Engine — removal and installation (Honda XRV750 Africa Twin)

0

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 used to support and lower or raise the engine if available.

Removal

1. Position the bike on its centrestand if fitted or support it securely In an upright position using an auxiliary stand - do not use a stand which attaches to the swingarm pivots because the swingarm must be removed. Work can be made easier by raising the machine to a suitable working height on an hydraulic ramp or a suitable platform. Make sure the motorcycle is secure and will not topple over.

2. If the engine is dirty, particularly around its mountings, wash it thoroughly before starting any major dismantling work. This will make work much easier and rule out the possibility of caked on lumps of dirt falling into some vital component.

3. Remove the seat and the side panels (see Chapter 8). Disconnect the battery negative (-) lead (see Chapter 9).

4. Remove the fairing side panels (XL600V and XRV750) or fairing (XLI550V), the stone guard and the belly pan (see Chapter 8).

5. Drain the engine oil and remove the oil filter (see Chapter 1).

6. Drain the coolant (see Chapter 1).

7. Remove the fuel tank (see Chapter 4)

8. Remove the carburettors (see Chapter 4). Plug the engine intake manifolds with clean rag. On XL650V models, remove the PAIR system control valve, detaching its hoses from the engine rather than the valve itself (see Chapter 4).


9. On XL models, remove the horn (see Chapter 9).

10. Remove the radiators along with their hoses (i.e. detach the hoses from the engine and water pump instead of the radiator) (see Chapter 3). Also detach and remove the hose(s) between the water pump and the inlet union(s) on the engine. On XRV750 models also remove the oil cooler (see Section 7).

11. Remove the front sprocket (see Chapter 6).

12. Remove the ignition HT coils (see Chapter 5).

13. Remove the exhaust system (Chapter 4).

14. Pull back the rubber boot covering the starter motor terminal, then unscrew the nut and detach the lead (see illustration). Also unscrew the relevant mounting bolt to release the earth cable.



15. Detach the clutch cable from the release arm on the clutch cover (see Section 19). Release the cable from any guides and secure it clear of the engine, noting its routing.

16. Trace the ignition pulse generator wiring and disconnect it at the connector - on XL models it exits from the front of the clutch cover on the right-hand side of the engine, and on XRV models from the alternator cover on the left-hand side. Coll the wiring between the cylinders so it does not impede engine removal.


17. Pull off the neutral switch wiring connector (see illustration). Pull back the rubber boot on the oil pressure switch, then undo the screw securing the wiring connector to the switch (see illustration). Free the wiring from any clips or guides and secure it clear of the engine, noting its routing. If you prefer to leave the wiring attached to the switches, trace it to its main connector and disconnect it, then feed the wiring back and coil it between the cylinders. Also check the routing of the sidestand switch wiring (from the switch to its connector) - If (as on some models) it is routed along with the neutral switch and oil pressure switch wires, then you need to free it from any clips and guides that attach it to the engine and position it clear. If (as on most models) it is routed away from the engine along the frame tube, then you can leave it alone.






18. Trace the alternator wiring from the cover on the left-hand side of the engine and disconnect it at the connector, then coil the wiring in between the cylinders so that it does not impede engine removal. Note that on XL600V models you will have to unscrew the air filter housing bolts, noting the collars, and push the housing back to enable the wiring connector to pass between it and the frame (see illustration). On XL600V models, also unscrew the coolant reservoir bolts and displace it back so that it will be clear of the engine - there is no need to detach the hoses (see illustration).






19. On XL650V and XRV750 models, remove the rear brake pedal (see Chapter 7).

20. On XL600V and XRV750-L to N (1990 to 1992) models, unscrew the bolts securing the frame cross-member, noting which way round it fits, and the earth wires secured by one bolt (see illustration).



21. As the swingarm pivot bolt doubles as one of the engine mounting bolts, removing the swingarm means that it will not interfere with the process of manoeuvring the engine within the frame. The alternative is to displace the swingarm rearwards as far as possible after the bolt is removed. The engine and swingarm do not remain tight in the frame after the nut has been unscrewed and the amount of interference created is not that great, so base your decision on the amount of assistance you have, the amount of time you have to carry out the extra work, and your experience as a mechanic. To remove the swingarm, refer to Chapter 6; otherwise follow the procedure below for your model for removing the swingarm pivot/engine mounting bolt.

22. At this point, position an hydraulic or mechanical jack under the engine with a block of wood between the jack head and sump. Make sure the jack is centrally positioned so the engine will not topple in any direction when the last mounting bolt is removed Raise the jack to take the weight of the engine, but make sure it is not lifting the bike and taking the weight of that as well. The idea is to support the engine so that there is no pressure on any of the mounting bolts once they have been slackened, so they can be easily withdrawn. Note that it may be necessary to adjust the jack as some of the bolls are removed to relieve the stress transferred to the other bolts. Also place rags between the engine and frame to protect the paintwork as some contact between them is inevitable. After removing any mounting bolt, fit any spacer and/or bracket that go with the bolt back onto it, in the correct order and way round, then thread the nut onto the end of the bolt - this ensures that everything can be reassembled with ease later on, and that no 2 brackets or spacers can be fitted the wrong way round or in the wrong place. In the case of through-bolts, also make a note of which side of the bike the bolt goes in from.

XL600V models

23. If the swingarm has not been removed, remove the cap from each end of the swingarm pivot/rear mounting bolt, then slacken the nut (see illustration). Also slacken the lower front mounting bolt nut (see illustration).





24. Unscrew the two bolts securing the fairing side panel and belly pan support piece and remove it, noting how it fits (see illustration). Unscrew the nut on the upper front engine mounting bolt (see illustration 5.23b) and withdraw the bolt (see illustration). Unscrew the nuts on the upper front mounting bracket bolts, then withdraw the bolts and remove the brackets, noting how they fit (see illustrations).









25. Check that the engine is properly supported on the jack. If the swingarm has not been removed, unscrew the nut on the swingarm pivot/rear mounting bolt. Withdraw the swingarm pivot/rear mounting bolt, then push the swingarm back so that it is clear of the engine (see illustrations).





26. Check that all wiring, cables and hoses are well clear of the engine, that the engine is still properly supported on the jack, and that your assistant(s) is/are ready. Unscrew the nut on the lower front mounting bolt, then withdraw the bolt and remove the spacer that fits between the right-hand frame bracket and the engine (see illustrations). Move the back of the engine to the right and disengage the drive chain from around the transmission output shaft and gearchange shaft (see illustration). Lift the front of the engine so that the front cylinder is raised, then tilt it to the left, and manoeuvre the engine out from the left-hand side, making sure the sump clears the frame tube to avoid scratching it (see illustration).

XL650V models

27. If the swingarm has not been removed, remove the cap from each end of the swingarm pivot/rear mounting bolt, then slacken the nut. Also slacken the lower front mounting bolt nut.

28. Unscrew the two bolts securing the fairing side panel and belly pan support piece and remove it, noting how it fits. Unscrew the nut on the upper front engine mounting bolt, then withdraw the bolt and remove the spacers that fit between the brackets and the engine. Unscrew the nuts on the bracket bolts, then withdraw the bolts and remove the brackets, noting how they fit.

29. Check that the engine is properly supported on the jack. If the swingarm has not been removed, unscrew the nut on the swingarm pivot/rear mounting bolt. Withdraw the swingarm pivot/rear mounting bolt, then push the swingarm back so that it is clear of the engine.

30. Check that all wiring, cables and hoses are well clear of the engine, that the engine is still properly supported on the jack, and that your assistant(s) is/are ready. Unscrew the nut on the lower front mounting bolt, then withdraw the bolt and remove the spacer that fits between the right-hand frame bracket and the engine. Move the back of the engine to the right and disengage the drive chain from around the transmission output shaft and gearchange shaft. Lift the front of the engine so that the front cylinder is raised, then tilt it to the right, and manoeuvre the engine out from the right-hand side, making sure the sump clears the frame tube to avoid scratching it.

XRV75O-L to N (1990 to 1992) models

31. If the swingarm has not been removed, remove the cap from each end of the swingarm pivot/rear mounting bolt, then slacken the nut.

32. Unscrew the two bolts securing the fairing side panel and fuel tank support piece and remove it, noting how it fits.

33. Unscrew the four bolts securing the front cylinder head bracket between the engine and frame and remove it, noting the spacer fitted with the outer bolt.

34. Unscrew the nut on the upper front engine mounting bolt, then withdraw the bolt and remove the fairing support piece brackets, noting how they fit. Unscrew the nuts and withdraw the bolts securing the upper front brackets and remove them, noting how they fit.

35. Unscrew the nut on the lower front mounting bolt, then withdraw the bolt and remove the spacer that fits between the righthand bracket and the engine. Unscrew the two bolts securing each lower front mounting bolt bracket and remove them, noting how they fit.

36. Check that the engine is properly supported on the jack. Unscrew the nut on the upper rear mounting bolt, then withdraw the bolt and remove the spacers that fit between the frame and the engine, noting which fits where. Unscrew the nuts and withdraw the bolts securing the upper rear mounting bolt bracket on the right-hand side and remove it, noting how it fits.

37. If the swingarm has not been removed, unscrew the nut on the swingarm pivot/rear mounting bolt. Withdraw the swingarm pivot/rear mounting bolt, then push the swingarm back so that it is clear of the engine.

38 Check that all wiring, cables and hoses are well clear of the engine, that the engine is still properly supported on the jack, and that your assistant(s) is/are ready. Move the back of the engine to the right and disengage the drive chain from around the transmission output shaft and gearchange shaft. Lift the front of the engine so that the front cylinder is raised, then tilt it to the right, and manoeuvre the engine out from the right-hand side, making sure the sump clears the frame tube to avoid scratching it.

XRV750-P models onward (1993-on)

39. If the swingarm has not been removed, remove the cap from each end of the swingarm pivot/rear mounting bolt, then slacken the nut.

40. Unscrew the four bolts securing the front cylinder head bracket between the engine and frame and remove it, noting the spacers fitted with the lower bolts.

41. Unscrew the nut on the lower front mounting bolt, then withdraw the bolt and remove the spacer that fits between the righthand bracket and the engine.

42. Unscrew the four bolts securing the lower frame section on the right-hand side and remove it, noting how it fits - the rear bolts have nuts which will have to be counter-held.

43. Unscrew the two bolts securing the lower front mounting bolt bracket on the left-hand side and remove it, noting how it fits.

44. Unscrew the nut on the upper rear mounting bolt, then withdraw the bolt and remove the spacers that fit between the frame and the engine, noting which fits where (see illustrations). Unscrew the nuts and withdraw the bolts securing the upper rear mounting bolt bracket on the right-hand side and remove it. noting how it fits.





45. Check that the engine Is properly supported on the jack. Unscrew the nut on the upper front engine mounting bolt and remove 2 the guide, then withdraw the bolt and remove the spacer from between the bracket and engine. Unscrew the nuts and withdraw the bolts securing the upper front brackets, noting the sub-bracket, and remove them, noting how they fit.

46. If the swingarm has not been removed, unscrew the nut on the swingarm pivot/rear mounting bolt. Withdraw the swingarm pivot/rear mounting bolt, then push the swingarm back so that it is clear of the engine.

47. Check that all wiring, cables and hoses are well clear of the engine, that the engine is still properly supported on the jack, and that your assistant(s) is/are ready. Move the back of the engine to the right and disengage the drive chain from around the transmission output shaft and gearchange shaft. Lift the front of the engine so that the front cylinder is raised, then tilt it to the right, and manoeuvre the engine out from the right-hand side, making sure the sump clears the frame tube to avoid scratching it.

Installation

48. Installation is the reverse of removal, noting the following points:

• Make sure no wires, cables or hoses become trapped between the engine and the frame when installing the engine.
• If the swingarm has not been removed, do not forget to loop the drive chain around the transmission output shaft as you install the engine.
• Do not tighten any of the engine mounting bolts until they have all been installed. Make sure the spacers are correctly positioned.
• Tighten the engine mounting bolts and any other bolts to the torque settings specified at the beginning of the Chapter.
• Use new gaskets at all exhaust pipe connections.
• Make sure all wires, cables and hoses are correctly routed and connected, and secured by any clips or ties.
• Fit a new oil filter and refill the engine with oil (see Chapter 1).
• Refill the cooling system with coolant (see Chapter 1).
• Adjust the throttle and clutch cable freeplay (see Chapter 1).

See this article in russian language

Article about repair motorcycles «Honda Africa Twin XRV 750» (1989-2003): «Engine — removal and installation»: https://motoinstruction.ru/en/Honda/Africa-Twin/XRV750/engine/repair/115044 <a href="https://motoinstruction.ru/en/Honda/Africa-Twin/XRV750/engine/repair/115044">Engine — removal and installation</a> - article about repair motorcycles «Honda Africa Twin XRV 750» (1989-2003) from section «Engine repair». [url=https://motoinstruction.ru/en/Honda/Africa-Twin/XRV750/engine/repair/115044]Engine — removal and installation[/url] - article about repair motorcycles «Honda Africa Twin XRV 750» (1989-2003) from section «Engine repair».