750XS (MaximX)

Radiator Pipes, Carburettor Joints and Oil Delivery Pipe

RADIATOR PIPES, CARBURETOR JOINT, AND OIL DELIVERY PIPE

1. Install: 
• Union bolt with copper washer 1
• Cylinder head side cover 2

Oil Delivery Pipe: 21 Nm (2.1 m-kg, 15 ft-lb)

Transmission

TRANSMISSION

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

Scoring/Bends/Wear->  Replace.

Upper Crankcase

UPPER CRANKCASE

 

Cylinder Head Removal

RADIATOR PIPES, CARBURETOR JOINT, AND OIL DELIVERY PIPE

1.  Remove:
• Radiator pipe 1
• Cover (Right) 2

2.  Drain the coolant (in the cylinder) by removing drain bolts 3  

Valves, Guides, Seats and Springs


1. Measure the valve stem clearance

Use a bore gauge 3 to determine the valve guide inside diameter.

Valve Guide Inside Diameter Limit: 5.05 mm (0.199 in)

Clutch

CLUTCH

1.  Inspect:
• Clutch housing dogs 1  

Cracks/Pitting (edges): Moderate ->  Deburr.
Severe -> Replace clutch housing.

2.  Inspect
• Clutch housing bearing 2
• Spacer 3 

Shifter, Middle Gear and Crankcase

SHIFTER AND MIDDLE GEAR

1. Remove:
• Crankcase cover (Left) 1
• Gasket
• Dowel pin 2
• Shift shaft 3
• Shift lever 4
• Oil level maintaining plug 5

2. Remove:

Starter Motor

STARTER MOTOR

Pistons and Cylinder

PISTON AND CYLINDER

 

 

1 Cylinder head gasket
2 Dowel pin
3 Drain bolt
4  Oil delivery pipe
5  O-ring
6 Cylinder base gasket
7 Piston ring
8
Piston pin clip
9 Piston pin 
10 Copper washer

1. Install:
• Piston rings (onto the pistons)

Middle Gear Inspection and Reassembly

INSPECTION

1. Check
teeth of middle gear for discoloration/Pitting/Wear. If necessary, replace all middle gears as a set.
Damper cam surfaces for wear/Unsmooth action. Replace if necessary.

2. Check bearing movement. Rotate the race by finger and replace if rough.