750XS (MaximX)

TCI Identification

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

 

Lighting System

LIGHTING SYSTEM

Signal System

SIGNAL SYSTEM

 

 

Transmission

TRANSMISSION

1. Inspect:
• Shift fork cam follower 1
• Shift fork pawl 2
• Guide bar 3  

Scoring/Bends/Wear->  Replace.

Middle Gear Removal and Disassembly

REMOVAL 

Middle Drive Gear

NOTE:
Middle drive gear and its shims can be removed without separating the engine.

1. Remove the clutch cover. Refer to "ENGINE DISASSEMBLY."

Crankshaft and Connecting Rods

CRANKSHAFT AND CONNECTING ROD

Crankshaft Runout

1.  Place both ends of crankshaft on V-blocks.

2.  Rotate Crankshaft

3.  Measure the crankshaft runout at main journal bearings. Use a Dial Gauge (90890-03097).

Oil Pump, Clutch and Water Pump

OIL PUMP AND OIL PAN

 

1   Chain cover
2   Oil pump sprocket
3   Oil pump drive sprocket 
4   Oil pump cover
5   Inner rotor
6   Spring
7   Relief valve
8   Shaft
9    Dowel pin
10   Outer rotor
11   Dowel pin

12   O-ring

Pistons, Starter, Generator and Pickup Coil

PISTON AND CAM CHAIN GUIDE

Mark each piston so it can be reinstalled in the appropriate cylinder. 
1. Remove: 
• Piston pin clips 1
• Piston pins 2

Camshafts, Chain and Sprockets

CAMSHAFT, CAM CHAIN, AND CAM SPROCKET

Camshaft

1. Measure:
• Large cam lobe length 1
• Small cam lobe length 2

Lower Crankcase

LOWER CRANKCASE