750R (Euro)

Pistons and Cylinder Reassembly

11. Pistons and Cylinder a. Install the pistons on the rods. The arrow on the piston must point to the front of the engine.


Before installing the piston pin clips, cover the crankcase with a clean rag so you will not accidentally drop the circlip into the crankcase. Always install new piston pin circlips.


Crankshaft, Con rods and Bearings -- Inspection and Repair

I. Crankshaft

1. Crankshaft run-out

Support the crankshaft at both ends on V-blocks. Measure the amount of crankshaft run-out on the main bearing journals with a dial gauge while rotating crankshaft.

Run-out limit: 0.040 mm (0.0016 in!

If run-out exceeds limit, replace crankshaft.

2. Inspection of bearings


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.



Middle Gear -- Inspection and Repair

P. Middle Gear

1. Damper disassembly


Disassembly of the middle gear damper requires the damper compressor (special tool) and a hydraulic press.

a. Place the middle drive shaft in a press with the damper compressor (special tool) in place as shown.

1. Damper compressor


Cylinder Head and Camshaft Reassembly

12. Cylinder head and Cam shafts 

a. Install the new cylinder head gasket. Install the dowel pins and "O-rings". Locate the cam chain cavity cylinder seal with the tabs down.

b.   Install the cylinder head onto the cylinder. Pull the cam chain through the cylinder head as it is installed. Tie the cam chain so that it does not fall into the crankcase.


Front Forks

XJ750RH Front Fork Disassembly/Reassembly

The XJ750RH front fork has a top and bottom bushing for the inner tube to ride in (reducing friction). Since the top bushing is pressed into the top of the outer tube, it is necessary to remove the oil seal before the inner tube may be removed from the outer tube. The procedure is as follows:


Piston, Pickup Coil, Shifter, Starter, Generator and Clutch Removal

C. Piston

1.   Mark each piston to aid in reassembly.

2.   Place a clean towel or rag into the crank-case to keep circlips and material from falling into the engine.

3.    Remove piston pin clips, piston pins, and pistons.

D. Pick-up Coil Assembly


Lighting System




Above circuit diagram shows only lighting circuit in wiring diagram.

B. Lighting Tests and Checks

Cable Routing