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 job.
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 not drop when the shock absorber is removed, but also making sure that the weight of the machine is off the rear suspension so that the shock is not compressed.
2. Make a note of which side the bolts go in from, and make a note of which way round the shock absorber fits (i.e. on XL650V and XRV750 models note which side the reservoir is on).
XL600V models
3. Remove the right-hand side panel (see Chapter 8).
4. Unscrew the nut and withdraw the bolt securing the linkage rods to the linkage arm, then swing the rods down (see illustration). Unscrew the nut and withdraw the bolt securing the bottom of the shock absorber to the linkage arm (see illustration).
![](https://motoinstruction.ru/img/honda/19/125739.jpg)
11.4a. On XL600V models unscrew the nut and withdraw the linkage rods-to-arm bolt
![](https://motoinstruction.ru/img/honda/19/125740.jpg)
11.4b. Unscrew the nut and withdraw the lower mounting bolt
5. Unscrew the nut on the shock absorber upper mounting bolt (see illustration). Support the shock absorber, then withdraw the bolt and manoeuvre the shock out of the bottom (see illustrations).
![](https://motoinstruction.ru/img/honda/19/125741.jpg)
11.5a. Unscrew the nut on the bolt (arrowed)...
![](https://motoinstruction.ru/img/honda/19/125742.jpg)
11.5b ...then withdraw the bolt...
![](https://motoinstruction.ru/img/honda/19/125743.jpg)
11.5c ...and remove the shock absorber from the bottom
XL650V models
6. Remove the seat and the side panels (see Chapter 8).
7. Undo the screws securing the mud deflector just behind the shock absorber and remove it. Unscrew the nut and withdraw the bolt securing the bottom of the shock absorber to the linkage arm (see illustration).
![](https://motoinstruction.ru/img/honda/19/125744.jpg)
11.7. On XL650V models unscrew the nut (arrowed) and withdraw the lower mounting bolt
8. Unscrew the nut on the shock absorber upper mounting bolt (see illustration). Support the shock absorber, then withdraw the bolt and manoeuvre the shock out of the left-hand side of the bike.
![](https://motoinstruction.ru/img/honda/19/125745.jpg)
11.8. Unscrew the nut (A) then withdraw the bolt (B)
XRV750 models
9. Remove the side panels (see Chapter 8).
10. Displace the fuel pump from its mount - there is no need to detach the hoses or disconnect the wiring connector (see illustration).
![](https://motoinstruction.ru/img/honda/19/125746.jpg)
11.10a. On XRV750 models displace the fuel pump from its mount
![](https://motoinstruction.ru/img/honda/19/125747.jpg)
11.10b. Slacken the clamp screw (arrowed) and draw the reservoir out
Slacken the reservoir clamp screw and draw the reservoir out of the clamp (see illustration).
11 Unscrew the nut and withdraw the bolt securing the linkage rods to the linkage arm, then swing the rods down (see illustration). Unscrew the nut and withdraw the bolt securing the bottom of the shock absorber to the linkage arm.
![](https://motoinstruction.ru/img/honda/19/125748.jpg)
11.11. Linkage rods-to-arm bolt (A), shock absorber-to-linkage arm bolt (B), linkage rods-to-frame bolt (C), linkage arm-to-swingarm bolt (D)
12. Unscrew the nut on the shock absorber upper mounting bolt (see illustration). Support the shock absorber, then withdraw the bolt and manoeuvre the shock out of the bottom.
![](https://motoinstruction.ru/img/honda/19/125749.jpg)
11.12. Unscrew the nut (A) and withdraw the bolt (B)
Inspection
13. Inspect the shock absorber for obvious physical damage and the coil spring for looseness, cracks or signs of fatigue.
14. Inspect the damper rod for signs of bending, pitting and oil leakage.
15. Inspect the pivot hardware at the top and bottom of the shock for wear or damage. On XL600V models the top bush is available -remove the old one and install the new one using a press or drawbolt arrangement (see Tools and Workshop Tips in the Reference Section for further information). On XL650V models remove the collars and seals to access the needle bearings in the top pivot. Remove the old one and install the new one using a press or drawbolt arrangement (see Tools and Workshop Tips in the Reference Section for further information).
16. If the shock absorber on XL600V models is in any way damaged or worn, it can be disassembled and the damaged or worn components replaced (see illustration). Disassembly of the shock absorber requires the use of a spring compressor.
![](https://motoinstruction.ru/img/honda/19/125750.jpg)
11.16. Shock absorber components - XL600V: 1. Locknut; 2. Adjuster nut; 3. Damper unit; 4. Spring; 5. Spring seat; 6. Spring guide; 7. Rubber damper; 8. Stopper plate; 9. Locknut; 10. Lower mount
17. With this in place on the spring, unscrew the adjuster locknut using a suitable C spanner and thread it all the way up the threads and off the shock absorber. Now mark the position of the adjuster so it can be installed in the same place, then unscrew and remove it in the same way. Draw the spring off the shock and release the compressor.
18. Measure the free length of the spring and replace it with a new one if it is below the minimum specified length. If required, slacken the locknut on the lower mount, then thread the mount and the stopper plate off the rod, noting how the pin on the plate locates against the cutout in the mount. Remove the spring guide and seat, and if required the locknut and rubber damper, noting how they all fit.
19. On XL650V models individual components are not available for the shock absorber, so if it is worn or damaged it must be replaced with a new one.
20. On XRV750-L to N (1990 to 1992) the shock absorber can be disassembled and components renewed in the same way as for the XL600V (see Step 8) (see illustration). On all other XRV750 models individual components are not available.
![](https://motoinstruction.ru/img/honda/19/125751.jpg)
11.20. Shock absorber components - XRV750: 1. Locknut; 2. Adjuster nut; 3. Spring; 4. Seal; 5. Spring seat; 6. Spring guide; 7. Damper unit; 8. Rubber damper; 9. Locknut; 10. Stopper plate; 11. Lower mount
21. Honda advise that the pressurised nitrogen gas should be released before discarding the shock absorber. Take the shock absorber to a Honda dealer for disposal - do not attempt gas dispersal yourself.
Installation
22. Installation is the reverse of removal, noting the following:
- Apply multi-purpose grease to the shock absorber and linkage plate pivot points.
- On XL600V and XRV750-L to N (1990 to 1992) models install the shock absorber with the breather tube facing the front.
- On XL650V models make sure the reservoir is on the left-hand side.
- On XRV750-P models onward (1993-on) make sure the reservoir hose is on the left, and on the right on all other XRV models.
- Do not tighten the nuts until both bolts (or all components if the suspension linkage has been removed as well) are in position, then tighten them to the torque setting specified at the beginning of the Chapter.