750RL (Seca)

TCI Identification

The following is a guide to determing if a used TCI is appropriate for a given machine:

 

Final gear Disassembly and Reassembly

Final gear disassembly

1.      Remove the nuts and bolts holding the bearing housing.

2.      Remove the ring gear assembly and thrust washer from the final gear case.

3. Remove the self-locking nut from drive pinion by using the holding tool (special tool) and remove the coupling.

Middle Gear

MIDDLE GEAR/DAMPER

a. Middle gear lash 0 2 mm (0.008 in)

d. Measure the gap between the driven gear bearing housing flange and the crankcase with a feeler gauge. This is the shim size required.

Cylinder, Head and Valves

Cylinder head cover

Place head cover on a surface plate. There should be no warpage. Correct by re-surfacing as follows:

Place # 400 or # 600 grit wet sandpaper on surface plate and re-surface head cover using a figure-eight sanding pattern. Rotate head cover several times to avoid removing too much material from one side.

Cylinder head

Engine Oil, Gear lube and Compression check

Engine oil level measurement

1.      Place the motorcycle on its centerstand. Warm up the engine for several minutes.

NOTE:

Be sure the motorcycle is positioned straight up when checking the oil level; a slight tilt toward the side can produce false readings.

Transmission, Clutch and Middle gear

TRANSMISSION

3. Crankcase assembly a. Apply Yamaha bond #4 sealant or equivalent to the crankcase mating surface. Be very careful not to allow any sealant to come in contact with the oil gallery "O-ring" and crankshaft bearings. It is extremely important, however, that sealant be applied around the case stud holes. Apply sealant to within 2 — 3 mm (0.08 0.12 in) of the bearings.

Steering Head Bearings

Steering head adjustment

1. Raise the front end of the motorcycle so that there is no weight on the front wheel.

WARNING: Securely support the motorcycle so there is no danger of it falling over.

2. Grasp the bottom of the forks and gently rock the fork assembly backward and forward, checking for looseness in the steering assembly bearings.

Pickup coil, Shifter, Starter Motor, Generator, and Clutch

Pick-up coil assembly

1. Remove the alien bolt that holds the timing plate.

2. Remove the pick-up coil securing screws and remove the pick-up coil assembly.

Shifter

Cam chain, Ignition timing and Air filter

Cam chain adjustment

This model has been equipped with the automatic cam chain tensioner. No adjustment is necessary.

Ignition timing check

1. Ignition timing is checked with a timing light by observing the position of the stationary pointer and the marks stamped on the timing plate.

Clutch and Handlebars adjustment

Clutch adjustment

This model has two clutch cable length adjusters. The cable length adjusters are used to take up slack from cable stretch and to provide sufficient free play for proper clutch operation. Normally, once the clutch cable length adjuster (crankcase) is properly set; the only adjustment required is maintenance of free play at the clutch cable length adjuster (handlebar lever).