MTB 10173 GL1800 overheating - ECM PIC FINAL
Contents
1. lt CLIN HONDA GL1800 A 13 JUNE 2003 Service Bulletin American Honda Motor Inc 2001 2003 GL1800 A ECM Replacement Cooling System Product Improvement Campaign American Honda s Motorcycle Division is con ducting a Product Improvement Campaign to replace Engine Control Modules ECMs that may affect engine coolant temperature during certain riding conditions A small number of 2001 2003 GL1800 A custom ers may experience high engine coolant temper ature readings This condition may occur during prolonged low speed low gear high ambient tem perature conditions To decrease the possibility of high engine coolant temperature readings during these conditions an ECM Replacement Cooling System Product Improvement Campaign has been initiated AFFECTED UNITS All 2001 2003 GL1800 A models Repair procedures are very specific Please fol low the INSPECTION REPAIR and IDENTIFI CATION procedures in this bulletin closely CUSTOMER NOTIFICATION American Honda is sending a letter to owners of all 2001 2003 model year GL1800 As informing them that they are entitled to receive this inspec tion and repair at no cost They will be instructed to call and make an appointment to have the inspection and update performed For your refer ence the text of the customer letter is repro duced on page 8 of this Service Bulletin 2003 American Honda Motor Co Inc All Rights Reserved INSPECTION Before yo2. P N 12012 MCA 305 H C 7530710 2003 American Honda Motor Co Inc All Rights Reserved Left Cylinder Head Set L P N 12020 MCA 305 H C 7450216 Gasket Set L P N 12022 MCA 305 H C 7530736 Sub harnesses Sub harness A White P N 32112 MCA 305 H C 7498546 Sub harness B Blue P N 32112 MCA 306 H C 7498553 Sub harness D Green P N 32112 MCA 307 H C 7498561 Sub harness E Brown P N 32112 MCA 309 H C 7498579 GL1800 A 13 JUNE 2003 5 of 8 GL1800 A 13 JUNE 2003 WARRANTY INFORMATION This Product Improvement Campaign will end on June 19 2006 This campaign features two 2 Template Claim Filing Guides 1 ECM amp Sub Harness Installation 2 Cooling System Inspection e Choose the Template numbers below that best describe the repair inspection you performed e Submit two 2 claims per VIN one for each Template Claim Filing Guide ECM amp Sub Harness Installation Template Claim Filing Guide Model Year VIN Left Head NO GOOD Left Head OK Replaced Head 2001 Early Non ABS Order and install sub harness A Order and install sub harness B thru VIN 1HFSC470 1A001672 32112 MCA 305 White 32112 MCA 306 Blue Template L93A Template L93B FRT 1 2 FRT 1 2 2001 Late Non ABS No sub harness should be installed Order and install sub harness D after VIN 1HFSC470 1A001672 32112 MCA 307 Green Template L93C Template L93D FRT 1 0 FRT 1 2 2001 ABS
3. IN 1HFSC470 3A204632 Late 03 ABS after VIN 1HFSC474 3A201020 e Perform the following procedure with the engine at room temperature e Both Left and Right cylinder heads must be inspected e Use the Cylinder Head Inspection Kit for the following procedure _ Remove the front lower fairing See S M 2 6 2 Remove and suspend the rear brake reser voir being careful not to stress the brake hose See S M 15 A 8 2003 American Honda Motor Co Inc All Rights Reserved 3 Remove and suspend the evaporative cannis ter See S M 5 72 It is not necessary to dis connect the hoses 4 Remove the right cylinder coolant hose from the drain joint Allow the coolant to drain com pletely and discard it in an appropriate man ner Use caution to avoid being burned by hot coolant Plug the hose and cap the joint 3 DRAIN JOINT W CAP INSTALLED e AJAO 5 Remove the front exhaust pipe protectors See S M 2 17 6 Remove the joint pipe from the head bypass outlet at the rear of each cylinder head See S M 8 12 7 Remove the rear coolant hose from each water hose joint then cap the joint W CAP 8 Fill the inspection kit measuring bottle with 560cc of tap water NOTE to ensure accurate filling do not allow the feed hose to protrude down into the bottle from the cap 2003 American Honda Motor Co Inc All Rights Reserved GL1800 A 13 JUNE 2003 9 Insert the fe
4. Model No sub harness should be installed Order and install sub harness D 32112 MCA 307 Green Template L93C Template L93D FRT 1 0 FRT 1 2 Order and install sub harness E 32112 MCA 309 Brown Template L93E FRT 1 2 AOSAN No sub harness should be installed Template L93F FRT 1 0 6 of 8 2003 American Honda Motor Co Inc All Rights Reserved GL1800 A 13 JUNE 2003 WARRANTY INFORMATION Cont Cooling System Inspection Template Claim Filing Guide NOTE X indicates parts that you replaced All 2001 and 2002 Models o Template L92A L92B L92C L92D L92E L92F FRT 1 7 5 1 5 1 10 6 1 7 5 1 Early 2003 Models Non ABS thru VIN 1HFSC470 3A204632 ABS thru VIN 1HFSC474 3A201020 L L92J L92K L92L L92M L92N L92P L92Q 1 7 S 3d 10 6 1 7 5 1 31 R Head Both Heads Radiator Template FRT Late 2003 Models Non ABS after VIN 1HFSC470 3A204632 ABS after VIN 1HFSC474 3A201020 L92U 1 7 Radiator Inspection only L92T 1 7 Template FRT 2003 American Honda Motor Co Inc All Rights Reserved 7 of 8 GL1800 A 13 JUNE 2003 TEXT OF CUSTOMER LETTER June 2003 Dear 2001 2003 GL1800 A Owner RE Product Improvement Campaign American Honda s Motorcycle Division is conducting a Product Improvement Campaign to replace 2001 2003 GL1800 A Engine Control Modules ECMs that may cause high engine coolant tem perature during prolonged low speed low
5. ed hose or a funnel approxi mately 5mm into the head bypass outlet and carefully pour in the water e If less than 560cc of water can be added before it overflows you MUST replace the cylinder head Refer to the Cylinder Head Set Replacement section below e If 560cc of water can be added without overflowing the cylinder head is OK 7 560cc TAP WATER b eee 10 Repeat the Cylinder Head Inspection proce dure for the other cylinder head 11 Drain the tap water from the cooling system 12 Proceed to the Left Side Radiator Outlet Inspection section below Cylinder Head Set Replacement NOTE Use only the indicated L or R cylinder head sets and gasket sets listed in this Service Bulletin Do NOT order individual parts 1 If cylinder head set replacement is necessary refer to the Service Manual Section 8 Cyl inder Head Valve for procedures 2 After replacing the cylinder head s proceed to the Left Side Radiator Outlet Inspection section below Left Side Radiator Outlet Inspection 1 Remove two trim clips carefully push out the left side front fairing and lift up the air duct See S M 6 10 2 Loosen the hose band on the left radiator outlet and remove the water hose See S M 1 37 6 11 3 of 8 GL1800 A 13 JUNE 2003 3 Using the inspection mirror from the Cylinder Head Inspection Kit visually check for foreign matter clogging the radiator outlet e If there is any
6. foreign matter clogging the radiator outlet you MUST replace the left side radiator Refer to the Left Side Radiator Replacement section below e If there is no foreign matter clogging the radiator outlet the left side radiator is OK 4 You MUST also check the main wiring har ness for damage Proceed to the Main Wir ing Harness Inspection section below Left Side Radiator Replacement 1 If left side radiator replacement is necessary refer to the Service Manual Section 6 8 Radiator Cooling Fan for procedures 2 After replacing the left side radiator proceed to the Main Wiring Harness Inspection sec tion below Main Wiring Harness Inspection 1 Inspect the wiring harness in the left side radi ator area for damage Look for any chafing or wires that are being pinched 2 Wrap any affected areas with electrical tape 3 Proceed to the Coolant Gauge Sub Harness Inspection section below Coolant Gauge Sub Harness Inspection 1 Using the ECM amp Sub Harness Installation Template Claim Filing Guide on page 6 of this Service Bulletin determine what Coolant Gauge Sub Harness if any should be installed on the vehicle NOTE For all models If any Coolant Gauge Sub Harness was previously installed remove it now 2 Refer to GL1800 1 2001 GL1800 Coolant Temperature Gauge Improvement for Sub harness replacement procedure 3 After verifying any sub harness replacement install new ProHonda HP Coolant a
7. gear high ambient temperature operation such as parade riding lf you want to have this campaign applied to your Gold Wing please contact your nearest autho rized Honda motorcycle dealer and make an appointment to have the ECM replaced and your GL1800 A s cooling system inspected The dealer will replace any necessary parts at no cost to you Please plan to leave your motorcycle at the dealer for at least one day to allow for dealer scheduling This Product Improvement Campaign ends June 19 2006 After this date your motorcycle will no longer be eligible to have this campaign performed free of charge As this campaign also applies to subsequent owners please keep this letter with the Owner s Man ual If you have moved or no longer own your 2001 2003 GL1800 A please take a moment to com plete and mail the enclosed Information Change Card so we can update our records You may visit our website at www hondamotorcycles com and click on locate a dealer to find a dealer who can assist you Should you need assistance locating a dealer or have questions about this campaign please call Motorcycle Customer Support at 866 784 1870 We apologize for any inconvenience this may cause you Thank you for your GL1800 A purchase Sincerely American Honda Motor Co Inc Motorcycle Division 2003 American Honda Motor Co Inc All Rights Reserved 8 of 8
8. nd pro ceed to the Cooling System Pressure Test section below 4of8 Cooling System Pressure Test 1 Perform a cooling system pressure test on the vehicle Refer to the Service Manual Sec tion 6 6 Radiator Cap System Pressure Inspection for procedures 2 After verifying correct cooling system relief pressure reinstall the top shelter and pro ceed to the IDENTIFICATION section below 3 Reinstall any additional parts removed during the Inspection Repair Procedures IDENTIFICATION Make a punch mark below the first letter of the engine number on the crankcase This will indi cate that the Product Improvement has been per formed on this unit GSVO0OLE 32798 OY MAKE A PUNCH MARK HERE 2003 American Honda Motor Co Inc All Rights Reserved PARTS INFORMATION Do not order ECMs or Sub harnesses at this time Initial parts will be automatically allocated by American Honda based on the number of units invoiced to your dealership You will be noti fied when these parts are available for open ordering Order any other parts listed below as needed based on inspection Engine control module ECM P N 38770 MCA 305 H C 7534654 HP Coolant Pre mix 1Qt P N 08C50 C321S01 H C 3922614 Radiator L P N 19060 MCA 003 H C 6538326 Gasket Set Cylinder Head Inspection P N 12013 MCA 305 H C 7530728 Right Cylinder Head Set R P N 12010 MCA 305 H C 7450208 Gasket Set R
9. nnectors A B and C from the Engine control module Remove the ECM ANS AS RS CONNECTORB _ Y CONTROL MODULE T abd in ys 4 Install the new ECM then reinstall the cruise reverse control module in the reverse order of removal NOTE When you start the vehicle after completing ALL procedures the new ECM will require initialization To initialize the new ECM perform the following procedure e Start the bike and allow it to warm up to normal operating temperature and remain at idle for at least 90 seconds Do not operate the throttle during this time if you do the ECU will not initialize properly and the process will need to be repeated 5 Proceed to the Cylinder Head Inspection section below 2 of 8 Cylinder Head Inspection Kit Use the Cylinder Head Inspection Kit for the Cyl inder Head Inspection procedure Use the kit for each GL1800 A you inspect Do NOT dispose of kit items 19X20 mm cap 2 cap B 8X15 mm cap cap A Hose plug Harness clips 10 Harness tape 7 Inspection mirror 1 2 3 4 Bottle cap w feed hose 5 6 A limited number of additional Cylinder Head Inspection Kits are available call TechLine at 800 421 1900 ext 1 if you need one Kit con tents are NOT available separately as parts Cylinder Head Inspection NOTE e The following late 03 models do not have to have their cylinder heads inspected Late 03 Non ABS after V
10. u begin the repair check for a punch mark below the first letter of the engine number on the crankcase see IDENTIFICATION section on page 4 for more information e If there is a punch mark the unit has been inspected and repaired and no further action is necessary e If there is no punch mark follow the REPAIR procedures below REPAIR PROCEDURES This campaign consists of the following steps _ Replace ECM 2 Inspect Cylinder Head coolant capacity some 2003 units excluded see section for details Inspect Left Side Radiator Inspect install Coolant Gauge Sub Harness Pressure test cooling system os File two 2 warranty claims ECM Replacement 1 Remove the top shelter See Service Manual page 2 10 2 Remove connectors A and B from the cruise reverse control module Remove the cruise reverse control module 1 of 8 MTB 10173 0306 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 ido it yourselfers i 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 A 13 JUNE 2003 26 BLK 4 VONIA CRUISE REVERSE CONTROL MODULE 3 Disconnect co
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