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9. LUBRICATION SYSTEM

SERVICE INFORMATION························ 9-2 OIL PUMP ············································ 9-5

TROUBLE SHOOTING ··························· 9-3 PRESSURE RELIEF VALVE ···················· 9-7

9
LUBRICATION SYSTEM DIAGRAM·········· 9-4 OIL STRAINER······································ 9-8

OIL PRESSURE INSPECTION ················· 9-5

9-1
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LUBRICATION SYSTEM
SERVICE INFORMATION
LUBRICATION SYSTEM

GENERAL

Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely
unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as
possible after handling used oil.

• The oil pump can be serviced with the engine installed in the frame.
• The service procedures in this section must be performed with the engine oil drained.
• When removing and installing the oil pump, use care not to allow dust or dirt to enter the engine.
• If any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as an assembly.
• After the oil pump has been installed, check that there are no oil leaks and that oil pressure is correct.
• For engine oil pressure indicator/EOP switch inspection (page 21-12).
• For piston oil jet service (page 14-16).

TOOLS
Oil pressure gauge set Oil pressure gauge attachment
07506-3000001 07406-0030000

or equivalent commercially available in or equivalent commercially available in

U.S.A. U.S.A.

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LUBRICATION SYSTEM
TROUBLE SHOOTING
Oil level too low
• Oil consumption
• External oil leak
• Worn piston rings (page 14-14)
• Improperly installed piston rings (page 14-15)
• Worn cylinders (page 14-14)
• Worn stem seals (page 10-16)
• Worn valve guide (page 10-17)
Low oil pressure
• Oil level low
• Clogged oil strainer
• Internal oil leak
• Incorrect oil being used
No oil pressure
• Oil level too low
• Oil pressure relief valve stuck open
• Broken oil pump drive chain
• Broken oil pump drive or driven sprocket
• Damaged oil pump
• Internal oil leak
High oil pressure
• Oil pressure relief valve stuck closed
• Clogged oil filter, gallery or metering orifice
• Incorrect oil being used
Oil contamination
• Oil or filter not changed often enough
• Worn piston rings
Oil emulsification
• Blown cylinder head gasket
• Leaky coolant passage
• Entry of water

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LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM
EXHAUST CAM SHAFT

INTAKE CAM SHAFT

PISTON

PISTON OIL JET PISTON OIL JET

CRANKSHAFT

EOP SWITCH

OIL ORIFICE OIL ORIFICE

MAINSHAFT

COUNTERSHAFT

RELIEF VALVE

OIL FILTER CARTRIDGE OIL PUMP

OIL STRAINER

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LUBRICATION SYSTEM
OIL PRESSURE INSPECTION
• If the engine oil pressure indicator remains on while
[2]
the engine is running, check the indicator system
before checking the oil pressure (page 21-12).
Remove the EOP switch (page 21-12).
Install the oil pressure gauge attachment [1] to the
switch base.
Connect the oil pressure gauge [2] to the oil pressure
gauge attachment.
TOOLS:
Oil pressure gauge set 07506-3000001 or
equivalent
commercially
[1]
available in U.S.A.
Oil pressure gauge attachment 07406-0030000 or
equivalent
commercially
available in U.S.A.
Check the oil level and add the recommended oil if
necessary (page 3-10).
Warm the engine to normal operating temperature
(approximately 80°C) and increase the engine speed to
1,200 rpm and read the oil pressure.
STANDARD:
93 kPa (0.9 kgf/cm2, 13 psi) at 1,200 rpm/
80°C (176°F)
Stop the engine and remove the tools.
Install the EOP switch (page 21-12).

OIL PUMP
REMOVAL/INSTALLATION
Remove the clutch (page 11-7).
[2]
Remove the bolts [1] and oil pump [2].

[1]

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LUBRICATION SYSTEM
Installation is in the reverse order of removal.

• Align the oil pump shaft end with the water pump
shaft groove.

Align

DISASSEMBLY/ASSEMBLY
Disassemble and assemble the oil pump as shown in the following illustration.

OIL PUMP BODY

DRIVE PIN

OIL PUMP PLATE

OUTER ROTOR

INNER ROTOR

OIL PUMP SHAFT

WASHER
OIL PUMP ASSEMBLY BOLT

INSPECTION
• For oil pump drive sprocket, driven sprocket and
drive chain inspection (page 11-10).
Inspect the following parts for damage, abnormal wear,
deformation or burning.
– oil pump shaft
– drive pin
– inner rotor
– outer rotor
– oil pump body
Measure the oil pump clearances according to
LUBRICATION SYSTEM SPECIFICATIONS (page 1-
8).
If any of the measurement is out of the service limit,
replace the oil pump as an assembly.

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LUBRICATION SYSTEM
PRESSURE RELIEF VALVE
REMOVAL/INSTALLATION
Remove the oil pump (page 9-5).
[2]
Remove the oil pressure relief valve [1] and O-ring [2].
Apply engine oil to a new O-ring.
Install the O-ring to the oil pressure relief valve groove.
Install the oil pressure relief valve into the crankcase.
Install the oil pump (page 9-5).

[1]

INSPECTION
Check the operation of the pressure relief valve by
[1] [2]
pushing on the piston [1].
Disassemble the pressure relief valve by removing the
snap ring [2].

Remove the washer [1], spring [2] and piston [3].

Check the piston for wear, sticking or damage.
Check the spring for fatigue or damage.
Assemble the pressure relief valve in the reverse order
of disassembly.
[4]

• Install the snap ring [4] with the chamfered edge

facing the thrust load side.
• Make sure the snap ring is seated in the groove.

[3] [2] [1]

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LUBRICATION SYSTEM
OIL STRAINER
REMOVAL
Drain the engine oil (page 3-10).
[2]
Remove the exhaust pipe (page 2-13).
Loosen the bolts [1] in a crisscross pattern in 2 or 3
steps, and remove the bolts, oil pan [2].

[1]

Remove the oil strainer [1] and seal ring [2].

[1] [3]
Clean the oil strainer screen [3] and check for damage.

[2]

INSTALLATION
Be careful not to Clean the oil pan and crankcase mating surfaces
[2]
damage the mating thoroughly.
Align
surfaces.
Apply engine oil to a new seal ring [1] and install it onto
the oil strainer [2].
Install the oil strainer into the crankcase while aligning
the oil strainer boss with the crankcase groove.

[1]

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LUBRICATION SYSTEM
Apply liquid sealant to the oil pan as shown (page 1-
18).
Install the oil pan and bolts [1] to the crankcase.
Tighten the bolts in a crisscross pattern in 2 or 3 steps.
Install the exhaust pipe (page 2-13).
Fill the engine with the recommended engine oil and
check that there are no oil leaks (page 3-10).

[1]

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MEMO