De Agostini MODEL SPACE Honda CB750 FOUR User manual

177
BUILD YOUR OWN
Pack 12
TM

CONTENTS
Assembly Guide
Stage 38: The right crankcase half
Stage 39: The IR sensor board
Stage 40: The left crankcase half
179
Editorial and design by Continuo Creative, 39-41 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 10010.
All rights reserved © 2015
Warning: Not suitable for children under the age of 14. is product is not a toy
and is not designed or intended for use in play. Items may vary from those shown.
TM
www.model-space.com

179
Honda CB750 FOUR: Assembly Guide
Stage 38
Right crankcase half
Screws (type E) × 3
Points cover
Long Phillips screwdriver
The right
crankcase half
Tools
Phillips screwdriver
Prepare
Pen
Push the points cover into the recess,
ensuring that the notch slots over the pin
in the recess (circled).
Use a type E screw to tap the hole in the
projection in the points cover.
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.
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.
1
2
3
4
Your parts

180
Honda CB750 FOUR: Assembly Guide
Tighten the type E screw into place, securing the points
cover to the crankcase half.
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 dierent tip sizes, as shown by the two red-handled screwdrivers.
Always cover the ends of your screwdrivers
when they are not in use, as this will help
prevent damage and injury.
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 harder-
to-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
Stage complete
5

181
Honda CB750 FOUR: Assembly Guide

182
Honda CB750 FOUR: Assembly Guide
Oil pan
IR sensor board
IR sensor window
Screws (type B) × 5
The IR sensor
board
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.
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.
Infrared transmitter
Infrared receiver
Connector cable
Stage 39
Tools
Phillips screwdriver
Prepare
Pen
1
2
Your parts

183
Honda CB750 FOUR: Assembly Guide
Align the screw holes of the IR sensor board with those of
the oil pan, as shown.
Tighten a type B screw into the second hole of the board,
xing the board in position in the oil pan. The outside of the oil pan should now look like this, with the
IR transmitter and receiver visible in the circular opening.
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.
Stage complete
345
67

184
Honda CB750 FOUR: Assembly Guide

185
Honda CB750 FOUR: Assembly Guide
Left crankcase half
Cord grommet
Screws (type E) × 2
Starter cover
Wire cables × 2
The left
crankcase half
Tools
Phillips screwdriver
File
Tape
Scissors
Pen
Prepare
Right crankcase half (Stage 38)
Oil pan (Stage 39)
IR sensor window (Stage 39)
Screws type B × 2 (Stage 39)
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.
Tighten the type E screw two-thirds of
the way into the hole, then remove it.
Prepare a type E screw to tap the
highlighted hole on the left
crankcase half.
Use a type E screw to tap the highlighted
hole in the right crankcase half.
Stage 40
1
2
3
4
Your parts

186
Honda CB750 FOUR: Assembly Guide
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.
Line up the oil pan from Stage 39 with the bottom of
the left crankcase half, as shown.
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).
Insert the projection on the oil pan into the hole in
the crankcase half.
Pen mark
5 6
7 8

187
Honda CB750 FOUR: Assembly Guide
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.
Put the left crankcase half on a at 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.
2cm
910
11 12

188
Honda CB750 FOUR: Assembly Guide
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.
Push the projections on the oil pan into the holes in
the bottom of the crankcase.
Insert a type E screw into the large hole in the side of
the left crankcase half.
Insert a type B screw, provided in Stage 39, into the
circled hole in the oil pan.
13 14
15 16

189
Honda CB750 FOUR: Assembly Guide
Tighten the type E screw into place. As with the oil
pan screws, don’t overtighten it.
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.
Turn the crankcase over and insert a type E screw into
the large hole in the right half.
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.
17 18
19 20

190
Honda CB750 FOUR: Assembly Guide
Fit the starter cover into place on the crankcase, and
gently but rmly press it down until it rests at against
the surface.
Press the thicker end of the cord grommet lightly into
the hole, as shown.
Identify the positions of the three pins of the IR sensor
window from Stage 39. The distances between the
pins dier, as shown above.
Align the projections on the underside of the starter
cover with the holes in the top of the crankcase.
Short
Long
21 22
23 24

191
Honda CB750 FOUR: Assembly Guide
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 t it yet. If you do decide to t
it now, press it lightly into place and make sure it is
secure yet removable.
Stage complete
25 26

20
Honda CB750 FOUR:
TM