Honda AFRICA TWIN XRV750 (1987-2002) [84/291] Engine clutch and transmission 2 35
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Honda AFRICA TWIN XRV750 (1987-2002) [84/291] Engine clutch and transmission 2 35

Honda AFRICA TWIN XRV750 (1987-2002) [84/291] Engine clutch and transmission 2 35

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Engine clutch and transmission 2 35 20 Remove the rags from around the piston taking care not to let the connecting rod fall against the rim of the crankcase and lay the new base gasket in place locating it over the dowels if they are in the crankcase 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 21 Space the piston rings gaps as described in Section 17 If required fit a piston ring clamp onto the piston to ease its entry into the bore as the cylinder is lowered This is not essential as there is a good lead in enabling the piston rings to be hand fed into the bore If possible have an assistant support the cylinder while this is done 22 Lubricate the cylinder bore piston and piston rings with clean engine oil then lower the barrel down over the studs until the piston crown fits into the bore see illustration 23 Gently push the cylinder down making sure the piston enters the bore squarely and does not get cocked sideways If you are doing this without a piston ring clamp carefully compress and feed each ring into the bore as the cylinder is lowered see illustration 24 When the piston is correctly installed in the bore press the cylinder down onto the base gasket making sure the dowels locate Hook the cam chain up the tunnel and secure It to prevent it dropping back down see illustration 25 On XL600V models if removed fit a new O ring onto the coolant inlet pipe then fit it into the cylinder and secure it with the bolt 26 On XL650V and XRV750 models slide the coolant joint collar across and over the O nng so that it is central on the stubs between the cylinders then secure it in place with its clips see illustration 15 3 If removed fit a new O ring to the coolant inlet hose union and install the union onto the front of the front cylinder tightening its bolts securely 27 Install the cam chain guide blade s see Section 11 and the cylinder head s see Section 12 16 Pistons removal inspection and installation 15 20 Always use a new gasket 15 22 Carefully lower the barrel onto the piston 15 23 and feed the piston rings into the bore 15 24 Hook the cam chain out of the tunnel be marked IN on the intake side of the cylinder though the mark is likely to be invisible until the piston is cleaned see illustration 3 Carefully prise out the circlip on one side of the piston using needle nose pliers or a small flat bladed screwdriver inserted into the notch see illustration Push the piston pin out from the other side to free the piston from the connecting rod see illustrations Remove 16 2 Note the IN mark on the piston which faces the intake side 16 3a Prise the piston pin circlip out from one side of the piston 16 3b Push the piston pin out from the other side 16 3c then withdraw it and remove the piston Note The pistons can be removed with the engine in the frame Removal 1 Remove the cylinder barrel s see Section 15 Stuff clean rag into the crankcase aperture to support the connecting rod and to prevent anything falling in such as the circlip 2 Before removing the piston from the connecting rod use a sharp scriber or felt marker pen to write the cylinder identity on the crown of each piston or on the inside of the skirt if the piston is dirty and going to be cleaned Each piston crown should already

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