valve in
the sequence as follows:
[2]
1. Right front caliper lower side bleed valve [2]
2. Rear caliper lower side bleed valve [3]
[3]
Manual pumping is
required to ensure
all contaminants
are removed from
the pedal brake
line.
Manually pump (no vacuum bleeder) another 200 cc of
fluid through each bleed valve in sequence; [1], [2], [3]
only. Do not flush any other bleed valves at this
time.
[2]
– Fill the reservoir to the UPPER level line.
– Pump the fluid through the bleed valve by operating
the pedal until the fluid comes down to the LOWER
level line.
– Repeat the procedure eight (8) times to pump about
200 cc (approx. 7 oz) through the system.
Use a graduated cylinder as a catch basin for manual
pumping to measure the amount of flushed brake fluid.
[1]
Drain the fluid from the system, with the brake bleeder
tool, through each bleed valve in sequence; [1], [2], [3].
[3]
TEMPORARILY REMOVE THE
FRONT WHEEL
Temporarily remove the front brake calipers and front
wheel.
10
GL1800 #23 - REPAIR PROCEDURE
INSTALL THE NEW SECONDARY
MASTER CYLINDER
Use a wire brush if
necessary to clean
the oil bolt threads.
Remove the cap nuts that were installed on the brake
hoses earlier.
Airbag models:
Non-airbag models:
[2]
Connect the front side brake hose [1] to the master
cylinder with the oil bolt [2] and new sealing washers
[3].
[2]
Install the new secondary master cylinder onto the fork
leg with the mounting bolts [4] and tighten them.
[6]
TORQUE: 30 N·m (3.1 kgf·m, 22 lbf·ft)
Tighten the oil bolt (front side).
[3]
[6]
TORQUE: 34 N·m (3.5 kgf·m, 25 lbf·ft)
[3]
Install the brake hose joint and tighten the bolt [5].
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
Connect the upper side brake hose(s) [6] to the master
cylinder with the oil bolt and new sealing washers, and
tighten the oil bolt.
[3]
TORQUE: 34 N·m (3.5 kgf·m, 25 lbf·ft)
[2]
[4]
[1]
[5]
REINSTALL THE
FRONT WHEEL
Refer to the Service Manual, reinstall the front wheel
and brake calipers.
Tighten all hardware to the specified torque values.
Do not reinstall the front fender at this time.
11
GL1800 #23 - REPAIR PROCEDURE
NEW
PEDAL BRAKE LINE FLUID FILLING
TRIKE CONVERSIONS
Follow all instructions within this procedure and make sure to also consult the trike conversion manufacturer’s
instructions for brake fluid filling.
• Use only Pro Honda DOT 4 brake fluid from sealed containers to ensure the quality of the repair
procedure.
• Feed fluid into the pedal brake line in the following sequence:
1. Left front caliper, upper side bleed valve [1]
2. Right front caliper, lower side bleed valve [2]
3. Rear caliper, lower side bleed valve [3]
4. Anti-dive plunger bleed valve [4]
5. Rear caliper, upper side bleed valve [5]
[1]
[5]
Left front caliper:
[3]
[4]
[2]
Rear caliper:
Anti-dive plunger:
Right front caliper:
FLUID FILLING
• It is not a problem if the fluid flowing out of the bleed
valve contains air bubbles because the lines will be
bled in later steps (AIR BLEEDING).
[1]
Fill the reservoir [1] with only Pro Honda DOT 4 brake
fluid from a sealed container.
Operate the brake pedal [2] several times until the
brake fluid level in the reservoir goes down.
[2]
12
GL1800 #23 - REPAIR PROCEDURE
Connect a commercially available brake bleeder to the
upper side bleed valve [1] of the left front caliper.
Activate the brake bleeder and loosen the bleed valve.
• Check the reservoir fluid level often while filling the
brake to prevent air from being pumped into the
system. If air is entering the bleeder from around the
bleed valve threads, seal the threads with Teflon
tape.
[1]
If an automatic refill system is not used, add brake fluid
when the fluid level in the reservoir is low.
Repeat the above procedure until a sufficient amount of
clean fluid flows out of the bleed valve.
Close the bleed valve.
• When using a brake bleeding tool, follow the
manufacturer’s operating instructions.
Perform the above procedure at each bleed valve in the
sequence as follows:
[2]
1. Right front caliper lower side bleed valve [2]
2. Rear caliper lower side bleed valve [3]
3. Anti-dive plunger bleed valve [4]
4. Rear caliper upper side bleed valve [5]
[3]
[4]
[5]
Manual pumping is
required to ensure
all contaminants
are removed from
the pedal brake
line.
Manually pump (no vacuum bleeder) another 200 cc
(approx 7 oz) of fluid through each bleed valve in
sequence:
[4]
1. Anti-dive plunger bleed valve [4]
2. Rear caliper upper side bleed valve [5]
– Fill the reservoir to the UPPER limit line.
– Pump the fluid through the bleed valve by operating
the pedal until the fluid comes down to the LOWER
level line.
[5]
– Repeat the procedure eight (8) times to pump about
200 cc (approx. 7 oz) through the system.
Use a graduated cylinder as a catch basin for manual
pumping to measure the amount of flushed brake fluid.
13
GL1800 #23 - REPAIR PROCEDURE
NEW
PEDAL BRAKE LINE AIR BLEEDING
TRIKE CONVERSIONS
Follow all instructions within this procedure and make sure to also consult the trike conversion manufacturer’s
instructions for brake fluid bleeding.
MANUAL AIR BLEEDING
• Use only Pro Honda DOT 4 brake fluid from sealed containers to ensure the quality of the repair
procedure.
• Note that you may feel strong resistance on the brake pedal during pumping to bleed air from the right front
caliper. This is caused by the activation of the delay valve. Be sure to depress the brake pedal fully to the
bottom.
• The air bleeding procedure must be performed in the same way as in the fluid filling procedure without using
a brake bleeder tool.
Repeat this procedure until air bubbles no longer appear in the plastic overflow hose at each bleed valve.
After air bubbles cease to appear in the fluid, repeat the air bleeding procedure 2 to 3 times.
• Make sure that the bleed valves are closed and operate the brake pedal. If it still feels spongy, bleed the
system again.
• After bleeding the air completely, tighten the bleed valves.
TORQUE: 5.4 N·m (0.6 kgf·m, 4.0 lbf·ft)
Fill the reservoir to the upper level line with only Pro
Honda DOT 4 brake fluid from a sealed container.
Remove the bolt [1] and reservoir then install the
diaphragm [2], set plate [3] and reservoir cap [4] to the
reservoir.
Install the reservoir and tighten the bolt securely.
[4]
Clean up any spilled brake fluid with soapy water.
Install the following:
– front fender B, both fender covers, and front fender
A
– rear fender A
[1]
[2]/[3]
CHECK THE REPAIR
Confirm that all bleed valves are tight and there are no
leaks.
Check the pedal brake operation.
IDENTIFICATION
After you have completed the entire repair procedure,
apply a punch mark on the rear master cylinder lower
mounting tab as shown.
Install the right engine side cover.
14
PUNCH MARK