Honda Goldwing GL1000 (1975–1979) & GL1100 (1980–1983) Repair Manual (P/N M340)

Clymer’s Honda Goldwing repair manual, P/N M340, published by Intertec, covers the 1975–1979 GL1000 and 1980–1983 GL1100 Standard and Interstate, with information for U.S. and U.K. machines. The main chapters cover the GL1000; the integrated GL1100 supplement supplies procedures and specifications that differ from the earlier models. ISBN: 0-89287-238-1.

PDF Search, Navigation and Diagram Detail

Search and diagram limitations: PDF text search and embedded bookmarks are not available. Small wiring labels require enlargement, and some remain blurred when enlarged. The GL1000 engine-specification page numbered 78 appears twice; its continuation numbered 79 is missing.

The ZIP contains one printable English PDF with 295 pages, including eight cover and reference pages: the front and back covers, chapter guide, three contents pages and two quick-reference pages. The GL1100 supplement and wiring diagrams are included in the same file.

Engine Overhaul, Chassis Service and Electrical Diagnosis

The following selected contents summarize the repair coverage rather than reproduce the full contents list. Other topics include maintenance schedules and preparation for storage.

• Engine and drivetrain: Engine removal, cylinder-head and valve service, camshaft and rocker inspection, timing-belt replacement, oil-pump inspection, crankcase separation, internal engine repair, clutch overhaul and transmission disassembly.

• Fuel and exhaust: Keihin constant-vacuum carburetor overhaul, float adjustment, synchronization, pilot-screw setup, air-cut valve service, GL1100 accelerator-pump adjustment, fuel-pump testing and exhaust replacement.

• Electrical diagnosis: Charging-system tests, alternator and stator inspection, rectifier and regulator checks, ignition troubleshooting, starter-motor service and starter-clutch repair.

• Cooling system: Radiator and fan removal, thermostat testing, water-pump repair, hose replacement, coolant renewal and temperature-sender and fan-control-switch replacement.

• Chassis and brakes: Wheel and tire service, steering bearings, forks, shocks, swingarm and shaft drive, hydraulic brake service, the 1983 unified brakes and TRAC anti-dive units.

• Wiring diagrams: Separate schematics for 1975–1977 and 1978–1979 GL1000, 1980–1982 GL1100 Standard and Interstate, and 1983 GL1100 Standard and Interstate models.

The book is suited to experienced DIY owners and mechanics using hand tools and test equipment; it directs press work, precision measurement and certain specialized repairs to a properly equipped shop.

Engine, Clutch and Transmission Work

Step-by-step procedures distinguish cylinder-head, valve, camshaft, rocker and timing-belt work possible with the engine in the frame from major internal repairs requiring engine removal. These separate sequences help you assess access and workshop requirements before starting a repair.

Crankcase procedures cover pistons, connecting rods and crankshaft components. Transmission work reaches the mainshaft, countershaft, shift forks, shift drum and gearshift linkage; the supplement identifies the changed GL1100 ratios used from 1982 onward. Inspection sections provide torque specifications, clearances, wear limits and service dimensions.

Clutch coverage includes cable and lifter service, disc and plate inspection, assembly and model-specific locknut arrangements. Removing the clutch housing requires engine removal and removal of the rear engine cover.

The GL1100 valve section distinguishes its specially surfaced valve faces from the earlier design: these valves must not be ground. The timing-belt material explains the risk of severe engine damage from incorrect crankshaft-to-camshaft indexing and weakened belt fibers from bending or twisting.

Carburetor Setup and Fuel Delivery

The carburetor chapters distinguish the GL1000 bank from the GL1100 arrangement, including the accelerator pump on the No. 3 carburetor. Pilot-screw procedures separate the January 1, 1978 emissions change from earlier GL1000 settings and address later U.S. limiter caps.

Fuel-delivery diagnosis includes pump pressure and delivery-capacity tests. Related procedures cover the petcock, tank removal and the different exhaust layouts.

Ignition and Later Electrical Systems

Electrical coverage follows the change from GL1000 breaker points and condensers to the GL1100 solid-state CDI system. The supplement adds pulse-generator tests, spark-unit assessment, mechanical and vacuum advance inspection, and combined regulator/rectifier checks.

GL1100 ignition timing is checked rather than adjusted. For the 1982-on self-canceling turn signals, fault finding is limited to wiring checks, dealer testing or known-good component substitution; detailed component test specifications are not provided.

Brakes, Suspension and Final Drive

Brake sections distinguish 1980–1981 single-piston calipers, 1982-on dual-piston calipers and the 1983 unified layout, where the rear pedal operates the rear and right-front brakes. Coverage includes the corresponding bleeding procedure, metal-line routing, pressure-control valve and master-cylinder service. The GL1100 supplement refers caliper rebuilding to a dealer, repair shop or brake specialist.

Suspension material covers air-assisted GL1100 forks and rear shocks, the 1982 low-air warning system, and 1983 TRAC anti-dive adjustment, disassembly and inspection. The manual refers 1980–1982 fork disassembly and internal GL1100 air-shock work to a dealer; detailed fork overhaul procedures are provided for 1983.

GL1000 final-drive procedures include tooth-contact inspection, preload-shim selection and backlash checks. Incorrect preload or tooth contact can cause premature gear wear. GL1100 coverage concentrates on removal, installation and external inspection, with internal work requiring specialist Honda tools.

Driveshaft and swingarm-bearing service are also included. Frame stripping and repainting are accompanied by Interstate fairing, travel-trunk, saddlebag, luggage-rack, bumper, engine-guard and windshield procedures. A separate sidecar chapter discusses mounting geometry, alignment, maintenance, wheels, tires and suspension changes.

Service Tools and Illustrated References

Named tools include timing cap HC63068, carburetor adjusting wrench 07908-4220100, GL1100 clutch locknut wrench socket 07716-0020202, fork seal driver 07947-4630100 and swingarm pivot locknut wrench 07908-4690001.

Illustrated references include the engine oil-pump assembly, clutch assembly, GL1100 ignition circuits, rear-suspension low-air warning circuit, 1983 unified brake-line layout and TRAC anti-dive unit.

Engine removal requires secure support for the motorcycle and powerplant. Brake and air-assisted suspension work requires the pressure-control precautions described in the manual.

Examples of GL1000 Engine Inspection Clearances

The GL1000 engine tables list piston-to-cylinder clearance of 0.03–0.07 mm when new, with a 0.15 mm wear limit. These figures accompany the piston and cylinder inspection material.

Crankshaft main-bearing clearance is listed separately at 0.02–0.044 mm when new, with a 0.08 mm wear limit. The inspection procedures describe clearance measurement with Plastigage and distinguish new-component specifications from service limits.