Periodic service of motorcycle Honda XRV750 Africa Twin (1989-2003)

Routine maintenance and servicing — specifications
Engine Engine idle speed XL600V models — 1300±100 rpm XL650V and XRV750 models — 1200±100 rpm Spark plugs Type Standard NGK — DPR8EA-9. or Denso X24EPR-U9 Cold climate (below 5°C/41°F) — NGK DPR7EA-9, or Denso X22EPR-U9 Extended high speed riding —...

Maintenance schedule
Daily (pre-ride) See " Daily (pre-ride) checks " at the beginning of this manual. After the initial 600 miles (1000 km) Note: This check is usually performed by a Honda dealer after the first 600 miles (1000 km) from new. Thereafter, maintenance is...

Component locations — XL600V models
1. Steering head bearing adjuster; 2. Clutch cable upper adjuster; 3. Idle speed adjuster; 4. Coolant reservoir filler cap; 5. Air filter; 6. Drive chain adjuster; 7. Crankcase breather drain; 8. Oil filter; 9 Coolant drain plug; 10. Oil drain plug;...

Component locations — XL650V models
1. Steering head bearing adjuster; 2. Clutch cable upper adjuster; 3. Fuel tap strainer; 4. Idle speed adjuster; 5. Coolant reservoir filler cap; 6. Drive chain adjuster; 7. Oil filter; 8. Crankcase breather drain; 9. Coolant drain plug; 10. Oil...

Component locations — XRV750 models
1. Steering head bearing adjuster; 2. Clutch cable upper adjuster; 3. Fuel tap strainers (L to N·models); 4. Air filter; 5. Idle speed adjuster; 6. Fuel filter (in-line type); 7. Drive chain adjuster; 8. Crankcase breather dram; 9. Oil filter; 10....

Maintenance procedures — introduction
1. This Chapter is designed to help the home mechanic maintain his/her motorcycle for safety, economy, long life and peak performance. 2. Deciding where to start or plug into the routine maintenance schedule depends on several factors. If your...

Drive chain and sprockets — check, adjustment cleaning and lubrication
Every 600 miles (1000 km). Check 1. A neglected drive chain won't last long and will quickly damage the sprockets. Routine chain adjustment and lubrication isn't difficult and will ensure maximum chain and sprocket life. 2. To check the chain, place...

Idle speed — check and adjustment
Every 4000 miles (6000 km) or 6 months 1. The idle speed should be checked and adjusted before and after the carburettors are synchronised (balanced), after checking the valve clearances, and when it is obviously too high or too low. Before...

Brake shoes/pads — wear check
Every 4000 miles (6000 km) or 6 months Front brake - all models 1. Each brake pad has wear indicators in the form of cutouts in the top and bottom edges of the friction material; these cutouts should be visible by looking at the edges of the...

Cutch — check and adjustment
Every 4000 miles (6000 km) or 6 months 1. Check that the clutch lever operates smoothly and easily. 2. If the clutch lever operation is heavy or stiff, remove the cable ( see Chapter 2 ) and lubricate it ( see Section 7 ). If the cable is still...

Spark plugs — check and adjustment
Every 4000 miles (6000 km) or 6 months 1. Make sure your spark plug socket is the correct size before attempting to remove the plugs - a suitable one is supplied in the motorcycle's tool kit which is stored under the seat. Note that each cylinder...

Battery — check
Every 4000 miles (6000 km) or 6 months Note: The references made to the type of battery used in the different models assumes original spec equipment is installed. In the case of older models, it is possible that the standard battery has been...

Wheels and tyres — general check
Every 4000 miles (6000 km) or 6 months Tyres 1. Check the tyre condition and tread depth thoroughly - Daily (pre-ride) checks . Wheels 2. Visually check the spokes for damage, breakage and corrosion. A broken or bent spoke must be renewed...

Air filter — check
Every 4000 miles (6000 km) or 6 months Caution: If the machine is continually ridden in wet or dusty conditions, the air filter should be checked more frequently. Air filter 1. On XL600V and XRV750-L to N (1990 to 1992) models, remove the left-hand...

Crankcase breather — check
Every 4000 miles (6000 km) or 6 months 1. Remove the plug from the end of the breather drain tube and allow it to drain into a suitable container (see illustration). Check the condition of the tube, making sure it has no cracks and splits. Replace...

Fuel strainer — check (XL600V models)
Every 4000 miles (6000 km) or 6 months Warning: Petrol (gasoline) is extremely flammable, so take extra precautions when you work on any part of the fuel system. Don't smoke or allow open flames or bare light bulbs near the work area, and don't work...

Spark plugs — renewal
Every 8000 miles (12,000 km) or 12 months 1. Remove the old spark plugs as described in Section 5 and install new ones.

Stand(s), lever pivots and cables — lubrication
Every 8000 miles (12,000 km) or 12 months Note: 4 centrestand is not fitted as standard on any of the models covered, but is available as an extra or aftermarket accessory/. 1. Since the controls, cables and various other components of a motorcycle...

Engine/transmission oil and filter — renewal
Every 8000 miles (12,000 km) or 12 months Warning: Be careful when draining the oil, as the exhaust pipes, the engine, and the oil itself can cause severe burns. 1. Consistent routine oil and filter changes are the single most important maintenance...

Fuel system — check
Every 8000 miles (12,000 km) or 12 months Warning: Petrol (gasoline) is extremely flammable, so take extra precautions when you work on any part of the fuel system. Don't smoke or allow open flames or bare light bulbs near the work area, and don't...

Throttle and choke cables — check and adjustment
Every 8000 miles (12,000 km) or 12 months Throttle cables 1. Make sure the throttle grip rotates smoothly and freely from fully closed to fully open with the front wheel turned at various angles. The grip should return automatically from fully open...

Valve clearances — check and adjustment
Every 8000 miles (12,000 km) or 12 months 1. The engine must be completely cool for this maintenance procedure, so let the machine sit overnight before beginning. 2. Remove the fuel tank and the air duct on XL600V and XRV750-L to N (1990 to 1992)...

Carburettor synchronisation
Every 8000 miles (12,000 km) or 12 months Warning: Petrol (gasoline) is extremely flammable, so take extra precautions when you work on any part of the fuel system. Don't smoke or allow open flames or bare light bulbs near the work area, and don't...

Cooling system — check
Every 8000 miles (12,000 km) or 12 months Warning: The engine must be cool before beginning this procedure. 1. Check the coolant level (see Daily (pre-ride) checks). 2. On XL600V and XRV750 models remove the fairing side panels, and on XL650V models...

Brake system — check
Every 8000 miles (12,000 km) or 12 months 1. A routine general check of the brake system will ensure that any problems are discovered and remedied before the rider's safety is jeopardised. 2. Check the brake lever and pedal for loose connections,...

Headlight aim — check and adjustment
Every 8000 miles (12,000 km) or 12 months Note: An improperly adjusted headlight may cause problems for oncoming traffic or provide poor, unsafe illumination of the road ahead. Before adjusting the headlight aim, be sure to consult with local...

Sidestand — check
Every 8000 miles (12,000 km) or 12 months Note: All models are fitted with a sidestand as standard equipment. A centrestand is available as an optional extra. 1. Check the stand spring(s) for damage and distortion. The spring(s) must be capable of...

Suspension — check
Every 8000 miles (12,000 km) or 12 months 1. The suspension components must be maintained in top operating condition to ensure rider safety. Loose, worn or damaged suspension parts decrease the motorcycle's stability and control. Front suspension 2....

Steering head bearings — check and adjustment
Every 8000 miles (12,000 km) or 12 months 1. Steering head bearings can become dented, rough or loose during normal use of the machine. In extreme cases, worn or loose steering head bearings can cause steering wobble - a condition that is...

Nuts and bolts — tightness check
Every 8000 miles (12,000 km) or 12 months 1. Since vibration of the machine tends to loosen fasteners, all nuts, bolts, screws, etc. should be periodically checked for proper tightness. 2. Pay particular attention to the following: Spark plugs...

Pulse secondary air injection (PAIR) system — check (XL650V models)
Every 8000 miles (12,000 km) or 12 months 1. Remove the fuel tank and air filter housing ( see Chapter 4 ), and the right-hand heat shield. Visually inspect the hoses between the reed valves on the valve covers and the PAIR control valve behind the...

Air filter — renewal
Every 12,000 miles (18,000 km) or 18 months Caution: If the machine is continually ridden in wet or dusty conditions, the filter should be replaced more frequently. 1. Refer to the procedure in Section 8 and replace the air filter with a new one.

Brake fluid — renewal
Every 12,000 miles (18,000 km) or two years 1. The brake fluid should be replaced at the prescribed interval or whenever a master cylinder or caliper overhaul is carried out. Refer to the brake bleeding section in Chapter 7 , noting that all old...

Coolant — renewal
Every 24,000 miles (36,000 km) or two years Warning: Allow the engine to cool completely before performing this maintenance operation. Also, don't allow antifreeze to come into contact with your skin or the painted surfaces of the motorcycle. Rinse...

Cylinder compression — check
Non-scheduled maintenance 1. Among other things, poor engine performance may be caused by leaking valves, incorrect valve clearances, a leaking head gasket, or worn pistons, rings and/or cylinder walls. A cylinder compression check will help...

Engine oil pressure — check
Non-scheduled maintenance 1. The oil pressure warning light should come on when the ignition (main) switch is turned ON and extinguish a few seconds after the engine is started - this serves as a check that the warning light bulb is sound. If the...

Wheel bearings — check
Non-scheduled maintenance 1. Wheel bearings will wear over a period of time and result in handling problems. 2. Support the motorcycle upright using the centrestand if fitted, or an auxiliary stand, and support it so that the wheel being checked is...

Steering head bearings — SU re-greasing
Non-scheduled maintenance 1. Over a period of time the grease will harden or may be washed out of the bearings by incorrect use of jet washes. 2. Disassemble the steering head for regreasing of the bearings. Refer to Chapter 6 for details.

Swingarm and suspension linkage bearings — re-greasing
Non-scheduled maintenance 1. Over a period of time the grease will harden or dirt will penetrate the bearings due to failed seals. 2. Remove the swingarm and suspension linkage as described in Chapter 6 for cleaning and re-greasing of the bearings....

Brake caliper and master cylinder seals — renewal
Non-scheduled maintenance 1. Brake seals will deteriorate over a period of time and lose their effectiveness, leading to sticking operation or fluid loss, or allowing the ingress of air and dirt. Refer to Chapter 7 and dismantle the components for...

Brake hoses — renewal
Non-scheduled maintenance 1. The hoses will In time deteriorate with age and should be renewed regardless of their apparent condition. Refer to Chapter 7 and disconnect the brake hoses from the master cylinders and calipers. Always replace the banjo...

Fuel hoses — renewal
Warning: Petrol (gasoline) is extremely flammable, so take extra precautions when you work on any part of the fuel system. Don't smoke or allow open flames or bare light bulbs near the work area, and don't work in a garage where a natural gas-type...

Front forks oil change
Non-scheduled maintenance 1. Fork oil degrades over a period of time and loses its damping qualities. Refer to the fork oil change procedure in Chapter 6. Section 7. The forks do not need to be completely disassembled.