And installation

Note On XL models, the timing rotor is mounted on the right-hand end of the crankshaft along with the primary drive gear. 20.12a Locate the stopper arm assembly on the crankcase . 21,4c and on XL models remove the timing rotor 21.4a Unscrew the bolt (arrowed) 21.4b locking the crankshaft as 21.8 and on XL models the timing rotor 21.9 Tighten the bolt to the specified 21.5 Slide the primary drive gear off the 21.7 Slide the primary drive gear onto the shaft shaft 21,4c and on XL models remove...

Ammeter

3.13 Unscrew the negative (-) lead (A) first, then the positive (+) lead (B) 4.2 If the charger doesn't have ammeter built in, connect one in series as shown. DO NOT connect the ammeter between the battery terminals or it will be ruined 5.2a Starter relay (arrowed) -XL600V models 5.2b Starter relay (arrowed) -XRV750-P models on 5.2a Starter relay (arrowed) -XL600V models becomes hot during charging stop. Further charging will cause damage. Note In emergencies the battery can be charged at the...

Every 8000 miles 12000 km

16.9a If necessary use new O-rings on the valve caps and covers 16.9b and the inspection and end caps 16.8 Turn the engine until the line next to the RT mark aligns with the notch not forgetting that on most models there is a difference between the inlet valve clearance and the exhaust valve clearance. On completion turn the engine anti-clockwise two full turns (720 ), then align the marks so it is at TDC on the compression stroke as before and recheck the clearances. 8 Moving to the rear...

Lubrication system

Oil type, viscosity and capacity Chapter 1 Oil pressure (at oil pressure switch, with engine warm) XL psi (4.5 Bar) 6000 rpm, oil 80 C XRV models 71 to 85 psi (5.0 to 6.0 Bar) 5000 rpm. oil 80CC Oil pump rotor tip-to-outer rotor clearance 0.15mm Oil pump outer rotor-to-body clearance 0.15 to 0.22 mm

Inspection

11 Inspect the head very carefully for cracks and other damage. If cracks are found, a new head will be required. Check the camshaft bearing surfaces for wear and evidence of seizure. Check the camshafts and holders for wear as well (see Section 9). 12 Using a precision straight-edge and a feeler gauge set to the warpage limit listed in the specifications at the beginning of the Chapter, check the head gasket mating surface for warpage. Refer to Tools and Workshop Tips in the Reference section...

Reassembly

19 If removed, fit the piston ring into the groove in the damper rod head, then slide the rebound spring onto the rod (see illustration 8.16). Insert the damper rod into the fork tube and slide it into place so that it projects fully from the bottom of the tube (see illustration). Fit the seat onto the bottom of the damper, then push the seat and rod up Into the tube (see illustrations). 20 Oil the fork tube and bottom bush with the specified fork oil and insert the assembly Into the slider...

Degrees of difficulty

Easy, suitable for J novice with little experience Fairly easy, suitable for beginner with some experience suitable for competent DIY mechanic Difficult, suitable for experienced DIY mechanic suitable for expert DIY or professional This Chapter covers the procedures necessary to remove and install the body parts. Since many service and repair operations on these motorcycles require the removal of body parts, the procedures are grouped here and referred to from other Chapters. In the case of...

Disc brake fluid level checks

All models are fitted with a front disc brake. Later XL600V models and all XL650V and XRV750 models are fitted with a rear disc brake. A Warning Brake hydraulic fluid can harm your eyes and damage painted surfaces, so use extreme caution when handling and pouring it and cover surrounding surfaces with rag. Do not use fluid that has been standing open for some time, as it is hygroscopic (absorbs moistui-e from the air) which can cause a dangerous loss of braking effectiveness. The front master...

O4 Introduction

There is no better example of the Japanese post-war industrial miracle than Honda. Like other companies which have become household names, it started with one man's vision. In this case the man was the 40-year old Soichiro Honda who had sold his piston-ring manufacturing business to Toyota in 1945 and was happily spending the proceeds on prolonged parties for his friends. However, the difficulties of getting around in the chaos of post-war Japan irked Honda, so when he came across a job lot of...

Rear Brake Fluid Level

2 If the amount of travel exceeds 30 mm, turn the adjusting wingnut on the end of the brake rod in until the amount of travel Is between 20 and 30 mm. 5 To view the rear brake fluid level, remove the right-hand side panel (see Chapter 8). The rear brake fluid level, visible through the reservoir body, must be above the LOWER level line. 7 Top up with fluid of the recommended type until the level is up to the UPPER level line. Do not overfill. 6 If the level is below the LOWER level line, undo...

Euu

A Warning The dust created by the brake system may contain asbestos, which is harmful to your health. Never blow it out with compressed air and don't inhale any of it. An approved filtering mask should be worn when working on the brakes. Do not, under any circumstances, use petroleum-based solvents to clean brake parts. Use clean brake fluid, brake cleaner or denatured alcohol only. Note On models with twin front disc brakes, always renew both sets of pads in the front calipers at the same...

General information

1 To reduce the amount of unburned hydrocarbons released in the exhaust gases, a pulse secondary air (PAIR) system is fitted. The system consists of the control valve (mounted behind the right-hand radiator), the reed valves (fitted in the valve covers) and the hoses linking them (see illustration). The control valve is linked by hose to the front cylinder intake duct and actuated by the vacuum created therein. 2 Under certain operating conditions, the vacuum in the front cylinder intake duct...

Check removal and installation

1 Before checking the electrical circuit, check the bulb (see Section 17) and fuse (see Section 5). 2 The switch is located in the left-hand side of the transmission casing below the front sprocket cover. You should be able to access it without removing anything, but if required remove the belly pan (see Chapter 8), and for best access the front sprocket cover (see Chapter 6). Detach the wiring connector from the switch (see illustration). Make sure the transmission is in neutral. 3 With the...

Onwards 1993on

4 Remove the fuel tank (see Section 2). 5 Release the clamp securing the hose to the sub-air cleaner and detach it (see illustration) Also detach the PAIR system, crankcase 4.10 Slacken the clamp screws (arrowed) 4.10 Slacken the clamp screws (arrowed) breather and drain hoses from the front, middle and back of the housing - if you find them difficult to access do this as they become accessible after lifting the housing off the carburettors (see illustration). 6 Slacken the clamp screws...

Bearing check and replacement

5 Remove the dust cap and or collar (where fitted according to model) from each swingarm pivot, then withdraw the spacers, noting what fits where (see Illustrations 14.7a and b). Lever out the grease seals (see Illustration). Clean off all old grease. 6 Refer to Tools and Workshop Tips (Section 5) In the Reference section and check the bearings - both caged ball bearings and needle bearings are fitted. XL600V models have two needle bearings in each pivot. XL650V models have two caged ball...

Contents

Alternator - removal, inspection and installation 32 Battery-removal, installation, inspection and maintenance 3 Brake light switches - check and replacement 14 Brake tail light bulb- replacement 9 Charging system - leakage and output test 31 Charging system testing - general information and precautions 30 Clutch switch - check and replacement 24 Oiode(s) - check and replacement 25 Electrical system - fault finding 2 Fuses - check and replacement 5 Handlebar switches - Handlebar switches -...

Removal and installation

1 On XL models, release the speedometer cable from its guide on the right-hand side (see illustration). Unscrew the four bolts securing the mudguard to the fork sliders, noting how one of the bolts secures the speedometer cable guide on some models, and remove the mudguard, noting how it fits (see illustration). Also remove the mudguard bridge, noting how it fits (see illustration). 2 On XRV models, remove the fork guards (see Section 4). Unscrew the two front bolts securing the mudguard to the...

Steering

3 Remove the right-hand side panel (see Chapter 8). 4 Unscrew the nut and withdraw the bolt securing the linkage rods to the linkage arm, then swing the rods down (see illustration). Unscrew the nut and withdraw the bolt securing the bottom of the shock absorber to the linkage arm (see illustration). 5 Unscrew the nut on the shock absorber upper mounting bolt (see illustration). Support the shock absorber, then withdraw the bolt and manoeuvre the shock out of the bottom (see illustrations). 6...

Leakage and output test

Disconnect the lead from the battery negative (-) terminal (see Section 3). 3 Set the multimeter to the Amps function and connect its negative (-) probe to the battery negative (-) terminal, and positive (+) probe to the disconnected negative (-) lead (see illustration). Always set the meter to a high amps range initially and then bring it down to the mA (milli Amps) range if there is a high current flow in the circuit it may blow the meter's fuse. 4 If the current leakage indicated exceeds the...

Drum brake checks

A rear drum brake is fitted to XL600V-H to L (1987 to 1990) models The amount of travel in the rear brake pedal before the brake takes effect will increase as the shoes wear down (refer to Chapter 1, Section 3 to check the amount of wear in the shoes if required). Check that the brake works effectively without binding when the pedal is released. Ensure that the rod linkage is properly lubricated (see Chapter 1). 1 Measure the amount of free travel at the tip of the brake pedal from its rest...

Replacement

Note It is a good idea to use a paper towel or dry cloth when handling the new bulb to prevent injury if the bulb should break and to increase bulb life. 1 To access the front turn signal bulbs, remove the fairing side panel (see Chapter 8), though the bulb can be changed with it in situ. Twist the bulbholder anti-clockwise and withdraw It from the lens (see illustration). Carefully push the bulb into the holder and twist it anti clockwise to remove it (see illustration). 2 Check the socket...

Removal

1 Separate the crankcase halves (Section 23). Remove the crankshaft (see Section 27) -though not essential, working with it in place restricts access and makes the procedure fiddly. 29.10 Measure the selector fork end thickness 29.11a Measure the internal diameter of 29.11b and the external diameter of its 29.14a Check the bearing (arrowed) each fork bore location on the shaft 29.5 Bend back the lockwasher tabs (A) and remove the bolt (B) 29.11a Measure the internal diameter of 29.11b and the...

Performance data

XL600V models 46.5 bhp (34.7 kW) 7542 rpm XL650V models 54 bhp (40 kW) 7500 rpm XRV750 models 61 bhp (45.5 kW) < 7500 rpm XL600V models 36.1 Ibf ft (49 Nm) 5798 rpm XL650V models 39 Ibf ft (53 Nm) 5500 rpm XRV750 models 45 Ibf ft (61 Nm) 6000 rpm XL600 650V models 110 mph (177 kmh) XRV750 models 112 mph (180 kmh) Time taken to cover a mile from a standing start .13.6 seconds Terminal speed after 'A mile 94.7 mph (152 kmh) XL650V models ., not available Time taken to cover a mile from a...

Fuel tap

22 The tap should not be removed unnecessarily. 23 Remove the fuel tank as described above. 24 Unscrew the nut securing the tap to the tank and withdraw the tap assembly, noting its orientation (see illustrations). 2.24c Fuel tap - XRV750-P models onwards 25 Remove the strainer (see illustration). Discard the O-ring (see illustration). Clean the strainer to remove all traces of dirt and fuel sediment. Check the gauze for holes. If any are found, a new strainer should be fitted. Fit the strainer...

Cbr 1000 Engine Number

Performance data sourced from Motor Cycle News road test features. See the MCN website for up-to-date biking news. The frame serial number is stamped into the right-hand side of the steering head. The engine number is stamped into the crankcase on the right-hand side of the engine. Both of these numbers should be recorded and kept in a safe place so they can be furnished to law enforcement officials in the event of a theft. There is also a colour code label on the top of The frame number is...

Bike spec

XL600V and XL650V models x 34 mm Keihin CV type XRV750-L to S (1990 to 1995) x 36.5 mm Keihin CV type XRV750-T models onwards x 36.0 mm Keihin CV type Ignition system XL600V-H to R (1987 to 1995) and XRV750-L to S (1990 to 1995) models with electronic advance XL600V-T to X (1996 to 1999), XL650V and XRV750-T models onwards transistorised with electronic advance multi-plate, cable-operated Frame type downtube with double-loop cradle, rectangular section Fuel tank capacity (Including reserve)...

Haynes

If an alarm system has been fitted, note that its current draw should be taken into account when measuring current leakage. 1 If the charging system of the machine is thought to be faulty, perform the following Caution Always connect an ammeter in series, never in parallel with the battery, otherwise it will be damaged. Do not turn the ignition ON or operate the starter motor when the ammeter is connected - a sudden surge in current will blow the meter's fuse. 2 Turn the ignition switch OFF and...

Removal rear cylinder head

Note On XL600V models the engine must be removed from the frame to enable removal of the rear cylinder head. On XL650V and XRV750 models removal of the rear cylinder head is possible with the engine in the frame. 13 On XL600V, remove the engine from the frame (see Section 5). 14 On XL650V and XRV750 models, drain the coolant (see Chapter 1). Remove the carburettors and the rear cylinder exhaust pipe (see Chapter 4). 15 Remove the spark plugs (see Chapter 1). 16 Remove the camshaft (see Section...

Installation

17 On XL650V and XRV750 models, fit a new O-ring onto the coolant joint collar stub on each cylinder, then slide the collar as far as possible onto the stub of one of them. 18 Check that the mating surfaces of the cylinder and crankcase are free from oil or pieces of old gasket. 19 If removed, fit the dowels either over the studs and into the crankcase or into the barrel, and push them firmly home (see illustration). 15.11b and measure at the points shown 15.19 Install the two dowels (arrowed)...

Nonscheduled maintenance

1 Among other things, poor engine performance may be caused by leaking valves, incorrect valve clearances, a leaking head gasket, or worn pistons, rings and or cylinder walls. A cylinder compression check will help pinpoint these conditions and can also Indicate the presence of excessive carbon deposits in the cylinder heads. 2 The only tools required are a compression gauge and a spark plug wrench. A compression gauge with a threaded end for the spark plug hole is preferable to the type which...

Every 600 miles 1000 km

1 A neglected drive chain won't last long and will quickly damage the sprockets. Routine chain adjustment and lubrication isn't difficult and will ensure maximum chain and sprocket life. 2 To check the chain, place the bike on its sidestand and shift the transmission into neutral. Make sure the ignition switch is OFF- 3 Push up on the bottom run of the chain midway between the two sprockets and measure the amount of slack, then compare your measurement to that listed in this Chapter's...

Cleaning and repair

1 All repairs to the fuel tank should be carried out by a professional who has experience In this critical and potentially dangerous work. 4.2a Slacken the joint piece clamp screw (arrowed) 4.2b and each carburettor clamp screw (arrow) 4.2a Slacken the joint piece clamp screw (arrowed) 4.2b and each carburettor clamp screw (arrow) 4.2c Where fitted, unscrew the resonator tank bolt (arrowed) 4.2d Lift the duct housing up off the carburettors 4.2c Where fitted, unscrew the resonator tank bolt...

Info

Fairty easy, suitable for beginner with some experience suitable for competent DIY mechanic Difficult, suitable for experienced DIY mechanic suitable for expert DIY or professional Fully charged A for 5 to 10 tirs A for 5 to 10 hrs A for 1.0 hr A for 5 to 10 hrs A for 1.0 hr 9 XL600V-H and J (1987 and 1988) models 5000 rpm XL600V-K to P (1989 to 1993) W 5000 rpm XL600V-R to X (1994 to 1999) W 5000 rpm XRV750-L and M (1990 and 1991) x 2. 20A x 2 XRV750-N (1992) x 1. 10A x 2, 20A x 3 XRV750-P to...

Component renewal

7 Remove the fairing (see Chapter 8). 8 Disconnect the vacuum hose from the top of the valve (see illustration 17.1). 9 Release the clamps securing the reed valve hoses and the air filter hose and disconnect them, then remove the control valve from the motorcycle. 10 Installation is the reverse of removal-Reed valves 11 Remove the fuel tank and the air filter housing (see Sections 2 and 4). 12 To remove either valve, first release the clamp and detach the air hose from its union (see...

Every 8000 miles 12000 km 121

17.6 Front cylinder vacuum take-off point - XL650V models 8 Connect the gauge hoses to the vacuum take-off points (see illustration). Make sure they are a good fit because any air leaks will result in false readings. 9 Arrange a temporary fuel supply, either by using a small temporary tank (a two-stroke motorcycle oil tank works very well as it has an outlet union on Its base to which a link hose can be attached. Similarly an old oil container with a nozzle type cap can be used (see...

Piston rings

16.17a Slide the pin through the piston and connecting rod 16.17a Slide the pin through the piston and connecting rod with the rings installed in the bore, as follows. 2 Lay out the pistons and the new ring sets so the rings will be matched with the same piston and bore during the end gap measurement procedure and engine assembly. 3 To measure the installed ring end gap, insert the top ring into the top of the bore and square it up with the bore walls by pushing it in with the top of the piston...

Fault diagnosis

Note To enter the fault diagnosis mode of the system you will need the Honda special tools (Part Nos. 0 7XMZ-MB WO 1 00, 07YMZ-MCB0100 or 07XMZ-MBW0101. and 07YMZ-0010100) which are a wiring loom adapter that plugs into the ignition pulse generator wiring connector. If this tool is not available, fault diagnosis must be carried at a Honda dealer with the special tool. 35 There are two fault diagnosis modes, one for if there is a fault during normal use, and one for a fault that occurs when...

Removal and installation it

1 Remove the fairing side panel (see Chap 13.4 Disconnect the relevant wiring connectors 13.3a Turn signal screws (arrowed) -XL600V 13.5 then unscrew the nut (arrowed) and remove the turn signal 13.7 Rear turn signal wiring connectors -XL650V 13.8a Rear turn signa nut (arrowed) -XL600V 13.8b Rear turn signal nut (arrowed) -XL650V 13.8c Rear turn signal nut (arrowed) -XRV750 13.8b Rear turn signal nut (arrowed) -XL650V in the bracket, and taking care as you draw the wiring through. 6 Remove the...

Clutch problems

Clutch cable incorrectly adjusted (see Chapter 1). Friction plates worn or warped. Overhaul the clutch assembly (Chapter 2). Plain plates warped (Chapter 2). Clutch springs broken or weak. Old or heat-damaged (from slipping clutch) springs should be replaced with new ones (Chapter 2). Clutch release mechanism defective. Replace any defective parts (Chapter 2). Clutch centre or housing unevenly worn. This causes improper engagement of the plates. Replace the damaged or worn parts (Chapter 2)....

Ignition system

A Warning The energy levels in electronic systems can be very high. On no account should the ignition be switched on whilst the plugs or plug caps are being held. Shocks from the HT circuit can be most unpleasant. Secondly, it is vital that the engine is not turned over or run with any of the plug caps removed, and that the plugs are soundly earthed (grounded) when the system is checked for sparking. The ignition system components can be seriously damaged if the HT circuit becomes isolated. 1...

Tps Problems Africa Twin

Motorcycle Tps

To record the pilot screw's current setting, turn the screw in until it seats lightly, counting the number of turns necessary to achieve this, then fully unscrew it On installation, the screw is simply backed out the number of turns you've recorded. 12 On XL models and XRV750-L to N (1990 to1992) models, remove the two screws securing the air cut-off valve cover and its plate, noting that 1 is under spring pressure (see illustration). Carefully release the cover and remove the spring and...

Cooling fan

1 If the engine is overheating and the cooling fan isn't coming on, first check the cooling fan circuit fuse (see Chapter 9). If the fuse is good, check the fan switch as described below. 2 If the fan does not come on (and the fan switch is good), the fault lies in either the cooling fan motor or the relevant wiring. Test all the wiring and connections as described in Chapter 9, following the relevant Wiring Diagram. Disconnect the fan wiling connector and check that there is battery voltage at...

By Matthew Coombs

XL600V Transalp. 583cc. 1987 to 1999 XL650V Transalp. 647cc. 2000 to 2002 XRV750 Africa Twin. 742cc. 1990 to 2002 A book in the Haynes Service and Repair Manual Series All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder.

Safety first 015

Professional mechanics are trained in safe working procedures. However enthusiastic you may be about getting on with the job at hand, take the time to ensure that your safety is not put at risk. A moment's lack of attention can result in an accident, as can failure to observe simple precautions. There will always be new ways of having accidents, and the following is not a comprehensive list of all dangers it is intended rather to make you aware of the risks and to encourage a safe approach to...

H32279

2.18d Front brake caliper -XRV750-P models onward (1993-on) 2.20b Slide the pads up into the caliper , 2.20a Make sure the shim is correctly fitted 2.20b Slide the pads up into the caliper , 2.20c . . . making sure they locate correctly (arrow) align the holes and insert the pad pin. then tighten it securely (see illustration). Install the pad pin plug - it is advisable to apply some copper or silicone grease to its threads (see illustration 2.18a). Repeat the pad renewal procedure on the other...

Ignition HT coils

XRV750-L to S (1990 to 1995) models Primary winding to 0.2 ohms at 20 C With plug cap to 10.8 K-ohms at 20*0 Without plug to 4.5 K-ohms at 20 C XL600V-T to X (1997 to 1999) models. XL650V models, XRV750 T models onwards (1996-on) Primary winding to 2.6 ohms at 20 C With plug cap to 36 K-ohms at 20 C Without plug cap to 30 K-ohms at 20 C

Steps For Replacing Icu In Honda Motorcycle

One short, one long, one short, one long Follow Troubleshooting procedure below present, the indicator unit is faulty and must be replaced with a new one (see Chapter 9). If there is no voltage, check for continuity in the wiring, referring to the Wiring Diagrams at the end of Chapter 9. The green wire goes to earth (ground). 41 If the lights have come on, remove the left-hand side panel (see Chapter 8). Disconnect the ICU 22-pin wiring connector. Using a voltmeter, connect the positive (+ve)...

Africa Twin Float Level Check

8 To check the float height, hold the carburettor so the float hangs down, then tilt it back until the needle valve is just seated, but not so far that the needle's spring-loaded tip is compressed. Measure the distance between the base of the carburettor body and the bottom of the float with an accurate ruler (see illustration). The correct setting should be as given in the Specifications at the beginning of the Chapter. If the float height is incorrect, on brass floats it can be adjusted by...

Inspection and servicing

1 After the crankcases have been separated, remove the oil pump, and on XRV models the oil distributor, the crankshaft and connecting rods, transmission shafts, selector drum and forks, neutral switch and oil pressure switch, referring to the relevant Sections of this 24.4a Check the transmission output shaft oil seal (A) and the gearchange shaft oil seal (B) Chapter, and to Chapter 9 for the neutral and oil pressure switches. Refer to Section 30 and to Tools and Workshop Tips in the Reference...

Every 4000 miles 6000 km

3.2 Front brake pad wear indicator cutouts (A) and grooves (B) -pad removed 3.5 Rear brake shoe wear indicator pointer (A) and triangular reference mark on brake plate (B) 3.2 Front brake pad wear indicator cutouts (A) and grooves (B) -pad removed 3.5 Rear brake shoe wear indicator pointer (A) and triangular reference mark on brake plate (B) an accumulation of road dirt and brake dust, or there is any doubt as to how much friction material is left, the pads should be removed from the caliper...

Africa Twin Rear Sprocket Torque Setting

Note If the primary drive gear has been removed and not yet installed, do so before installing the clutch (see Section 21). 23 Remove all traces of old gasket from the crankcase and clutch cover surfaces. 24 Smear the outside of the clutch housing guide with molybdenum disulphide oil (50 molybdenum grease and 50 engine oil), then slide the guide onto the input shaft (see illustration). 25 Slide the oil pump drive sprocket onto the shaft, making sure the tabs or pins (according to model) face...

Key registration procedure

To register a new key Note To do this you will need the Honda special tools (Part Nos. 07XMZ-MBW0100. 07YMZ-MCB0100 or 07XMZ-MBW0101, and 07YMZ-0010100) which are a wiring loom and adapter that plug into the ignition pulse generator wiring connector. If this tool is not available, registration must be carried at a Honda dealer with the special tool. 4 Obtain a new key from a Honda dealer, then have it cut to match the original key. 5 Remove the fuel tank (see Chapter 4), then disconnect the...

Socket Xrv 750 Repair

Note The pins on the bulbs are offset so they can only be installed one way. It is a good idea to use a paper towel or dry cloth when handling the new bulb to prevent injury if It breaks, and to increase bulb life. 1 Undo the two screws securing the tail light lens and remove it (see illustrations). Carefully push the bulb in slightly and twist it anti-clockwise to release it (see illustration). Check the socket terminals for corrosion ana clean them if necessary. 2 Install the new bulb by...

Honda Africa Chain Slider

7 Remove the dust cap and or collar (where fitted according to model) from each swingarm pivot, then withdraw the spacers, noting what fits where (see illustrations). Clean off all old grease, then lubricate the grease seals, bearings, collars, spacers and the pivot bolt with multi-purpose grease. Insert the spacers, then fit the collars and or caps according to model. 8 If removed, install the chain slider, making sure it locates correctly, then fit the collar(s) and tighten the screw(s)...

Africa Twin Digital Multimeter Aftermarket

Lead Resistance Messurements

1 Remove the fuel tank (see Chapter 4). Check the colls visually for loose or damaged terminals, cracks and other damage. 2 Remove the seat (see Chapter 8). Disconnect the battery negative (-) lead. 3 Remove the coil being tested (see Steps 16 to 18). 4 Set an ohmmeter or multimeter to the ohms x 1 scale and measure the resistance between the primary circuit terminals on the coil (see illustration). This will give a resistance reading of the primary windings of the coil and should be consistent...

Cooling fan switch

10 If the engine is overheating and the cooling fan isn't coming on. first check the cooling fan circuit fuse (see Chapter 9). If the fuse is blown, check the fan circuit for a short to earth (see the wiring diagrams at the end of this book). 11 If the fuse Is good, on XL600V and XRV750 models remove the right-hand fairing side panel, and on XL650V models remove the (airing (see Chapter 8). Disconnect the wiring connector from the fan switch on the radiator (see illustration 3.3b). Using a...

Rear shock absorber

4 Slacken the adjuster lockring using a suitable C-spanner (see illustration). Now thread the adjuster up or down as required, again using the C-spanner - thread it up to decrease pre-load or lower the ride height, and down to increase pre-load or raise the ride height. 5 Make sure you stay within the adjustment limits as defined by the installed length of the spring according to the Specifications at the beginning of the Chapter. Tighten the locknut securely against the adjuster on completion....

Harley 45 Crankcase Main Bearing Removal

4 Clean the crankshaft with solvent, using a rifle-cleaning brush to scrub out the oil passages. If available, blow the crank dry with compressed air, and also blow through the oil passages. Check the cam chain sprockets for wear or damage. If any of the sprocket teeth on the left-hand end are excessively worn, chipped or broken, the crankshaft must be replaced with a new one. 5 Refer to Section 26 and examine the main bearings (see illustration). If they are scored, badly scuffed or appear to...

Every 8000 miles 12000 km 125

Slowly move the handlebars from side-to-side. Any dents or roughness in the bearing races will be felt and the bars will not move smoothly and freely. Again point the wheel straight ahead, then tap the front of the wheel to one side. The wheel should 'fall' under its own weight to the limit of its lock, indicating that the bearings are not too tight. Check for similar movement to the other side. If the steering doesn't move freely through its entire lock, and it's not due to the resistance of...

Brakes XL600VH to L 1987 to 1990 models

to 30.199 mm to 12.743 mm mm mm Brakes - XL600V-M to P (1991 to 1993) models to 30.280 mm to 30.199 mm -000 to 11.040 mm to 10.910 mm to 38.230 mm to 38.148 mm to 13.984 mm to 5.2 mm Brakes - XL600V-R to T (1994 to 1996) models to 27.050 mm to 26.968 mm -000 to 11.043 mm to 10.984 mm to 38.230 mm to 38.148 mm Service to 14.043 mm to 13.984 mm Brakes - XL600V-V to X (1997 to 1999) models to 30.280 mm Brakes - XL600V-V to X (1997 to 1999) models (continued) to 30.199 mm to 12.743 mm to 12.684 mm...

H 73soo

1993 models and XRV750 models, unscrew the pad retaining pin plugs, then slacken the pad retaining pins see illustration 5 Unscrew the caliper bracket mounting bolts and slide the caliper assembly off the disc. Remove the pad retaining pins and remove the pads, noting how they fit. Note the pad spring in the top of caliper and the pad guide on the caliper bracket and remove them if required for cleaning or replacement, noting how they fit. 6 Inspect the surface of each pad for contamination and...

Leaking Fuel Tap On Xl 600 V

Check the old oil carefully -if it is very metallic coloured, then the engine is experiencing wear from break-in new engine or from insufficient lubrication. If there are flakes or chips of metal in the oil, then something is drastically wrong internally and the engine will have to be disassembled for inspection and repair. If there are pieces of fibre-like material in the oil, the clutch is experiencing excessive wear and should be checked. A Warning Petrol gasoline is extremely flammable, so...

Front forks

1 On XRV750-L to S 1990 to 1995 models only, the forks are air-assisted and the air pressure can be varied within the specified range see Specifications . The air valve is incorporated in the top bolt of each fork. 2 To check the air pressure use a gauge which is suitable for reading low pressures do not use a tyre pressure gauge. Gauges and hand-operated pumps are available for suspension system use. 12.12b . using a hammer and piece of wood if necessary 12.13 Make sure any directional arrows...

Xrv750 Connecting Rod B

5 Check the connecting rods for cracks and other obvious damage. 6 If not already done see Section 16 , apply clean engine oil to the piston pin, insert it into the connecting rod small-end and check for any freeplay between the two. Measure the pin OD see illustration 16.12b and the small-end bore ID and compare the measurements to the specifications at the beginning of the Chapter see illustration . Calculate the difference between the measurements taken to obtain the piston pin-to-small end...

Poor handling or stability

Steering head bearing adjuster nut too tight. Check adjustment as described in Chapter 1. Bearings damaged. Roughness can be felt as the bars are turned from side-to-side. Renew bearings and races Chapter 6 . Races dented or worn. Denting results from wear in only one position e.g., straight ahead , from a collision or hitting a pothole or from dropping the machine. Renew races and bearings Chapter 6 Steering stem lubrication inadequate. Causes are grease getting hard from age or being washed...

Every 8000 miles 12000 km 119

16.7a Insert the feeler gauge between the base of the adjusting screw and the top of the valve stem as shown 16.6b until the line next to the FT mark aligns with the notch 16.6a Turn the engine anti-clockwise using a socket on the timing rotor bolt 16.5b The covers are secured by two bolts arrowed 16.4 Remove the crankshaft end cap A and the timing inspection cap B 16.5a Unscrew the caps using a spanner on the hex arrowed 16.5b The covers are secured by two bolts arrowed 16.6b until the line...

Abnormal frame and suspension noise

II Low fluid level or improper viscosity oil in forks. This can sound like spurting and is usually accompanied by irregular fork action Chapter 6 . I1 Spring s weak or broken. Makes a clicking or scraping sound. Fork oil. when drained, will have a lot of metal particles in it Chapter 6 . U Steering head bearings loose or damaged. Clicks when braking. Check and adjust or replace as necessary Chapters 1 and 6 . Ii Fork yokes loose. Make sure all clamp pinch bolts are tightened to the specified...

XL600VT models onward 1996on XL650V models and XRV750T 1996on models onward

Always work on the fork legs separately to avoid interchanging parts and thus causing an accelerated rate of wear see illustration 8.1a or b . 10 If the fork top bolt was not slackened with the fork in situ, carefully clamp the fork tube in a vice equipped with soft jaws, taking care not to overtighten or score its surface, and slacken the top bolt see illustration . 11 Unscrew the fork top bolt from the top of the fork tube. A Warning The fork spring is...

Africa Twin Pressure Plate Replace

14 After an extended period of service the clutch friction plates will wear and promote clutch slip. Measure the thickness of each friction plate using a Vernier caliper see illustration . If any plate has worn to or beyond the service limit given in the Specifications at the beginning of the Chapter, the friction plates must be replaced as a set. Also, if any of the plates smell burnt or are glazed, they must be replaced as a set. 15 The plain plates should not show any signs of excess heating...

Poor running or no power at high speed

Clean or replace filter Chapter 1 . Spark plugs fouled, defective or worn out. See Chapter 1 for spark plug maintenance. Spark plug caps or HT wiring defective. See Chapters 1 and 5 for details of the ignition system. Spark plug caps not in good contact Chapter 5 . H Incorrect spark plugs. Wrong type, heat range or cap configuration. Check and install correct plugs listed in Chapter 1. J Ignition control unit defective Chapter 5 . D Ignition HT coils defective Chapter 5...

Oil cooler

1 The cooler is located on the front of the engine on the left-hand side. Remove the stone guard, and the belly pan see Chapter 8 . To prevent the possibility of damage should a tool slip, it Is advisable to remove the left-hand fairing side panel as well see Chapter 8 . 2 Drain the engine oil see Chapter 1 . Keep the oil container handy to catch any residue oil from the cooler. 3 To remove the cooler without its feed and return pipes, unscrew the bolts securing the hose unions to the cooler...

REF16 Tools and Workshop Tips

Installation ot bearings can be eased by placing them in a freezer the night before installation. The steel bearing will contract slightly, allowing easy insertion in its housing. This is often useful when installing steering head outer races in the frame. Plain shell bearings, ball bearings, needle roller bearings and tapered roller bearings will all be found on motorcycles see illustrations 5.14 and 5.15 . The ball and roller types are usually caged between an inner and outer race, but...

General information and fitting

1 The wheels fitted to all models are designed to take tubed tyres only. Tyre sizes are given in the Specifications at the beginning of this chapter. 2 Refer to the Daily pre-ride checks listed at the beginning of this manual for tyre maintenance. 15.32b Using a piece of wood as shown automatically sets the seal flush 3 When selecting new tyres, refer to the tyre information label on the swingarm and the tyre options listed in the owners handbook. Ensure that front and rear tyre types are...

How To Set Cam Timing Xrv750 Africa Twin

22 If removed, apply a smear of molybdenum disulphide grease to the contact faces of each rocker arm. then install the arms and their wave washers into the camshaft holder, making sure they are returned to their original positions see illustration . The wave washers fit on the inside of the intake rocker arms, and on the left-hand side of the front cylinder exhaust rocker arm, and the right-hand side of the rear cylinder exhaust arm. adjacent to the triangular mark on the holder see...

Honda Africa Twin Fork Gaiters

1995 Harley Front Fork Parts Pictures

Always dismantle the fork legs separately to avoid interchanging parts and thus causing an accelerated rate of wear. Store all components in separate, clearly marked containers see illustrations 2 Slacken the gaiter clamp screw s and slide the gaiter off the top of the fork, noting how its bottom end locates around the top of the fork slider see illustration . 3 Before dismantling the fork, it is advisable to slacken the damper rod bolt now as there is less...

Coolant level check

Srad Coolant Reservoir Location Bike

A Warning DO NOT remove the radiator pressure cap to add coolant. Topping up is done via the coolant reservoir tank filler. DO NOT leave open containers of coolant about, as it is poisonous. Make sure you have a supply of coolant available a mixture of 50 distilled water and 50 corrosion inhibited ethylene glycol antifreeze is needed . Always check the coolant level when the engine is at normal working temperature. Take the motorcycle on a short run to allow it Caution Do not run the engine in...

Every 8000 miles 12000 km 123

19.6 Adjusting the front brake lever span 19.6 Adjusting the front brake lever span the adjuster ring until the setting which best suits the rider is obtained. 7 The height of the rear brake pedal can be adjusted to suit the rider's preference. On XL600V-H to L 1987 to 1990 models, slacken the locknut on the pedal stopper bolt in the footrest bracket, then turn the bolt until the pedal is at the desired height. After adjustment, make sure you adjust the amount of freeplay in the pedal before...

Engine doesnt start or is difficult to start continued

Remove the plugs and inspect their threads. Reinstall and tighten to the specified torque Chapter 1 . Cylinder head s not sufficiently tightened down. If a cylinder head is suspected of being loose, then there's a chance that the gasket or head is damaged if the problem has persisted for any length of time. The head nuts bolts should be tightened to the proper torque in the correct sequence Chapter 2 . Improper valve clearance. This means that the valve is not closing...

Every 4000 miles 6000 km 111

4.4a Pull back the rubber boot to access the adjuster reduce freeplay, thread the adjuster out of the bracket. Tighten the lockring securely. 5 When adjusting the cable make sure that the slots in the adjuster and lockring are not aligned with each other and the slot in the lever bracket - these slots are to allow removal of the cable, and if they are all aligned while the bike is in use the cable could jump out. 6 If all the adjustment has been taken up at the lever, reset the adjuster to give...

Routine maintenance and servicing

Air filter - renewal Battery - charging see Chapter 9 Battery - removal, installation, inspection and Chapter 9 Brake caliper and master cylinder seals - renewal 34 Brake fluid - Brake hoses - Brake shoes pads - wear check 3 Brake system - Carburettors - Clutch - check and adjustment 4 Cooling system - Coolant - renewal Crankcase breather - check 9 Cylinder compression - check 29 Drive chain and sprockets - check, adjustment, cleaning Engine oil pressure - Engine transmission oil and filter -...

Abnormal engine noise

C Carbon build-up in combustion chamber. Use of a fuel additive that will dissolve the adhesive bonding the carbon particles to the piston crown and chamber is the easiest way to remove the buildup. Otherwise, the cylinder heads will have to be removed and decarbonised Chapter 2 . Incorrect or poor quality fuel. Old or improper fuel can cause detonation. This causes the knocking or pinking sound. Drain the old fuel and always use the recommended grade fuel Chapter 4 . Spark plug heat range...

How To Remove Xrv750 Bottom Steering Head Bearing Race

7 Smear a liberal quantity of multi-purpose grease onto the bearing races, and work some grease well into both the upper and lower bearings. Also smear the grease seal lip, using a new seal if necessary. Fit the lower bearing onto the steering stem see illustration 9.6c 8 Carefully lift the steering stem bottom yoke up through the steering head see illustration 9.5 . Fit the upper bearing and its inner race into the top of the steering head see illustrations 9.6b and a . Fit install the grease...

Disassembly

3 Before proceeding, arrange to label and store the valves along with their related 14.5d Remove any burrs 1 if the valve stem 2 won't pull through the guide 14.14a Measure the valve stem diameter with a micrometer 14.14b then measure the guide bore using a small hole gauge and micrometer 14.15 Check the valve face A , stem B and collet groove C for signs of wear and damage 14.5d Remove any burrs 1 if the valve stem 2 won't pull through the guide noting which way up it fits see illustration...

Torque settings

Engine mounting bolts - XL600V models Upper front mounting brackets bolt Nm Upper front mounting bolt nut 55 Nm Swingarm pivot rear mounting bolt nut Nm Engine mounting bolts - XL650V models Upper front mounting brackets bolt Nm Swingarm pivot rear mounting bolt nut Nm Engine mounting bolts - XRV750-L to N 1990 to 1992 models Mounting bracket-to-engine 10 mm bolts nuts 55 Nm Swingarm pivot rear mounting bolt nut Nm Engine mounting bolts - XRV750-P models onwards 1993-on Cylinder head...

Disassembly inspection and reassembly

1 As mentioned in the previous section, valve overhaul should be left to a Honda dealer. However, disassembly, cleaning and inspection of the valves and related components can be done if the necessary special tools are available by the home mechanic. This way no expense is incurred if the inspection reveals that overhaul is not required at this time. 2 To disassemble the valve components without the risk of damaging them, a valve spring compressor is absolutely essential, Make sure it is...

Abnormal driveline noise

Ill Clutch outer drum friction plate clearance excessive Chapter 2 . '1 Loose or damaged clutch pressure plate and or bolts Chapter 2 . Bearings worn. Also includes the possibility that the shafts are worn Overhaul the transmission Chapter 2 . H Gears worn or chipped Chapter 2 . Metal chips jammed in gear teeth. Probably pieces from a broken clutch, gear or selector mechanism that were picked up by the gears. This will cause early bearing failure Chapter 2 . lj Engine oil level too low. Causes...

Major engine repair

1 It is not always easy to determine when or if an engine should be completely overhauled, as a number of factors must be considered. 2 High mileage is not necessarily an indication that an overhaul is needed, while low mileage, on the other hand, does not preclude the need for an overhaul. Frequency of servicing is probably the single most important consideration. An engine that has regular and frequent oil and filter changes, as well as other required maintenance, will most likely give many...

Excessive exhaust smoke

The ring may be broken or damaged, causing oil from the crankcase to be pulled past the piston into the combustion chamber. Replace the rings with new ones Chapter 2 . Cylinders worn, cracked, or scored. Caused by overheating or oil starvation. Check the cylinder bores, lubrication system and cooling system see Chapters 2 and 3 . u Valve stem oil seal damaged or worn. Replace oil seals with new ones Chapter 2 . Valve guide worn. Perform a complete valve job Chapter 2 ....

Every 4000 miles 6000 km or 6 months

1 The idle speed should be checked and adjusted before and after the carburettors are synchronised balanced , after checking the valve clearances, and when it is obviously too high or too low. Before adjusting the idle speed turn the handlebars from side-to-side and check the idle speed does not change. If it does, the throttle cables may not be adjusted or routed correctly, or may be worn out. This is a dangerous condition that can cause loss of control of the bike. Be sure to correct this...

Every 24000 miles 36000 km 127

Disconnect the radiator overflow hose from the bottom of the reservoir and allow it to drain into the container. When the reservoir is empty, flush it out with clean water, then reconnect the hose. 5 On XL600V models, to drain and clean the reservoir you will either have to syphon out the coolant, or remove the reservoir and tip it out. Removing the reservoir involves removing the rear shock absorber see Chapter 6 . 6 Flush the system with clean tap water by inserting a garden hose in the...

Enginetransmission oil level check

Take the motorcycle on a short run to allow it to reach normal operating temperature. Caution Do not run the engine in an enclosed space such as a garage or workshop. Stop the engine and support the motorcycle upright use the centrestand if it has one. Allow it to stand undisturbed for a few minutes to allow the oil level to stabilise. Make sure the motorcycle is on level ground. Modern, high-revving engines place great demands on their oil. It is very important that the conect oil for your...

Oil pressure low

Inspect for leak or other problem causing low oil level and add recommended oil Daily pre-ride checks . Engine oil viscosity too low. Very old, thin oil or an improper weight of oil used in the engine. Change to correct oil Chapter 1 . PI Engine oil pump defective, blocked oil strainer gauze or failed relief valve Carry out oil pressure check Chapter 1 . Camshaft or journals worn. Excessive wear causing drop in oil pressure. Renew camshaft and or cylinder head. Abnormal...

Check and replacement

1 The electrical system is protected by fuses of different ratings. 2 The main fuse is integral with the starter relay, which is behind the right-hand side panel on XL models and XRV750-L to N 1990 to 1992 models see illustration and 3.7 , and behind the left-hand side panel on all other XRV models see illustration . To access the main fuse, disconnect the starter relay wiring connector see illustration . 3 All circuit fuses are housed in the fusebox, which is located as follows 5.2c Disconnect...

Tools and Workshop Tips refi

Use a bearing driver or socket which bears only on the outer hard edge of the seal to install it in the casing - tapping on the inner edge will damage the sealing lip. Oil seals are usually of the single-lipped type. Double-lipped seals are found where a liquid or gas is on both sides of the joint. Oil seals can harden and lose their sealing ability if the motorcycle has been in storage for a long period - renewal is the only solution. Oil seal manufacturers also conform to the ISO markings...

Air duct housing XL600V and XRV750L to N 1990 to 1992 models

1 Remove the fuel tank see Section 2 . 2 Slacken the clamp screws securing the an duct housing to the air filter housing joint piece and the carburettor intakes see illustrations . On XL600V-T to X 1997 to 1999 models, unscrew the bolt securing the resonator tank to the frame see illustration Remove the air duct, noting how it fits see illustration . If required, slacken the clamp screw securing the joint piece to the air filter housing and remove It, noting how it locates see illustration . 3...

XL650V models

1 Remove the top windshield screw on each side see below . Unscrew the lower fairing bolt on each side see illustration . 2 Release and withdraw the trim clip on each side securing the trim panel to the fairing inner panels see illustration . 4.19 Unscrew the bolts A and release the 5.1 Unscrew the fairing bolt arrowed on 5.2 Release the trim clip arrowed on tab B each side each side 4.19 Unscrew the bolts A and release the 5.1 Unscrew the fairing bolt arrowed on 5.2 Release the trim clip...

Inspection and repair

10 Changing the brake fluid is a similar process to bleeding the brakes and requires the same materials plus a suitable tool for siphoning the fluid out of the hydraulic reservoir. Also ensure that the container is large enough to take all the old fluid when it is flushed out of the system. 11 Follow Steps 3 and 5. then remove the reservoir cap. diaphragm plate and diaphragm and siphon the old fluid out of the reservoir Fill the reservoir with new brake fluid, then follow Step 7. 12 Retighten...

Removal and installationJx

1 Remove the fairing see Chapter 8 . 7.8d and remove the bulb -XL600V 2 On XL600V-H to P 1987 to 1993 models, undo the three screws securing the headlight retainer and remove it. Draw the headlight out of its bracket, then disconnect the headlight wiring connector and pull the sidelight bulbholder out, and remove the headlight. 3 On XL600V-R to X 1994 to 1999 models and XL650V models, undo the screws or bolts securing the headlight assembly to the fairing and remove the headlight, noting how it...

Check and replacementSk

1 Before checking the switches, and if not already done, check the brake light circuit see Section 6, Steps 8 and 9 . 2 The front brake light switch is mounted on the underside of the brake master cylinder. Disconnect the wiring connectors from the switch see illustration Using a continuity tester, connect the probes to the terminals of the switch. With the brake lever at rest, there should be no continuity. With the brake lever applied, there should be continuity. If the switch does not behave...

Rear cylinder cam chain Removal

10 Drain the engine oil see Chapter 1 . 11 Remove the camshaft see Section 9 . Remove the cam chain tensioner see Section 11 . 12 On XL models, remove the ignition pulse generator coil s see Chapter 5 . 13 Remove the clutch and primary drive gear see Section 18 . 14 Drop the cam chain down its tunnel, then slide the sprocket towards the end of the shaft so that the chain clears the guide blade and remove it from the sprocket see illustration . Slide the cam chain sprocket off the end of the...