Honda AFRICA TWIN XRV750 (1987-2002) [83/291] 34 engine clutch and transmission
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Honda AFRICA TWIN XRV750 (1987-2002) [83/291] 34 engine clutch and transmission

Honda AFRICA TWIN XRV750 (1987-2002) [83/291] 34 engine clutch and transmission

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2 34 Engine clutch and transmission 15 3 Remove one of the clips arrowed and slide the joint collar across cylinders see illustration Slide the collar either forwards or backwards depending on which clip was removed so that it is detached from the stub on one or other of the cylinders If required unscrew the bolt securing the coolant inlet union to the front cylinder and remove it Discard the O ring as a new one must be used 4 Let the cam chain drop down into its tunnel Lift the cylinder up off the studs taking care not to allow the connecting rod to knock against the side of the crankcase once the piston is free see illustration If it is stuck tap around its joint faces with a soft faced mallet to free it from the crankcase Don t attempt to free the cylinder by inserting a screwdriver between it and the crankcase you ll damage the sealing surfaces When the cylinder has been removed stuff clean rags around the piston to prevent anything falling into the crankcase 5 Note the location of the two dowels which will be either on the bottom of the cylinder or in the crankcase see illustration 15 19 Remove them if they are loose 6 On XL650V and XRV750 models remove the coolant joint collar from whichever barrel it is attached to then remove the collar O ring from the stub on each cylinder Discard the O rings as new ones must be used 7 Remove the gasket and clean all traces of old gasket material from the cylinder and crankcase mating surfaces If a scraper is used take care not to scratch or gouge the soft aluminium Don t let any gasket material fall into the crankcase or the oil passages 15 11a Use a bore gauge and the piston to bore clearance is within specifications see Section 16 the bores should be honed de glazed To perform this operation you will need the proper size flexible hone with fine stones or a bottle brush type hone plenty of light oil or honing oil some clean rags and an electric drill motor 14 Hold the cylinder sideways so that the bore is horizontal rather than vertical in a vice with soft jaws or cushioned with wooden blocks Mount the hone in the drill motor I compress the stones and insert the hone into the bore Thoroughly lubricate the cylinder walls then turn on the drill and move the hone 15 4 Lift the barrel up off the crankcase up and down In the bore at a pace which and remove it produces a fine cross hatch pattern on the Inspection cylinder wall with the lines intersecting at an 8 Do not attempt to separate the liner from angle of approximately 60 Be sure to use the cylinder plenty of lubricant and do not take off any more 9 Check the cylinder bore walls carefully for material than is necessary to produce the desired effect Do not withdraw the hone from scratches and score marks 10 Using a precision straight edge and a the cylinder while it is still turning Switch off feeler gauge set to the warpage limit listed in the drill and continue to move it up and down in the specifications at the beginning of the the cylinder until it has stopped turning then Chapter check the top mating surface of the compress the stones and withdraw the hone cylinder barrel for warpage Refer to Tools and Wipe the oil from the cylinder and repeat the Workshop Tips in the Reference section for procedure on the other one Remember do not details of how to use the straight edge If take too much material from the cylinder wall warpage is excessive the cylinder must be 15 Wash the bores thoroughly with warm replaced with a new one soapy water to remove all traces of the 11 Using telescoping gauges and a abrasive grit produced during the honing micrometer see Tools and Workshop Tips operation Be sure to run a brush through the check the dimensions of each cylinder bore to stud holes and flush them with running water assess the amount of wear taper and ovality After rinsing dry the cylinders thoroughly and Measure near the top but below the level of the apply a thin coat of light rust preventative oil top piston ring at TDC centre and bottom but to all machined surfaces above the level of the oil ring at BDC of the 16 If you do not have the equipment or desire bore both parallel to and across the crankshaft to perform the honing operation take the axis see illustrations Compare the results to cylinders to a Honda dealer or specialist the specifications at the beginning of the motorcycle repair shop Chapter If the cylinders are worn oval or tapered beyond the service limit they can be Installation rebored and an oversize 0 25 or 0 50 set of 17 On XL650V and XRV750 models fit a new O ring onto the coolant joint collar stub on pistons and rings are available from Honda Note that the person carrying out the rebore each cylinder then slide the collar as far as must be aware of the piston to bore clearance possible onto the stub of one of them for the oversize piston see Specifications 18 Check that the mating surfaces of the 12 If the precision measuring tools are not cylinder and crankcase are free from oil or available take the cylinders to a Honda dealer pieces of old gasket or specialist motorcycle repair shop for 19 If removed fit the dowels either over the assessment and advice studs and into the crankcase or into the barrel 13 If the cylinder bores are in good condition and push them firmly home see illustration 15 19 Install the two dowels arrowed 15 11b and measure at the points either into the barrel or over the studs and shown into the crankcase

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