Honda TRANSALP XL600-650V (1987-2002) [77/291] 28 engine clutch and transmission
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Honda TRANSALP XL600-650V (1987-2002) [77/291] 28 engine clutch and transmission

Honda TRANSALP XL600-650V (1987-2002) [77/291] 28 engine clutch and transmission

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2 28 Engine clutch and transmission 11 4a Unscrew the bolts arrowed the rubber cushion behind the top of the tensioner 2 Follow Steps 2 to 5 in Section 9 3 Slip the sprocket off Its boss on the camshaft Note Do not disengage the cam chain from the sprocket or the valve timing will have to be reset see Section 9 Caution Do not rotate either the camshaft or the crankshaft whilst the cam chain sprocket is displaced as damage could occur if a valve contacts a piston 4 Unscrew the two bolts securing the cam chain tensioner and withdraw it from the cylinder head see illustrations Also remove the rubber cushion noting which way up it fits see illustration Inspection 5 Examine the sliding surface of the tensioner for wear or damage and replace it if necessary 6 Check the tensioner spring for damage or a loss of tension and replace it if necessary 11 4b then withdraw the tensioner bolts and tighten them to the torque setting specified at the beginning of the Chapter 8 Mount the cam chain and sprocket onto the boss on the camshaft Apply a suitable non permanent thread locking compound to one camshaft sprocket bolt then install it in the exposed hole at the top of the sprocket and tighten it to the specified torque setting using a socket on the alternator bolt to stop the engine from rotating if necessary see illustrations 9 27 Rotate the crankshaft anti clockwise 360 to reveal the other sprocket bolt hole then threadlock the bolt and tighten it to the specified torque setting Again rotate the crankshaft anti clockwise 360 to bring it back to TDC on compression Before proceeding further check that everything aligns as described in Section 9 Step 2 If it doesn t the valve timing will be inaccurate and the valves will contact the piston when the engine is turned over 9 Follow Steps 30 to 35 in Section 9 10 Install the valve cover see Section 8 11 Check the engine oil level and top up if necessary see Chapter 1 11 4c and remove the rubber cushion noting how it fits Installation 15 Install the guide blade into the front of the cam chain tunnel making sure its base locates correctly in its seat and the lugs near the top seat correctly in their slots see illustration 16 Install the cylinder head see Section 12 12 Cylinder headsremoval and installation Caution The engine must be completely cool before beginning this procedure or the cylinder heads may become warped Removal front cylinder head 7 Fit the tensioner into the back of the cam chain tunnel in the cylinder head making sure the base is correctly seated in its slot Fit the rubber cushion with its widest end uppermost behind the top of the tensioner see illustration 11 4c The top of the cushion sits flush with the top of the cylinder head Make sure the sealing washers on the tensioner mounting bolts are in good condition and replace them with new ones if necessary see illustration Apply a suitable non permanent thread locking compound to the tensioner 12 Remove the cylinder head Section 12 13 Lift the cam chain guide blade out of the front of the cam chain tunnel in the cylinder barrel noting how it fits see illustration 14 Examine the sliding surface of the guide blade for wear or damage and replace It if necessary Note The engine must be removed from the frame to enable removal of the front cylinder head 1 Remove the engine from the frame see Section 5 2 Remove the valve cover see Section 8 3 Remove the spark plugs see Chapter 1 4 Remove the camshaft see Section 9 5 On XL600V H to K 1987 to 1989 models unscrew the bolts securing the external oil pipe and remove the pipe noting how It fits and taking care not to bend it Discard the sealing washers as new ones must be used 6 Remove the cam chain tensioner see Section 11 7 The cylinder head is secured by four 10 mm nuts one 8 mm nut which on all except XL600V H to K 1987 to 1989 models also 11 7 Use new sealing washers on the tensioner holts if necessary 11 13 Draw the guide blade out of the tunnel 11 15 Make sure the lugs locate correctly in the cutouts arrows Installation Cam chain guide blade Removal Inspection

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