Honda TRANSALP XL600-650V (1987-2002) [166/291] 8 frame suspension and final drive
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Honda TRANSALP XL600-650V (1987-2002) [166/291] 8 frame suspension and final drive

Honda TRANSALP XL600-650V (1987-2002) [166/291] 8 frame suspension and final drive

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6 8 Frame suspension and final drive HAYNES Slackening the fork clamp bolts in the top yoke before slackening the fork top bolts releases pressure on the top bolt This makes it much easier to remove and helps to preserve the threads HINT 5 Slacken the fork clamp bolts in the bottom yoke and remove the fork by twisting it and pulling it downwards see illustrations 5 15c and remove the handguard remove the choke lever and the clutch lever detaching the cable nipples as you do so see illustration Note the wave washer between the choke lever and the lever plate Remove the plate from the lever bracket if required noting how it fits 17 Installation is the reverse of removal Apply grease to the pivot bolt shaft and the contact areas between the lever and its bracket and to the cable nipples Adjust the clutch cable freeplay see Chapter 1 6 Forks removal and installation Removal Caution Although not strictly necessary before removing the forks it is 6 4a Slacken the fork clamp bolts arrowed in the top yoke 6 5b Draw the fork down and out of the yokes 5 16 Undo the screw arrowed lift off the choke lever slide out the clutch lever and detach the cable recommended that the fairing and fairing panels are removed see Chapter 8 This will prevent accidental damage to the paintwork 1 Remove the front mudguard see Chap ter 8 2 Remove the front wheel see Chapter 7 Tie the front brake calipers and hoses back so that they are out of the way 3 Release the speedometer cable and any wiring from the fork noting its routing 4 Working on one fork at a time slacken the fork clamp bolts in the top yoke see illustration If the fork is to be disassembled or if the fork oil is being changed It is advisable to slacken the fork top bolt at this stage see illustration On XRV750 L to S 1990 to 1995 models first remove the air valve cap then depress the valve to release any air under pressure Note the amount of protrusion of the fork above the top yoke 6 4b and if required the fork top bolt 6 7 Set the fork height as shown making sure it is the same on both sides HAYNES If the fork legs are seized in the yokes spray the area with penetrating oil and allow time for it to soak in before trying again HiNT Installation 6 Remove all traces of corrosion from the fork tube and the yokes Slide the fork up through the bottom yoke and into the top yoke making sure it passes through the cable tie s and all cables hoses and wiring are routed on the correct side of the fork see illustration 6 5b 7 Set the top of the fork tube not the top of the fork top bolt flush with the top surface of the top yoke see illustration Make sure it is the same on both sides 8 Tighten the fork clamp bolts in the bottom yoke to the torque setting specified at the beginning of the Chapter see illustration 6 5a If the fork has been dismantled or if the fork oil was changed tighten the fork top bolt to the specified torque setting see illustration Now 6 5a Bottom yoke fork clamp bolts arrowed 6 8 Tighten the fork top bolt to the specified torque setting

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