Honda AFRICA TWIN XRV750 (1987-2002) [78/291] Engine clutch and transmission 2 29
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Honda AFRICA TWIN XRV750 (1987-2002) [78/291] Engine clutch and transmission 2 29

Honda AFRICA TWIN XRV750 (1987-2002) [78/291] Engine clutch and transmission 2 29

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Engine clutch and transmission 2 29 12 7 Cylinder head 10 mm nuts A 8 mm nut B see text 8 mm bolts C 6 mm bolt D secures the main camshaft holder and has therefore already been removed two 8 mm bolts and one 6 mm bolt see illustration Slacken these evenly and a little at a time in a criss cross pattern until they are all loose Remove the nuts bolts and washers Take care not to drop any of the nuts or washers down the cam chain tunnel 8 Hold the cam chain up and pull the cylinder head up off the barrel then pass the cam chain down through the tunnel see illustration Do not let the chain fall into the crankcase secure It with a piece of wire or metal bar to prevent it from doing so If it is stuck tap around the base of the head with a soft faced mallet to free it Do not try to free the head by inserting a screwdriver between the head and cylinder barrel you ll damage the sealing surfaces Note that each head is marked F or R according to whether it is for the front or rear cylinder the mark is located in the centre of the top of the head between I he valves 9 Remove the old gasket see illustration 12 22 10 If they are loose remove the two dowels from the cylinder barrel studs see illustration 12 22 If either appears to be missing it is probably stuck in the underside of the cylinder head If required remove the cam chain guide blade from the front of the cam chain tunnel see Section 11 see illustration 11 13 11 Check the cylinder head gasket and the mating surfaces on the cylinder head and barrel for signs of leakage which could indicate warpage Refer to Section 14 and check the cylinder head for warpage Caution If you do not plan to remove the cylinder barrel take care not to break the gasket joint between the barrel and the crankcase when cleaning the top surface of the barrel or pulling out the dowels If the joint is broken the barrel must be removed see Section 15 and the gasket renewed otherwise oil leaks may result 12 8 Carefully lift the head up off the barrel 12 Clean all traces of old gasket material from the cylinder head and barrel If a scraper is used take care not to scratch or gouge the soft aluminium Be careful not to let any of the gasket material fail into the crankcase the cylinder bore or the oil passages Unless you are removing the cylinder barrel cover it with a clean rag to prevent any debris falling into the engine Removal rear cylinder head Note On XL600V models the engine must be removed from the frame to enable removal of the rear cylinder head On XL650V and XRV750 models removal of the rear cylinder head is possible with the engine in the frame 13 On XL600V remove the engine from the frame see Section 5 14 On XL650V and XRV750 models drain the coolant see Chapter 1 Remove the carburettors and the rear cylinder exhaust pipe see Chapter 4 15 Remove the spark plugs see Chapter 1 16 Remove the camshaft see Section 9 17 Remove the cam chain tensioner see Section 11 18 On XL60ÛV 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 19 The remainder of the procedure is the same as for the front cylinder follow Steps 7 to 12 above making sure it locates over the dowels see illustration The gasket can only fit one way so if the holes do not line up properly the gasket is upside down Never re use the old gasket 23 Make sure you have the correct head for the cylinder being worked on the front head is marked P and the rear R with the mark located in the centre of the top of the head between the valves Carefully lower the cylinder head over the studs and onto the barrel see illustration 12 8 It is helpful to have an assistant to pass the cam chain up through the tunnel and slip a piece of wire through it to prevent it falling back into the engine Keep the chain taut to prevent it becoming disengaged from the crankshaft sprocket 24 Install the 10 mm nuts with their washers on XL600V H to K 1987 to 1989 models the 8 mm nut with its washer the 8 mm bolts with their washers and the 6 mm bolt tighten them all finger tight at this stage see illustration 12 7 25 Now tighten the cylinder head nuts and bolts evenly and a little at a time in a criss cross pattern to the torque settings specified at the beginning of the Chapter see illustration Installation both heads 20 If removed fit the cam chain guide blade into the front of the cam chain tunnel see Section 11 see illustration 11 15 21 If removed fit the two dowels over the cylinder barrel studs and into the barrel see illustration 12 22 Lubricate the cylinder bores with new engine oil 22 Ensure both cylinder head and barrel mating surfaces are clean then lay the new head gasket in place on the cylinder barrel 12 22 Install the dowels arrowed then lay the new gasket on the barrel 2

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