700NC (Maxim)

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.

4.    Remove the neutral switch.

Oil Pump and Middle Gear Disassembly

H. Oil Pump Removal and Disassembly

1. Remove the strainer cover. Note the wire harness clip position.

2a. Remove the oil pump securing bolts and remove the sprocket cover and oil pump assembly.

 

2b. Remove the Oil pump drive sprocket (1), Chain (2) Collar (3) and thrust plate. 

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

Tags:

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.


1. Holding bolt 2. Rear cam chain guide

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.

Engine Removal

ENGINE REMOVAL

NOTE:
It is not necessary to remove the engine in order to remove the following components:

•   Piston
•   Clutch
•  Carburetor
•  Oil pump

PREPARATION FOR REMOVAL

Chapter 3, ENGINE OVERHAULING

CHAPTER3. ENGINEOVERHAULING

Electrical Maintenance

BATTERY

1.      Disconnect:
•   Negative lead (1)
•  Positive lead (2)
•  Breather hose (3)

2.      Pull:
•  Battery

3. Check:
• Fluid level

Incorrect — Refill.

Fluid level should be between upper (1) and lower (2) level marks.

Chassis Maintenance

 

FINAL GEAR OIL

Oil Level Measurement

1. Place the motorcycle on a level area and place on its centerstand. 

2 Remove:
•  Oil filler cap 

3. Observe:
•  Oil level (2)

Low level— Add oil. (1) Oil

Clutch, Timing and Compression

CLUTCH ADJUSTMENT

1.      Loosen:
•  Adjuster locknut (1)

2.      Adjust:
•  Clutch lever free play (3) 
(by turning adjuster (2) in or out)

Free play:
2-3 mm (0.08
- 0.12 in)