Honda TRANSALP XL600-650V (1987-2002) [110/291] Engine clutch and transmission 2 61
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Honda TRANSALP XL600-650V (1987-2002) [110/291] Engine clutch and transmission 2 61

Honda TRANSALP XL600-650V (1987-2002) [110/291] Engine clutch and transmission 2 61

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Engine clutch and transmission 2 61 To fit a new bearing remove the selector drum cam plate by unscrewing the bolt in its centre see illustration Note the locating pin in the end of the drum and remove it for safekeeping if required Remove the old bearing and fit a new one see Tools and Workshop Tips in the Reference Section if necessary Install the selector drum cam locating the pin in the cutout in the back of the cam plate Apply a suitable non permanent thread locking compound to the cam bolt and tighten it to the torque setting specified at the beginning of the Chapter 15 On XL models measure the diameter of the journal on the left hand end of the drum and compare the measurement to the specifications see illustration If it is worn beyond the service limit replace the selector drum with a new one Also check the drum journal hole in the crankcase for wear or damage Installation XL600V H to R 1987 to 1995 models 16 Slide the middle selector fork marked O onto the fork shaft so that the C faces the right hand end of the shaft Install the lockwasher and bolt then tighten the bolt securely and bend back the labs of the lockwasher to secure it in place see illustration 29 5 17 Lubricate the selector fork shaft with molybdenum disulphide oil a 50 50 mixture of molybdenum disulphide grease and clean engine oil Slide the selector fork marked L onto the left hand end of the shaft so that the L faces to the right hand end Slide the fork marked R onto the right hand end of the shaft so that the R faces to the right hand end 18 The selector drum and forks must be installed along with the transmission shafts as a complete assembly To achieve this without the entire assembly falling apart as it is installed it is advisable to obtain some cable ties so the shafts and selector forks can be strapped together Support the left hand half of the crankcase on wooden blocks so the end of the transmission output shaft does not contact the work surface as it is installed 19 Make sure that the thrust washer Is 29 25a Locate the left hand fork 29 14b Unscrew the bolt arrowed and remove the cam plate 29 15 Measure the selector drum journal diameter installed on the left hand end of each shaft apply a smear of grease to the inner face of each washer to make them stick to their adjacent pinions and so prevent them dropping off as the shafts are installed see illustrations 31 28b and 51d and 30 17 Also make sure that the thrust washer is installed on the right hand end of the output shaft see illustration 31 55d 20 Lay the transmission input shaft and output shaft side by side on the bench so that the pinions for each gear mesh together see illustration 30 18 Make sure that the shafts are the correct way round with the smallest pinion on the input shaft meshing with the largest pinion on the output shaft 21 Fit the selector fork assembly onto the transmission shafts locating each fork into the groove in its pinion and making sure their identification marks are positioned as described in Step 2 Also make sure that the fork assembly is positioned correctly in relation to each shaft as noted on removal 22 Engage the selector drum with the forks locating their guide pins in the selector drum tracks again making sure everything is correctly positioned the right hand end of the selector drum carries the bearing so the selector fork marked R must be engaged in the groove nearest the bearing and at the same end of the assembly as the smallest pinion on the input shaft and the largest pinion on the output shaft If you intend to use cable ties to hold the assembly together fit them now 23 Grasp the input shaft and output shaft and the selector drum and forks and install them into the left hand crankcase making sure that both input shaft and output shaft ends engage in their bearings and the selector fork shaft end and the selector drum journal engage in their holes in the crankcase Make sure the thrust washers do not drop off the ends of the shafts as they are installed If cable ties were used cut them and slip them out of position 24 Install the crankshaft see Section 27 Reassemble the crankcase halves see Section 23 29 25b the centre fork All other models 25 Apply molybdenum disulphide oil a 50 50 mixture of molybdenum disulphide grease and clean engine oil to the selector fork ends Install the selector fork marked L first with its letter facing up and locate it in the groove of its pinion on the output shaft you may have lift the pinion up the shaft a bit so that the fork clears the crankcase land see illustration Next install the fork marked C into the groove of its pinion on the Input shaft again with the letter facing up see illustration Finally install the fork marked R letter facing up into the groove of its pinion on the output shaft see illustration Position they forks so they will not get In the way of the selector drum when sliding it in 26 Apply molybdenum disulphide oil a 50 50 mixture of molybdenum disulphide grease and clean engine oil to the journal on the left hand end of the selector drum Align the drum so that the neutral contact will be against the 29 25c and the right hand fork in their pinions 2

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