![Honda TRANSALP XL600-650V (1987-2002) [3/291] Routine maintenance and servicing](/img/pdf.png)
Honda TRANSALP XL600-650V (1987-2002) [3/291] Routine maintenance and servicing
![Honda AFRICA TWIN XRV750 (1987-2002) [3/291] Routine maintenance and servicing](/views2/1121125/page3/bg3.png)
Содержание
- 87 to 02 1
- Contents intro specifications 1
- Haynes manuals just cannot be beaten 1
- Haynes service repair manual 1
- Hl600 650u transaid kru750 africa tun 1
- By matthew coombs 2
- Digitalized by k k with thanks ot a j for providing the media 2
- Haynes 2
- Honda xl600 650v transalp xrv750 africa twin 2
- Models covered xl600v transalp 583cc 1987 to 1999 xl650v transalp 647cc 2000 to 2002 xrv750 africa twin 742cc 1990 to 2002 2
- Please note that the material is copyright protected and that users should obtain an original copy 2
- Service and repair manual 2
- This pdf has been prepared to make it possible to go on tour with the whole workshop manual on a cd rom only 2
- Contents 3
- Daily pre ride checks 3
- Introduction 3
- Living with your honda 3
- Maintenance 3
- Routine maintenance and servicing 3
- Chassis components 4
- Contents 4
- Electrical system 4
- Engine transmission and associated systems 4
- Reference 4
- Repairs and overhaul 4
- Wiring diagrams 4
- The birth of a 5
- Introduction 6
- Introduction 7
- Honda transalp africa twin 8
- Introduction 8
- Introduction 9
- About this manual 10
- Acknowledgements 10
- Model development 10
- Xl600v h and v j transalp 1987 and 1988 model years 10
- Xl600v k transalp 1989 model year 10
- Xl600v m transalp 1991 model year 10
- Xl600v r transalp 1994 and 1995 model years 10
- Xl600v t transalp 1996 model year 10
- Xl600v v transalp 1997 model year 10
- Xl650v y v 1 and v 2 transalp 2000 to 2002 model years 10
- Bike spec 11
- Dimensions and weights xl600v models 11
- Model development bike spec 11
- Xrv750 l africa twin 1990 model year 11
- Xrv750 n africa twin 1992 model year 11
- Xrv750 p africa twin 1993 model year 11
- Xrv750 t africa twin 1996 model year 11
- Xrv750 v w x y 1 and 2 africa twin 1997 to 2002 model years 11
- Bike spec o n 12
- Dimensions and weights xl650v models 12
- Dimensions and weights xrv750 models 12
- Bike spec 13
- Cycle parts 13
- Engine 13
- Frame and engine numbers 14
- Identification numbers 14
- Li j www motorcyclenews com 14
- Performance data 14
- Performance data i id numbers 14
- Xl600v power and torque curves 14
- All uk market models and germany type 1 germany type ii models 15
- Buying spare parts 15
- Full power models 15
- O i4 id numbers 15
- Restricted power output 15
- Asbestos 16
- Electricity 16
- Remember 16
- Safety first 0 5 16
- The battery 16
- Before you start 17
- Bike care 17
- Daily pre ride checks 17
- Engine transmission oil level check 17
- The correct oil 17
- Coolant level check 18
- Daily pre ride checks 18
- Cis daily pre ride checks 19
- Disc brake fluid level checks 19
- Daily pre ride checks 0 9 20
- Drum brake checks 20
- Rear brake fluid level 20
- Drive chain 21
- Legal and safety checks 21
- Lighting and signalling 21
- O 2o daily pre ride checks 21
- Safety 21
- Suspension and steering 21
- Suspension steering and drive chain checks 21
- The correct pressures 21
- Tyre care 21
- Tyre checks 21
- Tyre tread depth 21
- Chapter 1 routine maintenance and servicing 22
- Contents 22
- Degrees of difficulty 22
- Engine 22
- Routine maintenance service 22
- Specifications 22
- Cycle parts 23
- Recommended lubricants and fluids 23
- Specifications 23
- Torque settings 23
- After the initial 600 miles 1000 km 24
- Daily pre ride 24
- Daily pre ride checks 24
- Every 12 000 miles 18 000 km or 18 months whichever comes first 24
- Every 12 000 miles 18 000 km or two years whichever comes first 24
- Every 24 000 miles 36 000 km or two years whichever comes sooner 24
- Every 4000 miles 6000 km or 6 months whichever comes sooner 24
- Every 600 miles 1000 km 24
- Every 8000 miles 12 000 km or 12 months whichever comes sooner 24
- Every 8000 miles 12 000 km or 12 months whichever comes sooner continued 24
- Maintenance schedule 24
- Non scheduled maintenance 24
- Component location 25
- Component locations xl600v models 25
- Component location 26
- Component locations xl650v models 26
- Component location 27
- Component locations xrv750 models 27
- Every 600 miles 1000 km 28
- Introduction 28
- Maintenance procedures 1 28
- Adjustment 29
- I every 600 miles 1000 km 29
- Cleaning and lubrication 30
- Every 4000 miles 6000 km or 6 months 30
- Every 600 miles 1000 km 1 30
- Front brake all models 30
- Check and adjustment 31
- Clutch 31
- Lio every 4000 miles 6000 km 31
- Rear brake 31
- Rear disc brake all models except the xl600v h to l 31
- Rear drum brake xl600v h to l 1987 to 1990 models 31
- Check and adjustment 32
- Every 4000 miles 6000 km 32
- Spark plugs 32
- Every 4000 miles 6000 km 33
- Standard type batteries xl600v and xrv750 l to n 1990 to 1992 models 33
- Air filter 34
- Maintenance free mf batteries xl650v and xrv750 p models onwards 1993 on 34
- Wheels 34
- Wheels and tyres 34
- ________________________every 4000 miles 6000 km 34
- Every 4000 miles 6000 km 35
- Sub air filter 35
- Engine transmission oil and filter 36
- Every 4000 miles 6000 km i is 36
- Every 8000 miles 12 000 km or 12 months 36
- Lubrication 36
- Renewal 36
- Spark plugs 36
- Stand s lever pivots and cables 36
- Every 8000 miles 12 000 km 37
- Every 8000 miles 12 000 km 1 7 38
- Choke cable 39
- Every 8000 miles 12 000 km 39
- Throttle cables 39
- Check and adjustment 40
- Every 8000 miles 12 000 km 40
- Valve clearances 40
- Carburettors 41
- I o every 8000 miles 12 000 km 41
- Cooling system check 42
- Every 8000 miles 12 000 km 42
- Brake system 43
- Every 8000 miles 12 000 km 43
- Every 8000 miles 12 000 km 44
- Headlight aim 44
- Xl600v h to p 1987 to 1993 models 44
- Xl600v r to x 1994 to 1999 models 44
- Xl650v models 44
- Xrv750 models 44
- Every 8000 miles 12 000 km 45
- Front suspension 45
- Rear suspension 45
- Sidestand 45
- Steering head bearings 45
- Suspension 45
- Adjustment 46
- Every 8000 miles 12 000 km 1 5 46
- Nuts and bolts 46
- Tightness check 46
- Every 12 000 miles 18 000 km or 18 months 47
- Every 12 000 miles 18 000 km or two years 47
- Every 24 000 miles 36 000 km or two years 47
- Every 8000 miles 12 000 km 47
- Cylinder compression m 48
- Engine oil pressure 48
- Every 24 000 miles 36 000 km 1 7 48
- Flushing 48
- Non scheduled maintenance 48
- Refilling 48
- Brake caliper and 49
- Brake hoses 49
- Front forks 49
- Fuel hoses 49
- Linkage bearings 49
- Master cylinder seals 49
- Non scheduled maintenance 49
- Steering head bearings 49
- Swingarm and suspension 49
- Wheel bearings 49
- Chapter 2 engine clutch and transmission 50
- Contents 50
- Degrees of difficulty 50
- Difficult 50
- Engine clutch tranmissison 50
- Fairly difficult 50
- Fairly easy 50
- General 50
- Specifications 50
- Very difficult 50
- 2 engine clutch and transmission 51
- Camshafts rockers and cam chain xl600v h and j 1987 and 1988 51
- Camshafts rockers and cam chain xl600v k to x 1989 and 1999 51
- Camshafts rockers and cam chain xl650v models 51
- Camshafts rockers and cam chain xl650v models continued 52
- Camshafts rockers and cam chain xrv750 models 52
- Cylinder head 52
- Engine clutch and transmission 2 3 52
- Valves guides and springs xl600v h to l 1987 to 1990 models 52
- 4 engine clutch and transmission 53
- Valves guides and springs xl600v h to l 1987 to 1990 models continued 53
- Valves guides and springs xl600v m to t 1991 to 1996 models 53
- Engine clutch and transmission 2 5 54
- Valves guides and springs xl600v m to t 1991 to 1996 models continued 54
- Valves guides and springs xl600v v to x 1997 to 1999 models 54
- Valves guides and springs xl650v models 54
- 6 engine clutch and transmission 55
- Valves guides and springs xl650v models continued 55
- Valves guides and springs xrv750 models 55
- Cylinders xl600v models 56
- Cylinders xl650v models 56
- Cylinders xrv750 models 56
- Engine clutch and transmission 2 7 56
- Pistons xl600v models 56
- Pistons xl650v models 56
- 8 engine clutch and transmission 57
- Piston rings xl600v models 57
- Piston rings xl650v models 57
- Pistons xl650v models continued 57
- Pistons xrv750 models 57
- Clutch xl600v models 58
- Clutch xl650v models 58
- Engine clutch and transmission 2 9 58
- Piston rings xrv750 models 58
- 10 engine clutch and transmission 59
- Clutch xl650v models continued 59
- Clutch xrv750 models 59
- Connecting rods xl600v and xl650v models 59
- Starter clutch xl600v models 59
- Starter clutch xl650v models 59
- Starter clutch xrv750 models 59
- Connecting rods xl600v and xl650v models continued 60
- Connecting rods xrv750 models 60
- Crankshaft and bearings xl600v and xl650v models 60
- Crankshaft and bearings xrv750 models 60
- Engine clutch and transmission 2 11 60
- Transmission xl600v models 60
- 12 engine clutch and transmission 61
- Transmission xl600v models continued 61
- Transmission xl650v models 61
- Engine clutch and transmission 2 13 62
- Transmission xl650v models continued 62
- Transmission xrv750 models 62
- 14 engine clutch and transmission 63
- Lubrication system 63
- Selector drum and forks xl600v models 63
- Selector drum and forks xl650v models 63
- Selector drum and forks xrv750 models 63
- Transmission xrv750 models continued 63
- Engine clutch and transmission 2 15 64
- Lubrication system continued 64
- Torque settings 64
- 16 engine clutch and transmission 65
- Engine 65
- General information 65
- General note 65
- Major engine repair 65
- Operations possible with the engine in the frame 65
- Operations requiring engine removal 65
- Removal 65
- Removal and installation 65
- Engine clutch and transmission 2 17 66
- 18 engine clutch and transmission 67
- Xl600v models 67
- Xl650v models 67
- Engine clutch and transmission 2 19 68
- Xrv750 l to n 1990 to 1992 models 68
- Xrv750 p models onward 1993 on 68
- 20 engine clutch and transmission 69
- Disassembly 69
- Engine disassembly and reassembly 69
- General information 69
- Installation 69
- Oil cooler 69
- Oil cooler and distributor 69
- Reassembly 69
- Removal 69
- Removal inspection and installation xrv750 models 69
- Engine clutch and transmission 2 21 70
- Inspection 70
- Installation 70
- Oil distributor 70
- Removal 70
- Removal and installation 70
- Valve covers 70
- 22 engine clutch and transmission 71
- Camshafts and rockers 71
- Installation 71
- Removal 71
- Engine clutch and transmission 2 23 72
- 24 engine clutch and transmission 73
- Inspection 73
- Engine clutch and transmission 2 25 74
- Installation 74
- 26 engine clutch and transmission 75
- And guide blades 76
- Cam chain tensioner 76
- Cam chain tensioners 76
- Cam chains 76
- Engine clutch and transmission 2 27 76
- Front cylinder cam chain 76
- Installation 76
- Rear cylinder cam chain 76
- Removal 76
- Removal and installation 76
- Removal inspection and installation 76
- 28 engine clutch and transmission 77
- Cam chain guide blade 77
- Cylinder heads 77
- Inspection 77
- Installation 77
- Removal 77
- Removal and installation 77
- Removal front cylinder head 77
- Engine clutch and transmission 2 29 78
- Installation both heads 78
- Removal rear cylinder head 78
- 30 engine clutch and transmission 79
- And reassembly 79
- Cylinder head and valves 79
- Disassembly 79
- Disassembly inspection sv 79
- Servicing 79
- Valve guides 79
- Valves valve seats 79
- Engine clutch and transmission 2 31 80
- Inspection 80
- 32 engine clutch and transmission 81
- Reassembly 81
- Cylinder barrels 82
- Engine clutch and transmission 2 33 82
- Removal 82
- Removal inspection and installation 82
- 34 engine clutch and transmission 83
- Inspection 83
- Installation 83
- Engine clutch and transmission 2 35 84
- Pistons 84
- Removal 84
- Removal inspection and installation 84
- 36 engine clutch and transmission 85
- Inspection 85
- Engine clutch and transmission 2 37 86
- Installation 86
- Piston rings 86
- 38 engine clutch and transmission 87
- Clutch 87
- Removal 87
- Removal inspection and installation 87
- Engine clutch and transmission 2 39 88
- 40 engine clutch and transmission 89
- Inspection 89
- Engine clutch and transmission 2 41 90
- Installation 90
- 42 engine clutch and transmission 91
- Engine clutch and transmission 2 43 92
- 44 engine clutch and transmission 93
- Clutch cable 93
- Removal 93
- Removal and installation 93
- Engine clutch and transmission 2 45 94
- Gearchange mechanism 94
- Installation 94
- Removal 94
- Removal inspection and installation 94
- 46 engine clutch and transmission 95
- Inspection 95
- Engine clutch and transmission 2 47 96
- Installation 96
- Primary drive gear 96
- Removal inspection and installation 96
- 48 engine clutch and transmission 97
- Inspection 97
- Installation 97
- Removal 97
- Removal inspection and installation 97
- Starter clutch 97
- Crankcase 98
- Engine clutch and transmission 2 49 98
- Installation 98
- Separation 98
- Separation and reassembly 98
- 50 engine clutch and transmission 99
- Reassembly 99
- Crankcase 100
- Engine clutch and transmission 2 51 100
- Inspection and servicing 100
- Inspection servicing and renewal 100
- 52 engine clutch and transmission 101
- Crankcase renewal 101
- Oil pump and pressure 101
- Relief valve 101
- Removal 101
- Removal inspection and installation 101
- Engine clutch and transmission 2 53 102
- Inspection 102
- 54 engine clutch and transmission 103
- Engine clutch and transmission 2 55 104
- Installation 104
- 56 engine clutch and transmission 105
- Crankshaft and 105
- General information 105
- Inspection 105
- Inspection and installation 105
- Main and connecting 105
- Main bearings 105
- Removal 105
- Removal ÿ 105
- Rod bearings 105
- Crankshaft selection 106
- Engine clutch and transmission 2 57 106
- Installation 106
- Main bearing selection 106
- Xl models 106
- Xrv models 106
- 58 engine clutch and transmission 107
- Connecting rods 107
- Inspection 107
- Oil clearance check 107
- Removal 107
- Removal inspection and installation 107
- And installation 108
- Bearing shell selection 108
- Engine clutch and transmission 2 59 108
- Installation 108
- Removal 108
- Removal inspection 108
- Selector drum and forks 108
- Xl models 108
- Xrv models 108
- 60 engine clutch and transmission 109
- All other models 109
- Inspection 109
- Engine clutch and transmission 2 61 110
- Installation 110
- Xl600v h to r 1987 to 1995 models 110
- 62 engine clutch and transmission 111
- All other models 111
- Installation 111
- Removal 111
- Removal and installation 111
- Transmission shafts 111
- Xl600v h to r 1987 to 1995 models 111
- All other models 112
- Disassembly inspection s and reassembly 112
- Engine clutch and transmission 2 63 112
- Input shaft disassembly 112
- Transmission shafts 112
- Xl600v models 112
- 64 engine clutch and transmission 113
- Input shaft inspection 113
- Xl650v models 113
- Xrv750 models 113
- Engine clutch and transmission 2 65 114
- Input shaft reassembly 114
- Xl600v models 114
- 66 engine clutch and transmission 115
- Engine clutch and transmission 2 67 116
- Output shaft disassembly 116
- Output shaft inspection 116
- Output shaft reassembly 116
- Xl600v models 116
- Xl650v and xrv750 models 116
- Xl650v models 116
- Xrv750 models 116
- 68 engine clutch and transmission 117
- Engine clutch and transmission 2 69 118
- Initial start up after overhaul 118
- Xl65ov and xrv750 models 118
- 70 engine clutch and transmission 119
- Recommended running in procedure 119
- Chapter 3 cooling system 120
- Contents 120
- Coolant 120
- Coolant temperature sender 120
- Cooling fan switch 120
- Cooling system 120
- Degrees of difficulty 120
- Radiator 120
- Specifications 120
- Thermostat 120
- Torque settings 120
- 2 cooling system 121
- Check and replacement 121
- Cooling fan 121
- Cooling fan and fan switch 121
- General information 121
- Radiator pressure cap 121
- Replacement 121
- Coolant temperature gauge 122
- Coolant temperature gauge and sender 122
- Cooling fan switch 122
- Cooling system 3 3 122
- 4 cooling system 123
- Coolant temperature sender 123
- Removal 123
- Thermostat and housing 123
- Cooling system 3 5 124
- Xl600v and xrv750 models 124
- Xl650v models 124
- 6 cooling system 125
- Installation 125
- Radiators 125
- Removal 125
- Check removal and installation 126
- Cooling system 3 7 126
- Installation 126
- Removal 126
- Water pump 126
- 8 cooling system 127
- Coolant hoses and unions 127
- Coolant reservoir 127
- Installation 127
- Removal 127
- Removal and installation 127
- Xl600v models 127
- Xl650v models 127
- Xrv750 models 127
- Carburettor adjustments 128
- Chapter 4 fuel and exhaust systems 128
- Contents 128
- Degrees of difficulty 128
- Fuel and exhaust 128
- Specifications 128
- 2 fuel and exhaust systems 129
- Fuel gauge sender unit xl650v models 129
- General information 129
- General information and precautions 129
- Jet sizes 129
- Torque settings 129
- Xl600v models 129
- Xl650v models 129
- Xrv750 models 129
- Fuel and exhaust systems 4 3 130
- Fuel tank 130
- Fuel tank and tap 130
- Precautions 130
- 4 fuel and exhaust systems 131
- Removal xrv750 models 131
- Fuel and exhaust systems 4 5 132
- Fuel tap 132
- Installation all models 132
- Removal 132
- 6 fuel and exhaust systems 133
- Air duct housing xl600v and xrv750 l to n 1990 to 1992 models 133
- Air filter duct housing 133
- Cleaning and repair 133
- Fuel tank 133
- Inspection 133
- Installation 133
- Removal 133
- Air filter housing xl650v and xrv750 p models onwards 1993 on 134
- Fuel and exhaust systems 4 7 134
- Installation all models 134
- Removal xl650v models 134
- Removal xrv750 models 134
- 8 fuel and exhaust systems 135
- Adjustment 135
- Air fuel mixture adjustment 135
- Carburettor overhaul 135
- Carburettors 135
- Removal 135
- Restrictions 135
- Fuel and exhaust systems 4 9 136
- 10 fuel and exhaust systems 137
- Carburettors 137
- Disassembly 137
- Installation 137
- Fuel and exhaust systems 4 11 138
- 12 fuel and exhaust systems 139
- Cleaning 140
- Fuel and exhaust systems 4 13 140
- Inspection 140
- Separation 140
- 14 fuel and exhaust systems 141
- Joining 141
- Carburettors 142
- Fuel and exhaust systems 4 15 142
- Reassembly and float height check 142
- 16 fuel and exhaust systems 143
- Fuel and exhaust systems 4 17 144
- Installation 144
- Removal 144
- Throttle cables 144
- 18 fuel and exhaust systems 145
- Choke cable 145
- Installation 145
- Removal 145
- Removal and installation 145
- Exhaust system 146
- Fuel and exhaust systems 4 19 146
- Removal 146
- 20 fuel and exhaust systems 147
- Catalytic converter 148
- Fuel and exhaust systems 4 21 148
- Fuel pump 148
- Installation 148
- 22 fuel and exhaust systems 149
- Check and replacement 149
- Check fuel sensor circuit 149
- Check warning light circuit 149
- Fuel level indicator circuit 149
- Installation 149
- Removal 149
- Xrv75o l to n 1990 to 1992 models 149
- Component renewal 150
- Control valve 150
- Fuel and exhaust systems 4 23 150
- General information 150
- Pulse secondary air pair system 150
- Reed valves 150
- Testing 150
- Xl650v models 150
- Chapter 5 ignition system 151
- Contents 151
- Degrees of difficulty 151
- General information 151
- Ignition ht coils 151
- Ignition system 151
- Ignition timing 151
- Pulse generator coil 151
- Specifications 151
- Throttle position sensor 151
- 2 ignition system 152
- General information 152
- Ignition system check 152
- Check removal and installation 153
- Ignition ht coils 153
- Ignition system 5 3 153
- Peak voltage test xl600v t to x 1997 to 1999 models xl650v models and xrv750 t models onwards 1996 on 153
- Primary windings check all models 153
- Removal 153
- Secondary windings check all models 153
- 4 ignition system 154
- Installation 154
- 6 ignition system 155
- General information 155
- Ignition control unit icu 155
- Ignition timing 155
- Installation 155
- Removal 155
- Throttle position sensor 155
- General information 156
- Ignition system 5 7 156
- Immobiliser system hiss 156
- Key registration procedure 156
- Replacement 156
- To register a new key 156
- To register new keys with a new ignition switch 156
- Xl650v models 156
- 8 ignition system 157
- Fault diagnosis 157
- Indicator light does not come on when ignition switched on 157
- To register new keys with a new icu 157
- Troubleshooting procedure 157
- Fault code indicated by flash pattern 158
- Ignition system 5 9 158
- Indicator light stays on when ignition switched on 158
- Replacement 158
- Chapter 6 frame suspension and final drive 159
- Contents 159
- Degrees of difficulty 159
- Frame suspension final drive 159
- Front forks 159
- Specifications 159
- 2 frame suspension and final drive 160
- Front forks continued 160
- Rear shock absorber 160
- Rear suspension linkage xl600v h and j models 160
- Final drive 161
- Frame suspension and final drive 6 3 161
- Rear suspension linkage xl600v h and j models continued 161
- Torque settings 161
- 4 frame suspension and final drive 162
- Brake pedal 162
- Footrests 162
- Footrests brake pedal and gearchange lever 162
- General information 162
- Inspection and repair 162
- Removal 162
- Removal and installation 162
- Centrestand 163
- Frame suspension and final drive 6 5 163
- Gearchange lever 163
- Removal and installation 163
- Sidestand 163
- Sidestand i 163
- Xrv750 l to n 1990 to 1992 models and xl600v k to v x 1988 to 1999 models 163
- Xrv750 p models onwards 1993 on 163
- 6 frame suspension and final drive 164
- Handlebars 164
- Handlebars and levers 164
- Installation 164
- Removal 164
- Removal and installation 164
- Clutch lever 165
- Frame suspension and final drive 6 7 165
- Front brake lever 165
- Handlebar levers 165
- 8 frame suspension and final drive 166
- Frame suspension and final drive 6 9 167
- Xl600v h to v r 1987 to 1995 and xrv750 l to s 1990 to 1995 models 167
- Xl600v t models onward 1996 on xl650v models and xrv750 t 1996 on models onward 167
- 10 frame suspension and final drive 168
- Disassembly 168
- Frame suspension and final drive 6 11 169
- 12 frame suspension and final drive 170
- Inspection 170
- Frame suspension and final drive 6 13 171
- Reassembly 171
- Frame suspension and final drive 6 15 173
- Removal 173
- Steering stem 173
- 16 frame suspension and final drive 174
- Inspection 174
- Inspection and replacement 174
- Installation 174
- Replacement 174
- Steering head bearings 174
- Frame suspension and final drive 6 17 175
- 18 frame suspension and final drive 176
- Xl600v models 176
- Xl650v models 176
- Xrv750 models 176
- Frame suspension and final drive 6 19 177
- Inspection 177
- 20 frame suspension and final drive 178
- Installation 178
- Frame suspension and final drive 6 21 179
- Inspection 179
- Rear suspension linkage 179
- Removal 179
- Removal inspection and installation 179
- 22 frame suspension and final drive 180
- Adjustments 180
- Compression damping xl650v models 180
- Front forks 180
- Installation 180
- Rear shock absorber 180
- Spring pre load all models 180
- Suspension 180
- Frame suspension and final drive 6 23 181
- Removal 181
- Removal and installation 181
- Swingarm 181
- 24 frame suspension and final drive 182
- Inspection 182
- Inspection bearing check ÿ and replacement 182
- Installation 182
- Swingarm 182
- Bearing check and replacement 183
- Drive chain 183
- Endless chains 183
- Frame suspension and final drive 6 25 183
- Staked link chains 183
- 26 frame suspension and final drive 184
- Replacement 184
- Sprockets 184
- Check and replacement 185
- Frame suspension and final drive 6 27 185
- Rear sprocket coupling rubber dampers 185
- Brakes wheels tyres 186
- Brakes xl600v h to l 1987 to 1990 models 186
- Chapter 7 brakes wheels and tyres 186
- Contents 186
- Degrees of difficulty 186
- Specifications 186
- 2 brakes wheels and tyres 187
- Brakes xl600v m to p 1991 to 1993 models 187
- Brakes xl600v r to t 1994 to 1996 models 187
- Brakes xl600v v to x 1997 to 1999 models 187
- Brakes wheels and tyres 7 3 188
- Brakes xl600v v to x 1997 to 1999 models continued 188
- Brakes xl650v models 188
- 4 brakes wheels and tyres 189
- Brakes xl650v models continued 189
- Brakes xrv750 models 189
- Torque settings 189
- Wheels 189
- Brake pads and shoes 190
- Brakes wheels and tyres 7 5 190
- Front brake pads xl600v h to p 1987 to 1993 models and xrv750 l to n 1990 to 1992 models 190
- General information 190
- 6 brakes wheels and tyres 191
- Front brake pads xl600v r to x 1994 to 1999 models xl650v models and xrv750 p models onwards 1993 on 191
- Brakes wheels and tyres 7 7 192
- 8 brakes wheels and tyres 193
- Rear brake pads xl600v m to x 1991 to 1999 models xl650v models and xrv750 models 193
- Rear brake shoes xl600v h to l 1987 to 1990 models 193
- Brake drum and discs front and rear 194
- Brakes wheels and tyres 7 9 194
- Rear brake drum xl600v h to l 1987 to 1990 models 194
- 10 brakes wheels and tyres 195
- Brake discs front and rear 195
- Front brake caliper s 195
- Removal 195
- Brakes wheels and tyres 7 11 196
- Overhaul 196
- 12 brakes wheels and tyres 197
- Installation 197
- Overhaul 197
- Rear brake caliper 197
- Removal 197
- Brakes wheels and tyres 7 13 198
- Installation 198
- Rear brake plate assembly 198
- 14 brakes wheels and tyres 199
- And installation 199
- Front brake master cylinder 199
- Inspection 199
- Installation 199
- Removal 199
- Removal overhaul 199
- Brakes wheels and tyres 7 15 200
- Installation 200
- Overhaul 200
- 16 brakes wheels and tyres 201
- Overhaul 201
- Rear brake master cylinder 201
- Removal 201
- Removal overhaul and installation s 201
- Brake hoses and unions 202
- Brakes wheels and tyres 7 17 202
- Inspection 202
- Inspection and replacement 202
- Installation 202
- 18 brakes wheels and tyres 203
- Bleeding 203
- Bleeding and fluid renewal 203
- Brake system 203
- Replacement 203
- Brakes wheels and tyres 7 19 204
- Renewing the fluid 204
- Wheels 204
- 20 brakes wheels and tyres 205
- Front wheel 205
- Removal 205
- Removal and installation 205
- Brakes wheels and tyres 7 21 206
- Installation 206
- Rear wheel 206
- Removal 206
- Removal and installation 206
- Xl600v h and v l models 1987 to 1990 206
- 22 brakes wheels and tyres 207
- Removal 207
- Xl60q f m models onward 1991 on xl650v and xrv750 models 207
- Brakes wheels and tyres 7 23 208
- Front wheel bearings 208
- Removal inspection and installation 208
- Wheel bearings 208
- 24 brakes wheels and tyres 209
- Rear wheel bearings 209
- Brakes wheels and tyres 7 25 210
- Sprocket coupling bearing 210
- 26 brakes wheels and tyres 211
- Fitting new tyres 211
- General information 211
- General information and fitting 211
- Bodywork 212
- Chapter 8 bodywork 212
- Contents 212
- Degrees of difficulty 212
- 2 bodywork 213
- Bodywork 8 3 214
- Cockpit trim panel s 214
- Fairing and body panels 214
- Fairing side panels 214
- Installation 214
- Rear view mirrors 214
- Removal 214
- Removal and installation 214
- Removal and installation xl600v models 214
- 4 bodywork 215
- Fairing 215
- Windshield 215
- Belly pan 216
- Bodywork 8 5 216
- Cockpit trim panel 216
- Fairing and body panels 216
- Removal and installation xl650v models 216
- Side panels 216
- Stone guard 216
- 6 bodywork 217
- Fairing 217
- Belly pan 218
- Bodywork 8 7 218
- Luggage rack and tail light cover 218
- Side panels 218
- Windshield 218
- 8 bodywork 219
- Cockpit trim panel s l to n 1990 to 1992 models only 219
- Fairing 219
- Fairing and body panels 219
- Fairing side panels 219
- Removal and installation xrv750 models 219
- Side panels 219
- Windshield 219
- Belly pan 220
- Bodywork 8 9 220
- Stone guard 220
- 10 bodywork 221
- Fork guards 221
- Front mudguard 221
- Installation 221
- Luggage rack and tail light cover 221
- Removal 221
- Removal and installation 221
- Battery 222
- Chapter 9 electrical system 222
- Contents 222
- Degrees of difficulty 222
- Electrical system 222
- Specifications 222
- 2 electrical system 223
- Alternator 223
- Regulator rectifier 223
- Starter motor 223
- Bulbs continued 224
- Electrical system 224
- Electrical system 9 3 224
- Fault finding 224
- General information 224
- Torque settings 224
- 4 electrical system 225
- Battery 225
- Removal and installation 225
- Removal installation inspection and maintenance 225
- Xl600v and xrv750 l to n 1990 to 1992 models 225
- Xl650v models 225
- Battery 226
- Electrical system 9 5 226
- Hilutl 226
- Inspection and maintenance 226
- 6 electrical system 227
- Check and replacement 227
- Electrical system 9 7 228
- Headlight 228
- Lighting system check 228
- 8 electrical system 229
- And sidelight bulb 229
- Brake light 229
- Headlight 229
- Headlight bulb 229
- Instrument and warning lights 229
- Tail light 229
- Turn signals 229
- Electrical system 9 9 230
- Headlight assembly 230
- Removal 230
- Removal and installation 230
- Sidelight 230
- 10 electrical system 231
- Brake tail light bulb 231
- Installation 231
- Xl600v and xrv750 models 231
- Xl650v models 231
- Electrical system 9 11 232
- Installation 232
- Removal 232
- Removal and installation 232
- Tail light assembly 232
- Turn signal circuit 232
- 12 electrical system 233
- Replacement 233
- Turn signal bulbs 233
- Xl600v models 233
- Xl650v models 233
- Electrical system 9 13 234
- Removal 234
- Removal and installation 234
- Turn signal assemblies 234
- Xl models front 234
- Xrv models 234
- Xrv models front 234
- 14 electrical system 235
- All models rear 235
- Brake light switches 235
- Check and replacement 235
- Front brake lever switch 235
- Installation 235
- Rear brake pedal switch 235
- Replacement 235
- Electrical system 9 15 236
- Instrument cluster and speedometer cable 236
- Instrument cluster xl models 236
- Instrument cluster xrv750 l and m models 236
- Instrument cluster xrv750 n models onwards 236
- Removal and installation 236
- 16 electrical system 237
- Check and replacement 237
- Installation 237
- Instruments 237
- Removal 237
- Speedometer cable 237
- Speedometer check 237
- Xl600v models 237
- Electrical system 9 17 238
- Speedometer replacement 238
- Tachometer check 238
- Tachometer replacement 238
- 18 electrical system 239
- Coolant temperature gauge check 239
- Coolant temperature gauge replacement 239
- Power check 239
- Speedometer check 239
- Speedometer replacement 239
- Tachometer check 239
- Tachometer replacement 239
- Xl650v models 239
- Coolant temperature gauge check 240
- Coolant temperature gauge replacement 240
- Electrical system 9 19 240
- Fuel gauge check 240
- Fuel gauge replacement 240
- Speedometer check 240
- Speedometer replacement 240
- Xrv750 models 240
- 20 electrical system 241
- Coolant temperature gauge check 241
- Coolant temperature gauge replacement 241
- Tachometer check 241
- Tachometer replacement 241
- Check removal and installation 242
- Digital trip meter check 242
- Digital trip meter replacement 242
- Electrical system 9 21 242
- Instrument and warning light bulbs 242
- Oil pressure switch 242
- Removal 242
- Replacement 242
- 22 electrical system 243
- Handlebar switches 243
- Ignition main switch 243
- Installation 243
- Removal 243
- Check and replacement 244
- Check removal and installation 244
- Electrical system 9 23 244
- Handlebar switches 244
- Installation 244
- Neutral switch 244
- Removal 244
- Removal and installation 244
- Sidestand switch 244
- 24 electrical system 245
- Check and replacement 245
- Clutch switch 245
- Diode s 245
- Replacement 245
- Check and replacement 246
- Electrical system 9 25 246
- Replacement 246
- 26 electrical system 247
- Check and replacement 247
- Installation 247
- Removal 247
- Removal and installation k 247
- Replacement 247
- Starter motor 247
- Starter relay 247
- Disassembly 248
- Disassembly inspection and reassembly 248
- Electrical system 9 27 248
- Starter motor 248
- 28 electrical system 249
- Inspection 249
- Charging system testing 250
- Electrical system 9 29 250
- General information and precautions 250
- Reassembly 250
- 30 electrical system 251
- Alternator 251
- Charging system 251
- Leakage test 251
- Output test 251
- Removal 251
- Electrical system 9 31 252
- Installation 252
- 32 electrical system 253
- Check and replacement 253
- Regulator rectifier 253
- Electrical system 9 33 254
- Replacement 254
- 34 wiring diagrams 255
- Wiring diagrams 9 35 256
- 36 wiring diagrams 257
- Wiring diagrams 9 37 258
- 38 wiring diagrams 259
- Xl600v r all markets except germany 259
- Wiring diagrams 9 39 260
- 40 wiring diagrams 261
- Xl600v t v v v wandv x 261
- H í j 262
- Li ii ii 11 262
- T cx3í i i 262
- Wiring diagrams 9 41 262
- Xl650v 262
- 42 wiring diagrams 263
- Xrv750 l and m all markets except germany 263
- 48 wiring diagrams 269
- L m 2 vl isa 269
- Xrv750 p r and s all markets except germany 269
- 50 wiring diagrams 271
- Xrv750 p r and s germany only 271
- 52 wiring diagrams 273
- Fan moroi 273
- Xrv750 t onwards 273
- Applying leverage 275
- Bearing removal and installation 275
- Bearings 275
- Ref bearings 275
- Tools and workshop tips 275
- Tools and workshop tips 276
- Bearing fault finding 277
- Bearing types and markings 277
- Oil seal removal and installation 277
- Oil seals 277
- Ref 16 277
- Tools and workshop tips 277
- Breaking a sealed joint 278
- Oil seal types and markings 278
- Ref gaskets 278
- Removal of old gasket and sealant 278
- Tools and workshop tips 278
- Types of gasket and sealant 278
- Breaking and joining final drive chains 279
- Ref chains 279
- Tools and workshop tips 279
- Tools and workshop tips 280
- Conversion factors 281
- Fuel consumption 281
- Length distance 281
- Mass weight 281
- Pressure 281
- Ref conversion factors 281
- Temperature 281
- Torque moment of force 281
- Velocity speed 281
- Volume capacity 281
- Abnormal driveline noise 282
- Abnormal engine noise 282
- Abnormal frame and suspension noise 282
- Braking problems 282
- Clutch problems 282
- Electrical problems 282
- Engine doesn t start or is difficult to start 282
- Excessive exhaust smoke 282
- Fault finding 282
- Gear changing problems 282
- Oil pressure low 282
- Overheating 282
- Poor handling or stability 282
- Poor running at low speed 282
- Poor running or no power at high speed 282
- Ref fault findings 282
- Engine doesn t start or is difficult to start 283
- Fault finding 283
- Engine doesn t start or is difficult to start continued 284
- Fault finding 284
- Fault finding 285
- Poor running at low speeds 285
- Fault finding 286
- Poor running or no power at high speed 286
- Fault finding 287
- Overheating______________ 287
- Clutch not disengaging completely 288
- Clutch problems 288
- Clutch slipping 288
- Doesn t go into gear or lever doesn t return 288
- Fault finding 288
- Gear changing problems 288
- Jumps out of gear 288
- Overselects 288
- Abnormal driveline noise 289
- Abnormal engine noise 289
- Clutch noise 289
- Engine lubrication system 289
- Fault finding 289
- Final drive noise 289
- Knocking or pinking 289
- Oil pressure low___________ 289
- Other noise 289
- Piston slap or rattling 289
- Transmission noise 289
- Valve noise 289
- Abnormal frame and suspension noise 290
- Excessive exhaust smoke 290
- Fault finding 290
- Battery dead or weak 291
- Battery overcharged 291
- Brake lever or pedal pulsates disc brakes 291
- Brakes are spongy don t hold disc brakes 291
- Brakes drag disc brakes 291
- Braking problems_________ 291
- Electrical problems_______ 291
- Fault finding 291
- Handlebar pulls to one side 291
- Handlebars hard to turn 291
- Handlebars shake or vibrates excessively 291
- Poor handling or stability 291
- Poor shock absorbing qualities 291
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Contents LIVING WITH YOUR HONDA Introduction The Birth of a Dream Page 0 4 Acknowledgements Page 0 9 About this manual Page 0 9 Model development Page 0 9 Bike spec Page 0 10 Performance data Page 0 13 Identification numbers Page 0 13 Buying spare parts Page 0 14 Safety first Page 0 15 Engine transmission oil level check Page 0 16 Coolant level check Page 0 17 Disc brake fluid level checks Page 0 18 Drum brake checks Page 0 19 Tyre checks Page 0 20 Suspension steering and drive chain checks Page 0 20 Legal and safety checks Page 0 20 Specifications Page 1 1 Recommended lubricants and fluids Page 1 2 Daily pre ride checks MAINTENANCE Routine maintenance and servicing Maintenance schedule Page 1 3 Component locations Page 1 4 Maintenance procedures Page 1 7
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