Cycle Innovations Installation and Troubleshooting Guide-3510B

8/8/2019 Cycle Innovations Installation and Troubleshooting Guide-3510B

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E7Installation& Trouhlesho ting guideFor GLIOO| andGLllOO Gotdwings

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xcffiPerform&nceSystemsfor MSJ*66gpcles {,


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About CycleInnovationsonc.

CycleInnovations,nc. Is a stronganddebt freecompanyhat is rapidlygrowingandstrives o providequalityperformance ystems or motorcycles. t is our goal o keepowpricesaffordableand o continuegrowingour product ine while maintaining he highestpossible ustomer atisfaction.Most of theparts hat makeup theInvaderandEliminatorkits are Manufactured rpurchasedwithin a 50 mile radius of our home own WinterHavenFlorida. Thepartsaredelivered o our WinterHaven acility where heyarepackaged nd shipped rom. This isone waywe keepourprices ow and affordable or our customers.

CycleInnovations,nc. currentlyholds heonly patents or intakemanifoldson boththefour and six cylinderGold Wing engines.All othermanifoldsbeing manufacturedor thefour or six cylinderhoiizontally opposedmotorcycleenginesarean nfringementon ourpatents.

Cycle nnovations,nc. wascreatedout of shear rustrationcaused rom working onstock GoldWingcarburetors ndhaving o pay heextremelyhighprices or replacementpafis.This s why it is so mportantor us o keepourpricesaffordable.

What will the fnvader and Eliminator kits do for my GoldWingThey will providesmootherhandlingandpowerresponsehroughout he entirepowerband.They will provideextremelyeasystarting.Justbump he starterbuttonandyourengines running.They will provide morepower.Because f a singleHolley carburetoranda speciallydesignedntakemanifold, all cylindersarebalancedand do not need o be adjusted.All cylinderspulling togethermakesa world of differencewhen t comes o 1rcwerandperformance.Theywill provideyou with a new and cleanair intakesystern, uel intake systemandcarburetorhat s tuned ust for your GoldWing.Most importantof all, It will getyour bike backon theroadagainperformingat leastasgoodas t did wheh t was new


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FigureL-A1977GL1000 FigureL-BRemoving idecovers

Figure3-A Sparkplugwireandboottiedoutof theway Figure 3-B Removalof90 deg. ntakesFigure 3-C ragsstuffed n holesto prevent oreignobjectentry

Figure 4-B Removaloffuel line to existingCarburetors

Figure1-CRemoving ir box

Figure 2-C Removalof theAir Box


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Figure5-CRemovingheAir BreakValve

Figure 6-8removingstockcarburetorsromleft side.

Figure7-BAttachinguel ines o filterbeforemountingthe ilter will makea rouble ree nstallation

Figure8-BMakesureyourmanifoldis free romdirt andmaterials


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FrequentlyAskedQuestionsDo your kits have essairvolume. han the originals?

particleatomizationandmaintainseven uel / air flowto all cylinderswith less otalair restriction hanoriginalcarbs.Which Ilolley carb is used? s it a singlebarrel? is the newair cleanersomethingthat is available n parts stores?

partsare availableat your localpartsstores.Thereplacement ir filter is a Mr. Gasketnumber14864How do I setmy timing?

plate"clockwise"until thegroovesqlignas heydo rnFieure 21-,4.Tighten he twolockingscrews, eplacehepointscovr, startthebike andallow it to warmup.Adjust the idle to 1150RPI!{.Note: Adjust idle to 1150RPM with the dle adjusrmentscrew"locatedon the eft sideofthe carhrretor"carefulnot to adjust hemixturescre%"locatedon the front-righ ofth carburetor".Shutdown he bikeand restart t,If the timing hasbeenadvancedoo much, hestarterwill not turn over correctly. fthis is thecase, otatethe iming back-plate ourfer clockwise n very srnallincrements ntil the starterworks correctlyagain.Note: this is an nitial place o setfts fiming, referto ourtroubleshootingguideline f furtheradjustments re required.What should my pointsbe setat?

How do I geta necommendeddle?idle to I150 RPM with the idle adjustment crew"locatedon the left sideof thebike" carefulnot to adjust hemixturescre%"locatedonthe front-rightofthe bike.

What shouH my pre-mixscrewbe setat?mixturescrewhasbeenadjustedoryou areoperdingyour bike at high elevations,tmaybe necessaryo adjust heair pre-mixscre%"locatedat the front-right ofthecarburetorneset t I turn open rom the closedseat or GLl000's and 1-118urnsopen romthe closed or GLl l00's. "carefulnot o over ighten he needlewhenfinding the closedseat". fPlugs burn darkathighelevations,t may be necessaryoturn theair pre-mixscrewclockrrise1/8 of a twn Thiswill leanout themixtureandcausehe sparkplugs o burn a lighter colorthuspreventingplug fouling.


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FrequentlyAskedQuestionsWhat kind of top end speeddo you getwith the Invader and Eliminator kits?

Wehave ound hatmost classicwings are not stableat speeds bove105MPH.IIow do the kits affect he bikesabilify to pull a trailer' etc?

balanced.Do the kits alfect the temperatureof the engine?

cylindersbeingbalanced, achcylinderpulls thesameoad,causinga moreevenburning emp.Temperaturesovary from bike to bike due o varying sosling systemconditions.IIow is the gasmileageaffectedby the kits?

average,est bikesreceivedan minimumratingof 38MPG with hard ridrngconditions,while 42MPG was obtainedwith moderate iding conditions.Do you have echsuPPort?

(863) 294-7500Monday hroughFriday from 9:00am o 5 00pmEasternimeAlthoughE-mail is ourpreferredmethodof support. [email protected] ree o call usand alk directlyto a knowledgeable erson ather lan a machine.How longdoes t take to getmY order?

hasbeen overwhebning.Therehavebeenoccasionswhen t tookrwo weekstoreceive he kits. Ivlanufacturing asbeen increasedo meet he demand. eel freetocall toll freefor availabilityand delivery imes l-877-294-7500Can I install the kit myselfor do I need o have t doneat a shop?

thatareprovidedwiththe kits. It is recommendedhatyouhaveaqualifiedshopinstallthekit if youarenot comfortablewith the installationyourself.Ourtechsupport s available o answerquestions nd help with installation. 863)29+7500I noticedyou necommend moco 93octane uel Can I useother fuels suchas 87octane?

not recommendedo use87 octane or aput away uel.


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RecommendationsFor trouble free nstallationandoperation

To start heenginecold,crack hrottlewith onehand"Note:do not twist throttlerepeatedly,heaccelerator rllnpwill flood thebike' With the other handpress hestarterbuttoruyour enginewill fire immediately.Maintainapproximatelya 2000 rpmidle with the hand on the throttle for approximately 0 secondshen release hethrottle. Thebike will drop nto an 1150 pmidle.Note: no choke s needed bove45degrees.Whenstoringyour bike for anyperiodof timeover hree weeks,drainyour fuel tank,including he reserve.Crankyour engineand unthecarburetordry then shut offthefuel valve.Follow yorn installation nstructions n orderandpaycloseattentionto detail. Referto our troubleshooting uideline f anyproblemsare encountered.Use all thepartssentwith you kit. Even f youhavenewsparkplWs already n yourbike. Use heplugssentwith the kit. If youhaveexperienced arburetorproblems,chances reyour plWs arenot all in the same onditionMake sureall fuel in your gas ank is drainedout and eplacedwith freshGas"if gashasbeen n the tank for more han breemonths"prior to introducing uel to thecarburetor.Note: Old fuel can cause moking, oughengineoperationand cause ourenginenot to start.Also Damage an occur o thenew carburetor. t will be worththeextratime o replacehe old fuel. Whichevergradeof fuelyou chooses up to you.If anyproblemsareencountered,eferto the roubleshooting uideonour website.This will be themostup to dateversionandwill mostoften take careof anyproblemsyouhave.Do not operde the bike with the chokeon any onger hannecessary.this is usually40 seconds nverycold mornings"It is our recommendationo follow theOEMpreventivemaintenanceuidelinespertaining1s iming belts.Note: if a bike hasbeensitting for years, he belts mayneed eplacingdue o being stretchedn oneposition or an excessive mountof time.We recommendo check he conditionof your ttrottte cablesprior to installing hecarburetor onversion its. Replace f frayedor dragging.Whenadjusting he idle air mixture scre%"locatedonthe front right sideofthecarburetor"do not over ighten when findingtheclosedseat.Note: theneedlewillpush hrough he seatanddamagehe lowerportionof thecarburetor.Ifproblems are encountered, onsult heCycle nnovations,nc. websitetroubleshooting ageor contactCycle nnovations,nc. techsupport 563)294-7500to obtainyour repair nformation ather hanconsultingnewsgroupsetc.Note:withthe conversion its installedon your bike, t is no longerOEM. The mostknowledgeable ourceof information s fromthe designers nd developers fthe kits"Cycle nnovations,nc."


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Removal of existing CarburetorsTools Needed

.,#':':":;;lr,i"m! :{:'r::ff".Placeyour bikeon its centerstandand emove he sidecoversand knobs o allowaccesso theair filter assembly,Seetigwe f-8. If removingGLll00 carburetors kipthis stepTo remove he entireair filter assembly,emove he two wing nuts ontop ofthe airfilter. Removehe Coverand ilter. Remove heexisting vent linesfromthe air bo:qSeeFigure 2-A.Usinga 10 mm socketand extensiorLemove he two bolts inside hehousing,SeeFigure |-C.Lrft outtheentireair filter assembly. t thispoint,youshouldbeable o view the top of your frctory carburetors.Thenextfew steps takeyou tbrough emoving he factory carburetors.You can eferto your ownersNdanualf needed.RemovehesparkplW wiresfromthe sparkplugsand ie thewhes andboots up outofthe wayoSeeFigure s-A.k sure o rememberwhich side ofthe bike eachsetofwiresbelongon.Usrng he 10mm socketwith exte,nsionnd a small Philips sclewdriver, emove he90 deg. ntake ittrngs hat attachyorr carhretors to tbe cylinder heads.Removeallfour intakes,SeeFigure 3-8. Stuffa rag in all four intake holes eading nto thecylinders.Thiswill prevent oreignobject entry SeeFigure 3-C.Tum offthe fuel valvefromyour fuel tank"SeeFigwe *,4Ustrrythe smallPhilipsscrewdriver,removehe fuel line from the fuelpump o the carburetors, eeFigure4-BThe abovestepswill allow thecarburetorso drop down and estontop of yourengine.Slide he carburetors s rr to theright sideofthe bike aspossible.Disconnecthechokecable.Now slide he carburetorso the left sideof the bike asfar aspossible.Removehe two throttlecablesand he vacuum ine from thecarburetors,eeFigwe !/ Note:TheGL1000doesnot hotteavacuum ine.Removehecarburetors ypulling themout the eft sideof the bike. Note: somemaneuveringmaybenecessaryo get hecarburetorso comeout. Note.' OnGLI000's, it maybenecessaryo remove he cap, sprrng,and diaphragmof the airbreakvalve o remove hecarburetors, eeFiguru 5-8, 5'C' 6A and 68. OnGLl100's it maybe necessaryo remove he slide covers,slidesand needlesoremove hecarburetors.Reassemblehe caps,springs,and diaphragfiN, overs,slidesandneedles fterthecarburetors avebeen emoved.

III

8 mm openendYqne One small lat bladescrewdrive,r10mm open end \ryTench One small Philips screwdriverl0 mm socketwith extensim One 18mm sparkplug socketwith exte,nsimA very short ll2 n&' openendwre'nch One5116nch wrenchand a 5116nch socket


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Figure 9-AManifold w'ithtwo 5176"studs

Figure 10-A Slidin.-qewmanifold nto position

Figure9-BManifoldwithgasketFigure9-CVlanifold -ithriser

Figure9-Dgasket n opofriser

-Figure 10-Cchoke ablebracket emoved

I Figure 11:A Choke able onnectedo II carLruretcr Ir


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FigureLz-CThrottle ables,Pullcables heshort newhenthrottle rip str,vistedFigure13-APullcableis nstalledn topholeofthecable upport racket

Figure 13-BPush able nstallednlowerhole of cablesupportbracketand ower holeof throttle evercam

Figure 13-CPull cable ssecuredn topholeof throttlelevercam

Figure L4Apushandpull cablesnstalled.Illustrated ith throttle n fuIl openposition

Figure 2-B slackadjusterocatedn themiddle f thepullcable

Figure 1.[-Cand 14-DNote 1/8tl'inchof plavatrnarks

Figure 14-B Throttle inkage estingagainstthe dle screwadjustment

-


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8 rnm open end wrench One small flat blade sctewdriver10mm open end !\4rq1ch One mall Philips screwdriver10 mm socketwith extension One 18mm spark plug socketwith extensionA very short Il2 nchoPen end urench Orre5116nchwrench nda5116nchsocketA hacksawo cutapieceof 1/4" all-thread Gapping tool for sparkplugs

Installation of your new performance kitTools Needed

Note: If yoar batury is not up tolull charge,Remwe it andplace t on u low charyefor 21hoan' Turn your fuel valveto tle reservepositionanddrainall existing uel from your fueltank nto a gari an,SeeFigure 7-A.Thenturnthe uelvalve o the offposition.Replacehefuelwith Amoco93octane,or equivalent uel. Note: 87 octanewillwork fine.This stepensureshere s fresh uel in the tank and hat fuelwill flow outof thetank o theengine.> Usrng he 5/16" socketandextension,emoveand eplaceyour existing uel filterwith the one rom your kit. Note: ft wiU makea lessdfficult installation o attachandclampattfuel lines oyour new uelfilter prior to remountingt, SeeFigure 7-8.Note: Paycloseattention o the directionarrow on theJilter. Thearrowshouldpointto thefuelpump.Note:notallfuelfilters hqvean arrow, somearemarked"IN" ononeendof thefuelJilter. Theend hat is stamped IN" will attach o thefuel linerunningfrom hefuel cockonyourfuel tanl6SeeFigure 8"4> Using the l4 inch fuel line sentwith your kit, replace he fuel line fromthe fuel cockonthegas ank to your new fuel filter. Cut thehose o therequired engthandattachusing hesqueeze lampsprovided,SeeFigure 23-A.

pumpclosesto theback of thebike. Cutthe hose o the requiredengthandattachuslng hesqueeze lampsprovided.

performanc ktt.No matterwhich tvoe of coils vouare wins. Ma+. s.arevqu saDthe newstoarkolws at .022for conect ooeration .Do not re-instatlplW wiresuntilafteryour performance it is installed.

your engine.Clean f necessary, eeFigure 8-8.

shouldscrew nto the manifold,SeeFigute 9-A-

Note:Do notusean or lubricants an


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Installation of your newper{ormancekitplaceoneofthe zupplied askets ntop of the manifold,using he 5/16*studso,.otrt rt,SeeFigiri 9-B Note:Do not usearryWe of sealantor lubricontarwhere'ectedoo.Now place he 3/8 inch riseronpt orientation Note: The10'32 idleldalreadybe nstalled nto the riser

t and closesto thefront of the bike. Theheodof thescrent houtdbepointing down-Placehe second asketontop of theriserpLte using hetwo 5/16 nch studs o center t, SeeFigure 9'D.With you bike still onthe centerstando lideyournew ntakemanifold nto positionr"d let it restonthe engine,SeeFigure 10-A. Note:ManifoldspurchasedafrerApril2001 anwt be nstalledbaclrwards.Manfolds purchasedprior toApril 2001 canbeinstalle . Located iust nside the too hole of the manifold is a lip that isthe tins. ManifoldspurchasedDrior to Auril 2001o be mounted toward the back q ur bike.Manifoldspurchased fterAbril 20ilhave2 ttPs ust inside the t which prevents he manifold from beins installdbacltwards.SeeFigure 9'E

, Thecablesupportbracketshouldcomealreadyattachedo thecarburetorwith thetfuee 0-32Xll2 " screws, eeFigare LbB., prior to loweringyourne\ilcarburetoronto he manifol4 remove he blackplasticairfilter adapter ing andnrbbergasket rom the top of the carburetor.SeeFigwe 17-C.Do not re-install his plasticadapter ing rmtil requestedo do so n a laterstepofthesenstallation nstructions.Remove he chokecableb'racket y removing hePhilipsheadscrewontop of the carbt[etor.SeeFigwe 10-C.> Withthe chokecablebracket n your hand,pullthe chokecableup throughthefrlsetankandattachthehousingofthe chokecable to the cableclarrp, SeeFigure 10-C.iotrt themetal ortionof thecablehowingshouldbeplacedflushagainst heendoftheclarnp nyoir hand.Tightendownthe cableclamponto hecablehousing.Reinstali heb,racket ntothe carbtretorand eplacehe Philipsheadscrew nto thecarburetor,SeeFigure 1I-A. Loosenthechokecable etainingscrewandslide hechokecable nto theslottedareaofthe choke inkagewith barbedendof the chokecableagainsthe front sideofthe choke inkage.Tightenthechokecable etainingscrewdownonto hechokecableholding it in place.Pull your chokeout andmakesnre he choke lapperon top ofthe carburetor losesall the way,SeeFigure 11'8.pushthe choke nanAmake sure hechoke lapperontop ofthe carburetoropensall

theway.Note:someGLL100'sequire he useof a smallcable ie onthehandlebarchoke ever o keep hecable n itsgroove'

carburetors orientatedso hat the fuel inlet is locatedonthe eft-handsideofthebike. Thetbrottlecableswill attach o thecarburetor ntheright handsideof thebikein a laterstepofthese nstallation nstructions.


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Installation of your new performance kitCarefully oweryour newcarburetor withthe chokecableattached" ownonto hestuds,Sie mguie 12-,4 Sesxethe carburetoro themanifoldusing hetwo 5116starwashers ndnutsSeeFigure 22-D. Note: h wiU benecessaryo use heveryshort 1/2 inch wrench o tighten he ront 5/16 nchnut.It will benecessaryo adjust he lengthof your throttlecable.Usingthe 8mmand10mmopenendwrenclr, loosenhe lockingnut on the slackadjuster,SeeFigure 12-8.Adjust thecableall thewaytogether.Thiswill cause he throttlecable o beas ongaspossible.Note: it alsomaybenecessaryo further ncreasehe lengthof yourttgotttecableby adjusting he engthadjustmentocatedonthe throttlegip. Note:only thepull cablewill adjust, here s no adjustmentsor thereturncableor "pushcable".Hold theendsof boththrottlecablesn onehand.With the otherhand rvist thethrottleto thewide openposition. Choosehe cable hat is the shortestengthSeeFigure 12-C.Also note: he cablewith the washeron it is thepull cabl9an{-st1ouldUeltreshortcablewhen hethrottlegrip is twisted. Slide hecable"pull cable"upinto thecablesupportbracket,past he lowerholeandsecuret in the top hole usingthe 10 mm*tenclr" SeeFigure 13-A. Note:the metalwasherooking pieceo locatedonthethrottle pull cable"shouldbemounted nthe same ideofthe cablesupportbracketas henut.Securehesecond able returnor push" nto the lowerhole ofthe cablesupportbracketusing he l0 mmwrench.Note:tighten henuts onthepushandpull ca-bles,thussecuringbothcableso thecablesupportbracket.No cableadjustmentswill bemadeat this location n the future.

thethrottle levercarn,SeeFigure 13-8. Let the cable ay outside hegroove n thelevercamuntil the top cablebarbedend s in place'

by turningthe levercamwith yotr hand "counterclockwise"until thehole isaiigned,SeeFigure 13-C.It maybenecessaryo twist the throttleonthehandlebarto itre idleposition.This will provide heextra cable engthneededo insert hepullcablebarbed nd.

I4-A-your cablesareattached"o insure t turns smoot}ly.The hro$leshouldoperate'freely.Note:The hrottle eturnspringwill notprovidea hard snapbackwhen hethrottte is released.For those hatprefer the hard snapbackwhen hethrottle isreleased,he useof a customer uppliedspring asslsfwill beneeded.


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Installation of your newperformancekitNowthat thethrottlecablesare n place,checkandmakesure hethrottle linkage srestrngagainsthe dle adjustment crew ocatedon the eft sideof the carburetor. fit isnot"Using he5/16 nch openendwrench,adjust he screwup until it makescontactwith thethrottle inkage,SeeFigure 14'8.Nowthat your Throule inkage s restingagainsthe idle adjustment crew, t is timeto take heextraslackout of your throttle cables. Usrng he 8mmand10 rnm openendwrench's adjust he slackadjuster Figure 12-8" locatedn themiddle of thepull cable,until there s approximately1/8 nchofplay at the throttle grip,Seefigure11-Cand14-D". Whenyou turn thethrottlegnp you shouldhave 1/8 nch of playbefore hethrottle evercam begins o operate.While adjusting hecable engtbfrequentlycheckandmakesureyour throttle inkage s still restingagainst he dleadjustment crew.This shouldgiveyou theproperamountof slack n you throttlecablesandpreventyou from idling onyour cables nsteadof the idle adjusmentscrew.Note: improperadjustment f the cablescan cause otr engine o die whenchopping hethrottleor exiting an interstate.If insta[ing theGL1000 nvaderKit, your vacuum itting "locatedon the front of thecarburetor"shouldalreadybe cappedoff. Check his vacuum itting to makesure tis cappedoff, If Installing he GLl l00 Eliminatorkit connecthevacuum inezuppliedwith your kit to this vacuum rtting "locatedonthefront of the carburetor".SeeFigare 15-A. Runthenewvzlcuumine under hemanifold o the right sideofthebiketowardthefuelpump,until you intercepthe old vacuum ine "whichuse oconnecto thestockcarbsu C\$ therwo vacuumines n a convenient laceandconnecthemtogetherusing hevacuum ine splicing block. SeeFigure 15-8." Thereareseveraldifferenttlpes of splicingblocks.However hey all do the sanrejob. Thesplicingblock s a smallplasticpiecewith a hole broughthemiddle."Replace he four O-rings ocatedonthe 90 deg. ntake ittings uwhichwas connectedto thecylinderheadsuwith the O'rings suppliedwith yoru kit, SeeFigare 15-CNote: a smallamountof greasecan beused o hold thenewO-rings nplace duringinstallation. Not silicqtrglRemoveheragsor ducttape romthe intakeholesonthecylinderheads.Whilelifting up thenewcarburetorandmanifold,Slip all four 90deg ntake ittrngs*withthenew O-rings nstalled"ontothenew manifold flowtube ends,SeeFigure 15-D.Note:Do Notuseanytupeof sealantor lubricant whenattachingtheflow tubes o themanifoldotherthana srnallamountof WD-40 f required.Reinstall he 8 bolts hatholdthe 90 deg. ntake ittnrgs o thehead.Note: do not tightenaryt of thebolts.untilall 8 boltsore started.SeeFigure lGA- Securehe 90 deg. ntake iulngs to thecylindersusing he 10 mm socketandextensionNote: tighten he bolts using he10mmsocketandextensiono the heads rior to tightening the bandsaround he.flowtubeswith the Philipsscrewdriver.Once he intake ittrngsare securedo the heads,tighten he bandsaround heendsof theflow tubesusing hePhilips screwdriver,SeeFigure 16.8. This will securehe carburetorandmanifold nto place.


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Installation of your newperformancekit, Installthenewfuel line from your fuel pump o your newly installedcarburetor-Route hefuel line fromthe fuel pumpunder hemanifold o the left sideofthecarbgretorandup betweenhe flow tubesand connect t to the fuel inlet tubing,SeeFigure I&C Cgtthehose o therequired engthandsecuret on bothendsusing hesqueezelamPsProvided., Untieyogr sparkplugwiresandroute hem o the appropriate ideof youbike.Note,spark t rg*ir"r rnoUa beroutedunderneathhe throtttecablesonthe left sideof thebike.Makesure heplugwiresaresecurelyseatednto thesparkplugboots'Cylinders#l and#3-arJontheright handsideofthe bike andcylinders#2 andlA ateonthe left handsideofthe bke., Theblackplastic air filter adapter ing shouldhavecamealreadyattached!o yourcarburetor eck,with ablackrubbergasket.This adapter ing shouldhavebeenremovedn anearlierstepof thesenstructions,prior to installing hechokecable. ftheadapter ing is still installed, emove t andput ahole n theendof thenipple

usingu atiUor-equivalent,SeeFigure I7-C andFigure 17-D. Reinstall heplasticadaperring to theneckof thecarburetorusing heblackrubbergaskel.Note: careshiutd betaken oprarcnt gettingplasticshwings or otherforeign objectsnto thecarbureor throttle bodY

vent o theold factoryair boA SeeFigure 2-8. If this is themodelyouhave,connectoneendof the l/2 " hoseprovidedwith your kit, to the enginecasingvent "locatedonthe op of your engine,eft side".Route he otherendof the l/2" hose o theblackairfilter adapier ing, "routethehoseaway iomthe acceleratorpumpinkageorrthecarburetor"Coniect thehoseover henippleof theadapter ing whereyou drilled thehole.Twist thethrottlegripto full openpositionandobservehat theacceleratorpump inkage angof motion s not restricted.Note: do not cap offthe casinsventline!

of your engine,eft side"routedacrosshebike to theright sideandconnectedo acoliectorb* SeeFigure 17-A.Thena secondine ran fromthecollectorbox to theold factoryair bor f tnir is themodelyou have, eave hecasingvent ing affachedto thecollectorbox andconnectoneendof your new l2" line suppliedwith your kitto thesecond ippleonthecollectorbox and oute he otherendof the ll2" ltneto theblackair fiher adapter tng,SeeFigure 17-8. "route hehoseaway romtheaccelerator ury tinkageonthecarburetor."Connecthehoseover henippleof theadapter ingwhere youdrilled thehole.Twist thethrottlegrip t9 the.full openporitioo andobservehat heaccelerator ump inkage angeof motion s notiestricted.Note:do not capoffthe casingvent line!


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Installation of your newperformancekitOthermodelsof GL1000's ndall modelsof GL1100's avea secondine hat wasconnectedo the old factory air box "DR.r{TN.'itting, SeeFigure 2-A If thrs s themodelof bikeyou bave, onnect neendofthe 1/2"hoseprovidedo theenginecasingventFigure 2-B and oute heotherendof the 1/2"hose o theblackplasticairfi"lteradapter ing, SeeFigure I7-D. Note: careshouldbe exercisedwhen outingthe1/2hosefromthe casingvent ine to theblackplasticair/ilter adapter ing. Thehosecan interferewith therange of motionof the accelerator umplinlage on thecarburetor.This can causea lossofpower when rying to accelerate.Also it cancausea stumblewhenstarting to rollfrom a standstill condition.Route hehoseclearof thisarea. The second ose an fromthe old factory air box "Drain" fitting toa collectorbox,"located n the eft sideofthe bikeu. If yourbike s equipped iththis extrahose,Somestatesmayrequire t to be connected.f your state s oneofthese,you will need o pr:rchase ll2 " lEE fitting andsplice t into the casingventline that connectso the blackplasticair filter adaptering. Otherwise,discard hehoseandcollectorbox.Note: do not cap offthe casingvent line!We arenow ready o install the air cleanerassembly.Open heMr. Gasketboxandremoveyour new air cleaner,SeeFigure 18-A Cut the l/4-20 tbreadedod "usingahacksawor equivalent"o 2-314nclfs, SeeFigure 18-8. Discard he restofthe rod.Thread heportionof the rod that is2-314 nch's ong into the top of thecarburetor.Note: only thread herod into thecarburetoruntil the hreadsstart to come hroughtheyoke.Now,screw he l4-20jam nut suppliedwith yourkit, onto he hreadedodand un thenut downand ighten t against heyokeof the carburetor. notice he amnut installation n Figure 19-8.Place he baseplateofthe air filter assembly nto heair fiher adapter ury,SeeFigure 19-A. Next place he air filter onto hebaseplate,SeeFigure 19-8. Nextplace he top of theair filter assembly nto theair filter and secure t with the wingnut or equivalentprovided n yourMr. Gasketbox, SeeFigure 19-C.Use he tie-wraps cable ies suppliedwith yourkit " SeeFigure 2&A. Ensureallcablesand oreignobjectsare securely ied away rom all movingpartsofyourcarburetor.Note: Cablesor foreisn obiec$ canbecome odeed n vour throttlelinkaeescausinevour throttle to stick whichcan causeniunt or dcath Mahesureall cablesare clear from all movingoar&.

After your batteryhasbeenchargingona2 ampcharge or 24 hours, einstall hebattery nto the bike.If youhavea GL1000 emove our iming.cover, eeFigure 20-8. Loosenhe wolocking screws,SeeFigure 20-C. Rotate he iming back-plate clockwise"until thegroovesalignas heydo rn Figure 21-A Tighten hetwo lockingscrews,eplace hepointscover. Note: this is an initial place to set he iming, refer to ourtroubleshooting uideline ffurther adjustments re required.


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fnstallation of your new performancekitInstall all coversetc. hatwere removedwhen your old carburetorswere akenout.All cablesand uel linesshouldbe connected tthis time. Thecarburetorhasbeeninstalledandyou are ready o put fuel into your newperformance ystem or the firsttime.Turnonthe fuel shut offvalve at your gas ank.Let the bike sit with thefuel valve onfor five minutes. During this time, check or fuel leaksat atl fittings and ighten fneeded.Waitingfor five minutes,helps o prime he fuel pumpand ill thecarburetorbole. vlakesureyour kill switch s in the "on" position.Pull thechoke cable o thefull chokeposition,"choking he bikewill helppull fuel into the empty carburetororthe first time.uChoking he bikewill not be requiredafterthe initial startingof theenginewhen emperaturesreabove45 deg.F.With onehand, wist the throttleabout l2 way. With the other handdepresshestarterbutton and allow the engine o turn overseveralimes, SeeFigure 21-8.Note: f thestarterdoesnot soundas f it is turning he bikeovernormally remoyethe timing cover, oosen he two ocking screwsandrotatethe tirning back-platecountercloclwise in verysmall increments, etighten hetwo ocking screwsandtryto start the engineagain. f the starter still doesnot turn the engineover normally,repeat his stepas needed ntil the starter soundsnormaland the enginedoesnotkick back against hestarter. Reinstall he timingcover.It will take some ime for the fuel pump o prime,fill the fuel lines and iIl the emptycarburetor.Once he enginehas started, Fush n theChokeand maintain he RPMabove2,000with the throttlegrip, until you arepositive he fuel systemhasbeenpurged.Allow the engineo warmup for approximately ive minutes.After yourengine aswarmed p for five minutes r more,using he 5/16 nchopenendwrenchadjust our dle to 1150RPM.Onceyour dle s set,shutdownyourengineandnote how easily t startswith the touchof thebutton.Note:doublecheckthe throttle linkage o makesure t is resting on the dle adjustment crewand re-check he hrottlecablesor theproperamountof cableslack.With the engineoperating, heckoncemore o makesure here are no fuel leaksandtlnt all cablesandforeign ob.iects re securellt ied out ofthe wqv of all movingpartsof the carburetorinkages n bothsidesqf thecarburetor.

If anyproblems reencountered ith the operation f yourbike,refer o ourtroubleshootinguide ust. Then ry our [email protected] ourTechnicalSupportDepartment t863-294-7500

This completesthe instaWafionguide

M


18/32

TroubleshootingMy bike lopes surges n RPM" excessivelyt idle. A smallair vacuumeak,sparkit"sr-t" a)ear foulid condttton ryour timing not beingadvanced nough oncause'iii t"p, at idle'speeds.lso,stretched eltsand ncorrectgap settings nthepointsalong'with oor or uneven ornpressionancause low speedope.

iirturetoi,,reset it I turnopenfrom heclosed eatforGLI000'sand -l 8 rurnsijrryro* theclosedforGiI100's. "carefulnot to over ighten heneedle 'henfinding theclosed eat"'y " Set iur plug gaps o .022,no matterwhatkind of coilsyou arerunning'wctnnbilreetc.> When ou returnfrofn your ride, If the opestill exist,checkforyacuumeaps.Check hLO-rtngsberweenhe ntake'sandtheheadsor cracksandflatness.Replacewithnewo-rings if integrity s iryTuestion. esurewhen e-"assembling,to tighten he ntakei to theheodsbefure ightening heclamps o themanifoldflow ubes'ofin, iiln ,,carefulnot to adjust hemixturescrew,"locatedon the ront-right of thebilrc.timingcoverand heckthe gap onthepoints to insure heyaresetat '014 Refer oyour ownersmanualforcorrectprocedure hen setting hegap'y 'If the ope sstillprisent:withthebike unning, oosenhe wo ockingscrews.Rotateih; tining back-platecloch,vise"n verysmall ncrementsntil the openo ongerexist r intil it i at anacceptableange.Once oufind the right spot" ighten hetwo ockingscrews ndreadiusthe dle to 1150 PM. Shutdown hebikeand estartit, lf the irninghasbeenadvancedoomuch, hestarterwill not turnovercorrectly.yinX is the se, rotate he imingback-plate ounter loclo.isen verysmallincrements ntil thestarterworkscorrectlyagain'downengine..Ensure hechoke spushed n all theway,hold thethlottl-ecompletelyopen, emove parkplugsandpedorm a compressionheckon eachcylinder'ionnect thecimprission tester o onecylinder ollowing manufacturer'snstructions.Havean assistantranktheengine veruntil there s nofurtherris,eryPrgssure.Removehetesterandrecord hereading.Repeat his stepfor eachcylinder-Goodreadings houldbe n the 170PSI angewitheachcylinderwithin15 psi rom eachorther."Readingselow 140PSIcould ndicate hatanengtne verhauls due.AMaximumdifrrtntt of 15 psi between ny2 cylinders s acceptable.Greaterdffirences indicaterlom o, broken ings, lealEor sticlEvalves,or a combinationofifi. Xotq if a bitrehasbeen ettingfora longperiodof time, he ingscouldbestuck'Sometineitheringscanbefreedupwith oil andgas reaftnents'


19/32

TroubleshootingIf compressions not thecouseofyour lope,remove hecamshaftbelt covers"locatedbehind he adiator".Turn hekill switch o theoffposition.Removehe imingmarkcap "located n topof the enginenear hefuelfilter". Do Notstart heengine,urnthe engine veruntil the TI rnarkisvisibleand inedupwith thecasemarker.Thisputs cylinder No. at top deadcenter.Look at eachcamshafipulley, making surethe UP markon eachcamshaftpulley are nearthe top. "if the UPmark s neartheboftom, otatethe engineagainuntil the TI mark is visibleand ined upwith the casemarlrer.Thisshouldplace the UPmarknear the top of thecamshaftpulley. Thesmallarrow should ine upEXACTLYwiththemark on thepulley bacHngplate. Ifthe small aftow doesnot line upexactlywith the markon thepulley backingplateyour bilre s out of time.This s an indicationyour belt hasstretchedor hasbeeninstalleda toothoff etc.Consult our ownersmanualand replacebelts f needed. or1975 o 1977useHondabeltnumber 4400-371-014for978and1979usebeltnumber1400-679-014X.Oncebeltshavebeen eplaced,einstall he imingmarkcap andreturn hekill s**itcho the runposition.Recheektheimingof thebikeandstart the engine.If the ope eturns oyour bike fier a weekor so, ull oneofyour sparkplugs,f it isdark or startingtofoul, clean hemand makesure hegap is set ot .022,adjust heidle mixturescrew 1/8of a turn "clochpise" owardtheclosedseat.Thiswill leanoutthe mixtureandpreventyour plugs romfouling and stopthe operom returning.

Note Note: the dlemtxturescrewon a GLI000 shouldneverbe nore than I turn openfromtheclosedseat.Note: Youshouldnot beable o obtainan idle of 950 f your timing s advanced noughfor the nvaderkit. Thenew dleRPM shouldbeI100 to 1150.Thiswill giveyou asmoothdle, and not erk or stretch he belts.My bikedoesnot havequick acceleration. orGLl000's hemost ommanause fthis s when he timing s not advancedfarenough. or GLl100 andGL1000's thercausecanbe ow compression n cylindersor loose conoded wires on the ballastresistor, eoils or wiring connectorsrom the coils leadingback o thetgnitionsystem..

lockingscrews.Rotate hetiming back-plate clocla,yise"n very small incrementsuntil the desired hrottle responses obtained.Onceyoufind the "rightspot" tightenthetu,o ocking screwsandreadjust he dle to 1150RPM.Shutdown hebtke andrestart it, If thetiming has beenadvanced oomuch, he starterwill not turn overconectly"thebatterywill soundas f it is dead.u fthis is thecase,otate he imingback-plate ountercloclcwisen verysmall increments 1/16 of an inch" until thestarter workscorcectlyagain.Twist hethrottle quicHy,observinghemotionof theacceleratorWmp linkage. The inkageshouldmovesmoothly hrough tsallowablerange of motion. f the inkage s not smooth"jerlcy" his could bethecauseof theproblem. ContactCycle nnovations,nc. techsupport ollfree at l-877-294-7500for repair nstntctions r replacement.

-* .*


20/32

TroubleshootingMy plugsare very black evenwhenI adjust the mixture screw' oncethemixturescrewhasbeen umedmore han1 tum openfrom heclosed eatfortheGL1000' theplugs will begin ofoul raPidlY'

circuitevenf closedagainstheseat'hair"

My number our cylindersp1lk Plugseemso foul afteronly a short imeofoperation.This s iytu, *rfi4 W-'ki;t soldbeforeAprit 2001"eitherhemanifoldbeinginstalledbacta,yardi r weakfire'to thenumbei4 cylinder example plugt+iresnot beingseatedroPerlY"holeshouldfaii'ti, totn of thebike.This ip helpsatomizehefuelas t entershemanifuld.wiresomakpiiiity are'seatedn theplugboois roperly.Checkthentegrity ftheptugwiresand heconnectionso thecoils'thebifteon thecenterstand,open hecenteralse tankcoverand removehesidecovers.n complete arbtess,-starthebikc,holding n thechrtchandplace nJirstgear.Holding'iefoot breah give hebikca linle gas.Ease heclutchout toplace alittle strainon thte"ike.Lookfor spmksumpingto groundrom thehighvoltagesystem.RePairasnecessary'

My enginewill not start after installingthe new manifoldand carburetorkrt' The

mostcofnmon ause f this sfuel not gettingto thecarburetor'

pump.and oosingPrime.

My bikewill not go faster han 95milesper hour' A common ause f thissymptomslow tire air Pressure.MpH lossn iftop endandalsocause he biketo beunstableat thosespeeds'


21/32

TroubleshootingSome arburetorsallow the butter/Iy o openpast thefull openposition. Thisrestrictsthe airflow slightly. Try backingof the throttleslightb.Malresureall the sparkplugssentwith the kit are installed. f all plugs are not in rhesameconditionor if one s breakingdownat high rpm it could costyou performance.Runa compressionheckon all cylindersper your ownersmanual.Low compressionwill costpower andperformance.

My throttle cablessometimes omeoffthe throttle cam.Thecommon ause f thisrymptom s incorrectthrottle cable ension.

tnstruction.Note: becarefulnot to remove oomuchslack. Thereshouldbeapproxirnately1/8 inchofplay in thethronle.My throttle stuck at a ver-vhigh RPM. Themosteommon ause f this symptomscables ndforeignobjects angtngup n the carburetorinknge's.

Check o make urecablesand otheroreign objects re not odged n themovingparts of thecarburetor inkoge.Use he cable ies sentwithyour performancekit totie cablesandforeign objectsout of the way.Damagedorpartially broken frayed cableswlll createdrag in the cablehousingcausing hethrottle to hang.My GL1100has o be beatwithcommoncauseof this symptom ssettings.

a stick to get 70 milesper hour out of it. Themostinadequotevacuumor incorcectsporkplug gap

The GLl 100 usevacuurn o advance he iming.Check o makesure hevacuum ineis attachedat bothendsand its ntegrity isgood.Note: ifyour timingdoesnotgetadvanced,ou will be ucky o get 70 milesper hour outyour bike.Makesure hesparkplug gap is setat Cycle nnovations,nc. Recommendedeaingof .022no matterwhatkind of coilsyou are using.Check o makesure hethrottle is opening hebutterfly valve all theway.Makesure hechokelapper is openall the way.My GLl100 enginedoesnot havea vacuum il'e.SometimeseoplenstallGLI IA0valvecovers n GL1000engines.f your bikehaspoints, hen t is a GL1000whichdoesnot requirea vacuumine attachment. he GL1000 ngineusesbolanceweights ocatedbehind hepoints o advancehe iming.


22/32

Troubleshooting

My bike stumbleswhenstartingfrom a stand stilll The womostcommonhings hatcousehis to happensa fouledor nearfoutedsparkplugsor .for theGLl000"s' thetimingnot beingadvanced nough'

,oo torg, ofgop, o, ih, plug, cancausehem o ot"ilorer a shonrimelockingscrews.Rotate'theimingback-plateclochise" in verT' mcl increments'Tightenhe wo-i;;i;; t;tws iyd.readjust he dle to 1150WM' Tesride rhebike'repeat hisstepot itq\ira,until thestimbteno ongerexist.'Shut oxn thebikeand,ftiirt it, If theti*inghas beenadvancedoomuch, hestarterwill nortwn orercorrectly, ft wiil soindas f thebattery s dead.' If thil is thecase, otate he imingback-plote ounter locltwisen verysmall ncrements 1/16of an inch"until thesturterworpscirrectly again.Note': imingnot beingadvanced noughwill causeheit"st tofoul or evencause omebaclrfire> y'i, oithe sparkplugsare in a nearfouledcondition, um themixturescrewlocatedon tneint oitt , carburetori'clochwise"1/8of a turn' Thiswill leanout themixtureandcouie thl pfug to burna lighter tglo!. Thedesiredcolor is a mediumotight Tan otor'ii tt, tipZ1tn" electrohe. ide hebikeseveralmilesbetween ach-aiiustnentof themixture crew,until theconectplug color s obtained'Never urnthemixturen * i'on, than1/8of a turn at a time.Neue'operate hebikevery ongwith a bright whitecoloredspar@lug'still, is thebalinceweights"andpringsnot workingcorrectly. locate-dehind he;;;;;; btickptite. Theieweights-advincehe imingvia mechanicalforces'heseweightsandspringsshouldop-erytereely. Note: tooweakof springs,will allow

the,i*7ig * ahance"too oonwhichcanalsocause stumble.

' ';;;;; offuel i* ln, enginewhen hethrottle is twisted.Thisstumblewill benoticeableat most prr6, not justwhenstartingfrom a stsndstill' Removeheaircleanerour*niy. m* tn, engineofr twist he-throttlequicHywhile lookingdowninto thecarburitorneckand Otr*i a tinysteady treamoffuel leinp squirtedtowardtnecenie)of thecarburetor "inside hethrottlebore"' If thisfuel is notbeingsquirted or is it itody andiuy kind of runsdown hesideof thecarburetor' hereis accelerar, iip iri1emi. Flrstchickto mape ure hereare nowiresor hosesrestrictingtndrinii otmotion o/the acceleratorWmp linkageoyth: left andrearcornerof the"orUTorior.If theIinkage s not "siittid, call

ow Techsupportat 863-294-7500or instructions r replacement'


23/32

Figure 5-AVacuumfitting forGL1100Figure15-Beither f two ypesof vacuuminesplicing locksarcsupplied ith kits

Figure 15D remove agsandinstall90 deg. ntakesFigure15-Co-ringin 90 deg. ntakefittine

Figure 16-8 Tightenbandsaroundendsof theflow tubes

Figure 17-Cdrillingholein air filteradaptering

Figure 17A collectcr ' 'cxlocated n right siie .' iGL1000's Figure 17-B outin,_uhose iom collectorbox to air filteradaptering


24/32

Figure19-Abase f air ilterassembleetting nair ilteradaPtering

Figu e 20-A ie-wrapsalsocalled lasticcabletles

Figure 21-B Ieu-ot t t t t tended\\ .ohar ldStaf i lngprocedr_ire.c f-.'r:. ll r t 'loodi's bike rn,ithacceierator unlp

Figure 19-Cair i l terassemb'nl 'cp. securedoai r filter u ith u-in.-eut

_'

Figure 1,9-Bai r filter settingon baseof air filter assemblyNote:Jamnut on ll4-20 rod

Figu e 20-B emovineir: i ing o\erFigu e 20-C oosen wolockinescrew's


25/32

Troubleshooting

My bike runs pretty goodbut sometimes acklires.The womostcommon ause f abacffire is holes n theexhaust ystem r or the GLI000's, he imingnot beingadvancedfarenough-Othercousesangefrom smallvacuutneaks o degradedelectricalsystems.

hearing.Repairtheexhausteaksbeforeproceedingwiththis troubleshootingguidelinethat the eft coilfeeds the tworear cylindersNo.3 and No.4. The ight coil shouldfeedthe wofront cylindersNo' I andNo.2.D Checkfor vacuumeaksandproper installation conditionof the O-rings ocatedbetweenheheadandninetydegreentakefittings.A small vacuum eakcan causealeanermixtureat the onecylinderwhere he eak is, causinga bacffire when hethrottle is chopped.ReplaceO-rings f integrity s in question.For GL1000's,alsocheck o insure hevacu,tmcap is installed on the carburetorand all intakebolts,fittings etc.Are tight.Oneet is set, t neverhas o betouchedagain.However, f someoneurned he screwwoyopen, t wouldput excessuel into the cylinders,which would ignite in theexhaust ystemwhichcouldccruse bacffire. Malce ure he dle air mkturescrewsnot openmore hanone urnfrom theclosedseatfor GLl000's and1-1/8 urnsfortheGLl I00. If thescrewwas n this range, eturn it to itsprevious setting.your timingcover.Loosenhe wo ockingscrews.Rotate he imingback-plate"cloch,sise"n verysmall increments.Tighten he two locking screwsand start thebilre.Readjusthe dle to 1150MM. Test ide the bike, epeat hisstepas requtred,until the btacffire no longer exist..Shutdovwrhe bike andrestart t, If the iming hasbeenadyancedoomuch, hestarterwill not turn overcorrectly, " it will soundas fthe battery s dead'. If this ts thecase, otate the timingback-platecounterclochwisein verysmall ncrementsl/16 of a inch"until thestarterworksconectlyagain.thealternator,plugging into the bikeselectricalsystemmelts"locatedbehind hebattery o the eft". Onceoneof the hree hasesfuires'havebeen evered,hebilce'srpm will hov.eo bemuchhighertoproduce he same KMSvoltages.With his We ofdegradedelectricalsystem nd spark,Baclc/iringand sparkplugfouling can occur.


26/32

Troubleshooting

My bikeused o be reallyeasy o start but it's progressivelJ-ettingharder andharder to start. Themostcommon duse f this s usinga sparkplug gaporher hsn heCycle nnovations,nc.recommendedettingof .022and he useo-rspr@irgs orker hantheHondarecommendedGKPlug.

using.Reinstall hesparkplugs.Thisshouldmake ow bikcvery cl"!-lL'i turtagain.

inr* "locatedon the ront - right of thecorburetor" locbciseL'8 ol'o nrm totuardtheclosedseat.Thiswill lean out the dle mixture,preventing heplugs-tromtbulingagain..My spark plugs arevery black and evengrowinghair. Thereare threemaincausesfor carbonfouling.First, using a sparkplug gap greater han theCycle nnovations,nc.-recommendedsettingof .022, Second,Having the air mixturescrew oo ar openfromtheclosed eat.Third,for GLl000's the imingnot beingadvanced nough.

Cleanandgap thesparkplugs at .022nomatterwhattlpe of coilsyou are using.Reinstall hesParkPlugs.Makesure he dle air /fuel mixturescrew s set nofurther than1 turn openfromtheclosed eatfor GL1000's ndnofurtherthan 1-1/8 urnsopenfrom he closed eatfor theGLL100. exercisextreme autionv'henocating he closed eat,be carefulnot topush heneedlehrough he seator (oter tightenl he screv'."iote: thesemixturescrewsettingsarea mmimumvalue.One wn can still be toofar openfromtheclosed eat,whichcanfoulplugs.Themixtwe sc'.w*s adjustedo set hecolor ofthesparlElugelectrode ip to a mediumor light tan color. Once t hasbeenset, t will,eve, need o beadjustedagain.Adjustments houldnerer be more han1/8 of o turnat a timeandthebikeshouldberiddenseveralmilesbetween achadjustment."cloch,vise r IN" will leantheplug andcause t to burna lighter color and viseversa.Ifyour bilce tartseasy,hasquickaccelerationanddoesnotsturnblewhenpulling out7ro* o standstill your timing is set correctly. f you are experiencing ne of thesesymptoms fterpedorming the above wo steps,For GLL000's,emove our timingiouir. Wtth hebike unning,loosenhe wo ockingscrews.Rotate he imingback-plote "clochuise" n verysmall increments.Tighten hetwo ockingscrewsand-readjustthe dle to 1150RPM.Test ide thebikefor severalmiles, epeat hisstepasreqiired, until thesymptomno longerwist.. Shutdown hebike andrestart it. I-f henii"S hasbeenadvancedoornuch, he starterwill not turn overcorrectlr' " it villsoundas f thebattery s dead " If this is the case, otate thetimingback'platecounter ioclwise n verysmall ncrements1/16of an inch" until thestartel vorkscorrectlyagain.Note: f the imingwasnot advanced nough,hesparkplug colorshouldberecheckpd ndset by theabovestepusing he mixturescrewadjustment.


27/32

TroubleshootingIf onlyoneor n+.o f thesparkplugs are black, or modelsbeforeApril 200LMakeiurt ih, manifoldx'asnot nstalledbacrcn+ards.The ip inside hemanifold,ocatedat mainfuelentry'hole houldbe closesto thebackof thebike.This ip helpsatomizefuel andre-direct he low to the othercylinders.-Note:othercausesor blacksparkplugsareplugwiresnot beingseatednto boots,Ieak1,igh voltagewires "grounding o rame", ring condition,valve seals,poorelectricalconnections nd weakcoils-

My bikesmokes n the left sidewhenI start it. This s a common roblemwithGoldwings.When epton thesidestand,a very small amountof oil will leakpast thepiston rlngs nto the eft cylinders,causing he eft side o smokefora shortwhilewhenstartedfromcold.My bike smokeswhite out of both tail pipes or a very long time after starting thenclearsap. Thereare twocommon auseso thisproblem.First, f the bile hasbeensittingfor a longperiod of time, hepiston ringsmqt be stuck Second,heheadgaskctsmoybeshot, eakingwaternto eachcylinder, huscausing hewhitesmoke.

not always eakoutof thepump when tfails. It ispossiblefor thepump tofail"brolren einsetc.Thiswill causehewaternot to ully circulate hrough heradiator. Theengine emperaturemayread slightly hot, andtheradiatorfeel cold tothe ouchwhenheengines actuallyhot.treatmentandgastreatmentmayPossiblyhelp oosen heringsalongwith milesofriding.

My bike dieswhenchopping he throttle while exiting an Interstate. Themostcommon auseof thiscondition s incorrect ensionon the throttleandretum cables.

moves,hus ncreasingPm.

My bikewill onl.v un above 000 pm . When cut the throttlebelow3000RPMtni Uitrewill die. Themostcommon ause f thiscondition s incotect tensionon thethrottleandreturncables.beginso riseabove3000RPMcable o increaseheamountof slack n thepull coble.lefi sideof thebike".Note: f the rpmwill notdropall theway o 1150 hortenhepull cablemore. t maybe necessaryo use he adjustmentt thehandlebar rip.) -Anothercausecouldbe a weakor dead batteryor a looseconnectionfromourbattery.har1bedsower oyour electricalsystem. owWM mustbeabove2200for


28/32

Troubleshootingyour chargingsystemo support heelectrical oad. WM less han2200withoutthesupportof thebatterymaycause our engine o misfireor ev-enuit'Note: f theengine round oframe s corrodedor loose.or mainelectricalconnectionsrom thebatteryaredegraded,Only healternatorssupportingheelectricaloadandMMwill have o beat least2200.Lov'er kPll can cot{\emisJireandengineailure.Therehavebeenafew occasions hen he hreeprongv'ireconnecnnep;uqeavingthealtemator, lugging nto thebikeselecfficalsystemmelts locarcdaekiwlthebattery o the eft".Onceoneof the hreephases\ires" havebeen st'eredl hebike'srpmwill have o bemuchhigher oproduce hesamektu[S ohages. hiswill causebatteries o require requentcharging. f you are on a longtrip, yotr banem'vill getwealcer, ntil it will no longersupport he electrical oad required b1' hebike. Oncethishappens,he bikewill only operateabove2200 o 3000RPM.

WhenI start my bike it goes traight to 3000RPM and will not run any slower,nomatterwhereI adjust the idle or throttle. Thecause f this s mostoftena largevacuumeak"Theexcess ir from thevacuum eakwill causea leancondition n allcylinders"becdusehemanifold s balanced".This ean conditionwill cause he RPM ofthe bike o shootdirectly o the 000 range.

My sparkptugsare very white whenI check hem after a goodrun, Thecouse f thisconditions the dle air mixturescrewnot beingopenfrom heclosed eatfar enoughCycle nnovationsmmimutnsettingsare I turn openfrom the closedseatfor GLl000'sand 1-1/8 urnsopenfrom heclosed eatfor GLI100's.anotherspinandchecktheplugs agoin.Repeat hisstepuntil theplugs are a mediumto light tan color on the electrode ip.

I haveadjustedhe air mixture screwand I don't knowwhere t belongs; oes tcomepreset.Yes,or GL|000's hemmimumsettings one urnopenfrom heclosedseat.For GLI100's hemmimumsetting s I-1/8 turn openfrom he closed eat.Turningthescrewn will causehemirture to bemore ean "causingheplugs o burna lightercolor" tlus turning hescrewout,will causehe mixture o becomemore ich "cottsingtheplugs to burna darlcer olor." Thedesired olor on thesparfulugelectrodeip isamediumo light tan color.Thebikemustberiddenfor seteralmilesond he plugs ulledandcheclcedforolorbetween achadjustment.{ote: do not turn the mLrtwessre'!r'more han1/8of a turnper adiustment'


29/32

\

Figure23-Bthree r.pes fvacuuminecaps

Figure 22-D 5116tstuds, tarwashers ndnutsigure 2-Cfuel nlettubingFigure 22-A iserplateu'ith dleadjustmentscrewand spring

Figure 22-Bchokecablebracket

Figure23-. \ u el inehcsec anrp Figure23-Dcablesupport racket nd I12inchmounting crews

Figure24-Bthreeuell ines ",9"and2I" Figu e 21-Catfilter adapterring gasket I casingent ine I

Figure 5-Dvacuuminesplicingblock


30/32


31/32

F

TroubleshootingMy engine s hard to stert ir fre momingg but starts extremelyeasilyafter it iswarmed up. The nostcamrnon ouseof thissymptoms incorrect sparkpluggaps

Check o rna*enre thesparkpluggap isset o theCycle nnovations,nc."ecownler&dsettingof .022,nomatterwhat Hnd of coilsyou areusing.TIE GL seriescmburetorcorwersionkits are fuiownfor their easeof starting.Oncoldmorningswith cold enginest may be necessaryo choke heenginefor a shorttime.This shouldenable our engine o start easily.Note:do notchoke he bikeany ongerthanthe timerequired o start it. Hold thethrottleto obtain approximately2000rpmwithout the useof the choke until bike swarm.Thisshould akeapproximately minuteor so. Then elease hethrottleandallow thebikB o drop into an idle.

lIy GL1100chokewill not open ully after choking he bike.

the chokBever ocatedoi the undle bar.If the cable s comingof of thecam,andhnching up "that's theproblem". Theuseof a small wire tie will mostolwayscurerheproblem whenattached o the everat the handlebar. Note:using oobig of wirerieuill restrict the rangeof motionof the choke ever causing hebikenot tofullyclnke..\ OIES;


32/32

)It

Cycle ltttt oYations, nc.'2124 Kirkland Lake Dr.Auburndale, FL . 33823

Ad ffi n@*rv*tri nq*vat ons c*nlTwh supp rt-@,cyclinnovat ons eom

Phone1-877-294-75ff9or ordersandshippingnfo1-863294-7500or techsupport.j,

Documents

Cycle Innovations Installation and Troubleshooting Guide-3510B