2020-2024 Honda GL1800, GL1800B, GL1800BD, GL1800D, GL1800DA Fuel Pump Replacement

SEOCONTENT-START

1 of 7
© 2024 American Honda Motor Co., Inc. – All Rights Reserved
Service Bulletin
American Honda Motor Co., Inc.
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 any other individuals 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.
GL1800 #27
Revised February 2024
SAFETY RECALL
MTB 55163A (2402)
BACKGROUND
Honda is launching a SAFETY RECALL on CERTAIN 2020-2024 GL1800/B/BD/D/DA motorcycles to
inspect and, if necessary, replace the fuel pump assembly. Due to a manufacturing defect, the
impeller inside the fuel pump can warp or swell when exposed to fuel, causing the impeller to lock
in place and prevent fuel flow to the engine. A locked impeller can cause the engine to stall without
warning while riding.
AFFECTED UNITS
As of February 9, 2024, YOU MUST NOT SELL CERTAIN NEW or USED 2020-2024 GL1800/B/BD/D/
DA motorcycles until they are repaired according to this Service Bulletin.
• To search for applicable recalls on a specific unit, you MUST use Unit Information on iN.
• To manage your affected new inventory, use your dealer eResponsibility Report on iN.
CUSTOMER NOTIFICATION
American Honda intends to mail customer letters to all owners of affected 2020-2024 GL1800/B/BD/
D/DA motorcycles in April 2024. Customers will be informed that their motorcycle may be affected
by a safety related defect and will be advised to make an appointment with an authorized Honda
dealer for repair.
PARTS INFORMATION
Parts are under TechLine control. You MUST contact TechLine to have the part released.
Model Description Part Number Qty.
GL1800/B/BD/D/DA Fuel Pump Kit 06150-MKC-306 1
Kit Includes:
Description Part Number Qty.
Fuel Pump Set N/A 1
Packing, Fuel Pump 17571-MKC-A00 1
Ring, Fuel Pump Locking 17719-HR3-A21 1
DEALER REPAIR RESPONSIBILITY
• Repairs must be performed by a qualified technician.
• Performing this repair exactly as shown in Repair Procedure instructions is critical for the
remedy 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.
2020-2024 GL1800/B/BD/D/DA
Fuel Pump Replacement
NEW
GL1800 #27
February 2024
2 of 7 ©2024 American Honda Motor Co., Inc. – All Rights Reserved
SPECIAL TOOL INFORMATION
The special tools listed below are necessary
to perform the repair.
* The Fuel Tank Lock Ring Wrench is a required Special
Tool and was auto-shipped to your dealership in 2014.
** The Fuel Module Separator tool was auto-shipped to
your dealership in 2020.
If either tool is missing, the tool can be ordered through the
Special Tool and Equipment program.
WARRANTY CLAIM INFORMATION
After completing this Service Bulletin update,
submit one warranty claim per unit with the
following template number. A photo of the
defective fuel pump identification label will
be required for all KQ1B replacement claims.
If the pump is found to be in the defective
range, contact TechLine for further
instructions.
Note: All KQ1B warranty template claims will
reimburse freight. To ensure your dealership
receives the freight credit, follow these steps.
1. Make sure ‘YES’ is selected from the
Freight Involved drop down window.
2. Make sure to include the Part Order Reference
Number.
3. Include the freight Amount associated with
the listed Part Order Reference Number.
• The Part Order Reference Number can
be found on your Parts Order Statement
on iN.
TECHNICAL QUESTIONS
If you have any technical questions relating to
this update procedure, please contact:
Motorcycle TechLine Online:
iN > Service > TechLine > TechLine > TechLine
Connect
Or call (800) 421-1900, option 9
WARRANTY QUESTIONS
If 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 Connect Filing
Or call (800) 421-1900, option 7
Before you begin the repair procedure, verify
that the unit has not already been repaired by
searching Unit Information on iN.
Remove the side covers and seat.
• Refer to the service manual for details.
Inspect the identification label affixed to the
top of the fuel pump.
1. Check the part number of the pump.
• For pumps with -A01 in the part number,
proceed to step 2 to check the LOT number.
• For pumps with -A02 in the part number,
the pump does not need to be replaced
and no repair is required. Proceed to filing
an “Inspection Only” warranty claim.
SPECIAL TOOL PART NUMBER QTY.
*Fuel Tank Lock Ring
Wrench
OTC6599 1
**Fuel Module
Separator
07AAF-T5RA100 1
(two pieces)
MODEL TEMPLATE FLAT RATE
GL1800/B/BD/D/DA Inspection only: KQ1A
Replacement: KQ1B
0.3
0.8
DEALER SUPPORT
RECALL REPAIR IDENTIFICATION
FUEL PUMP INSPECTION
GL1800 #27
February 2024
©2024 American Honda Motor Co., Inc. – All Rights Reserved 3 of 7
2. Check the LOT number located in the
bottom right-hand corner of the label. If the
LOT number shows a production date that
is before September 27, 2019, the fuel
pump must be replaced.
SIDE COVERS REMOVAL / INSTALLATION
Open both saddlebags. Release the bosses [1]
from the grommets [2] and remove the side
covers [3].
NOTES:
• Be careful not to dislodge the grommets.
• Align the side cover tab [4] with the saddlebag
upper cover slit [5]
Installation is in the reverse order of removal.
SEAT REMOVAL / INSTALLATION
Tour type only:
Release the seat heater 12P (Black)
connector [1] from area near the right
saddlebag and disconnect it.
Remove the socket bolts [2], washers [3].
Remove the seat [4]. Remove the collars [5]
from the seat.
Installation is in the reverse order of removal,
with these notes:
• Align the seat tabs [6] with the grab rail
lugs [7].
• Align the seat tab [8] with the top shelter
stay slot [9].
• Align the seat bosses [10] with the top
shelter grommets [11].
FUEL PRESSURE RELIEVING
Before disconnecting the fuel hose, relieve
any fuel pressure from the system as follows.
1. Disconnect the fuel pump unit 4P (Gray)
connector [1].
PART NUMBER LOT NUMBER
LOT NUMBER:
09 C 27
MONTH YEAR DAY
U: 2017 = Replace pump
B: 2018 = Replace pump
C: 2019 = Check Date
D: 2020 = OK
E: 2021 = OK
F: 2022 = OK
G: 2023 = OK
Replace the fuel
pump if the LOT
number is between
01C01 and 09C23
(Jan. 2019 and Sept.
23, 2019).
(reference only)
FUEL PUMP REPLACEMENT
GL1800 #27
February 2024
4 of 7 ©2024 American Honda Motor Co., Inc. – All Rights Reserved
2. Start the engine and let it idle until the
engine stalls.
3. Turn the ignition switch OFF.
FUEL REMOVAL / REFILL
Remove the fuel from the fuel tank so that the
fuel gauge [1] shows less than half (three
segments) before removing the fuel pump.
Drain the fuel into a clean container for
refilling the tank after procedure is complete.
FUEL PUMP REMOVAL / INSTALLATION
NOTES:
• Clean around the quick connect fitting
before disconnecting the fuel feed hose,
and be sure that no dirt is allowed to
enter into the fuel system.
• Do not bend or twist the fuel feed hose.
• Disconnect the battery negative (–)
cable [1] from the negative (–) battery terminal
[2].
• Push the retainer tab [2] forward. Press
down the retainer [3] and disconnect the
connector [4] from the fuel pump joint or
fuel pipe joint.
• To prevent damage and keep foreign
matter out, cover the disconnected connector
and joint end with the plastic bags.
1. Remove the fuel pump locking ring [1] by
rotating it counterclockwise using the
special tool.
SPECIAL TOOL:
NOTE:
It is recommended to use a long handle
wrench to remove the fuel pump locking ring.
[1]
[2] [1]
Wrench, fuel sender [2] 070AA-TBA0100
GL1800 #27
February 2024
©2024 American Honda Motor Co., Inc. – All Rights Reserved 5 of 7
2. Remove the locking ring and fuel pump
assembly [3] from the fuel tank.
NOTICE:
Be careful when releasing the locking ring.
It is possible that the fuel pump can jump
upwards because it is installed under
tension by a spring.
3. Remove the O-ring [4]. Clean the O-ring
seating area of the fuel tank, and be sure
that no foreign materials enter the tank.
NOTICE:
When the fuel pump is removed from the
tank, there may still be fuel in the pump. To
prevent the fuel from leaking, the pump
should be kept straight up, and then placed
in a fuel safe collection container.
Installation is the reverse order of removal.
• Install a new O-ring into the fuel tank
groove.
• Install the fuel pump assembly into the
fuel tank by aligning the tab [5] with the
arrow mark [6] on the fuel tank.
• Install and tighten a new locking ring by
rotating it clockwise using the special
tool.
• Make sure that the locking ring grooves
align with the index marks [7] on the fuel
tank. Connect the quick connect fitting to
the fuel pump.
• Be sure to press the connector onto the
fuel pump joint or fuel pipe joint until the
retainer locks with a “CLICK.” If it is hard
to connect, put a small amount of engine
oil on the joint end. Make sure the connection
is secure; check visually and by
pulling the connector.
Connect the battery negative (–) cable [1]
to the negative (–) battery terminal [2].
FUEL PUMP DISASSEMBLY / ASSEMBLY
1. Disconnect the fuel pump 2P connector [1]
and fuel reserve sensor 2P (Brown)
connector [2]. Release the wires from the
clamps [3].
2. Remove cap A [1] and release the return
hose [2] from the reservoir [3].
[2] [1]
GL1800 #27
February 2024
6 of 7 ©2024 American Honda Motor Co., Inc. – All Rights Reserved
3. Push the pump flange [1] and remove the Ering
[2] from the rod end. Remove the
pump flange/rods from the reservoir, then
remove the spring [3] from the rod.
Remove the fuel pump/strainer assembly
[4] from the reservoir [5] by releasing the
three tabs [6].
4. Insert the protruding part of the Special
Service Tool (SST) in the lock tab (under
the claw). Press the SST up until it clicks.
Repeat this process using a second SST for
the second lock tab.
NOTE:
After insertion, make sure the lock tab is
raised.
5. With the two lock tabs released, use a
screwdriver to remove the remaining lock
tab.
NOTICE:
Be careful to not spread the lock tab too
wide or it may be damaged. If a lock tab is
damaged, contact TechLine for further
instructions.
6. Remove the strainer bracket [1] from the
strainer case by releasing the tab [2].
[2]
Before inserting SST After inserting SST
Lock section
Lock
Image of installed SST.
SST
SST
SST
Image for reference only
GL1800 #27
February 2024
©2024 American Honda Motor Co., Inc. – All Rights Reserved 7 of 7
7. Remove the fuel pump/filter assembly [1]
from the strainer case [2] by releasing the
three tabs [3].
8. Disconnect the 2P connector [1] from the
fuel pump/ filter assembly [2].
Remove the O-ring [3] and spacer [4] from
the fuel pump/filter assembly.
Make sure to remove O-ring [3] from
strainer case.
Apply engine oil to both O-ring s[3] when
installing.
Assembly is in the reverse order of disassembly.
Installation is reverse order of this procedure.
FUEL PRESSURE NORMALIZATION
1. Refill the fuel tank with previously drained
fuel.
2. Connect the fuel pump unit 4P (Gray)
connector [1].
3. Turn the ignition switch ON. The fuel pump
will run for about 2 seconds and fuel
pressure will rise.
4. Turn the ignition switch OFF.
5. Repeat steps 3 and 4 two or three times,
and check that there is no leakage in the
fuel supply system.
6. Start the engine to verify proper engine
operation and check for leaks.
Reassemble the unit.
Image for reference only
[3]

**************************************************************************************************************

1 of 7
© 2024 American Honda Motor Co., Inc. – All Rights Reserved
Service Bulletin
American Honda Motor Co., Inc.
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 any other individuals 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.
GL1800 #27
Revised February 2024
SAFETY RECALL
MTB 55163A (2402)
BACKGROUND
Honda is launching a SAFETY RECALL on CERTAIN 2020-2024 GL1800/B/BD/D/DA motorcycles to
inspect and, if necessary, replace the fuel pump assembly. Due to a manufacturing defect, the
impeller inside the fuel pump can warp or swell when exposed to fuel, causing the impeller to lock
in place and prevent fuel flow to the engine. A locked impeller can cause the engine to stall without
warning while riding.
AFFECTED UNITS
As of February 9, 2024, YOU MUST NOT SELL CERTAIN NEW or USED 2020-2024 GL1800/B/BD/D/
DA motorcycles until they are repaired according to this Service Bulletin.
• To search for applicable recalls on a specific unit, you MUST use Unit Information on iN.
• To manage your affected new inventory, use your dealer eResponsibility Report on iN.
CUSTOMER NOTIFICATION
American Honda intends to mail customer letters to all owners of affected 2020-2024 GL1800/B/BD/
D/DA motorcycles in April 2024. Customers will be informed that their motorcycle may be affected
by a safety related defect and will be advised to make an appointment with an authorized Honda
dealer for repair.
PARTS INFORMATION
Parts are under TechLine control. You MUST contact TechLine to have the part released.
Model Description Part Number Qty.
GL1800/B/BD/D/DA Fuel Pump Kit 06150-MKC-306 1
Kit Includes:
Description Part Number Qty.
Fuel Pump Set N/A 1
Packing, Fuel Pump 17571-MKC-A00 1
Ring, Fuel Pump Locking 17719-HR3-A21 1
DEALER REPAIR RESPONSIBILITY
• Repairs must be performed by a qualified technician.
• Performing this repair exactly as shown in Repair Procedure instructions is critical for the
remedy 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.
2020-2024 GL1800/B/BD/D/DA
Fuel Pump Replacement
NEW
GL1800 #27
February 2024
2 of 7 ©2024 American Honda Motor Co., Inc. – All Rights Reserved
SPECIAL TOOL INFORMATION
The special tools listed below are necessary
to perform the repair.
* The Fuel Tank Lock Ring Wrench is a required Special
Tool and was auto-shipped to your dealership in 2014.
** The Fuel Module Separator tool was auto-shipped to
your dealership in 2020.
If either tool is missing, the tool can be ordered through the
Special Tool and Equipment program.
WARRANTY CLAIM INFORMATION
After completing this Service Bulletin update,
submit one warranty claim per unit with the
following template number. A photo of the
defective fuel pump identification label will
be required for all KQ1B replacement claims.
If the pump is found to be in the defective
range, contact TechLine for further
instructions.
Note: All KQ1B warranty template claims will
reimburse freight. To ensure your dealership
receives the freight credit, follow these steps.
1. Make sure ‘YES’ is selected from the
Freight Involved drop down window.
2. Make sure to include the Part Order Reference
Number.
3. Include the freight Amount associated with
the listed Part Order Reference Number.
• The Part Order Reference Number can
be found on your Parts Order Statement
on iN.
TECHNICAL QUESTIONS
If you have any technical questions relating to
this update procedure, please contact:
Motorcycle TechLine Online:
iN > Service > TechLine > TechLine > TechLine
Connect
Or call (800) 421-1900, option 9
WARRANTY QUESTIONS
If 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 Connect Filing
Or call (800) 421-1900, option 7
Before you begin the repair procedure, verify
that the unit has not already been repaired by
searching Unit Information on iN.
Remove the side covers and seat.
• Refer to the service manual for details.
Inspect the identification label affixed to the
top of the fuel pump.
1. Check the part number of the pump.
• For pumps with -A01 in the part number,
proceed to step 2 to check the LOT number.
• For pumps with -A02 in the part number,
the pump does not need to be replaced
and no repair is required. Proceed to filing
an “Inspection Only” warranty claim.
SPECIAL TOOL PART NUMBER QTY.
*Fuel Tank Lock Ring
Wrench
OTC6599 1
**Fuel Module
Separator
07AAF-T5RA100 1
(two pieces)
MODEL TEMPLATE FLAT RATE
GL1800/B/BD/D/DA Inspection only: KQ1A
Replacement: KQ1B
0.3
0.8
DEALER SUPPORT
RECALL REPAIR IDENTIFICATION
FUEL PUMP INSPECTION
GL1800 #27
February 2024
©2024 American Honda Motor Co., Inc. – All Rights Reserved 3 of 7
2. Check the LOT number located in the
bottom right-hand corner of the label. If the
LOT number shows a production date that
is before September 27, 2019, the fuel
pump must be replaced.
SIDE COVERS REMOVAL / INSTALLATION
Open both saddlebags. Release the bosses [1]
from the grommets [2] and remove the side
covers [3].
NOTES:
• Be careful not to dislodge the grommets.
• Align the side cover tab [4] with the saddlebag
upper cover slit [5]
Installation is in the reverse order of removal.
SEAT REMOVAL / INSTALLATION
Tour type only:
Release the seat heater 12P (Black)
connector [1] from area near the right
saddlebag and disconnect it.
Remove the socket bolts [2], washers [3].
Remove the seat [4]. Remove the collars [5]
from the seat.
Installation is in the reverse order of removal,
with these notes:
• Align the seat tabs [6] with the grab rail
lugs [7].
• Align the seat tab [8] with the top shelter
stay slot [9].
• Align the seat bosses [10] with the top
shelter grommets [11].
FUEL PRESSURE RELIEVING
Before disconnecting the fuel hose, relieve
any fuel pressure from the system as follows.
1. Disconnect the fuel pump unit 4P (Gray)
connector [1].
PART NUMBER LOT NUMBER
LOT NUMBER:
09 C 27
MONTH YEAR DAY
U: 2017 = Replace pump
B: 2018 = Replace pump
C: 2019 = Check Date
D: 2020 = OK
E: 2021 = OK
F: 2022 = OK
G: 2023 = OK
Replace the fuel
pump if the LOT
number is between
01C01 and 09C23
(Jan. 2019 and Sept.
23, 2019).
(reference only)
FUEL PUMP REPLACEMENT
GL1800 #27
February 2024
4 of 7 ©2024 American Honda Motor Co., Inc. – All Rights Reserved
2. Start the engine and let it idle until the
engine stalls.
3. Turn the ignition switch OFF.
FUEL REMOVAL / REFILL
Remove the fuel from the fuel tank so that the
fuel gauge [1] shows less than half (three
segments) before removing the fuel pump.
Drain the fuel into a clean container for
refilling the tank after procedure is complete.
FUEL PUMP REMOVAL / INSTALLATION
NOTES:
• Clean around the quick connect fitting
before disconnecting the fuel feed hose,
and be sure that no dirt is allowed to
enter into the fuel system.
• Do not bend or twist the fuel feed hose.
• Disconnect the battery negative (–)
cable [1] from the negative (–) battery terminal
[2].
• Push the retainer tab [2] forward. Press
down the retainer [3] and disconnect the
connector [4] from the fuel pump joint or
fuel pipe joint.
• To prevent damage and keep foreign
matter out, cover the disconnected connector
and joint end with the plastic bags.
1. Remove the fuel pump locking ring [1] by
rotating it counterclockwise using the
special tool.
SPECIAL TOOL:
NOTE:
It is recommended to use a long handle
wrench to remove the fuel pump locking ring.
[1]
[2] [1]
Wrench, fuel sender [2] 070AA-TBA0100
GL1800 #27
February 2024
©2024 American Honda Motor Co., Inc. – All Rights Reserved 5 of 7
2. Remove the locking ring and fuel pump
assembly [3] from the fuel tank.
NOTICE:
Be careful when releasing the locking ring.
It is possible that the fuel pump can jump
upwards because it is installed under
tension by a spring.
3. Remove the O-ring [4]. Clean the O-ring
seating area of the fuel tank, and be sure
that no foreign materials enter the tank.
NOTICE:
When the fuel pump is removed from the
tank, there may still be fuel in the pump. To
prevent the fuel from leaking, the pump
should be kept straight up, and then placed
in a fuel safe collection container.
Installation is the reverse order of removal.
• Install a new O-ring into the fuel tank
groove.
• Install the fuel pump assembly into the
fuel tank by aligning the tab [5] with the
arrow mark [6] on the fuel tank.
• Install and tighten a new locking ring by
rotating it clockwise using the special
tool.
• Make sure that the locking ring grooves
align with the index marks [7] on the fuel
tank. Connect the quick connect fitting to
the fuel pump.
• Be sure to press the connector onto the
fuel pump joint or fuel pipe joint until the
retainer locks with a “CLICK.” If it is hard
to connect, put a small amount of engine
oil on the joint end. Make sure the connection
is secure; check visually and by
pulling the connector.
Connect the battery negative (–) cable [1]
to the negative (–) battery terminal [2].
FUEL PUMP DISASSEMBLY / ASSEMBLY
1. Disconnect the fuel pump 2P connector [1]
and fuel reserve sensor 2P (Brown)
connector [2]. Release the wires from the
clamps [3].
2. Remove cap A [1] and release the return
hose [2] from the reservoir [3].
[2] [1]
GL1800 #27
February 2024
6 of 7 ©2024 American Honda Motor Co., Inc. – All Rights Reserved
3. Push the pump flange [1] and remove the Ering
[2] from the rod end. Remove the
pump flange/rods from the reservoir, then
remove the spring [3] from the rod.
Remove the fuel pump/strainer assembly
[4] from the reservoir [5] by releasing the
three tabs [6].
4. Insert the protruding part of the Special
Service Tool (SST) in the lock tab (under
the claw). Press the SST up until it clicks.
Repeat this process using a second SST for
the second lock tab.
NOTE:
After insertion, make sure the lock tab is
raised.
5. With the two lock tabs released, use a
screwdriver to remove the remaining lock
tab.
NOTICE:
Be careful to not spread the lock tab too
wide or it may be damaged. If a lock tab is
damaged, contact TechLine for further
instructions.
6. Remove the strainer bracket [1] from the
strainer case by releasing the tab [2].
[2]
Before inserting SST After inserting SST
Lock section
Lock
Image of installed SST.
SST
SST
SST
Image for reference only
GL1800 #27
February 2024
©2024 American Honda Motor Co., Inc. – All Rights Reserved 7 of 7
7. Remove the fuel pump/filter assembly [1]
from the strainer case [2] by releasing the
three tabs [3].
8. Disconnect the 2P connector [1] from the
fuel pump/ filter assembly [2].
Remove the O-ring [3] and spacer [4] from
the fuel pump/filter assembly.
Make sure to remove O-ring [3] from
strainer case.
Apply engine oil to both O-ring s[3] when
installing.
Assembly is in the reverse order of disassembly.
Installation is reverse order of this procedure.
FUEL PRESSURE NORMALIZATION
1. Refill the fuel tank with previously drained
fuel.
2. Connect the fuel pump unit 4P (Gray)
connector [1].
3. Turn the ignition switch ON. The fuel pump
will run for about 2 seconds and fuel
pressure will rise.
4. Turn the ignition switch OFF.
5. Repeat steps 3 and 4 two or three times,
and check that there is no leakage in the
fuel supply system.
6. Start the engine to verify proper engine
operation and check for leaks.
Reassemble the unit.
Image for reference only
[3]

**************************************************************************************************************

**************************************************************************************************************

SEOCONTENT-END