Honda TRANSALP XL600-650V (1987-2002) [145/291] 18 fuel and exhaust systems
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Honda TRANSALP XL600-650V (1987-2002) [145/291] 18 fuel and exhaust systems

Honda TRANSALP XL600-650V (1987-2002) [145/291] 18 fuel and exhaust systems

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4 18 Fuel and exhaust systems 11 8a Assemble the housing 11 8b aligning the mating surfaces with the punch mark arrowed purpose grease and attach them to the throttle cam on the carburettor see illustration 11 3b Fit the upper closing cable into the mounting bracket and tighten the locknut against it see illustration 11 3a Fit the lower opening cable into the bracket and draw the captive nut against the lug on the bracket see illustration Tighten the locknut against the bracket see illustration 11 2a 10 Operate the throttle to check that it opens and closes freely 11 Check the amount of freeplay in the throttle cables and adjust if necessary Chap ter 1 Turn the handlebars back and forth to make they don t cause the steering to bind 12 Install the fuel tank see Section 2 13 Start the engine and check that the idle speed does not rise as the handlebars are turned If it does the throttle cables are routed incorrectly Correct the problem before riding the motorcycle 1 Remove the fuel tank see Section 2 2 Unscrew each choke plunger assembly nut from the carburettors and withdraw the plunger assembly from each carburettor body see illustrations 7 4a and b Compress the spring and detach the cable end from the choke plunger noting how it fits Withdraw the cable from the assembly If the carburettor is not being disassembled for cleaning it Is advisable to reinstall the choke plunger assembly into the carburettor to avoid losing any of the components 3 Unscrew the bolt and remove the collar from the hand guard on the left hand side 12 3a Unscrew the bolt and remove the collar 12 3b Counter hold the screwhead and undo the nut on the bottom 12 3c and remove the handguard 12 Choke cable removal and installation Removal 12 4a Pull back the cover arrowed 11 9 Fit the cable into the bracket see illustration Counter hold the screw head and undo the nut on its bottom see illustration Remove the handguard see illustration 4 Pull back the rubber cover on the choke cable see illustration Undo the screw securing the lever then detach the lever noting the wave washer and plate beneath it see illustration Draw the cable end out of the lever bracket then slip the inner cable out using the slot and detach the nipple from the lever 5 Remove the cable from the machine noting its correct routing Installation 6 Install the cable making sure it is correctly routed The cable must not interfere with any other component and should not be kinked or bent sharply 7 Lubricate the upper cable nipple with multi purpose grease Fit the cable end into the lever then slip the inner cable into the bracket and fit the outer cable end into its socket Mount the lever on the bracket making sure the plate and wave washer are fitted and install the screw Fit the handguard then thread the locknut onto the bottom of the screw Fit the top bolt with its collar 8 Pass the lower end of each inner cable through its plunger assembly nut and spring then attach the nipple to the plunger making sure it is secure Install each plunger assembly into the carburettor body ano tighten its nut securely 9 Fit the cable in its guide Check the operation of the choke cable as described in Chapter 1 12 4b then undo the screw arrowed lift off the lever and detach the cable

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