Honda GL 1800 Gold Wing 2006 Service & Electrical Manual Set

The Service Manual covers mechanical service and repair, while the Electrical Troubleshooting Manual adds circuit operation and fault tracing. Feature-specific sections distinguish heated seat/grip, Premium Audio, navigation, ABS, Ultra Low Emission and Airbag configurations.

The ETM also lists A in its model-abbreviation table; that reference does not extend the Service Manual's mechanical coverage.

Search, Bookmarks and Wiring Detail

Finding procedures and circuit details: Text search and chapter bookmarks are available in both publications. The HOME bookmark links to a separate startup file that is not included. Small labels in the larger wiring diagrams require zooming.

One printable PDF contains 1,520 pages in total. The publication totals above already include five safety/introductory pages, 18 memo pages and one blank page.

Engine, Chassis and Electrical Service Coverage

The following highlights are a selection of the documented work. Scheduled maintenance and headlight-aim checks are also included.

• Engine and drivetrain repair: Step-by-step engine removal and installation, valve-train service, clutch repair, transmission disassembly/reassembly, reverse mechanism work and final-drive overhaul.

• PGM-FI diagnosis: Symptom and DTC troubleshooting, HDS/SCS test access, fuel-pressure and pump-flow testing, sensor/ECM checks, and fuel pump, tank and injector service.

• Lubrication and cooling: Oil-pressure and oil-pump inspection, cooling-system testing, coolant replacement, radiator/fan service, and water-pump/thermostat repair.

• Chassis and braking: Wheel, fork, steering-stem, rear shock, linkage and swingarm service; suspension-level control diagnosis, linked-brake bleeding, caliper work and ABS troubleshooting.

• Electrical and touring systems: Battery/charging, ignition, starter/reverse, cruise control, lights/meters/switches, power trunk lock, seat/grip heaters, audio/CB, navigation and Airbag diagnostics.

• Body removal and routing: Panel removal-order charts, cable/harness routing and component-location references, with separate information for Airbag and non-Airbag configurations.

• Factory reference data: Component-specific torque tables, fluid capacities, lubrication/seal points, wear limits, clearances, pressure-test data, electrical test values and Honda special-tool numbers.

Honda wrote these publications for qualified, professional technicians with the training, tools and equipment required for the work.

In-Frame Access and Internal Engine Repair

Cylinder-head/valve service, the clutch, throttle body/injectors, water pump/thermostat, alternator and starter/reverse motor can be serviced with the engine in the frame. Gearshift linkage is also accessible, except for the gearshift spindle.

Oil-pump, intake-manifold, transmission, primary-gear/output-shaft, piston/connecting-rod, crankcase/crankshaft and reverse-shifter/shift-drum-lock-arm work requires engine removal. That distinction helps a workshop plan labor, lifting equipment and bench space before dismantling the motorcycle.

Internal engine coverage includes cylinder compression testing, camshaft and cam-chain service, valve-guide replacement, valve-seat refacing, crankcase separation and select-fit crankshaft bearing identification. Inspection limits and final assembly checks support measurement-based repair.

Clutch coverage extends through hydraulic-system and clutch-pack service. Transmission and final-drive chapters document internal disassembly, bearing replacement, gear inspection, reassembly and installation.

Emissions and Linked-Brake Service

PAIR and EVAP procedures accompany PGM-FI diagnosis and fuel-system component work. The linked-brake sections distinguish the secondary master cylinder, delay valve, proportional control valve and anti-dive circuit, with brake-fluid replacement and bleeding procedures.

ABS problem-code diagnosis covers wheel-speed sensors and modulators. A faulty ABS modulator is replaced as a complete assembly; the manual does not provide an internal modulator overhaul procedure.

Circuit Schematics and Touring Electronics

Named references include Power Distribution, Ground Distribution, Starter/Reverse System, ABS, Navigation System and Airbag System circuit schematics. Circuit-operation explanations, test-point procedures, symptom charts, self-tests, connector views and component-location photographs support fault tracing beyond a single wiring sheet.

The navigation chapter documents symptom diagnosis, a system diagnosis mode, software upgrading and a forced-update procedure.

Variant Routing and Service Tools

The 96-page cable and harness routing section separates non-Airbag machines from VIIIA/IIICM Airbag models. It shows connectors, brake pipes, hoses, sensors, control units and sub-harnesses, including '06 and After '06 routing differences. Body-panel removal-order charts cover the fairing, top shelter, trunk and saddlebags.

For fuel-system diagnosis, Honda lists the U.S.-only HDS pocket tester TDS3557-0112-01 and fuel sender/pump wrench 07ZMA-MCAA201. Mechanical tool references include valve spring compressor 07757-0010000, clutch outer holder 07JMB-MN50100 and fork seal driver 07KMD-KZ30100. Airbag testing and disposal references include inflator simulator 07SAZ-TB4011A and dedicated test/deployment tools.

Engine Support and Airbag Precautions

The engine-removal section warns that supporting the engine by its oil filter can damage the engine. On VIIIA and IIICM machines, incorrect handling of yellow Airbag connectors, crash sensors, module installation or tether positioning can cause accidental deployment or leave the system inoperative.

Honda directs all Airbag-system service to an authorized Honda dealer. Airbag coverage includes diagnosis, component replacement and disposal; a deployed airbag cannot be repaired or reused.

A Preview of Valve-Clearance and Fuel-Pressure Data

Valve-clearance inspection data specify 0.15 ± 0.03 mm for the intake valves and 0.22 ± 0.03 mm for the exhaust valves, with the engine cold, below 35°C (95°F).

The fuel-pressure test specification is 343 kPa (50 psi) at idle with the pressure-regulator vacuum hose clamped. The PGM-FI chapter connects pressure-test results with checks of the filter, return hose, regulator and pump.