Honda GL1800, GL1800A, GL1800 (2005), GL1800A (2005) Setup Instructions

2005 GL1800/A SET-UP INSTRUCTIONS

Set-up and pre-delivery service must be performed by an authorized Honda motorcycle dealer.

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.

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 Torque Table

PAGE REVISED ITEM SIZE TORQUE

Seat bolts 8 mm 27 N·m (2.7 kgf·m, 20 lbf·ft) Final drive oil check cap 8 mm 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.

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.

4. Remove the motorcycle from the crate frame.

Remove the seat and rear backrest.

CROSS SUPPORT

ZIP TAB

SEAT

BACKREST

REAR CHOCK

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)

2005 GL1800/A

5. Loose Parts Information.

Unpack the remaining loose parts and check them against the parts list and this illustration.

7.

1.

3.

5.

2.

6.

4.

9.

10.

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

10. Seat

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

8.

11.

12.

13.

14.

(Continued on next page)

15.

16.

17.

*If missing, order from Helm Inc. **If missing, order from Resolve Corp. (formerly DDS)

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.

2005 GL1800/A

6. Attach the seat, passenger grips, and back rest.

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.

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.

SEAT

GROMMET

COLLAR

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)

Slide the backrest retainers into the trunk lid slots and open the trunk lid.

Attach the backrest to the trunk lid using two 5 x 16 mm self-tapping screws and washers.

PASSENGER GRIP

BACKREST RETAINERS

8 x 70 mm SOCKET BOLT (2 each side)

5 x 16 mm SELF TAPPING SCREWS

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

Remove the two 6 mm nuts (one each side) attaching the windshield holder to the windshield locking mechanism and remove the holder.

WINDSHIELD LOC KING MECHANISM

AIR VENT COVER

6 mm NUT (EACH SIDE)

2005 GL1800/A

7. Install the windshield (cont.).

Assemble the center adjustment plate and backup plate onto the windshield using a 6 x 8 mm screw.

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.

ADJUSTMENT PLATE

SPECIAL SCREWS

6 x 8 mm SCREW

BACK UP PLATE

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

7. Install the windshield (cont.).

Be sure that the windshield holder locator tab is hooked over the fairing tab.

Attach the windshield holder with the small head 6 mm bolt and two 6 mm nuts (one on 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.

HOLDER LOCATOR

6 mm BOLT

FAIRING TA B

6 mm NUT (EACH SIDE)

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.

WINDSHIELD GARNISH

GROMMET

STUDS

COLLARS

GROMMET

BOLTS

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.

Loosely install the mirror assembly (on both sides) using a 5 x 20 mm screw/washer in the top mounting hole.

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.

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.

MIRROR BOOT

MIRROR

TURN SIGNAL CONNECTORS

COWL STAY

5 X 20 mm SCREWS

5 X 20 mm SCREW

9. Install the auxillary input patch cord.

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.

LEFT FAIRING POCKET

TRIM CLIPS

10. Check that the cables, hoses, and wire harnesses are properly routed.

TURN SIGNAL/ RUNNING LIGHT

CONNECTORS:

Rider headset

Auxilary input

Optional for accessory socket

LEFT FRONT SPEAKER WIRE

LEFT PANEL SWITCH

To m et e r ( 1 6P Black and 20P Black connectors)

HIGH BEAM HEADLIGHT CONNECTOR

POSITION LIGHT RELAY

HEADLIGHT ADJUSTING MOTOR

To t u rn s ig na l relay (in meter) 3P connector

LOW BEAM HEADLIGHT CONNECTORS

RIGHT FRONT SPEAKER WIRE

HEADLIGHT ADJUSTING MOTOR

TURN SIGNAL/ RUNNING LIGHT

AMBIENT AIR TEMPERATURE SENSOR

HIGH BEAM HEADLIGHT CONNECTOR

BANK ANGLE SENSOR

RADIATOR HOSE (LH)

FRONT ABS MODULATOR

FRONT BRAKE LINES

REAR BRAKE LINES

RADIATOR HOSE

REAR ABS MODULATOR

2005 GL1800/A

10. Check that the cables, hoses, and wire harnesses are properly routed (cont.).

CLUTCH HOSE

CLUTCH SWITCH WIRE

SWITCH HARNESS

LH

RH

BRAKE

HOSE

THROTTLE CABLES

THROTTLE ADJUSTER

FUEL LEVER SENSOR

FUEL LINE (SUPPLY)

FUEL LINE (RETURN)

FUEL PUMP

NEGATIVE (-) CABLE & TERMINAL

BATTERY STAY BOLT

SWITCH HARNESS

POSITIVE (+) CABLE & TERMINAL BATTERY BOLT

11. Service the battery.

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.

LEFT SIDE COVER

Remove the push-pin by pulling the stem out. Remove the protective cover.

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.

Tighten the bolts securely, coat the terminals with dielectric grease, and pull the red cover over the positive terminal.

BATTERY HOLDER BOLT

BATTERY HOLDER

PROTECTIVE COVER

PUSH PIN

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.

2005 GL1800/A

12. Check the fluid level in the front and

rear brake reservoirs.

Turn the handlebar so that the front brake reservoir is level and check the fluid level.

Remove the right engine cowl to access the rear brake reservoir and check the fluid level.

Keep the engine cowl off until the completion of step 15.

LOWER LEVEL MARK

COVER

CAP

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.

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.

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

COVER

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.

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.

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.

3-6 mm (1/8 - 1/4 in.)

LOCK NUT

ADJUSTER

Place the motorcycle on its centerstand on a firm, level surface. Remove the right engine side cover.

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.

LOWER LEVEL MARK

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.

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.

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.

RIGHT FAIRING POCKET

TRIM CLIPS

OPENER CABLE

IGNITION KEY

RADIATOR CAP

17. Check the final drive gearbox oil level.

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.

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.

OIL LEVEL CHECK CAP

LOWER EDGE

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

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

± 50 rpm.

700

± 50 rpm

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.

Fuse Box

Not used

15

16

FI IGN FUSE

STOP LIGHT FUSE

IGN CRUISE FUSE

SUSP LEVEL FUSE

17

18

19

20

AUDIO/ACC FUSE

BATTERY FUSE

RVS SHIFT FUSE

HEAD HI FUSE

21

22

23

24

Not used

HEAD LO FUSE

HORN TURN FUSE

25

26

27

Not used

1

17

6

5

FUSE BOX

MAIN FUSE A

ABS MTR FR FUSE

ABS MTR RR FUSE

2

3

4

18

19

20

9

8

7

+

ACC

TERMINAL

TAIL FUSE

ACC. TERM. FUSE

FAN FUSE

5

6

7

21

22

23

12

11

10

–

ST. KILL FUSE

HEAD RLY FUSE

RVS START FUSE

8

9

10

24

25

26

15

14

13

1

2

3

RVS FUSE A

RVS FUSE B

ABS MAIN FUSE

11

12

13

27

16

MAIN FUSE B

4

Not used

14

100 A

SPEED LIMITER

FUSE 70 A

2005 GL1800/A

Fuse Box - Wire Routing

FUSE BOX

Y

–

BATTERY

+

STARTER RELAY SWITCH A

SPD LIMIT FUSE 70 A

MAIN FUSE B 100 A

15 A

5

20 A

17

15 A

18

15 A

19

15 A

20

15 A

21

20 A

22

15 A

23

10 A

24

15 A

26

15 A

27

30 A

3

30 A

4

Y

W

W/Y

Bl

W/R

Y

Br

Lg

R/Y

R/Bl

W/Bu

W/Y

Bl/W

R/Bu

R/G

SPEED LIMITER RELAY

ALTERNATOR

TAIL LIGHT RELAY

FI/IGNITION RELAY

STOP LIGHT RELAY

IGNITION CRUISE RELAY

SUSPENSION LEVEL MAIN RELAY

ACCESSORY RELAY

TRUNK LOCK CONTROL SYSTEM AUDIO SYSTEM COMBINATION METER (BACK-UP)

REVERSE SHIFT RELAY 1

HEADLIGHT HI RELAY

HEADLIGHT LO RELAY

HORN/TURN RELAY

ABS MOTOR DRIVER (FVBM)

ABS MOTOR DRIVER (RVBM)

LOCK

OFF

ON

ACC

R

Bl

R

Bl

IGNITION SWITCH

Lg/Bl

Bu/O

4P W

Bu/O

R

Bl

Bu/O

Lg/Bl

30 A

2

10 A

8

10 A

9

5 A

10

5 A

13

20 A

7

W

Br/R

Br

R/Bu

Bl/Bu

Lg/Bl

Bl

IGNITION SYSTEM

HEAD ADJUSTER RELAY STARTER/REVERSE SWITCH

STARTER/REVERSE SYSTEM

ABS CONTROL UNIT (MAIN)

FAN CONTROL RELAY

ACCESSORY RELAY

HORN TURN RELAY TAIL RELAY

Suspension Level Control

2005 GL1800/A

ABS

Fuel System

RELAY BOX

IAT SENSOR

G/R

3P Gr

4

FUEL PUMP RELAY

ENGINE CONTROL MODULE

2P Bl

Y/R

Lg/Y

MAP SENSOR

O/G

Bl/Y

O/G

Bl/Y

PAIR CONTROL

SOLENOID

VCC IMMO IND HTCNTL2 FANR FLR EX-AI RACV LG PG2 PCM IGPLS3&4 IGP

22P Bl22P Gr6P Bl

WARN HTCNTL 1 ACGF IDC PCS IMOAU SG PG1 IGPLS5&6 IGPLS1&2

RXD-TXD GP3 NLSW SCS IMOID KNOCK 2 TW PA O2-2 THL CYLP TACHO GP2 S STAND

VSP KNOCK 1 TA PB O2-1 IMOV PCP

INJ6 INJ4 INJ2 INJ5 INJ3 INJ1

2P W

VALVE

CONTROL

IDLE AIR

Lg

G/O

TP SENSOR

2

RIGHT O SENSOR

FI/IGNITION RELAY

W

Gr

G/R

Bl/YWBl/R

4. FUEL PUMP RELAY

Bl/Y Bl/Y

Br/Bl

Br

Y/R

W

Br/Bl O/G Lb

G G

W/Y

Bl/Y

W/Bu

W Bl

Y/Bl

G/R

G

W/R

Bu/R

Br

Bu

Y/Bu

Lg/Bl

Bl/O

Lg Gr

Bl/Y

W/Bl

R/Bu

Gr/Bu

Lg/Y Bl/R Bl/Y

Y

Lg

R/Bl R/Y P/W R/Bl

P/Bu

Gr/Bu G/R

VALVE

3P Gr

G

Lb

Bl/Y

LbLb G

G/R Lg/Y Y/R Bl/Y O/G

Lg

Y/R

3P Bu

2

CONTROL

VALVE

SOLENOID

EVAP PURGE

LEFT O SENSOR

SERVICE CHECK

CONNECTOR

3P Bl [MINI]

G

Br

Lg

R/Y

R/Bl

4P

Gr Gr

Br

Lg

R/Y

P/Bl

Lg Br

P/Bl

Br

R/Y

Br

2P Bl 2P Bl 2P Bl

4P Bl

2P Bl

Y/Bl

Bl/Y

Br

P/W

R/Bl

P/Bu

4P

P

Br

R/Bl

P/Bu Br P

Br

R/Bl

Br

P/Bu

Gr

MINI

S

W

S

G

G/R Lg/Y Y/R Bl/Y O/G

Lg

INJECTOR No. 5 FUEL

2P Bl2P Bl

INJECTOR No. 3 FUEL

INJECTOR No. 1 FUEL

2P Bl

Bl

W

G/R Gr

Bl/Y

Bl/O

Bl

4P W

8P

LEFT KNOCK SENSOR

RIGHT KNOCK SENSOR

1P Bl

Bu

R/Bu

INJECTOR No. 6 FUEL

INJECTOR No. 4 FUEL

INJECTOR

MALFUNCTION INDICATOR LAMP

No. 2 FUEL

W/Bu

(MIL)

TAIL LIGHT RELAY

ALTERNATOR

Bl

Br/W

REVERSE REGULATOR ASSEMBLY

REVERSE REGULATOR ASSEMBLY,

W/R

Bu/R

Gr

W/Bl

FUEL LEVEL SENSOR

CRUISE/REVERSE CONTROL UNIT

COMBINATION METER

CRUISE/REVERSE CONTROL UNIT

R/W

REVERSE REGULATOR ASSEMBLY,

CRUISE/REVERSE CONTROL UNIT

Lg/R

COOLANT TEMPERATURE GAUGE

OVERDRIVE INDICATOR

REVESE REGULATOR ASSEMBLY,

CRUISE/REVERSE CONTROL UNIT

G/O

Y/R

G/R

G

W/Y

Y

Gr

W/Y

G/R G/Bl

Lg/R

R/W W/R Bl/Y

Lg/Bl

W/Bl

Y/Bu

2P

6P

3P W

2P R

Gr

6P

FUEL PUMP

G

Br

G

Br

G

Br

BlMINI

3P Bl

[MINI]

MINI

Gr

5P Gr

Gr

Lg/R

G/O G/O R/W W/R Bl/Y

G G

W/Bl G Br Br/W

W/Y

Y

Gr W

Y/Bu

G/R G/Bl

FUEL LEVEL

SENSOR

BARO SENSOR

N

2

OD

3

4

2P Bl

Gr W

3P

Y/Bu G/R G/Bl

VEHICLE

SPEED SENSOR

GEAR POSITION SWITCH

IGNITION PULSECAM PULSE

GENERATOR GENERATOR

ECT SENSOR

2005 GL1800/A

Cooling/Charging/Ignition System

FUSE

17

8

7

REVERSE REGULATOR

ASSEMBLY

IGNITION CRUISE RELAY

MAIN FUSE B

RELAY BOX

FAN CONTROL

ENGINE CONTROL MODULE

Bl/Bu

W

Bu/R

Bl

3

15

FAN CONTROL RELAY 3.

15. FI IGN RELAY

Bl

Bl/W

R/W

FANR PCM I GPLS3&4 I GP ACGF I GPLS5&6 I GPLS1&2

22P

NLSW TACHO SSTAND PCP

22P

Bl/Y

Bl/Bu Bl/Bu

Br/R

Bu

Br/R W/Y

Bl

Y/Bu

Bl/Y

Bl

Y/R Y/W

Bu/R

Gr

Y/G G/W

Y

FI IGN RELAYRELAY

W

Bl/Y

[MINI]

3P G

Y/Bl

Y/Bl G/W

G/W

G

SIDE STAND SWITCH

4P

FR

Bl

Bl/Y

W

[MINI]

R

W/Y

Y

2P

(L)

IG

IC

P

B

BuBu

2P W

Bl G

Bl

RIGHT FAN MOTOR

W/Y

Y

EF

LATOR

REGU-

ALTERNATOR

GBl

2P Bl

Bu Bu

Bl

LEFT FAN MOTOR

GENERATOR

IGNITION PULSE

G G

GG

G

MINI

R/W

W

3P

SENSOR

ANGLE

BANK

Y/G

Y/Bl

Bl/Y

SIDE STAND INDICATOR

IGNITION CRUISE RELAY

FUEL SYSTEM

COMBINATION METER

CRUISE/REVERSE CONTROL UNIT

G/W

CRUISE/REVERSE CONTROL UNIT,

CLUTCH SWITCH

G

Bl/Y Y/W

Bl/Lg Bl/W

Bl/W

STARTER/REVERSE SWITCH

4P Bl 4P Bl

4P Bl

COILS

IGNITION

SPARK

#5

#6 #2 #1#3#4

PLUGS

OFF

RUN

ENGNE STOP SWITCH

G

Bl/Y Y/Bu

G

Bl/Y Y/R

W

Bl/W

18P G

Starter/Reverse System

2005 GL1800/A

Lighting System

Turn Signal Lights/Horn

2005 GL1800/A

Combination Meter

ACCESSORY RELAY

AMBIENT AIR

DIGITAL

ACC/Trunk Lock System

2005 GL1800/A

Cruise Control System

VEHICLE