Frame and attachments of motorcycle Honda XRV750 Africa Twin (1989-2003)

Frame, suspension and final drive — specifications
Front forks Fork oil type — 5 W fork oil Fork oil capacity XL600V models — 549 cc XL650V models — 542 cc XRV750-L to N (1990 to 1992) models — 635 cc XRV750-P models onward (1993-on) — 648 cc Fork oil level* XL600V models — 125 mm XL650V models —...

General information about frame
All models have a box-section steel cradle frame. Front suspension is by a pair of oil-damped telescopic forks, with air assistance on XRV750-L to S (1990 to 1995) models. The forks have a conventional type damper, and are not adjustable. At the...

Frame — inspection and repair
1. The frame should not require attention unless accident damage has occurred. In most cases, frame replacement is the only satisfactory remedy for such damage. A few frame specialists have the jigs and other equipment necessary for straightening...

Footrests, brake pedal and gearchange lever — removal and installation
Footrests 1. Remove the split pin and washer from the bottom of the footrest pivot pin, then withdraw the pivot pin and remove the footrest (see illustrations). On the front footrests, note the fitting of the return spring ends. 3.1a. Remove the...

Sidestand — removal and installation
Sidestand 1. The sidestand is attached to a bracket on the frame. Springs anchored between them ensure the stand is held in the retracted or extended position. Support the bike on the centrestand. 2. On models with a rotary type sidestand switch...

Handlebars and levers — removal and installation
Handlebars Removal Note: The handlebars can be displaced from the top yoke without having to remove the individual assemblies from them - follow Steps 8 and 9 only. 1. Remove the rear view mirrors (see Chapter 8). 2. Disconnect the wires from the...

Forks — removal and installation
Removal Caution: Although not strictly necessary, before removing the forks it is recommended that the fairing and fairing panels are removed (see Chapter 8). This will prevent accidental damage to the paintwork. 1. Remove the front mudguard (see...

Forks — oil change
XL600V-H to V-R (1987 to 1995) and XRV750-L to S (1990 to 1995) models Note: The forks fitted to early models are equipped with an oil drain bolt at the lower rear face of each fork slider, enabling the oil to be changed without removing the forks...

Forks — disassembly, inspection and reassembly
Disassembly 1. Remove the forks (see Section 6). Always dismantle the fork legs separately to avoid interchanging parts and thus causing an accelerated rate of wear. Store all components in separate, clearly marked containers (see illustrations)....

Steering stem — removal and installation
Removal 1. Remove the fuel tank (see Chapter 4). On XL600V and XRV750 models remove the fairing side panels, and on XL650V models remove the fairing (see Chapter 8). This will prevent the possibility of damage should a tool slip. Also remove the...

Steering head bearings — inspection and replacement
Inspection 1. Remove the steering stem (see Section 9). 2. Remove all traces of old grease from the bearings and races and check them for wear or damage. 3. The outer races should be polished and free from indentations. Inspect the bearing rollers...

Rear shock absorber — removal, inspection and installation
Warning: Do not attempt to disassemble this shock absorber. It is nitrogen-charged under high pressure. Improper disassembly could result in serious injury. Instead, take the shock to a dealer service department with the proper equipment to do the...

Rear suspension linkage — removal, inspection and installation
Removal 1. Support the motorcycle on its centrestand if fitted, or on an auxiliary stand that does not take the weight through any part of the rear suspension, or by using a hoist. Position a support under the rear wheel or swingarm so that it does...

Suspension — adjustments
Front forks 1. On XRV750-L to S (1990 to 1995) models only, the forks are air-assisted arid the air pressure can be varied within the specified range (see Specifications). The air valve is incorporated in the top bolt of each fork. 2. To check the...

Swingarm — removal and installation
Removal 1. Remove the rear wheel (see Chapter 7). 2. Unscrew the bolt(s) securing each rear brake hose guide to the swingarm (see illustrations), or release the hose from its guides, according to model (see illustration). Note the routing of the...

Swingarm — inspection, bearing check and replacement
Inspection 1. Remove the swingarm (see Section 14). Remove the chain adjusters if required, noting how they fit, especially the UP mark on XL models (see illustration). 15.1. Note how and which way round the chain adjusters fit - XL type shown 2....

Drive chain — removal, cleaning, and installation
Note: The original equipment drive chain fitted to XL600-H to R (1987 to 1995) models and XRV750-L to N (1990 to 1992) models is an endless chain, which means it doesn't have a split link and therefore cannot be split. Removal requires the removal...

Sprockets — check and replacement
Check 1. Unscrew the gearchange lever pinch bolt and slide the lever off the shaft, noting the alignment of the punch mark on the gearchange shaft end with either the punch mark on the lever or with the slit in the lever clamp (according to model)...

Rear sprocket coupling/rubber dampers — check and replacement
1. Remove the rear wheel (see Chapter 7). Caution: Do not lay the wheel down on the disc as it could become warped. Lay the wheel on wooden blocks so that the disc is off the ground. 2. Lift the sprocket coupling away from the wheel leaving the...

Bodywork — general information
This Chapter covers the procedures necessary to remove and install the body parts. Since many service and repair operations on these motorcycles require the removal of body parts, the procedures are grouped here and referred to from other Chapters....

Seat — removal and installation
Removal XL600V models 1. Remove the side panels (see Section 4). 2. Unscrew the two bolts (one on each side) securing the seat and remove it, noting how the tab at the front locates under the fuel tank bracket (see illustrations). 2.2a. Unscrew the...

Rear view mirrors — removal and installation
Removal 1. The mirrors simply screw into the handlebar mounting - pull up the rubber cover, then either unscrew the mirror using the hex at the base of the stem, or slacken the bottom locknut and then unscrew the mirror, according to model (see...

Fairing and body panels — removal and installation (XL600V models)
Note: All models have some rubber collars with captive threaded inserts that the screws thread into that fit into the panels at various places. Where the collar fits through both the panels it joins, it has to be removed before the panels can be...

Fairing and body panels — removal and installation (XL650V models)
Cockpit trim panel 1. Remove the top windshield screw on each side (see below). Unscrew the lower fairing bolt on each side (see illustration). 5.1. Unscrew the fairing bolt (arrowed) on each side 2. Release and withdraw the trim clip on each side...

Fairing and body panels — removal and installation (XRV750 models)
Cockpit trim panel(s) - L to N (1990 to 1992) models only 1 There is a panel on each side, each secured by three screws, with the rearmost screws having washers and nuts on the underside of the panel. Undo the screws, counter holding the nuts and...

Front mudguard — removal and installation
Removal 1. On XL models, release the speedometer cable from its guide on the right-hand side (see illustration). Unscrew the four bolls securing the mudguard to the fork sliders, noting how one of the bolts secures the speedometer cable guide on...