Honda AFRICA TWIN XRV750 (1987-2002) [114/291] Engine clutch and transmission 2 65
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Honda AFRICA TWIN XRV750 (1987-2002) [114/291] Engine clutch and transmission 2 65

Honda AFRICA TWIN XRV750 (1987-2002) [114/291] Engine clutch and transmission 2 65

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Engine clutch and transmission 2 65 bushes and the external diameter of the bushes which they run on see illustrations II either component has worn to or beyond its service limit it must be replaced with a new one Using the above measurements calculate the gear to bush clearance and compare the results to the specifications listed at the beginning of the Chapter If the clearance exceeds the specified limit replace the relevant gear and bush as a pair Also measure the internal diameters of the plain bushes and their corresponding shaft external diameter and calculate the shaft to bush clearance see illustrations The Specifications at the beginning ot the Chapter list which components need to be measured 21 The shaft is unlikely to sustain damage unless the engine has seized placing an unusually high loading on the transmission or the machine has covered a very high mileage Check the surface of the shaft especially where a pinion turns on it and replace the shaft if it has scored or picked up or if there are any cracks Place the shaft on V blocks and check the runout at the shaft centre using a dial gauge Damage of any kind can only be cured by replacement 22 Check the bearings for play or roughness and that they are a tight fit in the crankcase see illustration Renew any bearing that is worn Refer to Tools and Workshop Tips in the reference Section for more information on bearing checks and removal and installation methods Apply clean engine oil to the bearings 23 Check the circlips and thrust washers and replace any that are bent or appear weakened or worn It is a good idea to use new circlips as a matter of course 31 20a Measure the internal diameter of the gear 31 20b and the external diameter of its bush 31 20c Measure the internal diameter of the bush 31 20d and the external diameter of the shaft 25 Slide the thrust washer 4th gear pinion bush and 4th gear pinion with its dogs facing away from the integral 1 st gear onto the left hand end of the shaft see illustrations Slide the splined washer onto the shaft and fit the circlip making sure it locates correctly in its groove see illustrations 26 Slide the 3rd gear pinion onto the shaft with its selector fork groove facing away from the 4th gear pinion and secure it with the Input shaft reassembly XL600V models 24 During reassembly apply molybdenum disulphide grease to the inside and outside of the bushes and lubricate all the other components with engine oil Make sure the oil holes in the shaft are aligned with those on the bush or pinion When installing the circlips do not expand the ends any further than is necessary Install the stamped circlips and washers so that their chamfered side faces the pinion it secures see illustration 31 2 31 25b the 4th gear bush 31 22 Check the transmission shaft bearings 31 25a Slide the thrust washer 31 25c and the 4th gear pinion onto the shaft 31 25d Slide on the splined washer

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