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SYSTEM

LUBRICATION SYSTEM DIAGRAM

CAMSHAFTS

CRANKSHAFT

OIL FILTER CARTRIDGE1

OIL

1iouNTERSHAFT

PUMP

OIL STRAINER

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n T

LUBRICATION SYSTEM DIAGRAM 4-0 OIL STRAINERPRESSURE RELIEFSERVICE INFORMATION 4-1

TROUBLESHOOTING 4-2

OIL PRESSURE INSPECTION 4-3

VALVE 4-3

OIL PUMP 4-5

OIL COOLER 4-9

Engine oi l capacity

SERVICE INFORMATION

ENERAL

At draining

At oil filter change

Repeated, pro long ed exposure to used motor o il ma y cause skin cancer.

Wash your hands thor ough ly wi th st rong soap as soon as possible after handl ing used oil.

Oil pump rotor

The oil p ump can be serviced with the engine installed in the frame.

The service procedures in this section mu st be perform ed with t he engine o il drained.When rem oving and installing the oil pump, use care not to a llow dust o r dir t to enter the engine.

If any portion of the oi l p um p is worn beyond the specified service limits, replace the oil p ump as an assembly.After the oi l p um p has been installed, check that there are no oi l leaks and that oi l pressure is correct.

Tip clearance

Body clearance

Side clearance

PECIFICATIONS

1 At disassemblyRecommended engine oil

Oil pressure at oi l pressure switch

STANDARD

3.5 liter (3.7 US qt, 3.1 Imp qt)3.7 liter (3.9 US qt, 3.3 Imp qt )4.0 l iter (4.2 US qt, 3.5 Imp qt )Pro Honda GN4 or HP4 (without molybde-num additives) 4-stroke oil or equivalent

motor oi l

API service classification: SG or higher

JASO T 903 standard: MA

Viscositv: SAE IOW-40490 kPa (5.0 kgf/cm2, 71 psi) at5,400 rpm/(80"C/176"F)0.15 (0.006) max.

0.15 - 0.22 (0.006 - 0.009)0.02 - 0.07 (0.001 - 0.003)

Unit: mm (SERVICE LIMI-

__

0.20 (0.008)

0.35 (0.014)

0.10 (0.004)

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LUBRICATION SYSTEM

IL PRESSURE INSPECTION

the oil pressure

indicator light

on a f e wCheck the o il level (page 3-15).

Warm up the engine t o normal operating temperature

check (ae ero xim ate ly 80C/176"F).Ihe ndicator

system before

checking theoii

Sto'p the engine and remove the crankcase sealing

bolt.

pressure.

Connect an oil pressure gauge and attachment to the

crankcase.

TOOLS:Oil pressure gauge set 07506-3000001

(Equivalent

commerciallyavailable in U.S.A.)

Oil pressure gauge attachment07510-MA70000

(Equivalent

commercially

available in U.S.A.)

Start the engine and increase the rp m to 5,400 rpmand read the oil pressure.

OIL PRESSURE:

490 kPa (5.0 kgf/cm*, 71 psi) at 5,400 r pm /(80"C/176"F)

Stop the engine and remove the tools.

Appl y a locking agent to the sealing bo lt threads.

Install and tighten the sealing bolt to the specifiedtorque.

TORQUE: 29 N -m (3.0 kgf-m, 22 Ibf-ftl

IL STRAINER/PRESSURE RELIEFALVE

REMOVAL

Drain the engine oil (page 3-15).

Remove the exhaust pipe (page 2-13)

Remove the oil pan flange bolts and oil pan.

OIL PRESSlJRE GAUGE

I I

SEALING BOLT/

I I

4-3

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LUBRICATION SYSTEM

Remove the pressure relief valve and O -ring.

Remove the oi l strainer and gasket.

Clean the o il strainer screen.

INSPECTION

Check the operation of the pressure relief valve by

pushing on th e piston.

Disassemble the relief valve by removing the snapring.

Inspect the pi ston for wear, unsmooth m oveme nt or

damage.

Inspect the spr ing for fatigue o r damage.

Assemble the relief valve in the reverse order of dis-

assembly.

INSTALLATION

Appl y oil t o the new gasket and install it onto the oilstrainer.

Install the oi l strainer in to the crankcase whil e align-

ing its boss with the groove in the crankcase.

SNAP RING

4-4

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LUBRICATION SYSTEM

Measure the pump body clearance.

SERVICE LIMIT: 0.35 mm (0.014 in)

Measure the side clearance using a straight edge and

feeler gauge.

SERVICE LIMIT: 0.10 mm (0.004 in)

ASSEMBLY

PINS

INNER ROTOR

IOUTER ROTOR

/ n D I \ I E D l h l

8 N-m (0.8 k i f - r n , 5.8 I b f W

4-7

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UBRICATION SYSTEM

i ns ta l the outerrotor with its

unch mark facing

theoil pumpcover.

Install the outer and inner rotors into the oil pump

body.

Install the oil pump shaft through the inner rotor and

oil pump body.

Install the drive pin into the hole in the pump shaft

and align the pin with the groove in the inner rotor as

shown.

Install the thrust washer.

INNER ROTOR OUTER ROTOR

Install the dowel pins.

Install the oil pump cover and tighten the assembly

bolt t o the specified torque.

TORQUE: 8N-m (0.8kgf-m, 5.8 bf-ft)Check the oil pump operation by turning the pump

shaft.If necessary, reassemble the oil pump.

DOWEL PINS ASSEMBLY B0LT

OIL PUMP COVER

INSTALLATION

Install the oil pump into the crankcase while aligning

the pump shaft lug with the water pump shaft groove.

Install and tighten the three flange bolts securely.

4-8

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LUBRICATION SYSTEM

Apply oil to the clutch outer guide, oil pump drive

sprocket, driven sprocket and drive chain.

instali theof/pumpdriven

sprocket wf th fts"OUT"mark fac-

ingoutward

Install the clutch outer guide, driveidriven sprocketand drive chain as an assembly.

Appl y a locking agent to the oil pu mp driven sprocket

bolt threads.

Install and tighten the driven sprocket bolt/washer tothe specified torque.

TORQUE: 15 N-m (1.5 kgf-m, 11 Ibf-ft)Install the followin g:

- Oil straineripressure relief valve/oil pan (page 4-41- Clutch assembly (page 9-91

After installation, fill the crankcase with the recom -

mended oil a nd check that there is n o oil leaks.

Check the oil pressure (page 4-31.

OIL COOLER

REMOVALDrain the engine oil and remove the oil filter cartridge

(page 3-15).

Drain the coolant fro m the system (page 6-41.

Remove the radiator reserve tank (page 6-16).

Loosen the hose bands and disconnect the oi ! coolerwater hoses from the cooler.

Remove the oil cooler mo unti ng bolt, lock washer and

oil cooler.

Remove the O-ring.

INSPECTION

Check the oi l cooler for damage.

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LUBRICATION SYSTEM

INSTALLATIONWATER HOSES

\OIL FILT~RCARTRIDGE26 N - m (2.7 kg f -m, 20 I b f WLOCK WASHER

Coat a n ew O-ring with engine o il and install it in to theoil cooler groove.

Install the oil cooler aligning its guide groovewith the

projec tion o n the crankcase.

Apply oil to he oil oo le r mounting bolt threads andseating surface.Install the lock washer and oil cooler bolt.ns ta / /the lock

washer withitsconcave side

("0"mark) facingtheoilcooier

MOUNTING BOLT\

"0 MARK

\WASHER

4-10

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LUBRICATIONSYSTEM

Tighten the oil cooler mounting bolt to the specified

torque.

TORQUE: 74 N-m (7.5 gf-m, 54 Ibf-ftl

Connect the oil cooler water hoses, and tighten the

hose bands securely.

Install the oil filter cartridge and fill the crankcase wi th

the recommended oil (page 3-16).

Fill the cooling system and bleed any air (page 6-5).