Motorcycle engine repair Honda XRV750 Africa Twin (1989-2003)

Engine, clutch and transmission — specifications
General Capacity XL600V models — 583 cc XL650V models — 647 cc XRV750 models — 742 cc Bore XL600V models — 75.0 mm XL650V models — 79.0 mm XRV750 models — 81.0 mm Stroke XL600V and XL650V models — 66.0 mm XRV750 models — 72.0 mm Compression ratio...

General information about engine
The engine/transmission unit is a water-cooled 52° V-twin, fitted parallel with the frame. The engine has three valves per cylinder, two for the intake and one for the exhaust, operated by a single overhead camshaft via rocker arms. The camshafts...

Operations possible with the engine in the frame
The components and assemblies listed below can be removed without having to remove the engine/transmission assembly from the frame. If however, a number of areas require attention at the same time, removal of the engine is recommended. Valve covers...

Operations requiring engine removal
It is necessary to remove the engine/transmission assembly from the frame and separate the crankcase halves to gain access to the following components: Cylinder heads (XL600V) Front cylinder head (XL650V and XRV750) Cylinder barrels, pistons and...

Major engine repair — general note
1. It is not always easy to determine when or if an engine should be completely overhauled, as a number of factors must be considered. 2. High mileage is not necessarily an indication that an overhaul is needed, while low mileage, on the other hand,...

Engine — removal and installation
Caution: The engine is very heavy. Engine removal and installation should be carried out with the aid of at least one assistant; personal injury or damage could occur if the engine falls or is dropped. A hydraulic or mechanical floor jack should be...

Engine disassembly and reassembly — general information
Disassembly 1. Before disassembling the engine, thoroughly clean and degrease its external surfaces. This will prevent contamination of the engine internals, and will also make working a lot easier and cleaner. A high flashpoint solvent, such as...

Oil cooler and distributor — removal, inspection and installation (XRV750 models)
Note: The oil cooler and distributor can be removed with the engine in the frame. If the engine has been removed, ignore the steps which do not apply. Oil cooler Removal 1. The cooler is located on the front of the engine on the left-hand side....

Valve covers — removal and installation
Note: The valve covers can be removed with the engine in the frame. If the engine has been removed, ignore the steps which do not apply. Removal 1. Remove the carburettors ( see Chapter 4 ). 2. Drain the coolant ( see Chapter 1 ). If removing the...

Camshafts and rockers — removal, inspection and installation
Note: The camshafts and rockers can be removed with the engine in the frame. Removal 1. Remove the valve covers ( see Section 8 ). 2. If the belly pan on your model obscures the alternator cover, remove it ( see Chapter 8 ). Unscrew the crankshaft...

Cam chains — removal and installation
Note: The cam chains can be removed with the engine in the frame. Front cylinder cam chain Removal 1. Drain the engine oil ( see Chapter 1 ). 2. Remove the alternator rotor ( see Chapter 9 ). 3. Remove the camshaft ( see Section 9 ). Remove the cam...

Cam chain tensioners and guide blades — removal, inspection and installation
Note: The cam chain tensioners and guide blades can be removed with the engine in the frame. Cam chain tensioner Removal 1. Remove the valve cover ( see Section 8 ). The cam chain tensioner is located in the back of the cam chain tunnel. Note the...

Cylinder heads — removal and installation
Caution: The engine must be completely cool before beginning this procedure or the cylinder heads may become warped. Removal - front cylinder head Note: The engine must be removed from the frame to enable removal of the front cylinder head. 1....

Valves/valve seats/valve guides — servicing
1. Because of the complex nature of this job and the special tools and equipment required, most owners leave servicing of the valves, valve seats and valve guides to a professional. However, you can make an initial assessment of whether the valves...

Cylinder head and valves — disassembly, inspection and reassembly
1. As mentioned in the previous section, valve overhaul should be left to a Honda dealer. However, disassembly, cleaning and inspection of the valves and related components can be done (if the necessary special tools are available) by the home...

Cylinder barrels — removal, inspection and installation
Note: To remove the cylinder barrels the engine must be removed from the frame. Removal 1. Remove the engine from the frame ( see Section 5 ), then remove the cylinder head(s) ( see Section 12 ) and the cam chain guide blade(s) ( see Section 11 )....

Pistons — removal, inspection and installation
Note: The pistons can be removed with the engine in the frame. Removal 1. Remove the cylinder barrel(s) ( see Section 15 ). Stuff clean rag into the crankcase aperture to support the connecting rod and to prevent anything falling in, such as the...

Piston rings — inspection and installation
1. It is good practice to renew the piston rings when an engine is being overhauled. Before installing the new rings, check the end gaps with the rings installed in the bore, as follows. 2. Lay out the pistons and the new ring sets so the rings will...

Starter clutch — removal, inspection and installation
Note: The starter clutch can be removed with the engine in the frame. If the engine has been removed, ignore the steps which do not apply. Check 1. The operation of the starter clutch can be checked while it is in situ. Remove the starter motor (...

Crankcase — separation and reassembly
Separation 1. To access the crankshaft and connecting rods, bearings, oil pump and transmission components, the crankcase must be split into two parts. 2. To enable the crankcases to be separated, the engine must be removed from the frame (see...

Crankcase — inspection, servicing and renewal
Inspection and servicing 1. After the crankcases have been separated, remove the oil pump, and on XRV models the oil distributor, the crankshaft and connecting rods, transmission shafts, selector drum and forks, neutral switch and oil pressure...

Oil pump and pressure relief valve — removal, inspection and installation
Note: To access the oil pump the engine must be removed from the frame and the crankcases separated. Removal 1. Separate the crankcase halves ( Section 23 ). 2. Unscrew the bolt securing the pressure relief valve cover to the pump, then remove the...

Main and connecting rod bearings — general information
1. Even though main and connecting rod bearings are generally replaced with new ones during the engine overhaul, the old bearings should be retained for close examination as they may reveal valuable information about the condition of the engine. 2....

Crankshaft and main bearings — removal, inspection and installation
Removal 1. Separate the crankcase halves ( refer to Section 23 ). 2. Lift the crankshaft out of the left-hand crankcase half (see illustration). If it appears stuck, tap it gently using a soft-faced mallet. 27.2. Lift the crankshaft out of the...

Connecting rods — removal, inspection and installation
Removal 1. Remove the crankshaft ( see Section 27 ). 2. Before removing the rods from the crankshaft. measure the side clearance on each rod with a feeler gauge (see illustration). If the clearance on any rod is greater than the service limit listed...

Initial start-up after overhaul
1. Make sure the engine oil and coolant levels are correct ( see Daily (pre-ride) checks ). Make sure there is fuel in the tank. 2. Turn the engine kill switch to the ON position and shift the gearbox into neutral. Turn the ignition ON. Set the...

Recommended running-in procedure
1. Treat the machine gently for the first few miles to make sure oil has circulated throughout the engine and any new parts installed have started to seat. 2. Even greater care is necessary if new pistons/rings have been fitted or the cylinders...