2002 Honda 300ex Repair Manual
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1) Remove Seat 10mm KAW 1500 CARB ADPTOR QTY PARTS LIST 1 1500 CARB ADAPTOR 1 3″ PIECE OF HOSE 1 DOUBLE BARB 1 L-BARB 1 3/8″ RED PLUG 1 ¼” BLACK VACCUM PLUG 1 M6-1 NYLON INSERT LOCK NUT 3 M6-1 X 16 FLAT SOCKET HD CAP SCREW 1 170 MJ 1 INSTRUCTIONS 2) Remove Dash Plaque 8mm bottom Bolt only 3) Lift from bottom then Remove speedo cable 4) Disconnect Electric Plugs 5) Remove 12mm bolts holding tank 6) Turn petcock OFF – Pinch off fuel line. 7) Disconnect the electric Plug under speedo opening 8) Lift Tank at Rear – Disconnect two Vent Lines; Fuel gage Vent will Pull up – Remove. 9) Remove Chrome Air Cover. 10) Left side Remove two screws – 10mm bolt in side Air box. Pull hoses off Remove 1″ hose going to cross over Tube. K&L CARBURETOR ADJUSTMENT WRENCHES These tools use tough and accurate bevel gear actuation instead of cable for professional use. The aluminum handle includes index marks for accurate tuning.
Three types available: 35-9653 Slot-type Pilot Screw Adjustment Wrench for Kawasaki/Suzuki/Yamaha 35-9658 Slot-type Pilot Screw Adjustment Wrench with longer tip for Kawasaki/Suzuki/Yamaha 35-9650 D-type Keihin Pilot Screw Adjustment Wrench for Honda 90-DEGREE 1/4″ HEX DRIVER This gear driven, 1/4″ hex driver set is made of high-grade aluminum and stainless steel. Strongest tool of it’s type on the market.
Designed for use on hard-to-reach pilot air screws on inline fours. Can be used with any 1/4″ or 6mm hex bits. 35-7820 90-Degree 1/4″ Hex Driver Set: Includes straight slot, phillips, d-shape pilot screw bit, 6mm hex jet bit & 1/4″ – hex – 1/4″ drive bit. FCR CARB TOOL Set includes three bits – 6mm hex for main jets, long reach straight slot for pilot jets and 3mm allen for float bowl removal. Longer bits make this set ideal for reaching into recessed cavities when adjusting Keihin FCR carburetors. Sold as a set. 35-7978 FCR Carb Tool 12″ DRILL BIT For removal of carburetor plug.
(mixture screw plug) 1/8″ bit x 12 inch length. 35-1186 YM-33217-16 JET DRIVER 35-2270 Perfect for removal of jets from small recessed passages Incoming search terms:. Remove both seats and the plastic seat pans under the seats. Remove the engine cover 3. Remove the air-box by removing the cross-bar support that runs under the air-box to the framing on each side by the seat framing and disconnect the air box from the carburetor and from the plastic intake in the rear. Disconnect the engine breather hose from the bottom of the air box 5.
Set the air-box to the side 6. Disconnect the plug going to the stock carburetor, this is the electronic choke. Wrap the end left on the vehicle with electrical tape.
Cut the fuel line just above the fitting on the passenger side of the carb 8. Remove the side cover off the drivers side of the carb where the throttle cable goes in, see fig.
2002 Honda 400ex Repair Manual
Pull the throttle cable out and then remove the throttle cable end from the throttle plate See Fig. Loosen the clamp on the rear of the carb holding the carb on 11.
Pull the carb out of the intake boot 12. Set OE carb to the side. Push the new Carb into the intake boot making sure the carb is perfectly vertical and then tighten the clamp back up. The new carb is slightly larger than the stock one so some additional pressure will be needed to get it in. Route all the breather lines connected to the carb down under the carb.
Connect the throttle cable onto the new carb but putting the cable end in the bottom hole of the throttle plate on the passenger side of the carb allowing the cable to ride in the slot in the plate and then turn the throttle plate clock wise allowing the threaded end of the cable to fit into the lower round hole of the throttle cable connection plate. Make sure you have a nut on each side of the plate turn the nut on the outside of the plate to take up the slack in the throttle cable then tighten the nut on the inside of the plate. Push the fuel line onto the fuel inlet on the passenger side of the carb and install the supplied clamp to hold it on. The fuel line will be a little hard to push on. DO NOT ATTEMPT TO INSTALL THE CHOKE CABLE PARTS SUPPLIED IN THE KIT UNTIL AFTER THE CHOKE CABLE ITSELF IS INSTALLED AND READY TO SCREW INTO THE CARBUETOR. To install the supplied choke cable, drill a 3/8″ hole in the dash on the left side of the steering wheel in a location convenient to your left hand. Remove the plastic nut from the bottom of the choke handle on the choke cable.
Push the choke cable thru the hole you drilled and then slide the nut over the cable to the inside of the dash and reinstall back on the back of the choke mechanism. Some dash screws maybe needed to be removed to accomplish this. Inspect the motorcycle for a punch mark as described in Identification on page 2.
If a punch mark is present no further action is necessary, return the unit to the customer. Qualify the unit/customer as follows:.Is the tire on the motorcycle the original factory installed tire?.Is the air pressure loss more than three psi per month? Note: Refer to page 145 in the Owner’s Manual. “Even tires that are in good condition may lose one to two psi per month if not checked and adjusted regularly”. If the GL1800 meets the above qualifications, proceed with the repair procedure. Place the motorcycle on a lift and secure it on the centerstand. Remove the rear wheel as described on page 14-9 of the Service Manual.
Starting at the valve stem/balance mark area, carefully remove the rear tire from the wheel. Be sure to use plenty of commercially available tire lubricant on the inside and outside of both beads. Carefully inspect the entire circumference of both tire beads. Inspect both the inside and outside of the bead for any distortion or injuries. See examples of injuries below. 2001 – 2002 GL1800/GL1800A Rear Tire Inspection GL1800 #6 OCTOBER 2001 MTB 9430 (0109) 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 “do-ityourselfers,” 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. Service Bulletin American Honda Motor Co., Inc.
2001-2002 GL1800/GL1800A Rear Tire Inspection 0110 GL1800 #6.GL1800 #6.0110.2001-2002 GL1800/GL1800A Rear Tire Inspection.GL1800/GL1800A, Rear Tire Inspection, Bead, Tread.Motorcycle.1800 2 of 4 ©2001 American Honda Motor Co., Inc. – All Rights Reserved GL1800 #6 OCTOBER 2001 Inside BeadInjury Outside BeadInjury Outside BeadInjury 7. Carefully inspect the entire circumference of both tire beads. Inspect both the inside and outside of the bead for any distortion or injuries. See examples of injuries below. If there is no evidence of bead damage, re-install the tire on the rim.
Be sure to use plenty of commercially available tire lubricant on the inside and outside of both beads. Be sure to align the balance dot with the valve stem. Inflate the tire to 41 psi.
Install the wheel assembly on the motorcycle and proceed to the Identification and then to the Warranty section. If any damage or injury is present replace the tire and valve stem. Be sure to use plenty of commercially available tire lubricant on the inside and outside of both beads. Balance the new tire as necessary Incoming search terms:. If your inspection identifies a crack or cracks in or on either Left or Right lower crossmember frame welds, STOP – call your DSM or TechLine for further instructions.
If your inspection reveals no cracks, proceed to REPAIR PROCEDURE. NOTE: Verification of repair can also be found in the Dealer Responsibility Report and on the Honda Interactive Network (iN). If you have any questions about verification, please contact TechLine before proceeding. IMPORTANT: For complete Dealer and Welder Repair procedures, refer to the following items:.
2002-2003 GL1800/A Frame Weld Safety Recall Dealer Booklet (S0510). Frame Weld Inspection Chart (S0513) You MUST provide your TIG welder with the following items:. 2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual (S0511).
Welding Template Box (S0512) All of the above items were shipped to you with this Service Bulletin. If you need additional copies of the Dealer Booklet, Welding Manual, Welding Template Box, or Frame Weld Inspection Chart, you may order them at no cost from DDS at (440) 572-0725. For your reference, a brief repair procedure overview is provided below. INSPECTION/ADJUSTMENT PROCEDURE 1. Remove the right engine side cover (see S/M Page 2-4).
Check the cable clearance on the N (neutral) and R (reverse) cables. Note: It is not necessary to remove the center inner fairing or inspect the reverse shift actuator.
Push the reverse shift switch to “OFF” and turn off the ignition. Tighten the reverse cable lock nuts.
Reinstall the right engine side cover. PARTS INFORMATION No parts are required for this procedure. WARRANTY INFORMATION Normal warranty.
After completion of the inspection/adjustment, submit one claim per VIN using the following information only: Template #: GL#5 Flat Rate Time = 0.3 hours The reverse cable lock nuts may not have been properly tightened on some GL1800 units. We have developed a procedure to inspect and adjust any affected units.
Please follow the INSPECTION/ ADJUSTMENT procedures included in this Service Bulletin. AFFECTED UNITS 2002 GL1800 units with VIN range: 1HFSC470.2A102303 through 1HFSC470.2A102622. indicates check digit Any unit in the above VIN range may be affected and should be inspected according to the procedures in this Service Bulletin. All units outside of the above VIN range do not require inspection.
Incoming search terms:. IMPORTANT: During these procedures you may be using and referring to the following materials, originally sent to you with Service Bulletin GL1800 #14. 2002-2003 GL1800/A Frame Weld Safety Recall Dealer Procedures (S0510). Frame Weld Inspection Chart (S0516). 2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual (S0511).
2002-2003 GL1800/A Frame Weld Safety Recall Cracked Weld Repair Manual (S0515). Welding Template Box (S0512)If you need additional copies of these materi- als you may order them at no cost from Resolve at (440) 572-0725. Position the motorcycle on a firm, level surface, in an area where there is enough room to safely lay it on its left side. Remove the left side mirror by following the nstructions on page 2-7 of the Service Manual.
Remove the left engine side cover by following the nstructions on page 2-5 of the Service Manual. Remove the antenna whip(s). Remove the coolant reserve tank by fol- lowing the instructions on page 6-7 of the Service Manual.
Place thick, non-abrasive padding (such as furniture blankets) on the ground to protect the motorcycle when you lay it on its side. Lock the handlebars to the RIGHT, using the ignition key. Using two people, gently lay the motor- cycle down on its LEFT side on the pad- ding. The motorcycle will first rest on the wheels and left engine and saddlebag guards. Continue to lean the motorcycle to the left until it rests on the left handlebar end and left engine and saddlebag guards. The motorcycle should be laying on the padding, with its engine guard, saddlebag guard, and handlebar end resting on the padding – no painted parts should be con- tacting the padding. Clean the frame crossmember with acetone.
Draw a line on each side of the grinding template (S0512) 30 mm from the for- ward edge, stopping between the two arrows, as illustrated below. Put this template on the frame and, using a fine-tipped felt marker (such as a Sharpie), draw a 30 mm line on both crossmember welds. Start this line at the forward edge of the grinding template and stop between the two arrows as shown in the illustration on the next page.Now remove the grinding template. MULTI-RATE SPRINGS AND THE ARS SYSTEM Depending on the application dual–rate springs are fitted on the shocks. Dual-rate springs are just that– a spring set with two separate rates.
This is done with a short spring stacked on a longer spring. As both springs collapse they produce a soft, or initial, rate. Mighty comet milling machines.
The spring set will maintain this initial rate until the short spring stops compressing. At that point, the spring rate “crosses over” to the stiffer, or final, rate. This multi-rate system allows a soft initial rate for comfort on small bumps, but has the capability of soaking up the big pot-holes and other off road hazards. ARS stands for Adjustable Rate Suspension.
ARS is available on some dual-rate spring 4-wheel ATV shocks. ARS differs from spring preload.
The ARS system allows the rider to increase or decrease the load-carrying capacity of the shocks by turning a lever. Depending on the application and spring set, the rider can increase the load capacity of the shocks up to 50 percent.
The average preloader that makes a half-inch increase in preload will HONDA 450E/S MOUNTING & ARS ADJUSTMENT INSTRUCTIONS Continued on next page. #TRX450 – 5/28/99 #TRX450 – 5/28/99 Fig.
Front shock installation. Note that the shock body is at the top with the shaft pointing down. ARS shown is in the unloaded position. Rear shock mounting with ARS. Position the lever so that it will not come in contact with any vehicle parts around it. The cup can be rotated to reposition the lever if necessary. Increase the capacity of the shocks to only about 5 to 10 percent.
ARS allows the shocks to be correct for solo riding, but still handle the increased weight of an added load. ARS can also be employed to stiffen the rates for aggressive riding. The ARS system consists of an indexing lever and a stepped cup that contains the short spring of the dual- rate. The position of the lever in relation to the steps in the cup determines how long the spring set remains on the soft, or initial, spring rate. On most ARS applications, four positions can be selected from full stiff to full soft.
Indexing is done in a matter of seconds by rotating the lever or the cup by hand. Indexing the cup to the lever is usually preferable to avoid interference. Adjustment of the ARS system should only be made while the vehicle is unloaded to reduce the load on the springs. NOTE: It is important to make sure that a step in the cup is positioned directly over the tang on the lever. This will prevent damage to the cup and/or lever that can be caused by making partial contact between the tang and a step. In addition, make sure that the lever will not contact any vehicle parts around it, as the suspension moves up. TUNING TIPS—The “softest” setting on the ARS does not mean that the ride will be the most comfortable at that setting.
It means that this is the softest spring setting which would be employed on smooth trails or without a load. Excessive suspension bottoming caused by rough conditions or by the addition of a large load will cause a harsh ride when the shock is adjusted to this setting.
To eliminate this bottoming, adjust the ARS to the stiffer positions for a more comfortable ride. Hence, sometimes “stiffer is softer.” NITROGEN PRESSURES IN EMULSION SHOCKS.
If the VIN is within the preceeding range, inspect the front ABS speed sensor wire clamp according to the following illustrations. 2001-2002 GL1800A ABS Speed Sensor Wire Clamp Location INCORRECT Installation CORRECT Installation Service Bulletin American Honda Motor Co., Inc.
2001-2002 GL1800 ABS Speed Sensor Wire Clamp Location 0112 GL1800 #9.GL1800 #9.0112.2001-2002 GL1800 ABS Speed Sensor Wire Clamp Location.GL1800, ABS Speed Sensor Wire Clamp Location.Motorcycle.1800 2 of 2 ©2001 American Honda Motor Co., Inc. – All Rights Reserved GL1800 #9 DECEMBER 2001 IDENTIFICATION There is no identification mark associated with this Service Bulletin. PARTS INFORMATION There is no parts information associated with this Service Bulletin. WARRANTY INFORMATION The normal warranty claim submission requirements apply. Submit one warranty claim per VIN with the following information only: Inspected and REPAIRED Template: GL#9 Hours: 0.2 hours Parts: None If the clamp is installed correctly on top of the speed sensor, no further action is necessary. If the clamp is installed incorrectly under the speed sensor, remove and reinstall the clamp and speed sensor correctly.
Torque the bolts. Torque: 12 N. m (1.2 kgf. m, 9 lbf. ft) If the speed sensor wire clamp for the front ABS speed sensor is installed incorrectly, the ABS speed sensor air gap may be out of specification. This does not affect ABS speed sensor operation, but the clamp should be installed correctly.
Inspect and repair all affected units using the Inspection/Repair procedures listed below. Inspect all unsold units and customer units brought in for service.
AFFECTED UNITS 2001-2002 GL1800A units as follows: MODEL 2001 GL1800A All units 2002 GL1800A 1HFSC474.2A100001 – 1HFSC474.2A101643. = denotes check digit Any unit in the above VIN range may be affected and should be inspected according to the procedures in this Service Bulletin. All units outside of the above VIN range do not require inspection. CUSTOMER NOTIFICATION There is no customer notification associated with this Service Bulletin. Incoming search terms:. 2001-2002 GL1800/A CD Changer Replacement ORDERING AND REPLACING THE CD CHANGER 1. Before calling the CD Changer Order Desk, have the following information ready:.
VIN. Failure Information (i.e., symptom). Warranty Status 2. To order, call the CD Changer Order Desk toll free: (888) 997-7278. The CD Changer Order Desk hours are Monday thru Friday, 8:30am – 8:00pm EST. Part Number: 08A06-MCA-100RM Honda Code: 7097009 3.
After calling the CD Changer Order Desk, an exchange CD Changer will be shipped overnight (freight prepaid). Replace the faulty CD Changer with the exchange unit (see REPAIR PROCEDURE ). DO NOT remove the faulty CD Changer until you receive the exchange unit. DO NOT ATTEMPT TO REMOVE ANY STUCK CD’S. CHANGERS DAMAGED IN THIS WAY WILL BE RETURNED TO THE DEALER AND NO CORE CREDIT WILL BE ALLOWED.
2002 Honda 300ex Owners Manual
You will be billed $300.00 for the replacement unit. You must return the faulty CD Changer for a core credit and file a warranty claim to receive your total reimbursement (see TRANSACTION SUMMARY on page 3 for details). REPAIR PROCEDURE 1.
Refer to the Installation Instructions included with the replacement CD Changer. NOTE: You MUST remove the shipping bracket from the replacement unit before you complete the installation. If a CD is stuck inside the faulty unit, leave it there:. The vendor needs it for diagnosing and testing. If you try to remove it, you’ll damage the unit. The vendor will return the unit if it has been damaged during attempted CD removal. Fill in the customer information on the Audio System Diagnosis and Core Return form.
Honda 300ex Repair Manual Online
The vendor will remove the CD and mail it back to the customer. IDENTIFICATION No identification is necessary for this repair.