Diagnosis and troubleshooting of motorcycle Honda XRV750 (Africa Twin, 1989-2003)

Engine doesn’t start or is difficult to start
Starter motor doesn't rotate Engine kill switch OFF. Fuse blown. Check main fuse and starter circuit fuse ( Chapter 9 ). Battery voltage low. Check and recharge battery ( Chapter 9 ). Starter motor defective. Make sure the wiring to the starter is...

Poor running at low speeds
Spark weak Battery voltage low. Check and recharge battery ( Chapter 9 ). Spark plugs fouled, defective or worn out. Refer to Chapter 1 for spark plug maintenance. Spark plug cap or HT wiring defective. Refer to Chapters 1 and 5 for details on the...

Poor running or no power at high speed
Firing incorrect Air filter restricted. Clean or replace filter ( Chapter 1 ). Spark plugs fouled, defective or worn out. See Chapter 1 for spark plug maintenance. Spark plug caps or HT wiring defective. See Chapters 1 and 5 for details of the...

Engine overheating
Engine overheats Coolant level low. Check and add coolant ( Chapter 1 ). Leak in cooling system. Check cooling system hoses and radiator for leaks and other damage. Repair or replace parts as necessary ( Chapter 3 ). Thermostat sticking closed....

Clutch problems
Clutch slipping Clutch cable incorrectly adjusted ( see Chapter 1 ). Friction plates worn or warped. Overhaul the clutch assembly ( Chapter 2 ). Plain plates warped ( Chapter 2 ). Clutch springs broken or weak. Old or heat-damaged (from slipping...

Gear changing problems
Doesn't go into gear or lever doesn't return Clutch not disengaging. See above. Selector fork(s) bent, worn or seized. Overhaul the transmission ( Chapter 2 ). Gearchange shaft bent. Remove the gearchange mechanism and check the shaft and all...

Abnormal engine noise
Knocking or pinking Carbon build-up in combustion chamber. Use of a fuel additive that will dissolve the adhesive bonding the carbon particles to the piston crown and chamber is the easiest way to remove the buildup. Otherwise, the cylinder heads...

Abnormal driveline noise
Clutch noise Clutch outer drum/friction plate clearance excessive ( Chapter 2 ). Loose or damaged clutch pressure plate and/or bolts ( Chapter 2 ). Transmission noise Bearings worn. Also includes the possibility that the shafts are worn. Overhaul...

Oil pressure low
Engine lubrication system Engine oil level low. Inspect for leak or other problem causing low oil level and add recommended oil ( Daily (pre-ride) checks ). Engine oil viscosity too low. Very old, thin oil or an improper weight of oil used in the...

Abnormal frame and suspension noise
Front end noise Low fluid level or improper viscosity oil in forks. This can sound like spurting and is usually accompanied by irregular fork action ( Chapter 6 ). Spring(s) weak or broken. Makes a clicking or scraping sound. Fork oil, when drained,...

Excessive exhaust smoke
White smoke Piston oil ring worn. The ring may be broken or damaged, causing oil from the crankcase to be pulled past the piston into the combustion chamber. Replace the rings with new ones ( Chapter 2 ). Cylinders worn, cracked, or scored. Caused...

Poor handling or stability
Handlebars hard to turn Steering head bearing adjuster nut too tight. Check adjustment as described in Chapter 1 . Bearings damaged. Roughness can be felt as the bars are turned from side-to-side. Renew bearings and races ( Chapter 6 ). Races dented...

Braking problems
Brakes are spongy, don't hold - disc brakes Air in brake line. Caused by inattention to master cylinder fluid level or by leakage. Locate problem and bleed brakes ( Chapter 7 ). Brake pads or disc worn (Chapters 1 and 7 ). Brake fluid leak. See...

Electrical problems
Battery dead or weak Battery faulty. Caused by sulphated plates which are shorted through sedimentation. Also, broken battery terminal making only occasional contact ( Chapter 9 ). On non MF batteries, make sure the electrolyte level is correct (...