MTB 17012 Service Bulletin 2018 GL1800-D-DA-B-BD Loose .

Service BulletinAme ric an H onda Moto r C o., Inc.GL1800 #1ISSUED: February 20192018 GL1800/D/DA/B/BD - LOOSE HANDLEBAR REPAIRBACKGROUNDIf a customer complains of loose handlebars (up and down movement) on a 2018 GL1800, theproblem may be due to improper installation of the steering stem nut at the factory. If the steeringstem nut becomes loose, the handlebars can move up and down (Please note: front to rear handlebar movement is normal). A video providing instructions how to inspect the handlebars for looseness, inspect the steering stem (if needed), and replace the steering stem (if needed) can be foundunder the Reference Material section in this service bulletin. Written instructions can be foundunder the Inspection Procedure and Repair Procedure sections in this service bulletin.AFFECTED UNITSOnly 2018 GL1800 model motorcycles with a confirmed loose handlebar are affected by this bulletin.2018 GL1800/D/DA/B/BDAllPARTS INFORMATIONUndamaged Stem ShaftPart DescriptionWasher, LockPart Number90506-425-830Qty1Damaged Stem ShaftPart DescriptionShaft, StemPart Number53235-MKC-A00Qty1Dust Seal53214-KA4-7012Adjuster Nut53220-MW0-0001Lock Nut90302-425-8301Washer, Lock90506-425-8301WARRANTY CLAIM INFORMATIONNormal warranty terms apply.After completing the Service Bulletin Inspect or Replace procedure, submit one warranty claim perunit with the appropriate template number:ProcedureClaim TemplateFlat Rate TimeInspectKJ9A1.0 hoursReplaceKJ9B1.5 hours DEALER REPAIR RESPONSIBILITYRepairs must be performed by a qualified technician.Performing this repair exactly as shown in the Repair Procedure instructions is critical for theremedy to be effective. Carefully follow all instructions.Service Management should inspect and confirm the repair.Dealer submission of a warranty claim affirms this repair was properly performed.MTB 17012 (1901)1of 11 2019 American Honda Motor Co., Inc. – All Rights ReservedCUSTOMER INFORMATION: The information in this bulletin is intended for use only by skilled technicians who have the proper tools, equipment, and trainingto correctly and safely maintain your Honda. These procedures should not be attempted by "do-it-yourselfers,"and you should not assume this bulletin appliesto your Honda, or that your Honda has the condition described. To determine whetherthis information applies, contact an authorized Honda dealer.

GL1800 #1ISSUED: February 2019DEALER SUPPORTTECHNICAL QUESTIONSIf you have any technical questions relating torepair verification, repair procedure, or partsinformation please contact:Motorcycle TechLine OnlineiN Service TechLine TechLine ConnectINSPECTION PROCEDUREHANDLEBAR MOVEMENT INSPECTIONGrab the handlebar end with one hand and tryto move the handlebar up and down (not forward or backward). There should be no movement or looseness when the handlebar ismoved up and down (as shown).Or call (800) 421-1900, option 9.No up/down movementWARRANTY QUESTIONSIf you have any warranty administration questions relating to warranty claim templates,and claim filing procedures, please contact:Motorcycle Warranty Online:iN Service Warranty & HondaCare Warranty ConnectOr call (800) 421-1900, option 7.REFERENCE MATERIALBegin by viewing the linked video (below) inits entirety, then use the information in thisvideo and the written instructions in this service bulletin to determine if an inspection andpossible replacement of the steering stem isnecessary.Checkpoint: If the handlebar does not move up anddown, do not continue with this repair. If the handlebar moves up and down,proceed with the Steering Stem Inspection in the linked video and/or the writteninstructions provided under the RepairProcedure section in this service bulletin.REPAIR PROCEDURENOTICE: The information contained within thelinked video and this service bulletin offers amore efficient method than the service manual to perform many steps of this repair. It isnecessary to follow these instructions carefully, failure to do so could result in damageto the customer’s vehicle.2 of 11STEERING STEM INSPECTION1. Protect the mating surface between thecenter panel switch and lower top shelterusing protective tape (left and right sides).NOTE: If it is difficult to insert the tape into thegap (as shown), push the center panel switchto the other side to widen the gap.PROTECTIVETAPE - GAP 2019 American Honda Motor Co., Inc. – All Rights Reserved

GL1800 #1ISSUED: February 20192. Remove the trim clip (shown below) fromthe front edge of the top shelter (left andright sides, two clips total).3. Pull up both sides of the top shelter nearthe bottom of the center panel switch.5. Lift the end of the top shelter, then removethe trim clip on both sides of the centerpanel switch (left and right sides, two clipstotal).6. Lift the ends of the top shelter just enoughto remove the socket bolts from the centerpanel switch (left and right sides, two boltstotal).4. Protect exterior parts by covering thespeedometer and top shelter with cleanshop towels in the areas shown below.7. Wrap the rear part of the center panelswitch with a clean cloth. 2019 American Honda Motor Co., Inc. – All Rights Reserved3 of 11

GL1800 #1ISSUED: February 20198. Push the center panel switch forward,towards the meter panel, then lift the frontof it up to disengage from the front mount.Disengage the clip at the front of the center panel switch (shown below).10. Remove the cable clamp bolts and cableclamps (left and right sides, two total).NOTICE: Push the center panel switch fullyforward before lifting or damage can occur tothe center panel switch and the fairing frame.11. Remove the left rear handlebar bolt andwasher [1].CENTER PANELSWITCH CLIP9. Remove the screws [1] from the top bridgecover [2]. Disengage the cover by liftingthe rear of it then disengaging the front.Rotate center panel switch backwards,resting it on a clean towel. Note howcables and hoses are routed in the coverfor re-assembly.LEFT HANDLEBAR12. Loosen the handlebar bolt [1], move thehandlebar forward enough to make the tierod nuts accessible for a socket, then retighten the handlebar bolt to hold the handlebar in its new temporary position.[1]CABLES/HOSES4 of 11 2019 American Honda Motor Co., Inc. – All Rights Reserved

GL1800 #1ISSUED: February 201913. Repeat steps 11 and 12 for the right sidehandlebar.17. Using the assembled tool (previous step),hold the stem shaft from underneath.14. Remove the left rear tie rod by inserting a14 mm open end wrench between thesteering bridge and the tie rod to accessthe rod shaft. While firmly holding the rodshaft with the wrench, remove the selflocking nut and remove the tie rod fromthe steering bridge.NOTICE:NOTICE: If the rod shaft is not supported with the14 mm wrench, damage will occur to therubber bushing supporting the tie rod. Do not drop the tie rod washer.15. Repeat the step 14 for the right side tierod.16. Combine the following tools: 22 mm sixpoint socket, universal joint, extension bar,and ratchet or breaker bar. Extensionshould be around 20 inches in length. When holding the stem shaft, be carefulnot to damage the front fender, radiatoror inner cowls. When holding the stem shaft with a tool,the extension may touch the lower arm. Ifso, protect the lower arm with a cleancloth to prevent damage. Take care to route the extension andsocket so it will not damage hoses orcables.18. Turn the front suspension to full left lockand remove the stem nut using a six-point30 mm socket. Remove the washer aswell.NOTICE: When removing the stem nut, becareful the tool does not contact and damagethe windshield.20 in 2019 American Honda Motor Co., Inc. – All Rights Reserved5 of 11

GL1800 #1ISSUED: February 201919. Lift the top bridge and handlebars as anassembly and rotate backwards whilemoving it towards the meter assembly.NOTICE: Do not damage the meter assembly.20. Flatten the tabs of the lock washer andremove the lock nut, the lock washer, andadjuster nut.Checkpoint: How to determine if thestem shaft is damaged.STEERING STEM REPLACEMENT1. Remove the stem shaft from the steeringhead. If difficult, try tilting the stem backwards to ease removal.2. Clean the upper and lower bearing racesthen apply the specified grease to eachsteering bearing and dust seal lip.Specified grease (use where required):Honda Marine Grease P/N 08734-00033. Install the dust seal [1], lower inner race[2], and lower steering bearing [3] onto thestem shaft [4]. While removing the lock nut, if you areABLE to remove it smoothly (by hand),without any binding, the stem shaftthreads are not damaged. Skip to theReassembly section on page 7 to beginreassembling the vehicle (DO NOTREPLACE THE STEERING STEM). While removing the lock nut, if you areUNABLE to remove it smoothly (byhand), the stem shaft threads are damaged. Continue to the Steering StemReplacement section or follow theinstructions in the linked video to replacethe stem and related parts with newones.6 of 11 2019 American Honda Motor Co., Inc. – All Rights Reserved

GL1800 #1ISSUED: February 20194. Insert the stem shaft into the steering headpipe then install the following parts whileholding the stem shaft from below: Upper steering bearing [5] Upper inner race [6] Dust seal [7]7. Recheck the adjuster nut [1] tightness tothe specified torque below then recheckthat the steering stem moves smoothlywithout play or binding.Tool: Steering stem socket [2]TORQUE: 8.0 N·m (0.8 kgf·m, 5.9 lbf·ft)5. Apply the specified grease to the threadsof the adjustment nut. Hold the stem andtighten the adjustment nut [1] to thetorque specified below.Tool: Steering stem socket [2]TORQUE: 8.0 N·m (0.8 kgf·m, 5.9 lbf·ft))Reassembly1. Install a new lock washer [1] by aligning itstabs with the grooves in the adjuster nut.Install the lock nut [2] by hand until ittouches the lock washer then furthertighten the lock nut until its grooves alignwith the tabs of the lock washer (no morethan 90 degrees).NOTICE: Do not over-tighten the lock nut. Thiswill flatten the lock washer.6. Rotate the stem shaft [1] five times to seatthe bearings. 2019 American Honda Motor Co., Inc. – All Rights Reserved7 of 11

GL1800 #1ISSUED: February 20192. Install the top bridge.5. Install the right tie rod by first turning thehandlebar to the left then installing the following parts: Tie rod and washer (10x20x1.0 mm) Tie rod nutNOTE: Do not confuse this washer with thewasher used for fastening the handlebar bolt.3. Apply the specified grease to the steeringstem nut threads [1]. Install the steeringbridge [2], washer [3] then install andtighten the stem nut [4] to the specifiedtorque below while holding the stem shaft.NOTE: The torque specified below is differentthan the service manual due to the applicationof grease to the steering stem nut threads.Follow this procedure.TORQUE: 69 N·m (7.0 kgf·m, 51 lbf·ft)NOTICE: Hold the tie rod shaft firmly with anopen end 14 mm wrench to prevent damageto the rear tie rod bushing.TORQUE: 36 N·m (3.7 kgf·m, 27 lbf·ft)4. Wipe off any extra grease thoroughly aftertightening the stem nut. Make sure thestem shaft moves smoothly without playor binding.8 of 116. Install the left tie rod by first turning thehandlebars to the right then repeat step 5. 2019 American Honda Motor Co., Inc. – All Rights Reserved