750R (Euro)
Clutch and Shifter Reassembly
5. Clutch assembly
a. Install the thrust plate onto the transmission main axle.
1. Thrust plate
b. Install the oil pump drive sprocket onto the main axle without the spacer collar and place the oil pump drive chain on its sprocket.
1. Oil pump drive sprocket
Cylinder Head Removal
ENGINE OVERHAUL
A. Cylinder Head and Cylinder
1. Remove the cylinder head cover.
2. Remove the left crankcase cover (pickup coil cover).
3. Remove the cam chain tensioner.
Lower Crankcase Reassembly
2. Lower crankcase
a. Install the shift cam and secure it with the guide pin. Install the stopper plate and bolt and tighten securely.
b. Install the neutral switch.
c. Install the transmission drive axle assembly into the crankcase.
Cylinder and Cylinder Head Disassembly
13. Remove the front cylinder holding nut and remove the cylinder assembly. It may be necessary to tap the cylinder lightly to loosen it from the base gasket.
14. Remove the rear cam chain guide by loosening the holding bolt.
Lower Crankcase Disassembly
L. Lower Crankcase
1. Remove the dowel pin and "O-ring".
2. Remove the shift fork guide bar and shift forks. The shift forks are identified by numbers cast on their sides.
3. Remove the bolt securing the shift cam locating pin and remove the stopper plate and locating pin.
Transmission -- Inspection and Repair
L. Transmission
1. Inspect each shift fork for signs of galling on gear contact surfaces. Check for bending. Make sure each fork slides freely on its guide bar.
2. Roll the guide bar across a surface place. If the bar is bent, replace.
Generator, Starter and Pick-up Coil Reassembly
8. A.C. Generator
a. Install the rotor onto the shaft and tighten the bolt using the rotor holding tool (special tool) as shown.
1. Rotor holding tool
Tightening torque: 5.5 m-kg (39.8 ft-lb)
b. Install the stator coil assembly onto the crankcase and align the grooves on the stator core with the bolt holes on the crankcase.
Oil Pump and Middle Gear Disassembly
H. Oil Pump Removal and Disassembly
1. Remove the strainer cover. Note the wire harness clip position.
2. Remove the oil pump securing bolts and remove the sprocket cover and oil pump assembly.
CAUTION:
Cylinder Head and Valves -- Inspection & Repair
INSPECTION AND REPAIR
A. 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.