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 split pin and washer (A) and withdraw the pivot pin (B), noting the return spring ends (C) - front footrest, XL600V shown
3.1b. Remove the split pin and washer (A) and withdraw the pivot pin (B) - rear footrest, XL650V shown
2. Tine footrest rubbers can be separated from the footrest and renewed if required.
3. Installation is the reverse of removal.
Brake pedal
Removal
4. Unhook the brake pedal return spring and the brake light switch spring from the hook on the pedal (see illustration).
3.4. Unhook the brake light switch spring (A) and the pedal return spring (B) - XL600V shown
5. Mark the alignment between the brake pedal arm on the inside and the pedal itself so it can be installed in the same position - there should be a punch mark on the pedal shaft which aligns with the slit in the arm. but it may be difficult to see. Unscrew the pinch bolt on the brake pedal arm on the inside of the frame (see illustration). It you can't access it because of its position, on XL600V-H to К (1987 to 1989) models fully unscrew the adjusting wingnut on the end of the brake rod. and on all other models remove the split pin from the clevis pin securing the brake pedal to the master cylinder pushrod. then remove the clevis pin and separate the pedal from the pushrod (see illustrations). Rotate the pedal until the bolt can be accessed (see illustration). If access is still not possible (it varies between models), unscrew the footrest bracket bolts and displace the bracket.
3.5a. Brake pedal arm pinch bolt (arrowed) - XL650V
3.5b. Remove the split pin...
3.5c ...and withdraw the clevis pin
3.5d. Brake pedal arm pinch bolt (arrowed) - XL600V
6. Draw the pedal out of the arm and footrest bracket and remove the arm and pedal (see illustration 3.5). Depending on the height setting of the pedal, you may have to remove the footrest (see above) to prevent the pedal hitting it as you draw it out.
Installation
7. Installation is the reverse of removal, noting the following:
- Make sure the splines on the pedal shaft and those in the brake pedal arm are in good condition. If they are worn or damaged (i.e. flattened), there is a danger that the pedal could slip round in the arm. making the brake Ineffective. Replace them with new ones if necessary, or if you are in doubt.
- Apply some grease to the brake pedal pivot. Make sure the pedal and arm are correctly aligned (see Step 5).
- Use a new split pin on the clevis pin securing the brake pedal to the master cylinder pushrod (see illustration 3.5b).
- Tighten the footrest bracket mounting bolts securely.
- Check the operation of the rear brake light switch (see Chapter 9).
Gearchange lever
8. Before removing the lever, note 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) (see illustration). If no marks are visible make your own so that the lever can be installed in the correct position straight away.
3.8. Note the alignment of the punch mark, then unscrew the bolt and remove the lever
9. Unscrew the pinch bolt and slide the lever off the shaft.
10. Installation is the reverse of removal.