Oil Pump: Service and Repair

LUBRICATION SYSTEM

COMPONENTS:

REMOVAL
1. Drain engine oil.
2. Remove RH front wheel.
3. Remove RH side cover.
4. Remove the front exhaust pipe.
5. Remove the alternator from engine.
6. Remove the drive belt.
7. Turn the crankshaft and align the white groove on the crankshaft pulley with the pointer on the lower cover.
8. Remove the timing belt.




9. Remove the lower oil pan.





10. Remove the oil screen:
Remove the 2 bolts (B), oil screen (A) and gasket.





11. Remove the upper oil pan (A).





12. Remove the oil pump case(A).
1) Remove the screws(B) from the pump housing, then separate the housing and cover(A).





2) Remove the inner and outer rotors.

DISASSEMBLY

l. Remove the relief plunger.
Remove the plug(A), spring(B) and relief plunger(C).





INSPECTION

1. Inspect relief plunger.
Coat the valve with engine oil and check that it falls smoothly into the plunger hole by its own weight. If it does not, replace the relief plunger. If necessary, replace the front case.
2. Inspect relief valve spring. Inspect for distorted or broken relief valve spring.

Standard value
Free height: 43.8mm (91.724in.) Load: 4.6kg/39.1mm (10lb/l.547in.)

3. Inspect rotor side clearance.
Using a feeler gauge and precision straight edge, measure the clearance between the rotors and precision straight edge.





If the side clearance is greater than maximum, replace the rotors as a set. If necessary, replace the front case.
4. If the tip clearance is greater than maximum, replace the rotor as a set.
5. Inspect rotor body clearance.
Using a feeler gauge, measure the clearance between the outer rotor and body.





If the body clearance is greater than maximum, replace the rotors as a set. If necessary, replace the front case.

REASSEMBLY





1. Install relief plunger.
Install relief plunger(C) and spring(B) into the front case hole, and install the plug(A).

INSTALLATION
1. Install oil pump.
1) Place the inner and outer rotors into front case with the marks facing the oil pump cover side.
2) Install the oil pump cover(A) to front case with the 8 screws(B).





2. Check that the oil pump turns freely.
3. Install the oil pump on the cylinder block.
1) Remove any old liquid gasket and be careful not to drop any oil on the contact surfaces of the oil pump and cylinder block.
^ Using a razor blade and gasket scraper, remove all the old liquid gasket from the gasket surfaces and sealing grooves.
^ Using a non-residue solvent, clean both sealing surfaces.
2) Apply liquid gasket to the oil pump as shown in the illustration.
Use liquid gasket MS 721-40A.





NOTE:
^ To prevent leakage of oil, apply liquid gasket to the inner threads of the bolt holes.
^ Do not install the parts if five minutes or more have elapsed since applying the liquid gasket. Instead, reapply liquid gasket after removing the residue.
^ After assembly, wait at least 30 minutes before filling the engine with oil.

3) Place a new 0-ring on the cylinder block.
4) Engage the spline teeth of the oil pump drive gear with large teeth of the crankshaft, and slide the oil pump on the crankshaft.
5) Install the oil pump with 5 bolts. Uniformly tighten the bolts in several passes.








4. Apply a light coat of oil to the seal lip.





5. Using the special tool(09214-33000), install the oil seal.

6. Install the upper oil pan.

NOTE: Check that the mating surfaces are clean and dry before applying llquid gasket.

1) Using a razor blade and gasket scraper, remove all the old packing material from the gasket surfaces.








2) Install the oil pan (A) with the l7 bolts.

NOTE:
- To prevent leakage of oil apply liquid gasket to the inner threads of the bolt holes.
- Do not install the parts if five minutes or more have elapsed since applying the liquid gasket. Instead, reapply liquid gasket after removing the residue.
- After assembly, waft at least 30 minutes before filling the engine with oiL.




7. Install oil screen.
Install a new gasket and oil screen(A) with 2 bolts(B).
8. Install the lower oil pan.
1) Apply liquid gasket as an even bead, centered between the edges of the mating surface. Use liquid gasket MS 721 -40A or equivalent.

NOTE:
- To prevent leakage of oil apply liquid gasket to the inner threads of the bolt holes.
- Do not install the parts if five minutes or more have elapsed since applying the liquid gaskeL Instead, reapply Uquid gasket after removing the residue.
- After assembly, wait at least 30 minutes before filling the engine with oil.




2) Install the lower oil pan 10 bolts. Uniformly tighten the bolts serveral passes

9. Install the timing belt.
10. Install the drive belt
11. Install the alternator.
12. Install the front exhaust pipe.
13. Install the RH front wheel.
14. Fill engine with oil.
15. Start engine and check for leaks.
16. Recheck engine oil level.