Honda AFRICA TWIN XRV750 (1987-2002) [108/291] Engine clutch and transmission 2 59
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Honda AFRICA TWIN XRV750 (1987-2002) [108/291] Engine clutch and transmission 2 59

Honda AFRICA TWIN XRV750 (1987-2002) [108/291] Engine clutch and transmission 2 59

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Engine clutch and transmission 2 59 28 14 Measure the diameter of the crankpin to see if it is worn 28 20a Lubricate the nuts as described 12 Cut two lengths of the appropriate size particular connecting rod in accordance with Plastigauge they should be slightly shorter the table below The bearings themselves are than the width of the crankpin Place a strand identified by a letter and a corresponding colour see table below The dimensions of Plastigauge on each cleaned crankpin relating to the particular codes are given in the journal and fit the clean connecting rod specifications at the beginning of the Chapter assemblies shells and caps see illustration 28 4b Make sure the cap is fitted the correct Connecting rod selection way around so the previously made markings 18 If a connecting rod needs to be replaced align and tighten the bearing cap nuts evenly the weight of the replacement rod needs to be and a little at a time to the torque setting matched to the other rod being re used If specified at the beginning of the Chapter both rods are being replaced they need to be whilst ensuring that the connecting rod does matched together The connecting rod weight not rotate see illustration 28 20a and b code is marked on the flat face of the Slacken the cap nuts and remove the connecting rod and cap and will be either an connecting rod assemblies again taking great A B C or a D see illustration 28 3 Ideally care not to rotate the crankshaft each rod should have the same weight code 13 Compare the width of the crushed as the other but it is acceptable to be one Plastigauge on each crankpin to the scale letter different e g A and B coded rods could printed on the Plastigauge envelope to obtain be used together but not A and C coded rods the connecting rod bearing oil clearance 14 If the clearance is not within the specified Installation limits the bearing shells may be the wrong 19 Clean the backs of the bearing shells and grade or excessively worn if the original shells the bearing housings in both cap and rod If are being re used Before deciding that new shells are being fitted ensure that all different grade shells are needed make sure traces of the protective grease are cleaned off that no dirt or oil was trapped between the using paraffin kerosene Wipe the shells cap bearing shells and the connecting rod or cap and rod dry with a clean lint free cloth Fit the when the clearance was measured If the bearing shells in the connecting rods and clearance is excessive even with new shells of caps making sure the tab on each shell the correct size measure the diameter of the engages the notch in the connecting rod cap crankpin and compare it to the specifications see illustrations 28 10 11a and b Lubricate see illustration If it is worn the crankshaft the shells with molybdenum disulphide oil a should be replaced with a new one 50 50 mixture of molybdenum disulphide 15 On completion carefully scrape away all grease and clean engine oil Fit the traces of the Plastigauge material from the connecting rod onto the crankpin and fit the crankpin and bearing shells using a fingernail or other object which Is unlikely to score the shells Bearing shell selection 16 Replacement bearing shells for the big end bearings are supplied on a selected fit basis Codes stamped on the crankshaft and rod are used to identify the correct replacement bearings The crankpin journal size number Is stamped on the crankshaft middle web adjacent to the crankpin and will be either an A or a B see illustration 24 12a The connecting rod size code is marked on the flat face of the connecting rod and cap and will be either al or a 2 see illustration 28 3 17 A range of bearing shells is available Select the correct bearing shells for a 28 20b and tighten them to the specified torque setting cap onto the rod see illustration 28 4b Make sure the cap is fitted the correct way around so the previously made markings align Check to make sure that all components have been returned to their original locations using the marks made on disassembly 20 Apply some clean oil to the threads and under the heads of the connecting rod nuts if new rods are being fitted they should come supplied with new bolts and nuts Fit the nuts and tighten them evenly and a little at a time to the torque setting specified at the beginning of the Chapter see illustrations 21 Check that the rods rotate smoothly and freely on the crankpin If there are any signs of roughness or tightness remove the rods and re check the bearing clearance 22 Install the crankshaft see Section 27 29 Selector drum and forks removal inspection and installation ÿ Note To access the selector drum and forks the engine must be removed from the frame and the crankcases separated Removal XL600V H to R 1987 to 1995 models g 1 Separate the crankcase halves Section 23 Remove the crankshaft see Section 27 though not essential working with it in place restricts access and makes the procedure fiddly XL models Connecting rod code Crankpin journal code 1 43 000 to 43 008 mm 2 43 008 to 43 016 mm A 39 982 to 39 990 mm C Brown 0 Black B 39 974 to 39 982 mm B Black A Blue XRV models Connecting rod code Crankpin journal code 1 46 000 to 46 008 mm 2 46 008 to 46 016 mm A 42 982 to 42 990 mm F Pink E Yellow B 42 974 to 42 982 mm E Yellow D Green

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