Honda AFRICA TWIN XRV750 (1987-2002) [112/291] Engine clutch and transmission 2 63

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Engine clutch and transmission 2 63 making sure that both ends engage in their bearings see illustration 30 8 20 Install the selector drum and forks see Section 29 21 Install the crankshaft if removed see Sec tion 27 Join the crankcase halves Section 23 31 Transmission shafts disassembly inspection S and reassembly 30 17 Apply grease to each thrust washer to hold it in place 30 18 Position the shafts side by side so the relative pinions mesh 1 Remove the transmission shafts from the crankcase see Section 30 Always dis assemble the transmission shafts separately to avoid mixing up the components 11 Make sure that the thrust washer is transmission output shaft does not contact the installed on the left hand end of each shaft work surface as it is installed On XL600V Input shaft disassembly see illustrations 31 28b and 31 51d Apply models make sure that the thrust washer is installed on the left hand end of each shaft a smear of grease to the inner face of each When disassembling the HAYNES washer to make them stick to their adjacent and on XL650V models that one is installed on transmission shafts place pinions and so prevent them dropping off as the left hand end of the input shaft see the parts on a long rod or illustrations 31 28b and 31 51d Apply a the shafts arc installed see illustration thread a wire through them 30 17 Also make sure that the thrust washer smear of grease to the inner face of each to keep them in order and facing the is installed on the right hand end of the output washer to make them stick to their adjacent proper direction pinions and so prevent them dropping off as shaft see illustration 31 55d 12 Lay the input shaft and output shaft side the shafts are installed see illustration On by side on the bench so that the pinions for all models make sure that the thrust washer is Note When removing the circlips do not installed on the right hand end of the output each gear mesh together see illustration expand the ends any further than is necessary 30 18 Make sure that the shafts are the shaft see illustration 31 55d as they are easily distorted Also take care to 18 Lay the input shaft and output shaft side keep them square as they twist easily If in correct way round in which case the smallest pinion on the input shaft meshes with the by side on the bench so that the pinions for doubt about the condition of a circlip replace each gear mesh together see illustration largest pinion on the output shaft it with a new one It is advisable to use new 13 Fit the selector fork assembly onto the Make sure that the shafts are the correct way ones as a matter of course round in which case the smallest pinion on transmission shafts locating each fork into XL600V models the groove in its pinion and making sure their the input shaft meshes with the largest pinion 2 Remove the thrust washer from the left hand on the output shaft identification marks are positioned as end of the shaft followed by the 2nd gear 19 Grasp the input shaft and output shaft described in Step 2 Also make sure that the pinion see illustration and 31 28b and a and install them into the left hand crankcase fork assembly is positioned correctly in relation to each shaft as noted on removal 14 Engage the selector drum with the forks locating their guide pins in the selector drum tracks again making sure everything is correctly positioned the right hand end of the selector drum carries the bearing so the selector fork marked R must be engaged in the groove nearest the bearing and at the same end of the assembly as the smallest pinion on the input shaft and the largest pinion on the output shaft If you intend to use cable ties to hold the assembly together fit them now 15 Grasp the input shaft and output shaft and the selector drum and forks and install them into the left hand crankcase making sure that both input shaft and output shaft ends engage in their bearings and the selector fork shaft end and the selector drum journal engage in their holes in the crankcase Make sure the thrust washers do not drop off the ends of the shafts as they are installed If cable ties were used cut them and slip them out of position 16 Install the crankshaft see Section 27 Reassemble the crankcase halves see 31 2 Transmission input shaft XL600V Section 23 8 4th gear pinion 5 5th gear pinion 1 Thrust washer All other models 9 4th gear pinion bush 6 5th gear pinion 2 2nd gear pinion 10 Input shaft with integral bush 3 Circlip 17 Support the left hand half of the crankcase 1st gear pinion 7 3rd gear pinion 4 Splined washer on wooden blocks so the end of the