Honda TRANSALP XL600-650V (1987-2002) [199/291] 14 brakes wheels and tyres
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Honda TRANSALP XL600-650V (1987-2002) [199/291] 14 brakes wheels and tyres

Honda TRANSALP XL600-650V (1987-2002) [199/291] 14 brakes wheels and tyres

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7 14 Brakes wheels and tyres 7 4 Slacken the reservoir cover screws circumstances use petroleum based solvents to clean brake parts Use clean brake fluid brake cleaner or denatured alcohol only Removal 1 Remove the rear wheel see Section 14 2 Lift the brake plate out of the drum In the wheel hub Remove the brake shoes see Section 2 see illustration 2 24 Inspection 3 Visually inspect the surface of the brake plate for distortion cracks and other damage and replace it with a new one if necessary 4 Check the operation of the actuating cam If there are any signs of roughness or stiffness disassemble the plate assembly as follows 5 Unscrew the nut and withdraw the bolt securing the arm on the end of the actuating shaft and slide the arm off Note the alignment of the indicator plate then slide that off the shaft Withdraw the shaft Remove the thrust plate noting how it locates 6 Clean all components in solvent Check the condition of the splines on the shaft and arm and replace them with new ones if the splines are worn or deformed Remove the grease seals from the plate and clean the bore Fit new grease seals if the old ones are deformed damaged or deteriorated if there is evidence of dirt and water ingress in the bore and on the shaft then renew them whatever they look like Check the cam on the inner end of the shaft for wear 7 Grease the lips of the seals and press them into place Apply grease to the thrust plate 7 7 Counter hold the hose nut A then unscrew the locknut B and separate the hose from the hose joint C 7 5 Disconnect the brake light switch wiring connectors arrowed 7 6 Brake hose banjo bolt arrowed and place it on the brake plate locating its slot over the pin on the plate Apply grease to the shaft and carefully slide it into the brake plate making sure the thrust plate stays in place and taking care not to damage the seal lips it is a good idea to wrap a single layer of thin insulating tape around the shaft splines to prevent damage Slide the indicator plate onto the shaft with its pointer facing in and aligning its tab with the cutout on the shaft Slide the arm onto the shaft aligning the punch mark on the end of the shaft with that on the outside of the arm Fit the bolt and secure it with the nut fluid some clean rags and internal circlip pliers Note To prevent damage to the paint from spilled brake fluid always cover the fuel tank when working on the master cylinder Caution Disassembly overhaul and reassembly of the brake master cylinder must be done in a spotlessly clean work area to avoid contamination and possible failure of the brake hydraulic system components Installation 8 Install the brake shoes see Section 2 Fit the plate assembly into the drum in the rear wheel hub 9 Install the wheel see Section 14 7 Front brake master cylinder removal overhaul ÿ and installation 1 If the master cylinder is leaking fluid or if the lever does not produce a firm feel when the brake is applied and bleeding the brakes does not help see Section 10 and the hydraulic hoses and unions are all in good condition then master cylinder overhaul is recommended 2 Before disassembling the master cylinder read through the entire procedure and make sure that you have the correct rebuild kit Also you will need some new DOT 4 brake 7 8 Front master cylinder clamp bolts arrowed Removal Note If the master cylinder is being displaced from the handlebar and not being removed completely or overhauled follow Steps 5 and 7 only 3 Remove the rear view mirror see Chapter 8 Remove the front brake lever see Chapter 6 4 Loosen but do not remove the screws holding the reservoir cover in place see illustration 5 Disconnect the electrical connectors from the brake light switch see illustration 6 On XL600V M to X 1991 to 1999 models and XL650V models unscrew the brake hose banjo bolt and separate the hose from the master cylinder noting its alignment see illustration Discard the two sealing washers as they must be replaced with new ones Wrap the end of the hose In a clean rag and suspend it in an upright position or bend it down and place the open end in a clean container The objective is to prevent excessive loss of brake fluid fluid spills and system contamination 7 On XL600V H to L 1987 to 1990 models and XRV750 models counter hold the hose nut then unscrew the locknut and separate the hose from the hose joint in the master cylinder see illustration Wrap the end of the hose in a clean rag and suspend it in an upright position or bend it down and place the open end in a clean container The objective is to prevent excessive loss of brake fluid fluid spills and system contamination If required unscrew the hose joint and remove it from the master cylinder Discard the sealing washer as a new one must be used 8 Unscrew the master cylinder clamp bolts then lift the master cylinder and reservoir away from the handlebar noting how the top mating surfaces of the clamp align with the punch mark on the top of the handlebar see illustration

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