Honda GL1800 / GL1800A Gold Wing Service Manual (2002)

Honda GL1800 / GL1800A Gold Wing Service Manual (2002)
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Original Honda factory Service Manual for the GL1800 Gold Wing and GL1800A ABS model. The 757-page PDF covers general specifications, body panels and exhaust, scheduled maintenance, lubrication, PGM-FI fuel injection and diagnostics, cooling, complete engine removal and overhaul, cylinder heads and valves, hydraulic clutch, five-speed transmission and reverse, pistons and crankshaft, shaft final drive, front and rear suspension, linked standard and ABS brake systems, battery and charging, ignition, starter/reverse system, lighting and instruments, cruise control, audio system, wiring diagrams, technical-feature explanations, troubleshooting and index.

About the Manual

Manual type
Factory Service Manual
Years covered*
2002
Pages
757
Language
English
Format
PDF
Main sections
26
Searchable PDF
Yes
Printable PDF
Yes
File size
35.9 MB
Delivery
Digital download

* Indicative only. Please do your own research and confirm compatibility with your exact motorcycle and model year before purchasing.

Honda Gold Wing GL1800 GL1800 (non-ABS) / GL1800A (ABS) Motorcycle Details

Manufacturer
Honda
Series
Gold Wing
Models Covered
GL1800
Generation / variant
GL1800 (non-ABS) / GL1800A (ABS)
Engine
Horizontally opposed six-cylinder 4-stroke, liquid-cooled, OHC
Displacement
1,832 cm³
Bore × Stroke
74.0 × 71.0 mm
Compression Ratio
9.8:1
Cooling System
Liquid-cooled
Fuel System
Honda PGM-FI electronic fuel injection; 40 mm throttle bore
Clutch
Hydraulically operated multi-plate wet clutch
Transmission
5-speed constant-mesh transmission with reverse
Final Drive
Shaft final drive with hypoid gear oil; final reduction ratio 2.750 (33/12)
Overall dimensions
2,635 × 945 × 1,455 mm (L × W × H)
Wheelbase
1,690 mm
Seat height
740 mm
Ground clearance
125 mm
Dry weight
359 kg GL1800 / 362 kg GL1800A
Curb weight
399 kg GL1800 / 402 kg GL1800A
Front suspension
Telescopic fork; 122 mm axle travel
Rear suspension
Swingarm; 105 mm axle travel
Brake system
Linked Brake System on all models; ABS additionally fitted to GL1800A
Front brake
Hydraulic twin discs
Rear brake
Hydraulic single disc
Front tire
130/70R18M/C 63H
Rear tire
180/60R16M/C 74H
Final drive oil
SAE 80 hypoid gear oil; 120 cm³ after draining / 150 cm³ after disassembly
Fuel pressure
343 kPa (50 psi) at idle
Idle speed
700 ± 70 rpm
Battery
12 V 18 Ah
Alternator
1 kW at 2,400 rpm
Starting system
Electric starter with integrated reverse system
Ignition
Full transistorized ignition; 0° BTDC at idle
Spark plug
BKR6E-11 (NGK) / K20PR-U11 (DENSO), 1.0-1.1 mm gap
Gear ratios
1st 2.375 / 2nd 1.454 / 3rd 1.068 / 4th 0.843 / 5th 0.686

What’s Included in the Honda Gold Wing GL1800 GL1800 (non-ABS) / GL1800A (ABS) Service Manual?

  1. General Information
  2. Frame / Body Panels / Exhaust System
  3. Maintenance
  4. Lubrication System
  5. Fuel System - Programmed Fuel Injection (PGM-FI)
  6. Cooling System
  7. Engine Removal / Installation
  8. Cylinder Head / Valves
  9. Clutch
  10. Gearshift Linkage / Transmission
  11. Cylinder / Piston / Crankshaft
  12. Final Drive
  13. Front Wheel / Suspension / Steering
  14. Rear Wheel / Suspension
  15. Brake System - Standard
  16. Brake System - ABS
  17. Battery / Charging System
  18. Ignition System
  19. Starter / Reverse System
  20. Lights / Meters / Switches
  21. Cruise Control System
  22. Audio System
  23. Wiring Diagrams
  24. Technical Features
  25. Troubleshooting
  26. Index

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About the Honda GL1800

Honda introduced the GL1800 in 2001 as the fifth generation of the Gold Wing and the first complete redesign of the flagship tourer since the GL1500 appeared in 1988. Honda's own history says development began in the early 1990s with extensive research into how owners actually used the Gold Wing, including long-distance riding in the United States. The resulting brief was not simply to make a larger touring motorcycle, but to combine first-class passenger comfort with much more agile handling than the GL1500. Honda's official 2001 Gold Wing history documents that development program and the move to the new generation.

The defining change was the new 1,832 cm³ horizontally opposed six-cylinder engine. Honda retained the smooth low-center-of-gravity flat-six layout but increased displacement from the GL1500's 1,520 cm³, added PGM-FI electronic fuel injection and improved both output and emissions performance. The engine was mounted in a newly developed aluminum twin-tube frame and used as part of the chassis structure, helping reduce weight despite the larger engine. Honda's 2001 technical review describes the GL1800 as combining long-distance touring ability with sports-type handling and identifies the aluminum frame as a major step in making the motorcycle lighter and more responsive.

The chassis and equipment established the character of the six-cylinder luxury touring platform that would define Gold Wing production for well over a decade. The factory specification used a 1,690 mm wheelbase, telescopic fork, shaft final drive, 130/70R18 front and 180/60R16 rear radial tires and Honda's Linked Brake System. The GL1800A added ABS while retaining the linked braking layout. Touring equipment was equally central to the design, with cruise control, integrated audio, large luggage capacity and an electric reverse system allowing the 399-402 kg curb-weight motorcycle to be maneuvered more easily at parking speeds.

Honda continued developing the same basic GL1800 generation through the 2000s rather than replacing it quickly. One of the most important milestones was the world's first production motorcycle airbag, announced in 2005 and introduced on the Gold Wing for the 2006 model year. Honda's official Gold Wing chronology also records the end of U.S. Gold Wing production in 2009 and the restart of production in Japan at the Kumamoto factory in 2011. Those changes belong to the continuing GL1800 family, but they also show why later motorcycles should not automatically be treated as identical to an early service-manual edition.

The next complete generational break came in 2018, when Honda fully redesigned the Gold Wing for the first time in 17 years. The new machine retained a flat-six engine but adopted a substantially lighter and more compact power unit, double-wishbone front suspension, a six-speed manual or optional seven-speed DCT, throttle-by-wire and new electronic riding systems. Honda's official 2018 Gold Wing history documents that full redesign. This listing is specifically for the factory GL1800/GL1800A publication dated August 2002; because the manual itself gives no broader model-year range, catalog coverage is conservatively limited to 2002. Related publications are grouped in the Honda GL1800 manual catalog.

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