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1800SB20

1. A SLIN HONDA GL1800 20 REVISED MAY 17 2012 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 freeplay 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 2012 American Honda Motor Co Inc All Rights Reserved Honda m
2. 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 3 Reinstall the right engine side cover 2012 American Honda Motor Co Inc All Rights Reserved 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 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 Template claim includes reimbursement for one bottle of brake fluid Determined SMC to be disabled removed or modified to be non functional Template SO3C reads S zero 3 C Flat Rate Time 0 2 hrs PARTS INFORMATION 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 with a limited allocation to follow If you have confirmed the seconda
3. ft AIRBAG TYPE JEE f i Tighten both bracket bolts while firmly rotating the cylinder KS bracket counter 4 s clockwise 13 Reinstall the left fender cover and then the front fender A left side bolts Proceed to the IDENTIFICATION section of this bulletin 2012 American Honda Motor Co Inc All Rights Reserved GL1800 20 REVISED MAY 17 2012 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 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 RUBBER BOOT 5 of 9 GL1800 20 REVISED MAY 17 2012 2 Using the procedures in the appropriate Service Manual install the updated sec onda
4. should not slip out If the wheel drag is less than specified the If the inspection tool slips out loosen the secondary master cylinder is OK proceed lower bolt repeat Step 8 and re check the to Step 11 tension i Make sure the strap is at Lightly pull out on the the 6 o clock position inspection tool to confirm it is properly seated 10 Firmly depress and slowly release the brake pedal five times then release the brake pedal wait five seconds then try to rotate the rear wheel as shown 4of9 2012 American Honda Motor Co Inc All Rights Reserved 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 Tighten both mounting bolts while firmly rotating the cylinder i counter clockwise For all Step 13 non airbag types proceed to 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
5. to have the replacement part inspected by the dealer as it may have the same condition that is the subject of this SAFETY RECALL Please make an appointment with your Honda dealer to have your motorcycle inspected and if necessary secondary master cylinder replaced IF YOU ARE QUALIFIED FOR REIMBURSEMENT Fill in the blanks please print clearly Name Street Address City State Zip Code Telephone 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 2012 American Honda Motor Co Inc All Rights Reserved 9 of 9
6. units in your inventory refer to e Responsibility Report and Unit Information on iN Then proceed with the 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 Factory punch mark ve Dealer center punch mark 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 is a trike conversion or has a modified disabled or removed secondary 2of9 master cylinder and the SMC is non func tional note these facts on the R O and be certain to inform the customer of this brake system status In case any of the above apply you must call TechLine befor
7. 800 20 REVISED MAY 17 2012 5 Loosen the lower secondary master cylin der mounting bolt by 90 degrees only LOWER MOUNTING BOLT 6 Insert the inspection tool into the upper sec ondary master cylinder bolt hole until it is fully seated as shown 7 Grasp 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 3 of 9 GL1800 20 REVISED MAY 17 2012 8 While firmly holding the secondary master e Ifthe rear wheel rotates freely the secondary cylinder in this position tighten the lower master cylinder is OK Proceed to Step 11 cylinder mounting bolt as shown Y g e f the rear wheel is locked does not rotate the secondary master cylinder mountiniabalt while es must be replaced Proceed to the REPAIR firmly rotating the 2 PROCEDURE section of this bulletin Tighten the lower 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 If the wheel drag is greater than specified the secondary master cylinder must be 9 Grasp the inspection tool and check the replaced Proceed to the REPAIR PROCE tension by pulling lightly on the tool as DURE section of this bulletin shown The tool
8. ar brake to catch fire How do get this defect repaired free of charge Call any authorized Honda motorcycle dealer and make an appointment to have your motorcycle inspected and if necessary the secondary master cylinder replaced free of charge While the inspection may be completed in less than 30 minutes you may need to leave your motorcycle with the dealer for approximately three days If replacement of the secondary master cylinder is necessary the dealer will contact Honda for a replacement part that will be delivered in two to three days Upon receipt of the part replacing the secondary master cylinder may be completed in approximately one hour Please plan to leave your motorcycle for several days to allow the dealer flexibility in scheduling 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 http www powersports honda com Who to contact if you experience problems If you are not satisfied with the service you receive from your Honda dealer you may write to or call American Honda Motor Co Inc Motorcycle Customer Service 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 defect in your motorcycle without charge and within a reasonable period of time 60 days from the date you first contact the deal
9. e proceeding The inspection procedure for the airbag type VIHA 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 1 Remove the mounting bolts from the left side of front fender A and then remove the left fender cover as shown 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 2012 American Honda Motor Co Inc All Rights Reserved 3A Airbag type only for all other types go to Step 4 Loosen both bracket bolts as shown AIRBAG TYPE BRACKET BOLTS PS SECONDARY MASTER CYLINDER J T E 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 UPPER BOLT Tighten the bracket bolts while firmly rotating the cylinder bracket clockwise LOWER BOLT _ 4 Remove the upper secondary master cyl inder mounting bolt only a UPPER MOUNTING BOLT i P SECONDARY MASTER _ m CYLINDER 2012 American Honda Motor Co Inc All Rights Reserved GL1
10. er 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 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 show that you are the current owner or lessee of a 2001 to 2010 and 2012 model year GL1800 A motorcycle involved in this recall If this is not the case or the name address information is not correct complete sign and return the enclosed postage paid nformation Change Card We will then update our recall records If prior to receiving this notice you paid to have the secondary master cylinder replaced you may be eligible for reimbursement Please refer to the enclosed Request for Reimbursement form for 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 2012 American Honda Motor Co Inc All Rights Reserved GL1800 20 REVISED MAY 17 2012 TEXT OF CUSTOMER LETTER Z HONDA American Honda Motor Co Inc Request For Reimbursement 2001 2010 2012 GL1800 A Secondary Master Cyl
11. inder Inspection Replacement Use this form only if you have previously paid for this repair You may be eligible for reimbursement if you previously paid to have a repair typically replacement of the secondary master cylinder to address the problem that is the subject of this recall No reimbursement will be made for other costs or repairs 1 The vehicle must be a 2001 2010 or affected 2012 GL1800 A 2 The repair must have been required due to a problem that is directly related to the subject of this recall If the secondary master cylinder was not replaced as part of the repair we may require additional information in order to confirm your eligibility for reimbursement Unrelated repairs will not be reimbursed 3 The previous repair must have occurred before February 1 2012 4 You must have a repair bill showing itemized parts and labor costs GL1800 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 GL1800 A motorcycle but you must have been the owner when the repair was completed Only the owner at the time of the repair may request reimbursement Do not request reimbursement for the expenses of any other owner 6 Even if you previously paid to have the secondary master cylinder replaced you need
12. otorcycle 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 For your reference a copy of the Customer Letter is reproduced on Page 7 of this Service Bulletin 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 JH2SC68H CK000001 thru JH2SC68H CK001746 VIIA JH2SC68L CK000001 thru JH2SC68L CK001294 VIIA JH2SC68M CK000001 thru JH2SC68M CK000164 denotes check digit 1 of 9 MTB 13938 14116 1205 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 REVISED MAY 17 2012 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 customer To identify affected
13. ry master cylinder requires replace ment and do not have the allocated parts avail able 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 2012 American Honda Motor Co Inc All Rights Reserved GL1800 20 REVISED MAY 17 2012 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 7 of 9 GL1800 20 REVISED MAY 17 2012 8 of 9 TEXT OF CUSTOMER LETTER Z HONDA American Honda Motor Co Inc January 2012 NHTSA Recall 11V 567 IMPORTANT SAFETY RECALL NOTICE Dear GL1800 A Owner This notice is sent to you in accordance with the requirements of 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 some 2001 to 2010 and 2012 model year GL1800 A motorcycles Under certain conditions there is a possibility that the combined braking system s 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 re
14. ry 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 when tighten ing the bolts to the specified torque during installation Tighten both mounting i bolts while firmly 2 eh rotating the cylinder counter clockwise fi a 7 if if r cS a Tighten both bracket fF d bolts while firmly rotating the cylinder F H S K NY 1 and bracket counter aS TAD L3 H 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 6 of 9 IDENTIFICATION IMPORTANT NOTE If during the inspection procedure the second ary master cylinder was determined to be dis abled removed or modified to be non functional do not punch mark the frame

1800SB20

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