Complete map of motorcycle repair instructions Honda
Repair motorcycles Honda Africa Twin
Honda XRV 750 (1989-2003)
Information for owner
The birth of a dream
Acknowledgements about this manual
Model development
Bike characteristics
Performance data
Identification numbers
Buying spare parts
Engine/transmission oil level check
Coolant level check
Disc brake fluid level checks — all models are fitted with a front disc brake
Front brake fluid level
Drum brake checks — a rear drum brake is fitted to XL600V-H to L (1987 to 1990) models
Tyre checks
Suspension, steering and drive chain checks
Legal and safety checks
Routine maintenance and servicing — specifications
Maintenance schedule
Component locations — XL600V models
Component locations — XL650V models
Component locations — XRV750 models
Maintenance procedures — introduction
Drive chain and sprockets — check, adjustment cleaning and lubrication
Idle speed — check and adjustment
Brake shoes/pads — wear check
Cutch — check and adjustment
Spark plugs — check and adjustment
Battery — check
Wheels and tyres — general check
Air filter — check
Crankcase breather — check
Fuel strainer — check (XL600V models)
Spark plugs — renewal
Stand(s), lever pivots and cables — lubrication
Engine/transmission oil and filter — renewal
Fuel system — check
Throttle and choke cables — check and adjustment
Valve clearances — check and adjustment
Carburettor synchronisation
Cooling system — check
Brake system — check
Headlight aim — check and adjustment
Sidestand — check
Suspension — check
Steering head bearings — check and adjustment
Nuts and bolts — tightness check
Pulse secondary air injection (PAIR) system — check (XL650V models)
Air filter — renewal
Brake fluid — renewal
Coolant — renewal
Cylinder compression — check
Engine oil pressure — check
Wheel bearings — check
Steering head bearings — SU re-greasing
Swingarm and suspension linkage bearings — re-greasing
Brake caliper and master cylinder seals — renewal
Brake hoses — renewal
Fuel hoses — renewal
Front forks oil change
Engine doesn’t start or is difficult to start
Poor running at low speeds
Poor running or no power at high speed
Engine overheating
Clutch problems
Gear changing problems
Abnormal engine noise
Abnormal driveline noise
Oil pressure low
Abnormal frame and suspension noise
Excessive exhaust smoke
Poor handling or stability
Braking problems
Electrical problems
Engine and systems
Engine, clutch and transmission — specifications
General information about engine
Operations possible with the engine in the frame
Operations requiring engine removal
Major engine repair — general note
Engine — removal and installation
Engine disassembly and reassembly — general information
Oil cooler and distributor — removal, inspection and installation (XRV750 models)
Valve covers — removal and installation
Camshafts and rockers — removal, inspection and installation
Cam chains — removal and installation
Cam chain tensioners and guide blades — removal, inspection and installation
Cylinder heads — removal and installation
Valves/valve seats/valve guides — servicing
Cylinder head and valves — disassembly, inspection and reassembly
Cylinder barrels — removal, inspection and installation
Pistons — removal, inspection and installation
Piston rings — inspection and installation
Starter clutch — removal, inspection and installation
Crankcase — separation and reassembly
Crankcase — inspection, servicing and renewal
Oil pump and pressure relief valve — removal, inspection and installation
Main and connecting rod bearings — general information
Crankshaft and main bearings — removal, inspection and installation
Connecting rods — removal, inspection and installation
Initial start-up after overhaul
Recommended running-in procedure
Clutch — removal, inspection and installation
Clutch cable — removal and installation
Gearchange mechanism — removal, inspection and installation
Primary drive gear — removal, inspection and installation
Selector drum and forks — removal, inspection and installation
Transmission shafts — removal and installation
Transmission shafts — disassembly, inspection and reassembly
Cooling system — specifications
General information about cooling system
Radiator pressure cap — check
Cooling fan and fan switch — check and replacement
Coolant temperature gauge and sender — check and replacement
Thermostat and housing — removal, check and installation
Radiators — removal and installation
Waterpump — check, removal and installation
Coolant reservoir — removal and installation
Coolant hoses and unions — removal and installation
Fuel and exhaust systems — specifications
General information and precautions
Fuel tank and tap — removal and installation
Fuel tank — cleaning and repair
Air filter/duct housing — removal and installation
Air/fuel mixture adjustment — general information
Carburettor overhaul — general information
Carburettors — removal and installation
Carburettors — disassembly, cleaning and inspection
Carburettors — separation and joining
Carburettors — reassembly and float height check
Throttle cables — removal and installation
Choke cable — removal and installation
Exhaust system — removal and installation
Catalytic converter — general information (XL650V models)
Fuel pump — check, removal and installation (XRV750 models)
Fuel level indicator circuit — check and replacement
Pulse secondary air (PAIR) system — XL650V models
Ignition system — specifications
General information about ignition
Ignition system — check
Ignition HT coils — check, removal and installation
Pulse generator coil(s) — check
Ignition control unit (ICU) — check, removal and installation
Ignition timing — general information and check
Throttle position sensor — check and replacement
Immobiliser system (HISS) — XL650V models
Running gear and frame
Brakes, wheels and tyres — specifications
General information about brake system
Brake pads and shoes — replacement
Brake drum and discs (front and rear) — inspection, removal and installation
Front brake caliper(s) — removal, overhaul and installation
Rear brake caliper — removal, overhaul and installation
Rear brake plate assembly — removal, overhaul and installation (drum brake)
Front brake master cylinder — removal, overhaul and installation
Rear brake master cylinder — removal, overhaul and installation
Brake hoses and unions — inspection and replacement
Brake system — bleeding and fluid renewal
Wheels — inspection and repair
Wheels — alignment check
Front wheel — removal and installation
Rear wheel — removal and installation
Wheel bearings — removal, inspection and installation
Tyres — general information and fitting
Frame, suspension and final drive — specifications
General information about frame
Frame — inspection and repair
Footrests, brake pedal and gearchange lever — removal and installation
Sidestand — removal and installation
Handlebars and levers — removal and installation
Forks — removal and installation
Forks — oil change
Forks — disassembly, inspection and reassembly
Steering stem — removal and installation
Steering head bearings — inspection and replacement
Rear shock absorber — removal, inspection and installation
Rear suspension linkage — removal, inspection and installation
Suspension — adjustments
Swingarm — removal and installation
Swingarm — inspection, bearing check and replacement
Drive chain — removal, cleaning, and installation
Sprockets — check and replacement
Rear sprocket coupling/rubber dampers — check and replacement
Bodywork — general information
Seat — removal and installation
Rear view mirrors — removal and installation
Fairing and body panels — removal and installation (XL600V models)
Fairing and body panels — removal and installation (XL650V models)
Fairing and body panels — removal and installation (XRV750 models)
Front mudguard — removal and installation
Electric equipment
Electrical system — specifications
General information — electrical system
Electrical system — fault finding
Fuses — check and replacement
Brake light switches — check and replacement
Instrument cluster and speedometer cable — removal and installation
Instruments — check and replacement
Instrument and warning light bulbs — replacement
Oil pressure switch — check, removal and installation
Ignition (main) switch — check, removal and installation
Handlebar switches — check
Handlebar switches — removal and installation
Neutral switch — check, removal and installation
Sidestand switch — check and replacement
Clutch switch — check and replacement
Diode(s) — check and replacement
Horn — check and replacement
Lighting system — check
Headlight bulb and sidelight bulb — replacement
Headlight assembly — removal and installation
Brake/tail light bulb — replacement
Tail light assembly — removal and installation
Turn signal circuit — check
Turn signal bulbs — replacement
Turn signal assemblies — removal and installation
Battery — removal, installation, inspection and maintenance
Battery — charging
Starter relay — check and replacement
Starter motor — removal and installation
Starter motor — disassembly, inspection and reassembly
Charging system testing — general information and precautions
Charging system — leakage and output test
Alternator — check, removal and installation
Regulator/rectifier — check and replacement
Wiring diagrams XL600V-H and V-J
Wiring diagrams XL600V-K and V-L
Wiring diagrams XL600V-M, V-N and V-P (all markets except Germany)
Wiring diagrams XL600V-M, V-N and V-P (Germany only)
Wiring diagrams XL600V-R (ail markets except Germany)
Wiring diagrams XL600V-R (Germany only)
Wiring diagrams XL600V-T, V-V, V-W and V-X
Wiring diagrams XL650V
Wiring diagrams XRV750-L and M (all markets except Germany)
Wiring diagrams XRV750-L and M (all models except Germany)
Wiring diagrams XRV750-L and M (Germany only)
Wiring diagrams XRV750-N
Wiring diagrams XRV750-P, R and S (all markets except Germany)
Wiring diagrams XRV750-P, R and S (Germany only)
Wiring diagrams XRV750-T onwards
Repair motorcycles Honda CB series
Honda CB400SF (1 generation, 1992-1999)
Information for owner
The main dimensions and technical parameters of the motorcycle
Identification data
Motorcycle Maintenance and Repair Safety Precautions
Controls and monitoring devices
Tools, fixtures and operating materials
Universal Tool
Special tools and accessories
Operational and repair materials
Preparing for departure
Engine starting
Motorcycle conservation
Washing and caring for your motorcycle
Maintenance plan
Threaded connections — check
Wheels and tires — check
Engine Troubleshooting
Transmission Troubleshooting
Running gear troubleshooting
Diagnostics of malfunctions of electrical equipment
Engine and systems
Power unit — removal and installation
Description of the engine design
Compression in cylinders — check
Cylinder head — checking and adjusting valve clearances
Cylinder head — removal and installation
Valves — removal and installation, grinding in
Timing chain tensioner — removal, inspection and installation
Starter drive mechanism — disassembly and assembly
Checking the oil level
Possible causes of high engine oil level
Changing engine oil and oil filter
Oil pump — removal
Oil pump — disassembly and inspection
Oil pump — installation
Oil pressure sensor — removal and installation
Checking the coolant level
Checking technical condition
Coolant — replacement
Expansion tank — removal and installation
Thermostat — check without removal
Thermostat — removal and installation
Coolant pump — removal and installation
Radiator of the cooling system — removal and installation
Radiator fan — removal, disassembly, assembly and installation
Fan on sensor — removal and installation
Coolant temperature sensor — removal and installation
Safety measures for the maintenance and repair of the power system
General scheme of the power system
Air filter — replacing the filter element
Idle system — speed control
Fuel valve — removal, disassembly, assembly and installation
Carburetor bar — removal and installation
Carburettors — disassembly, assembly and flushing
Carburettors — Synchronization
System of release of the fulfilled gases — check of a technical condition
System of release of the fulfilled gases — removal and installation
Description of the design of the motorcycle transmission
Checking and adjusting chain tension
Wheel drive chain lubrication
Flushing the wheel drive chain
Drive chain — replacement
Drive chain drive sprocket — check, removal and installation
Main gear driven sprocket — check, removal and installation
Clutch — disassembly and assembly, replacement of discs and springs
Running gear and frame
Front wheel — removal and installation
Front wheel — replacement of bearings and seals
Rear wheel — removal and installation
Rear wheel — replacing bearings and seals
Final drive sprocket hub dampers — check and replace
Steering wheel — removal and installation
Front fork legs — oil change
Front fork feathers — removal and installation
Front fork legs — disassembly
Front fork legs — assembly
Steering column — check without disassembly
Steering column — disassembly, assembly, replacement of bearings
Rear suspension shock absorber — removal and installation
Rear suspension shock absorber — spring replacement. adjustment
Drive chain slider — check, replace
Rear suspension pendulum — check, removal and installation
Swingarm rear suspension — bearing replacement
Safety Precautions When Repairing and Maintaining the Motorcycle Brake System
Brake system — check of technical condition
Brake Fluid — Level Check
Front brake pads — replacement
Rear brake pads — replacement
Front wheel brake disc — checking, removal and installation
Rear wheel brake disc — inspection, removal and installation
Brake Fluid Replacement
Bleeding hydraulic brakes
Front brake caliper — removal, cleaning, installation
Rear brake caliper — removal, cleaning, installation
The sensor of a signal of braking of a forward brake — removal and installation, check
Front brake master cylinder — removal and installation
Front brake master cylinder — disassembly and assembly
Rear brake signal sensor — removal and installation, check
Rear brake master cylinder — removal and installation
Rear brake master cylinder — disassembly and assembly
Description of the frame structure
Verification of geometry and main welds
Seat — removal and installation
Rear trim — removal and installation
Side trim — removal and installation
Fuel tank — removal and installation
Front wheel guard — removal and installation
Rear wheel guard — removal and installation
Driver footrests — removal and installation
Passenger footrests — removal and installation
Footrest brackets — removal and installation
Seat box — removal and installation
Air filter housing — removal and installation
Side stop, side stop sensor — removal and installation
Center stand — removal and installation
Seat box lock — removal and installation
Fuel filler cap — maintenance
Rear-view mirrors — removal and installation
Electric equipment
Steering wheel and attachments — disassembly and assembly
Instrument panel — disassembly and assembly
Control cables — inspection and lubrication
Speedometer drive cable — removal and installation
Clutch cable — removal and installation, adjustment
Throttle actuator cables — removal and installation
Starting enricher drive cable — removal and installation
Gear shift pedal — removal, installation and adjustment
Rear brake pedal — removal and installation
Precautions for the repair and maintenance of electrical equipment
Scheme of the ignition system
Spark plugs — replacement
High voltage wires and caps — replacement
Ignition coils — removal and installation
Breaker — removal and installation
Engine control unit — removal and installation
Diagnostics of the ignition system
Checking the side stop sensor
Checking the neutral sensor
Clutch Lever Sensor Check
Checking ignition coils and high voltage wires
Breaker test
Scheme of the engine start system
Diagnostics of the engine start system
Starter relay — removal and installation
Starter — removal and installation
Starter — disassembly and assembly
General scheme of the battery charging system
Battery — removal and installation, maintenance
Relay regulator — checking, removal and installation
Generator — removal and installation
Fuses — Replacement
Headlight — beam adjustment
Headlight — lamp replacement
Headlamp — removal and installation
Taillight and Brake Light — Bulb Replacement
Rear position lamp and brake signal — removal and installation
Turn Signal — Bulb Replacement
Turn signal — removal and installation
Instrument panel — replacing backlight and indicator lamps
Sound signal — check, removal and installation
Switch (lock) ignition — check, removal and installation
Turn signal relay — check, removal and installation
Scheme of instrumentation
Wiring diagram of the CB400N modification motorcycle (without warning lamp for exceeding the permissible speed)
Wiring diagram of the CB400N modification motorcycle (with overspeed warning lamp)
CB400F motorcycle wiring diagram
Repair motorcycles Honda VTX series
Honda VTX 1800 C (2001-2008)
Information for owner
Controls and their location
Instruments and indicators
Odometer and trip odometer display
Egnition lock
Right Handle Controls
Left Handle Controls
Motorcycle steering lock
Helmet holder
Document compartment
Motorcycle side panel
Removing and installing the seat
Adjusting the headlight direction vertically
Motorcycle Specifications
Important safety information
Protective clothing for motorcyclists
Maximum permissible load and recommendations
Additional equipment and design changes
Adjusting the suspension shock absorbers
Brake system
Checking the motorcycle clutch
Cooling liquid
Fuel and fuel tank
Checking the engine oil level
Checking the oil level in the main gear
Tubeless tires
Inspecting the motorcycle before the ride
Starting a motorcycle engine
Running in a new motorcycle
Motorcycle driving tips
Motorcycle parking
Recommendations for protecting your motorcycle from theft
Importance of Maintenance
Safety precautions for maintenance
Maintenance schedule
Maintenance tool kit
Motorcycle identification numbers
Choosing engine oil
Changing the engine oil and oil filter
Crankcase ventilation
Spark plug
Final drive oil
Throttle valve operation
Idle speed control
Coolant replacement
Air filter
Checking the front and rear suspensions
Side support — check
Removing and installing the front wheel
Removing and installing the rear wheel
Brake pad wear
Accumulator battery
Replacing fuses
Adjusting the brake light switch
Replacing lamps
Cleaning the motorcycle
Recommendations for storing your motorcycle
Catalytic converter
Specifications for motorcycle repair
Torque values for motorcycle repair
Special tools for motorcycle repair
Lubrication & seal points
Emission control systems
Emission control information labels (USA only)
Engine and systems
Service information of engine removal
Engine removal
Engine installation
Service information of cylinder head and valves
Troubleshooting of cylinder head and valves
Cylinder compression
Cylinder head cover removal
Camshaft removal
Camshaft holder disassembly
Camshaft inspection
Cylinder head removal
Cylinder head disassembly
Cylinder head inspection
Valve guide replacement
Valve seat inspection and refacing
Cylinder head assembly
Cylinder head installation
Camshaft installation
Cylinder head cover installation
Service information of cylinder and piston
Troubleshooting of cylinder and piston
Cylinder removal
Cylinder inspection
Piston removal
Piston/piston ring inspection
Cylinder stud bolt replacement
Piston ring installation
Piston installation
Cylinder installation
Service information of fuel system
Troubleshooting of fuel system
Fuel system location
Fuel system diagram
PGM-FI (programmed fuel injection) system
PGM-FI self-diagnosis malfunction indicator failure codes
PGM-FI MIL 1 blink (MAP sensor)
PGM-FI MIL 2 blinks (MAP sensor)
PGM-FI MIL 7 blinks (ECT sensor)
PGM-FI MIL 8 blinks (TP sensor)
PGM-FI MIL 9 blinks (IAT sensor)
PGM-FI MIL 10 blink (BARO sensor)
PGM-FI MIL 11 blinks (vehicle speed sensor)
PGM-FI MIL 12 blinks (rear injector)
PGM-FI MIL 13 blinks (front injector)
PGM-FI MIL 18 blinks (cam pulse generator)
PGM-FI MIL 19 blinks (ignition pulse generator)
PGM-FI MIL 21 blinks (O2 sensor/California type only)
PGM-FI MIL 23 blinks (O2 sensor heater/California type only)
PGM-FI MIL 33 blinks (E2-prom)
Fuel pressure inspection
Fuel flow inspection
Fuel pump — removal and installation
Fuel cut-off relay
Fuel tank — removal and installation
Air cleaner housing — removal and installation
Throttle body removal
Intake manifold removal
Intake manifold installation
Throttle body installation
Injectors — removal and installation
Starter valve — disassembly and assembly
Air screw synchronization
BARO and MAP sensor — removal and installation
IAT sensor — removal and installation
ECT sensor — removal and installation
Cam pulse generator — removal and installation
TP sensor — removal and installation
Bank angle sensor — removal and installation
Engine stop relay — inspection
ECM (Engine Control Module) — removal and installation
Intake duct control solenoid valve — inspection
Pair solenoid valve — removal and installation
Pair check reed valve — removal and installation
EVAP purge control valve (California type only)
O2 sensor (California type only) — removal
Service information of cooling system
Troubleshooting of cooling system
Coolant (hydrometer test)
Radiator сар/system pressure inspection
Coolant replacement
Radiator and cooling fan — removal and installation
Radiator reserve tank — removal and installation
Thermostat — removal and installation
Water pump — removal and installation
Service information of lube system
Troubleshooting of lube system
Oil pressure check
Oil pump and filter — removal
Relief valve check
Oil pipe — removal and installation
Oil pump and filter — disassembly
Oil pump and filter — inspection
Oil pump and filter — assembly
Oil pump and filter — installation
Service information of clutch and gearshift linkage
Troubleshooting of clutch and gearshift linkage
Clutch fluid draining
Clutch fluid filling and air bleeding
Clutch master cylinder — removal and installation
Clutch slave cylinder — removal and installation
Right crankcase cover — removal and installation
Clutch — removal and installation
Primary drive gear — removal and installation
Primary driven gears — removal and installation
Gearshift linkage — removal and installation
Service information of crankshaft and transmission
Troubleshooting of crankshaft and transmission
Crankcase separation
Primary shaft — removal and installation
Crankshaft/connecting rod — removal and installation
Transmission — removal and installation
Crankcase assembly
Output gear — removal and installation
Crankcase bearing replacement
Service information of final drive
Troubleshooting of final drive
Final drive removal
Final drive gear
Final drive installation
Running gear and frame
Cable & harness routing
Service information
Exhaust troubleshooting
Seat — removal and installation
Side cover — removal and installation
Left crankcase rear cover — removal and installation
Rear fender — removal and installation
Muffler/exhaust pipe — removal and installation
Muffler/exhaust pipe — disassembly and assembly
Service information of front suspension
Troubleshooting of front suspension and steering
Handlebar — removal
Handlebar — installation
Front wheel — removal
Front wheel — inspection
Front wheel — disassembly
Front wheel — assembly
Front wheel — installation
Front fork — removal
Right fork — disassembly
Left fork — disassembly
Front fork — inspection
Right fork — assembly
Left fork — assembly
Front fork — installation
Steering stem — removal
Steering stem — installation
Steering head bearing pre-load
Service information of rear suspension
Troubleshooting of rear suspension
Rear wheel — removal
Rear wheel — inspection
Rear wheel — disassembly
Rear wheel — assembly
Rear wheel — installation
Shock absorber — removal and installation
Swingarm — removal
Swingarm — inspection
Swingarm — installation
Service information of hydraulic brake
Troubleshooting of hydraulic brake
Brake fluid draining
Brake fluid filling/air bleeding
Brake pad replacement
Brake disc inspection
Front master cylinder — removal
Front master cylinder — disassembly
Front master cylinder — inspection
Front master cylinder — assembly
Front master cylinder — installation
Front caliper — removal
Front caliper — disassembly
Front caliper — inspection
Front caliper — assembly
Front caliper — installation
Rear master cylinder — removal
Rear master cylinder — disassembly
Rear master cylinder — inspection
Rear master cylinder — assembly
Rear master cylinder — installation
Rear master cylinder reservoir — removal and installation
Rear caliper — removal and installation
Brake pedal — removal and installation
PCV (Proportional Control Valve) — removal and installation
Electric equipment
Service information of lights, meters and switches
Troubleshooting of vehicle speed sensor and speedometer
Headlight — bulb replacement
Headlight case — removal and installation
Turn signals — bulb replacement
Front turn signal assembly — removal and installation
Tail/brake light — bulb replacement
License light — bulb replacement
Indicator box — removal and installation
Speedometer — removal and installation
Vehicle speed sensor — voltage inspection
Vehicle speed sensor — output signal inspection
Vehicle speed sensor — removal and installation
Neutral switch — removal and installation
Front brake light switch
Rear brake light switch
Clutch switch
Ignition switch — removal and installation
Handlebar switch
Fan motor switch — removal and installation
Coolant temperature indicator
ECT/thermo sensor unit — inspection
Side stand switch — removal and installation
Oil pressure indicator — removal and installation
Horn — removal and installation
Turn signal relay — inspection
Fuel reserve sensor — inspection
Wiring diagram of motorcycle
Service information of ignition system
Troubleshooting of ignition system
Ignition system inspection
Ignition coil primary peak voltage
Ignition pulse generator peak voltage
Ignition coil — removal and installation
Ignition timing
Service information of charging system and alternator
Troubleshooting of charging system and alternator
Battery — removal and installation
Battery — inspection and testing
Battery — charging
Charging system inspection
Battery case — removal and installation
Regulator/rectifier — removal and installation
Alternator — inspection
Alternator — left crankcase cover removal
Alternator — stator removal and installation
Alternator — left crankcase cover installation
Service information of electric starter
Troubleshooting of electric starter
Starter motor — removal
Starter motor — disassembly
Starter motor — inspection
Starter motor — assembly
Starter motor — installation
Starter relay switch — inspection
Starter relay switch — removal and installation
Starter driven gear/torque limiter removal
Left crankcase cover bearing replacement
Left crankcase bearing replacement
Starter drive gear inspection
Starter torque limiter inspection
Flywheel — removal
Starter clutch — removal
Starter clutch — inspection
Starter clutch — installation
Flywheel — installation
Starter driven gear/torque limiter installation
Balancer weight — removal and installation