Example of Service Manual short comings

[GoldWingrGreg]

Hopefully, everyone uses the Maintenance Schedule as described in the Honda Service Manual and doing all the scheduled recommendations as listed. However, in some cases the maintenance schedule falls short. Below is an example of this. Anything that comes in for a 4, 8, 12, 16, 20, 24k, etc service always gets its brake, clutch lever and side stand lubed, as well as the battery connections cleaned. These are not listed but are an important part of servicing a GL1800.

Below is a picture as to why. That Wing had 78k on it and most likely the clutch lever, pivot bolt, brass bushing, and push rod were never lubed. As a result, its clutch lever, pivot bolt, and brass push-rod bushing was replaced. As an FYI, the levers are to be lubed with silicone grease, and side stand with lithium based grease (white lithium grease).

In green is the tip of the clutch push rod that has worn through the pivot bushing and worn into the clutch lever. In blue is a worn pivot bushing.

[kikker]

That's very good information. I made a note of that in my owner’s manual. Would a Teflon or Nylon bushing help in those applications?


Thanks for sharing!

[Orrin]

Yeah, that does look dry. Thanks for pointing that stuff out.

[Larry Price]

Common maintenance procedures that apply to any motorcycle or quad are covered in Honda's Common Maintenance Manual. Very few people have that manual sitting on the bench. I am on the road this week and can't quote a page number, but I am positive that it covers the cleaning and lubing at the lever pivot points. Model specific maintenance manuals usually cover unique maintenance procedures for specific models.

[kampinguru]

Here is a link to the PDF file for the manual

http://goldwingchrome.com/Manuals/GL...e%20Manual.pdf

[howsonIII]

Here is a link to the PDF file for the manual

http://goldwingchrome.com/Manuals/GL...e%20Manual.pdf

Awesome--thank you!

[LarryM]

Greg, the Honda Service Manual was not written for end users. Like all Helm manuals, they are written for OEM servicers. There are many basic items in all of these manuals that are left out. If your read the beginning of these manuals, it states that the procedures are intended for professional technicians.

If a professional tech needs to be told that the pivots need to be lubed, then there is something very wrong with his training.

FWIW, I remember reading somewhere in the factory manual where it shows lubrication points and the type of Honda grease to use for each point. It was not in the maintenance section.

[techdude2000]

For this topic the common manual is OK, but be careful when you dig into it for a specific item, there's big differences in the model year break between 05 and 06 and the common manual will definitely have some things wrong because of the changes.

[techdude2000]

Greg, the Honda Service Manual was not written for end users. Like all Helm manuals, they are written for OEM servicers. There are many basic items in all of these manuals that are left out. If your read the beginning of these manuals, it states that the procedures are intended for professional technicians.

If a professional tech needs to be told that the pivots need to be lubed, then there is something very wrong with his training.

FWIW, I remember reading somewhere in the factory manual where it shows lubrication points and the type of Honda grease to use for each point. It was not in the maintenance section.

It's in the General information section under "Lubrication and Seal Points."

Silicone grease for all of these

Clutch lever pivot
Clutch lever joint piece-to-push rod contacting area
Clutch master piston-to-push rod contacting area
Anti-dive plunger tip
Front brake lever pivot
Front brake lever-to-master piston contacting area
Rear master cylinder push rod boot groove
Rear master piston-to-push rod contacting area
Secondary master cylinder push rod boot groove
Secondary master piston-to-push rod contacting area
Brake caliper pad pin stopper ring
Brake caliper pin boot inside

[LarryM]

Thanks Techdude.

I agree with Greg from the standpoint that the levers need lube once in awhile. Minor things like this should be done by a shop whenever a bike is in for service. It is such a quick and easy job that it is a nice goodwill gesture.

But I never really bought into the every 4K routine. I think I have done mine once or twice in 70K miles, and they are fine. I don't know about most people, but I can feel when the levers need lubrication because they get sluggish and don't easily move back into the rest position.

To me, this is one of those items that I figure if they ever wear out, that will be a good excuse to buy a nice set of chrome levers.

Most people don't follow service manuals when doing regular maintenance. They use T-CLOC