Honda Transalp XL600V

This page applies most directly to the 1989-1990 US-spec Honda Transalp. See http://www.ta-deti.de/ta/ for thorough technical information on all Transalp models.

Specifications

These specifications are from the Honda service manual for the 1989 XL600V (manual dated October 1988).

DIMENSIONS	Overall length	2,265 mm (89.2 in)
	Overall width	865 mm (34.1 in)
	Overall height	1,265 mm (49.8 in)
	Wheelbase	1,505 mm (59.3 in)
	Seat height	850 mm (33.5 in)
	Ground clearance	225 mm (8.9 in)
	Dry weight	181 kg (399.0 lb)
	Curb weight	201 kg (443.1 lb)
FRAME	Type	Semi double cradle
	Front suspension, travel	Telescopic fork, 200 mm (7.9 in)
	Rear suspension, travel	Swing arm/Shock absorber, 187 mm (7.4 in)
	Front tire size	90/90-21 54S
	Rear tire size	130/890-17 65S
	Front brake	Hydraulic disc
	Rear brake	Internal expanding shoes
	Fuel capacity	18 liters (4.8 US gal, 4.0 Imp gal)
	Fuel reserve capacity	2.9 liters (0.77 US gal, 0.64 Imp gal)
	Caster angle	28°
	Trail	108 mm (4.3 in)
	Fork leg oil capacity	549 cm³ (185.7 US oz, 19.3 Imp oz)
ENGINE	Type	Water cooled 4-stroke
	Cylinder arrangement	2 cylinders, 52°V
	Bore and stroke	75.0 x 66.0 mm (2.95 x 2.60 in)
	Displacement	583.2 cm³ (35.59 cu in)
	Compression ratio	9.2 : 1
	Valve train	Silent, multi-link chain drive and OHC with rocker arms
	Oil capacity	2.8 lit (2.96 US qt, 2.46 Imp qt) after disassembly, 2.2 lit (2.32 US qt, 1.94 Imp qt) after draining
	Lubrication system	Forced pressure and wet sump
	Air filtration	Paper filter
	Cylinder compression	1177 kPa (12.0 kg/cm³, 171 psi)
	Intake valve	Opens 10° (BTDC) Closes 40° (ABDC)
	Exhaust valve	Opens 40° (BBDC) Closes 10° (ATDC)
	Valve clearance (cold)	intake 0.15mm (0.006 in) exhaust 0.20 mm (0.008 in)
	Engine dry weight	59.5 kg (131.17 lb)
CARBURETOR	Type	Piston valve, dual carburetor
	I.D. number	VDFHA <VDFJA>
	Main jet	FRONT: #120 REAR: #120
	Pilot screw opening	2-1/2 turns out
	Float level	7mm (0.28 in)
	Idle speed	1,300 +/- 100 rpm
DRIVE TRAIN	Clutch	Wet, multi-plate
	Transmission	5-speed constant mesh
	Primary reduction	1.888 (68/36)
	Final reduction	3.133 (47/15)
	Gear ratio I	2.571 (36/14)
	Gear ratio II	1.777 (32/18)
	Gear ratio III	1.380 (29/21)
	Gear ratio IV	1.125 (27/24)
	Gear ratio V	0.961 (25/26)
	Gear shift pattern	Left foot operated return system, 1-N-2-3-4-5
ELECTRICAL	Ignition	DC-CDI
	Ignition timing	Initial 10° BTDC at idle Full advance 30° BTDC at 4,500 rpm
	Alternator	AC GENERATOR 0.31 kw/5,000 rpm
	Battery capacity	12V 12AH
	Spark plug	NGK ND Standard DPR8EA-9 X24EPR-U9 For cold climate (below 5°C/41°F) DPR7EA-9 X22EPR-U9 For extended high speed driving DPR9EA-9 X27EPR-U9
	Spark plug gap	0.8 - 0.9 mm (0.031 - 0.035 in)
	Fuse	Main 30A Sub 10A x 3 15A
	Starting system	Electrical starter
	Headlight	12V 60/55W
	Position light	12V 4W
	Turn signal light	12V 21W
	Stop & taillight	12V 21/5W
	Meter lights	12V 1.7W x 3
	Indicator light	Neutral 12V 3.4W High beam 12V 1.7W Turn signal 12V 3.4W Oil warning 12V 3.4W

Consumables

Spark Plugs

NGK

These part numbers come from the NGK parts finder for the 1989-1990 XL600V:

• Standard p/n DPR8EA-9, stock no. 4929, gap 0.035" ($2.24 from Amazon.com)
• Iridium p/n DPR8EIX-9, stock no. 2202, gap 0.035" ($7.32 from Amazon.com)

Oil Filters

The Purolator PureOne PL14612 filter fits the Transalp (and every other Honda I've tried). It's designated for the Mazda MX6. The PL14610 also fits, and is longer, which should give better filtration (note: I previously had mixed the two up and listed the wrong one as longer). It may be difficult to get an oil filter wrench between the longer PL14610 and the swingarm. Personally, I just remove the filter by hand, and if it's too tight to do so, I puncture it with a screwdriver and loosen it that way.

This Goldwing site mentions that the L14459 fits Goldwings, in addition to the L14610 and L14612. The L14459 is fatter and shorter than the L14610, and has published specs placing it between the classic L14610/L14612 and the PureOne PL14610. It may be worth considering.

Chain

The stock chain is size 525, with 118 links.

Sprockets

• Front: 15 tooth, Honda part number 23801-MM9-010, listed on "Transmission" page of microfiche.
• Rear: 47 tooth

NT650 Hawk 16 Tooth Sprocket

• Honda part number 23801-MN8-000. This drops engine speed by about 400 RPM at 60mph.

Tires

This post discusses how an 80/100-21 front tire might fit the Transalp's 1.85 inch rim better than a 90/90-21. Newer 21 inch rims are generally 2.15 inches wide.

Modifications

Africa Twin Conversion

For information on putting Africa Twin parts onto a US-spec Transalp, go to: Honda Transalp and Africa Twin.

Bodywork

• Thunder Dan's Boano fairing installation.

Engine

Engine swaps are detailed on Transalp Engine Swaps page.

Suspension

Rear Suspension

Works Performance

The Works Performance Catalog provides detailed specifications on the stock Transalp rear shock (source):

Make/Model	Years	NO.	OAL	STK	SPRING	Duracross		Ultracross Adj. Damping
						STD	REZ	REB
XL 600V	1989	Un	14.69	Y	SRS	569	619	749

Legend:

• NO.: Pr for pair, Un for Unit (i.e. single shock)
• OAL: Over-all length (unstressed, bolt-center to bolt-center)
• STK: Stock size (Y=Yes, S=Short, L=Long, WS=Works Stock)
• SPRINGS: Single Rate (SRS), Dual Rate (DRS), Triple Rate (TRS)
• STD: Standard shocks without reservoir
• REZ: Hose mounted remote reservoir
• ADJ Ultracross: Rebound adjustable with reservoir.

So, the shock is sold as a single unit, it's 14.69 inches long, which is stock length, it's a single-rate spring, and it's available as standard, with a reservoir, or with both adjustable rebound damping and a remote reservoir.

Lengthening Stock Suspension

• This post describes the "Moab" shock that Cogent Dynamics builds. This shock gives 2" additional height and travel to the rear of a Transalp.

Africa Twin Suspension

An Africa Twin swingarm and rear shock can be used to gain height and travel. See the Honda Transalp and Africa Twin page for more information.

Front Suspension

Stock fork specifications:

• Free length: 571.5mm (22.5 in)
• Fork fluid capacity: 549cc (18.6 US oz)
• Fork fluid level: 125mm (4.9in)
• According to Race Tech, the stock Transalp fork spring strength is 0.51kg/mm.
• Front suspension travel 200mm (7.9in)
• Upper fork leg diameter: 41mm

Racetech Gold Valve Emulators

Race Tech Gold Valve Emulators for the NT650V Hawk (Race Tech part number FEGV S4101)can be used in the Transalp, since the forks are the same diameter (41mm).

NX650 Forks

NX650 forks have the same upper tube diameter as Transalp forks, but have longer upper tubes. The bolt spacing for the brake caliper may be different.

XR600 and XR650L Forks

• This post details one person's experience putting XR650L forks onto a Transalp. He used SRC Mudskins for fork protection, the SRC fork brace, and modified the Transalp fender to fit.
• This post provides a bracket template for the fuse box holder on XR600 and XR650 forks.

XR650L Fork Specifications:

• Spring free length: 576.0mm (22.68")
• Recommended fluid: Pro Honda Suspension Fluid SS-7
• Fork oil level: 145mm (5.7")
• Fork oil capacity: 564cc (19.1 US oz)
• Spring stiffness: 0.44kg/mm (according to Race Tech)
• Front fork travel: 295mm (11.6in) (note that rear suspension is 11.0 inches)
• Upper fork leg diameter: 43mm
• Bearings are Nachi 32005J/26 (the /26 is important, the inside diameter is 26mm versus the industry standard 25mm for 32005 bearings)

My own measurements show that the wire diameter is 4.99mm, and that there are 44 coils, including both ends. This adds up to approximately 220mm fully-compressed length.

Spring Rates

Putting XR600, XR400, or XR650L forks on a bike as heavy as the Transalp will require stiffer fork springs. It appears that Eibach and Progressive are the only manufacturers selling fork springs for the XR650L. Race Tech resells Eibach springs.

• This post mentions 0.52 kg Eibach springs for a 170 pound rider and 400 pound bike.
• The preceeding post mentions 0.47kg springs.
• This post says 0.52kg springs for a 260 pound rider with good results.
• This post mentions that stock XR600 (?) springs may be only 0.38kg.
• This post says the first two years of XR400s had 0.38kg springs, after which they switched to 0.40kg.
• This post says a tuner calculated 0.54kg/mm to be optimal for road use.

• XR's Only has Eibach 0.45kg/mm, 0.47kg/mm, and 0.50kg/mm springs for $99. They are listed for XR400R, XR600R, and XR650L.

Cutting Fork Springs

Aftermarket fork springs are usually nothing more than shorter equivalents of standard fork springs. Given the same material, coil diameter, and wire diameter, a fewer coils yield a stiffer spring.

This SuperHunky article explains how to cut truck springs using a torch and bench grinder. This Fork Spring Worksheet will help determine the number of coils to cut.

Brakes

Stock

The US-spec 1989 through 1992 Honda Transalps use a rigid rotor which is 276mm in diameter. The brake caliper is a floating, twin-piston unit (each piston is 30mm in diameter).

Upgrades

Rotors for Transalps

No upgraded rotors appear to be available for US Transalps. Rotors intended for some other bikes may work, however. In Europe, various brake upgrade kits have been sold.

NT650 Hawk

The Honda NT650 Hawk uses the same bolt pattern as the Transalp, but with a 316mm diameter (this page has excellent Hawk information). A Hawk rotor with a caliper-relocation bracket is probably the most common braking upgrade performed on Transalps.

Several companies produce stock-size Hawk rotors:

• 

  EBC MD1021LS
  • 316mm diameter.
  • Listed in the EBC catalog as an 'S/F' type, meaning floating conversion for solid rotors.
  • Also fits 1991-2003 CB750 Nighthawk, 1994-2003 VF750C Magna, 1991-2002 ST1100, 1995 ST1100A.

Oversize Hawk rotors are also available:

• 

  Braking HO26FLD ('wave' or 'petal' style rotor)
  • 318mm diameter
  • There is no available brake caliper spacer to accommodate a 318mm brake rotor when using Transalp fork legs.

Brake Caliper Spacer for Honda Hawk Rotors

Since the 316mm Hawk disc is larger than the Transalp's 276mm disc, a new brake caliper bracket or a spacer is required. There are two options you may read about, only one of which is in production:

M.A.P. Engineering

M.A.P. Engineering has a brake caliper spacer to accommodate a Honda Hawk rotor. Update: the M.A.P. Engineering website is no more. No additional information is available at this time.

Lenac

There was a brake caliper spacer known as the "Lenac," "Lenac Brake Kit," etc. When M.A.P. discontinued the brake rotor, Steve Lenac began producing his Big Brake Kit. Unfortunately, he passed away. M.A.P. Engineering has begun producing the Hawk spacer again.

Horsepower by Gary Davis

In this thread, Gary Davis of HPbyGD says he produces caliper relocation brackets.

Brakes for XR650L Fork Legs

This section is for those who have upgraded to XR650L forks.

XR650L Front Wheel

If you acquire an XR650L wheel to match your XR650L forks, there are several Supermoto kits available for the XR650L.

Another XR Front Wheel

Theoretically, any XR wheel can be put together with the XR650L front forks. The XR650L wheel has a different brake bolt pattern than the XR-R wheels. Axles may be different diameters, but this can probably be fixed by replacing bearings and machining or replacing the bearing spacer.

Transalp Front Wheel

A Transalp wheel can be put into XR650L forks. The XR-L axle is thicker, so the wheel bearings will have to be replaced, and the bearing spacer will have to be machined or replaced. In this configuration, a Transalp or Honda Hawk brake rotor can be fitted, and the brake caliper can be placed on a relocation bracket made for the XR650L. An XR-compatible brake caliper will be required.

Braking offers several types of caliper relocation brackets for the XR series. The Transalp brake caliper will not fit.

XR Brake Caliper Compatibility

According to this post, all the XR models share the same caliper bracket mount dimensions:

The XR400, XR600R, XR650L and XR650R all share the same caliper. You can use a front wheel from a later model XR on an XR650L if you use the correct caliper bracket for that sized disk. All of the fork legs have the same caliper bracket mounting dimensions and all of the bikes use the same sized caliper. They just use slightly different brackets for the different sized disks, which are easily swapped.

Note that this is not strictly true. By comparing Honda part numbers, it appears that the XR650L caliper and bracket are unique to the XR650L (1993 - 2008):

• Bracket with shim: BRACKET, L. FR. 45110-KAS-902 $76.41
• Entire caliper: CALIPER SUB-ASSY. 45150-MY6-305 $183.35

Meanwhile, the XR650R shares the caliper with the CR250R, CR125R, CRF230F, CRF150F, and CR230F and the bracket with the CR250R, CR125R, CRF450R, CRF150F, and CRF230F (note: the caliper may be different on the CR450R).

• Bracket with shim: BRACKET SUB-ASSY. 45190-KZ4-J21 $44.52
• Entire caliper: CALIPER SUB-ASSY. 45150-KZ4-J21 $123.16

The brake pads are identical across all of these, and more, models.

I am personally using XR650L fork legs, a Transalp wheel, a Braking 318mm rotor, a Braking 'Supermoto' relocation bracket, and a CR250 brake caliper. The CR250 caliper is twin piston, with 27mm pistons. The stock Transalp brake has 30mm pistons. Using the stock Transalp master cylinder, braking feels 'wooden', but effective. The "Supermoto" brake caliper offered by Braking is 36mm, which will probably yield much better feel at the lever.

The Braking USA Catalog is here.

• POW21 - caliper spacer for XR/XR-L/CR calipers and 320mm rotors
• POW90 - caliper spacer for Braking's CA2501 SM caliper and 320mm rotors

Caliper Spacer/Adapter

With the larger diameter disc, a new spacer must be used to move the Transalp's brake caliper outward.

This thread (advrider.com) mentions a guy making a spacer so you can use a stock Hawk rotor (316mm) on the TA (276mm stock).

Anyway- potential very good news- I asked the guy who built a brake 
kit for Honda Hawks (a 6 piston caliper and GSXr rotor- works great- 
I have one on my Hawk) to look at a potential TA solution. He designed 
and built a bracket that relocates the stock TA caliper so that you 
can use a stock Hawk rotor which is larger (and I think a little 
thicker) than the stock TA rotor. Combined with steel braided lines 
and HH pads (which he thinks might not even be necessary) this should 
provide a relatively inexpensive upgrade to the TA.

I should be doing this in the next month or so and will let you all 
know how it works. Keep fingers crossed

This thread (advrider.com) mentions the Hawk rotor again.

Stainless brake line is a good investment. Speigler, and Galfer both offer
one. Maybe others. The trick brake upgrade is get a used rotor from 88-91
NT650 Hawk. Same bolt pattern but 40mm bigger diameter. Then you have to
machine an adapter to offset the caliper. I'm working on this now.

Also:

Steve (Fast By Big Boy) Lenac (bigboy11@sigmaweb.net) has (or will
shortly have) the full kits for this. I have one on mine (shown in 
the "show me" thread) and it makes a difference.

Sources and Prices

EBC MD1021LS
$168.95	MAW
$174	Ron Ayers
$179	AZ Motorsports
Braking (wave) HO26FLD (that's ho, not h-zero)
$186.95 ($200.36 w/S/H)	Streetbike Accessory Warehouse
$203.88	Motorcycleproshop
$212	Cyclepages
$214.95	AZ Motorsports
Galfer (stainless) DF022 (022)
$185.35	AZ Motorsports

Exhaust

GSXR-1000

According to this thread (advrider.com), 2001 - 2004 GSXR1000 mufflers are a relatively easy add-on.

Not quite a direct bolt-on but close. I got two 15° bend stainless steel tubes from Burns Stainless and rotated them until I got the right angle. Then I made the flange to bolt on the muffler. I attached the muffler and then tacked the flange and the two sections in place. I'm not a welder so you won't see a close-up shot. I originally had a GSXR1000 muffler on because it was titanium. But when I put the bags and mounts on, the muffler was too big and in the way. So I swapped it out for a 750 or 600 unit, shorter but not titanium. Fortunately, it weighs the same due to the shorter length.

Electrical

Battery

Sealed Batteries

YTX14AH-BS

According to this thread, the stock lead-acid battery, YB12A-B, can be replaced with a sealed lead-acid battery, YTX14AH-BS. The only modification necessary is to remove the battery insulator sleeve.

• Froogle: $66 - $100+

Deka

This post details the Deka ETX15, which fits in the stock Transalp battery cage without the battery sleeve, and has redundant lugs which could be helpful with auxiliary wiring.

• Froogle: $55 - $72

NT650

This post details how a sealed battery specified for a Hawk NT650V can be used on the Transalp, but it requires a 1/8" shim underneath and possible cutting of the battery sleeve.

Regulator/Rectifier

The Transalp regulator/rectifier isn't really a known weak point. Jim Davis used a MOSFET-type unit from a CBR600 (labeled FH008-EB) on his Africa Twin. 'dreamer' references this and mentions that CBR600RR regulator/rectifier units from 2007 - 2010, labeled FH008, are suitable.

'ravelv' indicates that these are still shunt-type regulators.

CDI (Ignition) Modules

Transalp CDIs seem to go bad at 30k - 40k miles. Some last longer, some shorter. The typical cause of failure seems to be soldered joints coming apart. Usually, removing the plastic casing will reveal that the connector's leads have become detached from the circuit board.

Stock Honda

The Honda CDI for a 1989 Honda Transalp is part number 30410-MS8-610. It appears on parts finder websites under 'Wiring Harness'. The best price I can find (as of 9/14/2011) is $103.05 from Honda Peninsula, but their shipping is exorbitant at $25.

CDI Holder Update

The molded rubber CDI holder has been updated to reposition the CDI boxes. The connectors will come out toward the back of the bike, rather than upward toward the seat. This may prevent the seat from pressing down onto the connectors. However, the benefit may actually be due to better vibration isolation.

The updated CDI holder is Honda part number 30401-MM9-010.

M.S. Dual Line

This post talks about M.S. CDI modules for Transalps, and RD03 Africa Twins.

"The new CDIs "Dual Line" have advanced spark angle (for 95 octane fuel). They can be switch to standard advance by cutting the long, black wire loop. The short yellow wire loop activates the side stand switch stop the engine. Cut it only after thorrowly testriding the bike. Detailed description in German is enclosed, I work on the English version.

This Transalp.org thread, by Götz Stelzenmüller, announces the digital CDIs and describes them in-depth. The 'Dual Line' CDI has two spark advance curves. The increased-advance curve ( is default and requires 95 ROZ gas (equivalent to 91 octane in the U.S. and Canada, see AKI vs RON/ROZ). The standard-advance curve is selected by cutting the black wire.

• M&S Dual Line for Honda Transalp (pair) (manufacturer's website). 139 Euros for one (p/n H003) or 259 Euros for a pair (H004) as of 9/14/2011.
• Cheaper analog option (p/n H009) 90 Euros each. Cannot be mixed with the digital model.

Argentinian CDIs

There are several brands of CDIs which are made in Argentina. Most likely, they are all the same. They are listed as model "1553" or "IHA6001".

Ladder106 on AdvRider bought two Argentinian CDIs from eBay seller Zorko's. He reported that they were still working well 8,000 miles later.

mas335 provides a link to the manufacturer and reports his own success with these units:

Here's a link to the CDI manufacturer, DZE in Argentina. They appear to be a major supplier to aftermarket and OEM companies including Lear, Ford, VW, and GM. I have been using these as well and can't tell any difference, great value.

• Manufacturer's website (DZE).
  • Link to model 1553 for XLV600 and XRV650

Rick's Motorsport Electrics

• Hot Shot line - no longer available? Where is/was it made?
• OEM style on Rick's website 15-611 $105.

This post dissects the stock CDI, shows photos of the Rick's Motorsport Electrics 15-611 (CDI unit itself reads "CDI 1553"). "Made in Argentina" is clearly visible on the blister pack.

Arrowhead Electrical IHA6001

• Arrowhead Electrical Powersports catalog (see pp 86).
• $67.69 from Powersport Superstore.

Repair

Fuel

Petcock Diaphragm

The petcock diaphragm develops a leak and cuts off fuel to the engine. This is a common problem. K&L sells a diaphragm repair kit. It's available here and other places as well (presumably the K&L part number is 18-2701).

Also note that the vacuum line running from the cylinder head to the petcock diaphragm (vacuum side) can develop a leak, leading to backfiring.

Paint and Bodywork

Frame

Duplicolor DE1615 is a very good match for the Transalp's silver frame color.

Accessories

Luggage

Racks

• Happy Trails makes aluminum panniers and steel luggage racks. Their mounting kits are also usable with GIVI and Pelican cases.
• GIVI offers topcase adapters which replace the plate on the Transalp's rear carrier. They also produce crashbars.
  • The E200 Monorack plate is available for 1988-1996 applications (note that the E211 may also be listed, but is for 1997-1998 applications):
    • Midwest Cycle Supply
    • AZ Motorsports
    • Happy Trails

Crashbars

• The TN363 crash bars are available from AZ Motorsports and Happy Trail. Mounting these to a US-spec Transalp requires longer bolts across the front and minor trimming of the bike's plastic radiator guard.

Misc

• African Queens sells hard-core accessories.

Wheels

Front

The Transalp front wheel is a 1.85"x21" D.I.D. rim with 36 spokes.

Spoke Length

Honda's parts catalog microfiche lists the following part numbers for the front wheel spokes:

• 44610-MM9-405 (supersedes part 446A0-MM9-000) Spoke set A front B9x250.5 18x
• 44611-MM9-405 (supersedes part 446B0-MM9-000) Spoke set B front B9x247.0 18x

Presumably the "B9" indicates 9-gauge and 250.5 and 247.0 are millimeter lengths.

Cross Center sells a 1989-1996 Honda Transalp spoke kit. They only sell to dealers, but they list some useful information:

This spoke set has 36 spokes with nickel plated steel nipples. For: 21” front wheel.

Spoke size: 18 spokes of 3,6x247 mm. Left side. OEM Ref. 44611-MM9-405. Spoke size: 18 spokes of 3,6x250 mm. Right side. OEM Ref. 44610-MM9-405.

Resources

• The great "Show us your TransAlp modifications" thread on ADVrider.com.
• "Transalp Transformation" on ADVrider.com (90k mile Transalp gets XR-L forks, a 30mm rear spacer, a custom dash, and ProTaper bars).
• Jeff Stoess's Transalp to AfricaTwin 'conversion' thread. Uses XR600 forks, a 30mm rear spacer, and Africa Twin tank, headlights, and body parts.
• Modifications thread on Transalp.org.
• Photos of "marathon" and auxiliary tanks.
• Transalp build-up featuring a hand-built exhaust.