BUILD YOUR OWN. Pack 12

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Franklin Turner
5 years ago
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1 BUILD YOUR OWN TM Pack

CONTENTS Assembly Guide 179 Stage 38: The right

40: The left crankcase half Editorial and design by

Published in the UK by De Agostini UK Ltd,

Inc., 915 Broadway, Suite 609, New York, NY 10010.

2 CONTENTS Assembly Guide 179 Stage 38: The right crankcase half Stage 39: The IR sensor board Stage 40: The left crankcase half Editorial and design by Continuo Creative, North Road, London N7 9DP. Published in the UK by De Agostini UK Ltd, Battersea Studios 2, 82 Silverthorne Road, London SW8 3HE. Published in the USA by De Agostini Publishing USA, Inc., 915 Broadway, Suite 609, New York, NY All rights reserved 2015 Warning: Not suitable for children under the age of 14. This product is not a toy and is not designed or intended for use in play. Items may vary from those shown. TM

Stage 38 The right crankcase half 1 2 Use a type E screw

Hold the points cover over the circular recess in the

of the cover with the pin and hole indicated on the

Your parts Right crankcase half Screws (type E) 3 Points

cover into the recess, ensuring that the notch slots

Tools Prepare Phillips screwdriver Pen Turn the

3 Stage 38 The right crankcase half 1 2 Use a type E screw to tap the hole in the projection in the points cover. Hold the points cover over the circular recess in the right crankcase half, aligning the notch and projection of the cover with the pin and hole indicated on the crankcase half. Your parts Right crankcase half Screws (type E) 3 Points cover Long Phillips screwdriver 3 4 Push the points cover into the recess, ensuring that the notch slots over the pin in the recess (circled). Tools Prepare Phillips screwdriver Pen Turn the crankcase half over while holding the points cover in place. Insert a type E screw into the hole on the inside of the crankcase half. 179

Stage complete 5 Tighten the type E screw into place, securing the points cover

Screwdriver sizes With this stage, you have received a long Phillips

While this is also a size 1 screwdriver, the length and width of it make it

area of the right crankcase half in Step 5.

choosing the correct one to use can be confusing.

4 Stage complete 5 Tighten the type E screw into place, securing the points cover to the crankcase half. Screwdriver sizes With this stage, you have received a long Phillips screwdriver. While this is also a size 1 screwdriver, the length and width of it make it better for accessing harderto-reach areas, such as the back of the recessed area of the right crankcase half in Step 5. Selecting the correct tool to use will make assembling your Honda CB750 much easier. The same size tip Size 1 Size 0 There are many sizes of screwdriver, so choosing the correct one to use can be confusing. This is especially so when screwdrivers of the same tip size (size 1, size 0 etc) can be either thick or thin, like the two circled above, while two of a similar size and shape can have different tip sizes, as shown by the two red-handled screwdrivers. 180 Always cover the ends of your screwdrivers when they are not in use, as this will help prevent damage and injury.

5 181

Stage 39 The IR sensor board 1 Infrared receiver Infrared transmitter Connector cable Your parts Oil

Check your IR sensor board to make sure that the components indicated above the infrared transmitter,

The back of the board, which carries the connection strips, is green.

6 Stage 39 The IR sensor board 1 Infrared receiver Infrared transmitter Connector cable Your parts Oil pan IR sensor board IR sensor window Screws (type B) Tools Prepare Phillips screwdriver Pen Check your IR sensor board to make sure that the components indicated above the infrared transmitter, the infrared receiver and the connector cable are all correctly in place. The back of the board, which carries the connection strips, is green. 2 Turn the oil pan over and locate the two raised screw holes, indicated here by the two arrows. The two holes in the sensor board correspond to these screw holes.

7 3 4 5 Align the screw holes of the IR sensor board with those of the oil pan, as shown. Place a type B screw into one of the holes in the board. Tighten the screw into place. Hold the board in position so that the other holes don t move out of alignment. 6 Tighten a type B screw into the second hole of the board, fixing the board in position in the oil pan. 7 Stage complete The outside of the oil pan should now look like this, with the IR transmitter and receiver visible in the circular opening. 183

8 184

Stage 40 The left crankcase half 1 2 Locate the

This is where the IR connector cable will be

File the edges smooth to ensure that the cable won

Your parts Left crankcase half Cord grommet Screws

type E screw to tap the highlighted hole on the

3 4 Tools Prepare Phillips screwdriver File Tape

pan (Stage 39) IR sensor window (Stage 39) Screws

9 Stage 40 The left crankcase half 1 2 Locate the square cut-out section of the left crankcase half. This is where the IR connector cable will be positioned. File the edges smooth to ensure that the cable won t be damaged. Your parts Left crankcase half Cord grommet Screws (type E) 2 Starter cover Wire cables 2 Prepare a type E screw to tap the highlighted hole on the left crankcase half. 3 4 Tools Prepare Phillips screwdriver File Tape Scissors Pen Right crankcase half (Stage 38) Oil pan (Stage 39) IR sensor window (Stage 39) Screws type B 2 (Stage 39) Tighten the type E screw two-thirds of the way into the hole, then remove it. Use a type E screw to tap the highlighted hole in the right crankcase half. 185

5 6 Line up the oil pan from Stage 39 with the

Insert the projection on the oil pan into the hole

7 8 Position the cable of the IR sensor board in

Use a pen to mark the cable with a line where it

186 Pen mark Remove the oil pan from the crankcase

10 5 6 Line up the oil pan from Stage 39 with the bottom of the left crankcase half, as shown. Insert the projection on the oil pan into the hole in the crankcase half. 7 8 Position the cable of the IR sensor board in the cut-out from Step 1. Use a pen to mark the cable with a line where it meets the edge of the crankcase half, as shown. 186 Pen mark Remove the oil pan from the crankcase half, and wrap a 10cm length of tape around the cable, up against the line that you marked on it (indicated here by the green line).

9 10 2cm Put the left crankcase half on a flat surface,

cable in position, and take the right crankcase half in

Align the points indicated at either end of the arrows.

11 9 10 2cm Put the left crankcase half on a flat surface, and place the IR sensor cable in the position shown above. The line you marked on the cable should be about 2cm from the edge. Hold the left crankcase half in one hand, holding the cable in position, and take the right crankcase half in your other hand. Align the points indicated at either end of the arrows Push the two halves of the crankcase together. Hold the two halves of the crankcase together, and align the projections on the oil pan with the holes in the bottom of the crankcase. 187

13 14 Push the projections on the oil pan into the holes

Insert a type B screw, provided in Stage 39, into the

15 16 Tighten the screw into place, but stop turning it

much could damage the screw or the hole.

12 13 14 Push the projections on the oil pan into the holes in the bottom of the crankcase. Insert a type B screw, provided in Stage 39, into the circled hole in the oil pan Tighten the screw into place, but stop turning it when it becomes hard to continue, because tightening too much could damage the screw or the hole. Repeat for the hole on the opposite side of the window. 188 Insert a type E screw into the large hole in the side of the left crankcase half.

17 18 Tighten the type E screw into place.

Turn the crankcase over and insert a type E

19 20 Tighten the type E screw into place, being

Check the screw in the left side as it may be

Hold the cord grommet over the two circled holes

13 17 18 Tighten the type E screw into place. As with the oil pan screws, don t overtighten it. Turn the crankcase over and insert a type E screw into the large hole in the right half Tighten the type E screw into place, being careful not to overtighten it. Check the screw in the left side as it may be slightly looser now. If so, tighten it. Hold the cord grommet over the two circled holes in the top of the crankcase, with the thicker end forward and the round end further back. 189

21 22 Press the thicker end of the cord grommet lightly into the hole, as

Align the projections on the underside of the starter cover with the holes in

23 24 Short Long Fit the starter cover into place on the crankcase, and

14 21 22 Press the thicker end of the cord grommet lightly into the hole, as shown. Align the projections on the underside of the starter cover with the holes in the top of the crankcase Short Long Fit the starter cover into place on the crankcase, and gently but firmly press it down until it rests flat against the surface. 190 Identify the positions of the three pins of the IR sensor window from Stage 39. The distances between the pins differ, as shown above.

15 25 26 Hold the crankcase with the oil pan uppermost, and align the pins on the sensor window with the holes in the oil pan. It may be necessary to remove the window later, so you may choose not to fit it yet. If you do decide to fit it now, press it lightly into place and make sure it is secure yet removable. Stage complete 191

16 Honda CB750 FOUR: TM 20

BUILD YOUR OWN. Pack 22

BUILD YOUR OWN. Pack 22 BUILD YOUR OWN TM Pack 22 01 CONTENTS Assembly Guide 339 Stage 70: The front brake lever Stage 71: The oil hose and the twistgrip Stage 72: Fitting the front fork assembly Editorial and design by Continuo