Engine fuel supply and exhaust system of motorcycle Honda XRV750 Africa Twin (1989-2003)

Fuel and exhaust systems — specifications
Fuel Grade — Unleaded, minimum 91 RON (Research Octane Number) Fuel tank capacity XL600V models — 18 litres XL65OV models — 19.6 litres XRV750-L to N (1990 to 1992) — models 24 litres XRV750-P models onward (1993-on) — 23 litres Fuel tank reserve...

General information and precautions
General information The fuel system consists of the fuel tank, the fuel tap(s) and strainer(s), the carburettors, fuel hoses and control cables, and on XRV750 models the fuel pump and in-line filter. XL600V models The fuel tap is semi-automatic in...

Fuel tank and tap — removal and installation
Warning: Refer to the precautions given in Section 1 before starting work. Caution: The fuel tanks on these machines are quite large, which means if they are full they will be heavy. It is advisable therefore to only remove the tank when it is at...

Fuel tank — cleaning and repair
1. All repairs to the fuel tank should be carried out by a professional who has experience In this critical and potentially dangerous work. Even after cleaning and flushing of the fuel system, explosive fumes can remain and ignite during repair of...

Air filter/duct housing — removal and installation
Air duct housing - XL600V and XRV750-L to N (1990 to 1992) models Removal 1. Remove the fuel tank (see Section 2). 2. Slacken the clamp screws securing the air duct housing to the air filter housing joint piece and the carburettor Intakes (see...

Air/fuel mixture adjustment — general information
Adjustment 1. If the engine runs extremely rough at idle or continually stalls, and if a carburettor overhaul does not cure the problem (and it definitely is a carburation problem - see Section 6), the pilot screws may require adjustment. It is...

Carburettor overhaul — general information
1. Poor engine performance, hesitation, hard starting, stalling, flooding and backfiring are all signs that major carburettor maintenance may be required. 2. Keep in mind that many so-called carburettor problems are really not carburettor problems...

Carburettors — removal and installation
Warning: Refer to the precautions given in Section 1 before starting work. Removal 1. Remove the fuel tank (see Section 2). 2. Remove the air filter/duct housing, according to model (see Section 4). On XL models, also remove the rear cylinder...

Carburettors — disassembly, cleaning and inspection
Warning: Refer to the precautions given in Section 1 before starting work. Disassembly 1. Remove the carburettors (see Section 7). Note: Do not separate the carburettors unless absolutely necessary: each carburettor can be dismantled sufficiently...

Carburettors — separation and joining
Warning: Refer to the precautions given in Section 1 before proceeding Separation 1. The carburettors do not need to be separated for normal overhaul. If you need to separate them (to replace a carburettor body, for example), refer to the following...

Carburettors — reassembly and float height check
Warning: Refer to the precautions given in Section 1 before proceeding. Note: When reassembling the carburettors, be sure to use the new O-rings. seals and other parts supplied in the rebuild kit. Do not overtighten the carburettor jets and screws...

Throttle cables — removal and installation
Warning: Refer to the precautions given in Section 1 before proceeding. Removal 1. Remove the fuel tank (see Section 2). Mark each cable according to its position at each end. 2. Slacken the lower (opening) cable locknut and thread it up the...

Choke cable — removal and installation
Removal 1. Remove the fuel tank (see Section 2). 2. Unscrew each choke plunger assembly nut from the carburettors and withdraw the plunger assembly from each carburettor body (see illustrations 7.4a and b). Compress the spring and detach the cable...

Exhaust system — removal and installation
Warning: If the engine has been running the exhaust system will be very hot. Allow the system to cool before carrying out any work. Removal 1. Remove the right-hand side panel, the belly-pan, on XL600V and XRV750 models the right-hand fairing side...

Catalytic converter — general information (XL650V models)
1. A catalytic converter is incorporated in the exhaust system to minimise Ihe level of exhaust pollutants released Into the atmosphere. It is of the open-loop type, with no feedback to the ignition or fueling systems. 2. The catalyst is automatic...

Fuel pump — check, removal and installation (XRV750 models)
Warning: Refer to the precautions given in Section 1 before starting work. Check 1. The fuel pump is controlled through a cutoff relay, so that it runs whenever the ignition is switched ON and the ignition is operative (i.e., only when the engine is...

Fuel level indicator circuit — check and replacement
XRV750-L to N (1990 to 1992) models Check - warning light circuit 1. XRV750-L to N (1990 to 1992) models are fitted with a fuel warning light circuit checker (see illustration 15.2b). When the ignition is switched ON, both low fuel warning lights...

Pulse secondary air (PAIR) system — XL650V models
General information 1. To reduce the amount of unburned hydrocarbons released in the exhaust gases, a pulse secondary air (PAIR) system is fitted. The system consists of the control valve (mounted behind the right-hand radiator), the reed valves...