Honda TRANSALP XL600-650V (1987-2002) [170/291] 12 frame suspension and final drive
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Honda TRANSALP XL600-650V (1987-2002) [170/291] 12 frame suspension and final drive

Honda TRANSALP XL600-650V (1987-2002) [170/291] 12 frame suspension and final drive

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6 12 Frame suspension and final drive 8 8a Unscrew and remove the damper rod bolt 8 8b then tip the damper rod out of the fork 8 9 Prise out the dust seal using a flat bladed screwdriver 12 With the tube removed slide off the oil seal washer and top bush noting which way up they fit see illustration 8 11b Discard the oil seal as a new one must be used Caution Do not remove the bottom bush from the tube unless it is to be replaced 13 Tip the damper rod seat out of the slider you may have to push it from the bottom via the damper bolt hole see illustration Discard the O ring as a new one must be used Inspection 8 10 Prise out the retaining clip using a flat bladed screwdriver 8 11a To separate the fork tube from the slider pull them apart firmly several times withdraw the spacer spring seat and the spring from the tube On XL600V T to X 1996 to 1999 models and XL650V models withdraw the spring from the tube see illustration 7 12 On XRV750 models withdraw the upper spring spring seat and lower spring from the tube Note which way up the spring fits 7 Invert the fork over a suitable container and pump the fork tube vigorously to expel as much oil as possible see illustration 7 13 Support the fork upside down in the container for a while to allow as much oil as possible to drain and pump the fork again 8 Remove the previously slackened damper rod bolt and its copper sealing washer from the bottom of the slider see illustration Discard the sealing washer as a new one must be used on reassembly Invert the fork and tip the damper rod out of the top of the tube 9 Carefully prise out the dust seal from the top of the slider to gain access to the oil seal retaining clip see illustration Discard the dust seal as a new one must be used 10 Carefully remove the retaining clip taking care not to scratch the surface of the tube see illustration It is advisable to compress the fork beforehand because then any accidental damage to the tube will be away from its main point of contact with the seal 11 To separate the tube from the slider it is necessary to displace the oil seal and top bush The bottom bush does not pass through the top bush and this can be used to good effect Push the tube gently inwards until it stops against the damper seat Take care not to do this forcibly or the seat may be damaged Now pull the tube sharply outwards until the bottom bush strikes the top bush see illustration Repeat this operation until the top bush and seal are tapped out of the slider see illustration 8 11b the slide hammer effect will displace the oil seal and bush 8 13 Remove the damper rod seat from the slider 14 Clean all parts in solvent and blow them dry with compressed air if available Check the fork tube for score marks scratches flaking of the chrome finish and excessive or abnormal wear Look for dents in the tube and replace the tube in both forks if any are found Check the fork seal seat for nicks gouges and scratches If damage is evident leaks will occur Also check the oil seal washer for damage or distortion and replace it II necessary 15 Check the fork tube for runout using V blocks and a dial gauge If the amount of runout exceeds the service limit specified the tube should be replaced Warning If the tube is bent or exceeds the runout limit it should not be straightened replace it with a new one A 16 Check the springs the main spring the rebound spring on the damper rod and on XRV750 the upper spring for cracks and other damage see illustration Measure the mam spring free length and compare the measure 8 16 Check the compression spring s and rebound spring arrowed

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