2. |
Remove RH front
wheel. |
4. |
Remove the front exhaust pipe. (See page EMA -
46) |
5. |
Remove the alternator from engine. (See EE
group - alternator) |
6. |
Remove the drive belt. (See page EMA -
13) |
7. |
Turn the crankshaft and align the white groove
on the crankshaft pulley with the pointer on the lower cover. (See
page EMA - 13) |
8. |
Remove the timing belt. (See page EMA -
13) |
9. |
Remove the oil pan and oil screen.(see page
EMA- 51, 52) |
10. |
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. | |
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 8screws(B).
Tightening torque
8 ~ 12Nm (80 ~ 120kgf.cm, 6 ~
8.8lbf.ft)
|

| |
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.
A. |
Using a razor blade and gasket
scraper, remove all the old liquid gasket from the
gasket surfaces and sealing
grooves. |
B. |
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.

• |
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 O-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
5bolts.
Uniformly tighten the bolts in several
passes.
Tightening torque
12 ~ 15Nm (120 ~ 150kgf.cm, 8.8 ~
11lbf.ft)
|

Bolt
|
Size
|
Number
|
A B C
|
8 × 25 8 ×
35 8 × 45
|
3 1 1
|
| |
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 oil pan and oil screen. (See page
EMA - 69) |
7. |
Install the timing belt. (See page EMA -
17) |
8. |
Install the drive
belt |
9. |
Install the alternator. (See EE group -
alternator) |
10. |
Install the front exhaust pipe. (See page EMA
- 91) |
11. |
Install the RH front
wheel. |
12. |
Fill engine with
oil. |
13. |
Start engine and check for
leaks. |
14. |
Recheck engine oil
level. |
1. |
Remove the relief plunger.
Remove the plug(A), spring(B) and relief
plunger(C).

|
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/1.547in.)
| |
3. |
Inspect rotor side clearance.
Using a feeler gauge and precision straight
edge, measure the clearance between the rotors and precision
straight edge.
Side
clearance
0.04 ~ 0.095mm (0.0016 ~
0.0037in.)
|

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.
Body
clearance
0.100 ~ 0.181mm (0.0039 ~
0.0017in.)
|

If the body clearance is greater than maximum,
replace the rotors as a set. If necessary, replace the front
case. |
1. |
Install relief plunger.
Install relief plunger(C) and spring(B) into
the front case hole, and install the plug(A).
Tightening
torque
40 ~ 50Nm (400 ~ 500kgf.cm, 30 ~
37lb.ft)
|

| |