Honda TRANSALP XL600-650V (1987-2002) [162/291] 4 frame suspension and final drive

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6 4 Frame suspension and final drive 3 1a Remove the split pin and washer A and withdraw the pivot pin B noting the return spring ends C front footrest XL600V shown 1 General information All models have a box section steel cradle frame Front suspension is by a pair of oil damped telescopic forks with air assistance on XRV750 L to S 1990 to 1995 models The forks have a conventional type damper and are not adjustable At the rear a box section aluminium swing arm acts on a single shock absorber via a three way linkage The shock absorber is adjustable for spring pre load on all models and for compression damping on XL650V models The drive to the rear wheel is by chain and sprockets 2 Frame inspection and repair 3 1b Remove the split pin and washer A and withdraw the pivot pin B rear footrest XL650V shown specialists have the jigs and other equipment necessary for straightening the frame to the required standard of accuracy but even then there is no simple way of assessing to what extent the frame may have been over stressed 2 After the machine has accumulated a lot of miles the frame should be examined closely for signs of cracking or splitting at the welded joints Loose engine mount bolts can cause ovaling or fracturing of the mounting tabs Minor damage can often be repaired by welding depending on the extent and nature of the damage 3 Remember that a frame which is out of alignment will cause handling problems If misalignment is suspected as the result of an accident it will be necessary to strip the machine completely so the frame can be thoroughly checked 3 Footrests brake pedal and gearchange lever removal and installation 1 The frame should not require attention unless accident damage has occurred In most cases frame replacement is the only satisfactory remedy for such damage A few frame 1 Remove the split pin and washer from the bottom of the footrest pivot pin then 3 4 Unhook the brake light switch spring A and the pedal return spring B XL600V shown 3 5a Brake pedal arm pinch bolt arrowed XL650V Footrests withdraw the pivot pin and remove the foot rest see illustrations On the front footrests note the fitting of the return spring ends 2 The footrest rubbers can be separated from the footrest and renewed if required 3 Installation Is the reverse of removal Brake pedal Removal 4 Unhook the brake pedal return spring and the brake light switch spring from the hook on the pedal see illustration 5 Mark the alignment between the brake pedal arm on the inside and the pedal itself so it can be installed in the same position there should be a punch mark on the pedal shaft which aligns with the slit in the arm but it may be difficult to see Unscrew the pinch bolt on the brake pedal arm on the Inside of the frame see illustration It you can t access it because of its position on XL600V H to K 1987 to 1989 models fully unscrew the adjusting wingnut on the end of the brake rod and on all other models remove the split pin from the clevis pin securing the brake pedal to the master cylinder pushrod then remove the clevis pin and separate the pedal from the pushrod see illustrations Rotate the pedal until the bolt can be accessed see 3 5b Remove the split pin