GL1800 ABS-Linked 2001-2005 D533C Complete Kit
Contents
1. FRONT LEFT BRAKE ASSEMBLY LINE 9 ANTI DIVE PLUNGER Created by JT MG0034 CLOSE Fig MG0034 CLOSE Front brake line routing and overview line map Created by JT INSTALATION OF CLUTCH MASTER CYLINDER LINE 1 Install Line 11 into clutch master cylinder MGO0002 following stock routing under left handle bar cover across top triple clamp retainer MGOOO9MOD Route Line 1 1 down along left side steering OEM 1 head down behind rear ABS modulater OEM 2 across front engine to slave cylinder Note Remove mounting bolt coolant drain valve OEM 3 pull forward and up to access slave cylinder CLUTCH MASTER CYLINDER Fig MG0002 eB He Left Top Clutch TA An d x Master Cylinder line 11 positioned like shown Fig MG0009MOD Triple tree area Line 11 is shown routed left front side of the bike Created by JT Fig OEM 1 Following stock routing under left handle bar cover across top triple clamp retainer Fig OEM2 Route Line 11 down along left side steering OEM 1 head down behind rear ABS modulater OEM 2 across front engine to slave cylinder Fig OEM3 Remove mounting bolt coolant drain valve pull forward and up to access slave cylinder Created by JT Fig MG0003 Line 11 shown connected to clutch slave cylinder In between banjo stopper Fig MGO034 Completed front brake line Lines 1 11 should be installed Y o E mr 16 Creat2. REAR WHEEL SPEED SENSOR Siar REAR MASTER CYLINDER LAFRONT ABS REAR MASTER MODULATOR CYLINDER DELAY VALVE ear RIGHT FRONT FRONT WHEEL SPEED SENSOR LEFT FRONT BRAKE CALIPER GOLOCWING Fig Location of Brake System This is provided as a Legend guide technical name and location on bike 23
3. 23 CIDNWRWN HE 20 Created by JT PEDAL BRAKE LINE FUILD FILLING AIR BLEEDING ANTI DIVE PLUNGER OEM m e NOTE BEFORE PERFORMING HAVE AT LEAST 16 9 OZ OR 500CC OF BRAKE FLUID 21 Created by JT Before performing this service have at LEAST 500cc DOT 4 brake fluid Feed fluid and bleed air from the pedal brake line in the following sequence 1 Left front caliper upper side bleed valve Fig Principles of Front Brake 2 Right front caliper lower side bleed valve Fig Principles of Front Brake 3 Rear caliper lower side bleed valve Fig Principles of Rear Brake 4 Anti dive plunger bleed valve Fig Principles of Rear Brake 5 Rear caliper upper side bleed valve Fig Principles of Rear Brake BRAKE FLUID DRAINING i LEVER BRAKE LINE FRONT MASTER CYLINDER f zi RIGHT FRONT gs is ge CALIPER al LEFT FRONT CALIPER PEDAL BRAKE LINE gt P S CALIPER Ty aes REAR MASTER Iba a Vv E CYLINDER ig T ma ioe SE e Ai DELAY Jamk ye VALVE SECONDARY MASTER CYLINDER ANTI DIVE PLUNGER PROPORTIONAL AUL REAR CALIPER tet e CONTROL VALVE p A Lf PCV Madi LEFT FRONT CALIPER 22 Created by JT LOCATION OF BRAKE SYSTEM Tn FRONT MASTER CYLINDER Pa ZO PROPORTIONAL CONTROL VALVE PCV REAR ABS MODULATOR SECONDARY S MASTER LOS 4 CYLINDER pip rd ww r
4. ATION OF NEW BRAKE LINE SYSTEM Note Remove brake fluid from the system Factory service manual 15 6 7 and 8 FRONT MASTER CYLINDER 1 Install Line 1 into front master cylinder MG0008 following stock routing under handle bar cover across top triple clamp retainers down to right OEM tubing w brass olive Secure to right front brake hose stay w cable tie MGO0009 MG0021 FRONT MASTER CYLINDER Fig MG0008 Starting from the Front Master Cylinder Line 1 route to very right top OEM tubing ee ee Y wee WW 1 z nW w i N Ys aS CMA LINE 1 MG0008 i FA _ a F LINE 1 FROM FRONT MASTER TO DEM TUBING Fig MG0009 Triple tree area Line 1 Connected to 1 A F CEN very right top hard pipe mm amp DH with brass olive as shown below Note Use brass olive to OEM tube 6 Created by JT FRONT BRAKE HOSE ASSEMBLY AND ROUTING Note Remove wind protector 13 42 factory manual remove brake hose clamps from brake hose clamp stay RIGHT HAND SIDE 1 Install Line 2 on the MG0021 into OEM tubing with brass olive Secure to right front brake hose stay with cable tie Install lower end of Line 2 to top banjo bolt hole of delay valve MG0025 2 Install Line 3 into OEM tubing with brass olive MG0027 Install lower end Line 3 into new Galfer T block MG0025 use mounting bolt from stock block 3 Install Line 7 into delay valve MGO0030 and lay over the top of the t
5. Created by JT INSTRUCTIONS FOR INSTALLING GALFER BRAKE LINE KIT 2001 2006 HONDA GOLDWING 1800A 310 Irving Dr Oxnard CA 93033 Galfer Tech 1 800 685 6633 tech galferusa com Thank you for purchasing Galfer lines In order to get the maximum performance and enjoyment out of your Galfer lines please read the instructions thoroughly before you begin installation Must have items Torque wrench line wrenches a commercial available vacuum pressure bleeder for brake systems replacement DOT 4 brake fluid two 500cc bottles needed shop towels and a general assortment of metric tools NOTE THIS IS A TIME CONSUMING TASK REQUIRING KNOWLEDGE OF THE MOTORCYCLE S BRAKE SYSTEM MECHANICAL ABILITY AND THE USE AND OPERATION OF SPECIALIZED TOOLS HAVING THE FACTORY HONDA SERVICE MANUAL FOR THIS MOTORCYCLE IS NEEDED PREP THE MOJ ae YCL i Ter Lb A Dash See ene Teflon Hose enan New Banja Bog a RETS g Reduce ade EEES prne d Quality Above All Else Lifetime Warranty Created by JT Fig MG0033 Park the motorcycle on the center stand in a well lit shop Note It is absolutely necessary to remove the fuel tank and body panels see factory manual Brake fluid 1s VERY CORROSIVE TO PAINT Remove the g MG0033 lower fairing left E j and right rear sides fuel tank Roni fender seat and black plastic i inner fairing front parts battery cover battery and rear master cylinder cover according to the servic
6. ck hole from the OEM tube with brass olive Line 4 is the farthest left line connected the OEM tube with brass olive Line 4 goes to Secondary Master Cylinder on a Double banjo with Line 9 ae Check with Fig LINE 5 MG0009 OEM for _ a picture overview 3 Note Use brass olive to OEM tube Created by JT Fig MG0022 Line 2 1s now routed right side and connected to the upper delay valve top hole Lower Delay valve hole will have Line 5 going to the right lower caliper hole Line 8 1s connected to the right upper caliper hole Fig MG0023 Line 8 is connected to front right top caliper hole Line 5 connected to front right bottom caliper hole LOWER DELAY VALVE LINE TO RIGHT CALIPER ISN MG0022 ness c as oa RIGHT CALIPER LINE amp GALFER S T BLOCK TO RIGHT CALIPER TOP VALVE HOLE LINE 5 LOWER DELAY VALVE TO RIGHT CALIPER BOTTOM VALVE HOLE 120023 Created by JT Fig MG0025 Analyzing front right back side fork line routing Using a Galfer T block replacing OEM split Line 6 A LINE 7 DELAY VALVE TO 2ND MASTER CYLINDER A LINE 5 FRONT RIGHT CALIPER FROM DELAY VALVE connected to Galfer T block routed to left lower caliper LINES amp hole Line 7 is FROM GALFER S T BLOCK pries k behind the T block a GT HOLE OEM SPLIT where it is a j connected to Delay W mcoo25 valve shooting ai towards left fork Line 7 g
7. d by JT Fig OEM 6 Follow stock line routing OEM4 OEM 6 across INSIDE LINE 13 E OEM TUBE top of the swing arm using OEM hose clamps to the a da rear caliper ica Y OUTSIDE LINE 14 OEM TUBE GALFER FEMALE W BRASS OLIVE FROM REAR CALIPER TO OEM TUBING PROPORTIONAL CONTROL VALVE T LINE13 INSIDE Fig MG0006 Line 13 amp 14 are connected to the OEM tubing with brass olives Location is between swing arm and frame cross member _ FROM CALIPER TO OEM TUBING SAND PCV Note Use brass olive to OEM tube 19 Created by JT Fig MG0007 Line 13 amp 14 are connected to right rear caliper i i rit YOU ARE NOW READY TO FOLLOW WORD FOR WORD THE FACTORY PROCEDURE FOR BLEEDING THE SYSTEM A COPY OF THE HONDA PROCEDURE IS INCLUDED WITH THESE DIRECTIONS All banjos and Double banjos are torque to 12 15 ft lbs A copy of the factory instructions Fig OEM BLEED has been included with this kit on how to properly and safely drain fill and bleed the brake fluid from the brake systems Follow the bottom directions closely and remove the fluid according to the instructions Dispose of the old fluid properly DO NOT REUSE 8 Parts included in the kit Single Banjo Bolt 13 Double Banjo Bolt 1 Air Free Double Banjo Bolt 1 Crush Washer 32 Brass Olive 7 T Block 1 SS Lines 14 Instruction pg
8. e manual Fig MG0033 amp MG0035 After safely storing the body panels and fuel tank remove wind shield brake fluid even a drop will permanently mark any clear plastic cover the dash and all gauges with a towel DRAINING THE BRAKE FLUID FROM THE SYSTEMS Created by JT Note e A contaminated brake disc or pad reduces stopping power Discard contaminated disc with a high quality brake degreasing agent e Do not allow foreign material to enter the system when filling the reservoir e Avoid spilling fluid on painted plastic or rubber parts Place a rag over these parts whenever the system is serviced e Use only DOT 4 brake fluidfrom a sealed container e Do not mix different types of fluid They are not compatible e Once the hydraulic system has been opened or if the brake feels spongy the system must be bled e When using a commercially available brake bleeder follow the manufacture s operating instructions BRAKE FLUID DRAINING LEVER BRAKE LINE FRONT MASTER CYLINDER f ane RIGHT FRONT a J7 CALIPER ai gb F 1i m i m FaFa he d 7 a j or F j I Y be f dapi LEFT FRONT CALIPER Remove front fender and fender covers FRONT MASTER CYLINDER Support the motorcycle on its center stand Reservoir Cap screws Turn the handlebar to the left until the front master cylinder reservoir is level before removing the reservoir cap Remove the screw
9. ed by JT REAR BRAKE LINE INSTALLATION Note Prep motorcycle follow factory manual to remove fuel tank and right hand saddle bag MG0035 1 Install Line 12 to top of rear master cylinder MG0004 routing to OEM tubing with brass olive MG0005 using stock mounting bracket 2 Install Line 13 inside Line 14 outside with brass olives to OEM tubing MGO0006 Follow stock line routing OEM4 OEM 6 across top of the swing arm using OEM hose clamps to the rear caliper 3 Line 13 mounts to upper banjo bolt hole in rear caliper Line 14 mounts to lower banjo bolt hole in rear caliper MG0007 Note Rear wheel speed sensor wire must be secured to brake lines with cable locks to keep it out of rear wheel REAR MASTER CYLINDER LINE 12 Fig MG0004 Right middle Rear Master Cylinder banjo position as shown Created by JT REAR LINE FROM MASTER CYLINDER ITO GALFER FEMALE TO OEM TUBING UNDER SEAT RIGHT SIDE FRAME i LINE 12 Fig MG0005 Line 12 rear line from master connected to OEM tubing with brass olive right side frame under the seat MG 0005 Note Use brass olive to OEM tube REAR TIRE r Fig OEM 4 Stee NSIDE LINE 13 ig 4 Follow stock line i binini routing OEM4 OEM 6 a OUTSIDE LINE 14 top of the swing h OEM TUBE arm using OEM Ma T hose clamps to the R a i FRONT OF THE BIKE rear caliper we anin 18 Create
10. ire 4 Install Line 6 into new Galfer T block MGO0025 and lay over the top of the tire 5 Install Line 8 into new Galfer T block MG0025 Install lower end line 8 into top banjo bolt hole of right caliper 6 Install line 5 into lower banjo bolt hole of delay valve to the lower bolt hole of the right caliper LEFT HAND SIDE 1 Install Line 4 MG0027 into OEM tubing with brass olive Secure to left front brake hose stay with cable ties Install lower end Line 4 with double banjo bleeder bolt to top of Line 9 into top of second master cylinder MG0028 2 Install Line 10 on top of Line 7 with double banjo bolt into the front of the second master cylinder MGO0031 Bottom Line 10 attaches to upper banjo bolt hole of the left caliper MG0032 3 Install Lower end Line 6 to lower banjo bolt hole left caliper MG0032 4 Install lower end Line 9 to plunger MG0029 S Fig MG0009 OEM Visual look at stock set up to compare with Fig MG0009 MG0021 amp MG0027 for line 1 2 3 amp 4 Created by JT ee j TOP FRONT MASTER CYLINDER Fig MG0021 Line TO HARD TUBING 2 is connected to LINE 4 lower right hard OEM i tube with brass olive Line 2 goes to right upper delay valve banjo hole Check with Fig MG0009 OEM for picture overview LINE 2 TO HARD TUBING TO FRONT DELAY VALVE LINE 2 Note Use brass olive to OEM tube Fig MG0027 Line 3 goes to upper Galfer T blo
11. oes to Secoutan eS Cylinder using a double pano on the same double banjo Line 10 is connected to 2 Master Cylinder FRONT BRAKE ASSEMBLY Fig MG0030 Picture is showing the back side of Right fork Behind the new T block Line 7 is Connected to Delay Valve and routed to 2 Master Cylinder Fig MG0031 Created by JT Fig MG0031 LINEA 9 ta Back side of 2 Master Cylinder Note Double banjo connected to Line 7 amp Line 10 SECONDARY MASTER CYLINDER LEFT CALIPER o lt Fig MG0032 ASSEMBLY Left caliper is y Eo I shown with Line o a N ee 6 connected to oy A bottom hole from J i Ze f Galfer s T block RIA Ua MG0025 see ref a 7 dae g Line 10 is connected to upper hole from the l LINE 6 a 5 d 3 i Fa E a backside of the 2 a k ia Fi Master Cylinder MGO0032 Created by JT Fig MGO028 Line 4 connected on the top of the 2 Master Cylinder where it s connected to the very left upper hard tube Located in the triple tree Line 9 is also connected on an air free double banjo where it connected to the anti dive Fig MG0029 Left front fork Line 9 is connected to Anti Dive plunger from the Secondary Master Cylinder FRONT LEFT BRAKE ASSEMBLY AIR FREE 1 DOUBLE BANJO BOLT i LINE 4 LINES 9 r s SECONDARY MASTER CYLINDER MG0028
12. s reservoir cap set plate and diaphragm Created by JT Connect a I as on eH px conme aliy LEFT FRONT CALIPER RIGHT FRONT CALIPER available brake B i bleeder to the bleed RO valve of the front caliper at the position as shown Loosen the bleed valve and pump the brake bleeder until no more fluid flows out of the bleed valve Tighten the bleed valve Perform the above procedure at the other front caliper PEDAL BRAKE LINE F F RIGHT FRONT _ a pej fh CALIPER 5 al U _ REAR MASTER UPPER BLEED VALVE cS Vv s f CYUNDER if ve 1 a A ry VALVE SECONDARY MASTER CYLINDER fr a ae REAR CALIPER ANTI DIVE PLUNGER gt f LEFT FRONT CALIPER aa PROPORTIONAL i Age CONTROL VALVE 4 aL Ne Created by JT Remove the following Right engine side cover Front fender A and fender covers Support the motorcycle on its center stand Remove the rear master cylinder reservoir cap As shown on the right Connect a commercially available brake bleeder to the bleed valve of the front caliper at the position as shown Loosen the bleed valve and pump the brake bleeder until no more fluid flows out of the bleed valve Perform the above procedure at each remaining valve of the brake pedal brake line REAR MASTER I4 ANTI DIVE PLUNGER REAR CALIPER A Li Created by JT BEGIN INSTALL
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