HONDALINE

'82

HONDALINE FAIRINGHie

AppIteation

GL1100

Public8tions No.

HP 144 8104

luue CawAPRIL 1981

"

PARTS LISTIndex Put Neme IQ'..,

Index Put NemeN,. N,.

; Fairing mount I ,

iBand, Left inertia weight

Bolt, flange, 8 )( 80 mm , Fairing set collar BFairing inner co,er, Right , Lower biring bracket, RightFairing inner cover,left , lower fairing bracket, Left

5 Screw, 6 x 12 mm 5 ~ Bah flange, 6 x 22 mm

6 Wnher, plain, 6 mm 6 ~ Lower bracket, Right

7 Inner co,er set rubber A 2

~Lower bracket, Left

8 Inner eo'er set rubber B 4 Inertia weight

~Fairing inner cover seal 2

IWasher, lock, 8 mm

Nut, flange, 8 mm , Nut,8 mm

([1 Nut, flange, 6 mm 8 Caution label@ Fairing set collar A 4 Horn, low

<i$ Screw, 6 x 16 mm 4 Bolt, flange, 6)( 12 mm

(ji Collars 4

~Sub wire harness C

<is Nut, cap, 6 mm 4 Horn, High(16 Washer,Iock,6 mm 4 3 "u" boh17 Front cover , Bracket18 Bolt, flange, 6 x 14 mm 4 Sub wire harness F19 Screw,6 x 20 mm 2 Meter'isor<lI Connector holder , Wnher, plain, 4 mm.1 Bolt, flange, 8 x 20 mm 2 WiIIS"r, lock, 4 mm

~cket,illftrtia _i9tt 2 Bolt, hex, 4 x 35 mm~ Band, Right inertNi wei!t't 1 Wire band B1

• Wire band

Fi9. 1

~3~5.

" n U'~ '\~0Y'\, ,

J.1.32 .31 J6 38 1:9 _d. I' ~ •

,. ~

~ " ",,-4 '_"

a'ty,2,14,,,222,2,,22,12222,

"

"HONDA MOTOR CO., LTD. 1981 ·All Riihu A_fWd

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08154-46333-95 Printed in J..-,

Fig. 3VIEW X

FRONT FORK ICOVER P!'=='......

leh

,

SCREWDRIVER I-I

,Fi,.2

11) Remove the radiator upper cover @.12) Remove the radiator lower cover ©.13) Remove and discard the right and

radiator covers @and ®.

VIEW X

~I

14) Remove and discard the horn assemblies.

15) Remove the right and left front forkcovers as follows:a. Remove the two 4 mm pan head

screws and nuts holding each frontfork cover.

b. Remove the front fork covers fromthe fork pipes by prying between thegap in each cover with the end of ascrewdriver.

c. Remove the cushions from the frontfork pipes. Discard the front forkcovers and cushions.

NOTE,Avoid damaging the wire harnesses bythe screwdriver when removing thefront fork covers.

TOOLS REQUIREO

• 8,10.12.14 BOO 19mmcombination wrenches

• #2 Screwdri.,er (+11-)• 6mm socket• Torque wrench

• Ratchet

ItemTorque val,,"

N~ Ikll-n>l ~bs'-6 mm bolt and nut 10 1.~ _ 88 mm bolt and nut_I- 2~_ 2.~ _

W~

10 mm boh and nu!_ 3~_ 3.5 2{;

8 mm screw 0 0.0 16 mm flange bolt 12 1.2 0and nut -8 mm flange bolt 25 2.5 I.¥ld nut

PRECAUTIONS

• Proper torque of the attaching hardware isessential.Be sure to tighten all bolts, nuts and otherfasteners to their specified torques.

• Standard torque values:

PREPARATION FOR FAIRINGINSTALLATION

Refer to the G l1100 Owner's Manual, ShopManual and Parts List for detailed proceduresof the following:

11 Remove the seat.2) Remove the shelter assembly.3) Disconnect the battery ground cable from

the negative battery terminal.

4) Remove and discard the right and leftfront reflex reflectors.

5) Remove the headlight and retain only theheadlight unit and bulb.

6) Disconnect the wire harness connectorsinside the headlight case.

7) Remove and discard the front turn signals.

8) Remove and discard the headlight case.

9) Remove and discard the lower fork bridgecover. (Retain the screws.)

10) Remove the radiator grill ®.CAUTION: Do not damage the radiator

fins.

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..... -

CLUTCHCABLE

IGNITIONSWITCH

THROTTLECABLES

~CHOKE CABLE

/SUB WIRE

HARNESS F

"irt-="', SUB WIRE'J HARNESS F@

(FAIRING,CONNECTORI

LEFT HANDLEBARSWITCH WIRES

RIGHT ,~~~~~~~HANDLEBARSWITCH WIRE

INSTRUMENTWIRES I

WIRE BAN,WIRE HARNESS

TURN SIGNAL BUZZER WIRE

install the connector holder @ using two8 x 20mm flange bolts @.NOTE: Tighten the flange bolts to the

specified torque.

5) Connect all wires to wire harness color­to-color inside the connector holder ®.place the wire connectors as shown andsecure the wires with a wire band ®.Note that connect the light blue/whiteand brown wire of the sub wire harness F@ to the light blue/white wire of theright turn signal.

NOTE:• Check that the connectors are con­

nected securely.• Re-check the routing before going to

the next step.

• Neatly arrange the wires inside theconnector holder ® before installingthe cover.

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Fig_ 5

RIGHT HANDLEBARSWITCH WIRES

LEFT HANDLEBARSWITCH WIRES

Fig. 6

SUB WIRE HARNESS F@(IGNITION SWITCHI

Fig. 5-'TO'

~

@

LEFT FRONT FORK

RIGHT/LEFT TURN SIGNALWIRE HARNESSES SUB WIRE

~C""3>4iiF@

FAIRI~CONNECTOR

HEAOLIGHTUNIT

®

............... IGNITtON SWITCHWIRE HARNESS

"'----<x

LOWER FORK BRIDGE

3) Re-route the ignition switch wires asfollows:a. Disconnect the ignition switch con­

nector.b. Connect the sub wire harness F @

connector to the ignition switch con­nector.

1) Install the turn signal buzzer on the leftinertia weight band.

2) Position the inertia weight brackets @and bands @ and @ on the front forksand install using an 8 x 20 mm flange bolt® for each.NOTE: Position the bands@and ® so

that the flange ® is downagainst the surface @ (shad­owed) of the lower fork bridge.

4) Route the wire harnesses through theupper and lower holes of the wire harnessconnector holder ® as shown. Insert thelugs on the connector holder ® into holesin the inertia weight brackets @ and

Fig. 4 TURN SIGNAL BUZZER

FAIRING MOUNT INSTALLATION

Fig. 4-1

6) Secure the sub wire harness F @with thewire bands @ and @ furnished with thefairing. (The band @ is longer than theband @ )

Fig. 7

".,

"

'O __ FAIRING

CONNECTOR

7) Install the inertia weight 31 on thebrackets ~ using two 8 mm nuts 33 andlock washers 32.

CAUTION: Do not pinch the wires be­tween the weight and con­nector holder.

Tighten the nuts to the specified torque.

8) Reinstall the radiator lo......er cover CI.(Refer to Fig. 2)

9) Reinstall the radiator upper cover Bandwire harness guard.

10) Install the radiator grill ':g;_11) Remove and retain the two 6 mm nuts

and lock washers attaching the instru·ments to the bracket.

12) Remove and discard the two 4 mm screwsattaching the cover to the back of theindicator light panel.

13) Install the meter visor~ as follows:

a. Remove the two 6 mm nuts @ , 6mm lock washers @ and 4 x 20 mmpan head screws © from the back ofthe meter and discard only the 4 x 20mm pan head screws © (Fig. 8).

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b. Install the meter visor ,g, using thetwo 4 x 35 mm bolts .~ , 4 mm plamwashers 4~ and 4 mm lock washers@and reinstall the two 6 mm nuts l.8Jand lock washers @(Fig. 81.

14) Position the fairing bracket I on theframe and install as follows:a. Install the fairing mount taking care

not to damage the wires, cables, andwire harnesses.

b. Insert the 8 x 80 mm flange bolt 2through the mount and loosely installthe 8 mm flange nut 10 .

c. Attach the mount to the down tubesusing a "U" bolt 39 , a bracket 40 andtwo 6 mm flange nuts lion each side.Do not tighten at this time.

d. Route the cables and wire harnessthrough the mount to the left andright of the steering head as shown:Left side: Throttle cables, chokecables and wire harness.Right side: Tachometer cable andclutch cable.

NOTE: Tighten the bolts and nuts to thespecified torques, being cartainthat the cables and wires are notpinched between the mount andframe.

Fig. 9

'0 11

.,15) Install the horns ~~ and ~using a 6 x 12

mm flange bolt 36 for each.NOTE: Tighten the bolts to the specified

torque.

16) Position the right and left lower fairingbrackets ~ and <ft on the fairing mountI and loosely install using four 6 x 14

mm flange bolts (Jjl.

17) Install the right and left fairing innercovers ([ and @ using three 6 mm plainwashers ® and 6 x 12mm screws @ foreach cover. Tighten the screws @to thespecified torque.Install inner cover set rubber A-S (jj ®and fairing inner cover seal@.

18) Install the front cover @using the screwsretained in step 9 in PREPAR ING FORFAIRING INSTALLATION.

19) Connect the sub wire harness C ® to thehigh and low horns ~ and @.NOTE: The sub wire harness C ® is

rotlted behind the mount.

Fig. 10

"Fig. 11

FRONT FORKS

FAIRING AND WINDSHIELD

1) Install the headlight on the fairing.a. Remove the headlight mount assemb­

ly ® from the fairing.b. Remove the two 3 x 12 mm screws

from the mount assembly ® andinstall the headlight unit as shown.Connect the socket to the headlight.

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b. Engage the hooks in the holes in thelower fairing sections © and @ ;install the fairing sections using twosnort collars @ @. two 6 x 16 mmscrews 1 at the top and a long collar@ 3 and a 6 x 20 mm screw @ atthe bottom for each section.

4) Reinstall the shelter.

5) Reinstall the seat.6) Retighten all bolts and nuts.7) Connect the sub wire harness F to the

wire harness connector inside the lowerleft of the fairing; place the boot over theconnector.

8) Reconnect the battery ground cable tothe battery negative terminal.

9) Fill the front forks to the recommendedair pressure.NOTE:• Refer to the Owner's Manual 11.0-1.5

kg/cm 1 114-21 psi)).• Check for leaks by applying soapy

water around the valve and valve joint.

Fit. 13

FAIRING

2) Install the fairing on the fairing bracketCD as follows:a. Position the right and left fairing nut

plates ® and ® on the fairing align·ing holes in the fairing with the holesin the mount 1 . Install 6 mm flangenuts on the studs from underneathand tighten securely.

b. Attach the fairing to the lower fairingbrackets @and rit using four collars® . 6 mm lock washers @ . 6 mm capnuts @ and 6 x 22 mm flange bolts@.

NOTE: Tighten all bolts and nuts to thespecified torques.

c. Tighten the lower fairing bracketflange bolts Qj.. to the specifiedtorque.

3) Install the right and left lower fairing sec·tions.a. Install the right and left lower brackets

.iJ and ~O.

c. Install the headlight assembly on thefairing.

F.... 12

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10jlnstall the windshield as follows:a. Remove the six bolts <AI •windshield

trim @collars © and special nuts @.b. Install the windshield on the fairing as

shown in Fig. 14. Remove the handle­bar mirrors and install the fairingmirrors using the two bolts @ andfour bolts furnished with mirrors.Press grommets into the holes left bythe handlebar mirrors.

F'" 14

D

E

c

WINDSHIELD

NYLON /WASHER

•

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