2001-2012 GL1800-A Secondary Master Cylinder_w-o
Contents
1. A N HONDA GL1800 20 DECEMBER 2011 Service Bulletin American Honda Motor Co Inc SAFETY RECALL 2001 2012 GL1800 A Secondary Master Cylinder Inspection Replacement Honda Motor Co Ltd is conducting a Safety Recall to inspect and if necessary replace the combined braking system s secondary master cylinder on affected GL1800 A motorcycles The secondary master cylinder on some affected motorcycles may have insufficient internal freeplay between the pressure cup and the compensating port hole If the free play is insufficient the compensating port can become blocked by the pressure cup which can cause the rear brake to drag after the rider has released the brakes A dragging rear brake increases the risk of a crash and can generate enough heat to cause the rear brake to catch fire This Service Bulletin details how to inspect the secondary master cylinder and if neces sary replace it with one that has sufficient free play The Inspection Tool used in the INSPECTION PROCEDURE section of this bulletin was auto matically shipped to your Service Department on December 1 2011 CUSTOMER NOTIFICATION American Honda is sending a letter to owners of all potentially affected 2001 2012 GL1800 motorcycles informing them that their motor cycle is being recalled for a safety related defect The customer will be advised to have a 2011 American Honda Motor Co Inc All Rights Reserved Honda motorc2. INSPECTION PROCEDURE section of this Ser vice Bulletin REPAIR VERIFICATION Before you begin the inspection repair proce dures check if the recall has been performed on the unit See the IDENTIFICATION section of this Ser vice Bulletin for specific details e f there is a punch mark on the frame under the right engine side cover the unit has been inspected repaired No further action is necessary e f there is no punch mark on the frame under the right engine side cover You must proceed with the INSPECTION PROCEDURE section of this Service Bul letin If you have any questions about repair verifi cation please contact TechLine at 800 421 1900 option 9 INSPECTION PROCEDURE IMPORTANT NOTES The inspection procedure includes the installa tion of an inspection tool jig that will put the secondary master cylinder into a worst case installation angle and ensure positive identifica tion of a defective secondary master cylinder e f a GL1800 A has a modified brake sys tem or is a trike conversion you must call TechLine before proceeding e The inspection procedure for the airbag type VIIIA is different than the procedure for non airbag types Steps 3A 3B and Step 12 apply only to the airbag type All other steps apply to both airbag and non airbag types e Before proceeding click the link below for a video demonstration of the inspection procedure GL1800 Secondary Master Cy
3. CLAIM TEMPLATES Inspection Only Template S03A reads S zero 3 A Flat Rate Time 0 4 hrs Inspection and Repair Template S03B reads S zero 3 B Flat Rate Time 1 2 hrs 6 of 6 REQUIRED PARTS AND TOOL Secondary Master Cylinder Set 1 Contact TechLine to order see Controlled Parts below P N 06453 MCA 305 Contents Cylinder assy second master 1 Washer oil bolt 5 Inspection tool secondary m cyl pin 1 Automatically shipped P N 45601 MCA X01 CONTROLLED PARTS Initially the Secondary Master Cylinder Set will only be available from TechLine If you have confirmed the secondary master cylin der requires replacement send an e mail to or call TechLine mcdealersup ahm honda com Subject line GL1800 20 Information required in the text body e VIN e Mileage e Dealer Number e Technician s Name TechLine will either call you within 24 hours to request additional information or respond by e mail confirming that a Secondary Master Cylinder Set has been shipped To order the controlled part by telephone or for additional information call TechLine at 800 421 1900 option 9 2011 American Honda Motor Co Inc All Rights Reserved
4. ender A left side bolts Proceed to the IDENTIFICATION section of this bulletin REPAIR PROCEDURE Proceed with this section only after determin ing the secondary master cylinder requires replacement as shown in the INSPECTION PROCEDURE section of this bulletin Call or e mail TechLine to order the updated secondary master cylinder as directed in the PARTS INFORMATION section of this bulletin IMPORTANT NOTES e Replacement of the secondary master cyl inder requires the removal of the front brake calipers and front wheel e Do not use new brake caliper mounting bolts for this repair procedure e Installation of the updated secondary mas ter cylinder requires special handling not indicated in the Service Manual review Step 2 below thoroughly before proceed ing with the replacement 2011 American Honda Motor Co Inc All Rights Reserved GL1800 20 DECEMBER 2011 1 Remove the secondary master cylinder from the left fork leg using the procedures in the appropriate Service Manual Cut the rubber boot off this master cylin der to identify it as defective 2 Using the procedures in the appropriate Service Manual install the updated sec ondary master cylinder set as identified in the PARTS INFORMATION section of this bulletin To ensure the optimum operating angle for the secondary master cylinder grasp it and bracket with one hand as shown and firmly rotate the cylinder in a counter clockwise direction
5. linder Inspection 2 of 6 1 Remove the mounting bolts from the left side of front fender A and then remove the left fender cover as shown ap X LEFT SIDE BOLTS FENDER A 2 With the motorcycle on its centerstand rotate the rear wheel with your hand and note the amount of drag on the rear wheel This will be a reference point for Step 10 3A Airbag type only for all other types go to Step 4 Loosen both bracket bolts as shown 2011 American Honda Motor Co Inc All Rights Reserved 3B Airbag type only for all other types go to Step 4 Grasp the secondary master cylin der with one hand as shown and firmly rotate the cylinder and bracket in a clock wise direction While firmly holding the secondary master cylinder and bracket in this position tighten both mounting bracket bolts AIRBAG TYPE z i nL E r UPPER BOLT Tighten the bracket BS bolts while firmly Pe Os rotating the cylinder ER BOLT bracket clockwise A 4 Remove the upper secondary master cyl inder mounting bolt only a UPPER MOUNTING BOLT SECONDARY MASTER E CYLINDER 5 Loosen the lower secondary master cylin der mounting bolt by 90 degrees only LOWER MOUNTING BOLT 2011 American Honda Motor Co Inc All Rights Reserved GL1800 20 DECEMBER 2011 6 Insert the inspection tool into the upper sec ondary master cylinder bolt hole until it is fully seated as shown 7 Gras
6. p the secondary master cylinder with one hand as shown and firmly rotate the cylinder in a clockwise direction f Grasp and rotate the cylinder against the Inspection tool in a clockwise direction 8 While firmly holding the secondary master cylinder in this position tighten the lower cylinder mounting bolt as shown Tighten the lower mounting bolt while firmly rotating the cylinder 3 of 6 GL1800 20 DECEMBER 2011 9 Grasp the inspection tool and check the tension by pulling lightly on the tool as shown The tool should not slip out If the inspection tool slips out loosen the lower bolt repeat Step 8 and re check the tension Lightly pull out on the inspection tool to confirm it is properly seated 10 Firmly depress and slowly release the brake pedal five times then release the brake pedal and immediately try to rotate the rear wheel as shown e f the rear wheel rotates freely the secondary master cylinder is OK Proceed to Step 11 e f the rear wheel is locked does not rotate the secondary master cylinder must be replaced Proceed to the REPAIR PROCEDURE section of this bulletin e f the wheel is not locked but feels like it has more drag than noted in Step 2 check the drag as shown with a spring scale T N SAMIN12MRP The rear wheel drag should be no more than 50 N 5 1 kgf 11 2 Ibf 4 of 6 all If the wheel drag is greater than specified the secondary mas
7. ter cylinder must be replaced Proceed to the REPAIR PROCE DURE section of this bulletin If the wheel drag is less than specified the secondary master cylinder is OK proceed to Step 11 Make sure the strap is at the 6 o clock position 11 If the secondary master cylinder passed Inspection loosen the lower mounting bolt and remove the inspection tool from the secondary master cylinder Reinstall the upper bolt Grasp the secondary master cylinder with one hand as shown and firmly rotate the cylinder in a counter clockwise direction opposite of before and tighten the bolts to the specified torque TORQUE 30 N m 3 1 kgf m 22 Ibf ft J Tighten both mounting E bolts while firmly A rotating the cylinder i counter clockwise L FS s i 3 i 7 k For all non airbag types proceed to Step 13 2011 American Honda Motor Co Inc All Rights Reserved 12 Airbag type only f the secondary master cylinder passed the inspection loosen both secondary master cylinder bracket bolts Grasp the secondary master cylinder with one hand as shown and firmly rotate the cylinder bracket in a counter clockwise direction and tighten the bolts to the spec ified torque TORQUE 30 N m 3 1 kgf m 22 Ibf ft Tighten both bracket bolts while firmly gt rotating the cylinder KS N bracket counter clockwise 13 Reinstall the left fender cover and then the front f
8. when tighten ing the bolts to the specified torque during installation Tighten both mounting bolts while firmly rotating the cylinder i counter clockwise Tighten both bracket d bolts while firmly rotating the cylinder and bracket counter _ y clockwise 3 Using the procedures in the appropriate Service Manual reinstall the front wheel and brake calipers 4 Using the procedures for Pedal Brake Line Fluid Filling and Air Bleeding in the appro priate Service Manual fill and bleed the pedal brake line To ensure that all the fluid in the pedal brake line is fresh pump a volume equiva lent to at least two rear brake reservoirs of fresh brake fluid through the system 5 Using the procedures in the appropriate Service Manual reinstall the remaining removed parts Proceed to the IDENTIFICATION section of this bulletin 5 of 6 GL1800 20 DECEMBER 2011 IDENTIFICATION PARTS INFORMATION After you have completed the INSPECTION REPAIR PROCEDURE 1 Remove the right engine side cover 2 Apply a punch mark to the right frame spar just above the rear master cylinder reservoir See the following photo for placement PUNCH MARK 3 Reinstall the right engine side cover WARRANTY INFORMATION This Safety Recall has no expiration date Nor mal claim submission requirements apply After inspecting repairing the unit submit one warranty claim per unit using the following information WARRANTY
9. ycle dealer inspect and if nec essary replace the secondary master cylin der They will be instructed to call their dealer to make an appointment to have the Recall performed AFFECTED UNITS 2001 2010 GL1800 A All units and types within the above model year range 2012 GL1800 A All types within the following VIN ranges VIN Range JH2SC68G CK000001 thru JH2SC68G CK002608 VA JH2SC68H CKO000001 thru JH2SC68H CK001746 VIIA JH2SC68L CKO000001 thru JH2SC68L CK001294 VIIA JH2SC68M CK000001 thru JH2SC68M CK000164 denotes check digit DEALER INVENTORY Do not sell any un repaired units According to Federal Law any affected new or used unit in your inventory must be inspected and if necessary repaired with the updated sec ondary master cylinder before delivery to the 1 of 6 MTB 13938 1111 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 20 DECEMBER 2011 customer To identify affected units in your inventory refer to e Responsibility Report and Unit Information on iN Then proceed with the
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