Honda AFRICA TWIN XRV750 (1987-2002) [61/291] 12 engine clutch and transmission

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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2 12 Engine clutch and transmission Transmission XL600V models continued Gear bushing ID Input shaft 4th gear output shaft 2nd and 3rd gears Standard Service limit Output shaft 1st gear Standard Service limit Gear to bushing clearance Standard Service limit Input shaft OD at 4th gear bush point Standard Service limit Output shaft OD 1st gear bush point Standard Service limit 2nd and 3rd gear bush point Standard Service limit Shaft to bushing clearance Standard Service limit Gear backlash 1st gear Standard Service limit 2nd 3rd 4th and 5th gears Standard Service limit 25 000 to 25 021 mm 25 04 mm 20 016 to 20 037 mm 20 06 mm 0 020 to 0 062 mm 0 10 mm 24 959 to 24 980 mm 24 90 mm 19 980 to 19 993 mm 19 92 mm 24 959 to 24 980 mm 24 90 mm 0 005 to 0 047 mm 0 06 mm 0 089 to 0 170 mm 0 24 mm 0 068 to 0 136 mm 0 18 mm Transmission XL650V models Gear ratios No of teeth 1 763 to 1 67 38T Primary reduction 3 200 to 1 Final reduction 2 500 to 1 35 14T 1 st gear 1 722 to 1 31 18T 2nd gear 1 333 to 1 28 21T 3rd gear 1 111 to 1 30 27T 4th gear 0 961 to 1 25 26T 5th gear Gear ID input shaft 4th and 5th gears output shaft 1st 2nd and 3rd gears mm Standard 28 000 to 28 021 Service limit 28 03 mm Gear bush OD input shaft 4th and 5th gears output shaft 1st 2nd and 3rd gears 27 959 to 27 980 mm Standard 27 95 mm Service limit Gear bush ID input shaft 4th gear output shaft 2nd and 3rd gears 25 000 to 25 021 mm Standard 25 03 mm Service limit Gear to bijsh clearance input shaft 4th and 5th gears output shaft 1st 2nd and 3rd gears 0 020 to 0 062 mm Standard 0 08 mm Service limit Input Shafi OD 4th gear bushing point Standard Service limit Crankcase journal A Standard Service limit Crankcase journal B Standard Service limit Output shaft OD 2nd and 3rd gear bush point Standard Service limit 24 959 to 24 980 mm 24 95 mm 19 980 to 19 993 mm 19 96 mm 21 967 to 21 980 mm 21 94 mm 24 959 to 24 980 mm 24 95 mm