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 procedure (see illustrations overleaf).
9.1a. Carburettor assembly - XL models and early XRV models: 1. Front cylinder carburettor; 2. Rear cylinder carburettor; 3. Joining screws; 4. Fuel hose; 5. Fuel hose union; 6. Throttle return spring
9.1b. Carburettor assembly - later XRV models: 1. Front cylinder carburettor; 2. Rear cylinder carburettor; 3. Joining bolts; 4. Fuel hoses; 5. Split pin; 6. Washer; 7. Plastic washer; 8. Washer; 9. O-ring
2. Remove the carburettors from the machine (see Section 7). Mark the body of each carburettor with its cylinder location to ensure that it is positioned correctly on reassembly.
3. Make a note of how the throttle return spring, linkage assembly and carburettor synchronisation spring are arranged to ensure that they are fitted correctly on reassembly (see illustrations). Also note the arrangement of the various hoses and their unions (see illustration). On XRV750-P models onwards (1993-on), remove the split pin and washers from the arm between the carburettors at the front, noting the order of the washers.
9.3a. Note the linkage and return spring arrangement...
9.3b ...the synchronisation screw and spring arrangement...
9.3c ...and the arrangement of the hoses and their unions...
4. Undo the two screws (XL models and XRV750-L to N (1990 to 1992) models) or bolts (XRV750-P models onwards (1993-on)) securing the carburettors together and carefully separate them (see illustration). On XL models and XRV750-L to N (1990 to 1992) models retrieve the synchronisation spring.
9.4 ...then undo the joining screws or bolts (arrow) - XL600V type carburettor shown
Joining
5. Assembly is the reverse of the disassembly procedure, noting the following.
- Obtain a new seal and O-ring set for your model and use all the parts contained (see illustration 9.1a or b).
- Make sure the fuel and air hoses and elbows are correctly and securely inserted into the carburettors (see illustrations 9.4 and 9.3c and b).
- On XL models and XRV750-L to N (1990 to 1992) models Install the synchronisation spring after the carburettors are joined together. Make sure it is correctly and squarely seated (see illustration 9.3b).
- Check the operation of the throttle linkage ensuring that it operates smoothly and returns quickly under spring pressure.
- Install the carburettors (see Section 7) and check carburettor synchronisation and idle speed (see Chapter 1).