2. |
Remove RH front
wheel. |
4. |
Remove the front exhaust
pipe. |
5. |
Remove the alternator from engine. (Refer to
Alternator in EE Group) |
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. (Refer to Timing
system in this group.) |
9. |
Remove the lower oil pan(A).

•
|
Insert the SST between the oil pan
and the ladder frame by tapping it with a plastic hammer
in the direction of
arrow. |
•
|
After tapping the SST with a
plastic hammer along the direction of arrow around more than 2/3 edge
of the oil pan, remove it from the ladder
frame. |
•
|
Do not turn over the SST abruptly
without tapping. It is result in damage of the
SST. | | |
10. |
Remove oil screen.
Remove the 2bolts(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. | |
ENGINE OIL AND FILTER
REPLACEMENT |
•
|
Prolonged and repeated contact with
mineral oil will result in the removal of natural fats from
the skin, leading to dryness, irritation and dermatitis. In
addition, used engine oil contains potentially harmful
contaminants which may cause skin
cancer. |
•
|
Exercise caution in order to minimize
the length and frequency of contact of your skin to used oil.
Wear protective clothing and gloves. Wash your skin thoroughly
with soap and water, or use water-less hand cleaner, to remove
any used engine oil. Do not use gasoline, thinners, or
solvents. |
•
|
In order to preserve the environment,
used oil and used oil filter must be disposed of only at
designated disposal
sites. | |
1. |
Drain engine oil.
(1) |
Remove the oil filler
cap. |
(2) |
Remove the oil drain plug(A), and drain
the oil into a container.

| |
2. |
Replace oil filter.
(1) |
Remove the oil
filter(B). |
(2) |
Check and clean the oil filter
installation surface. |
(3) |
Check the part number of the new oil
filter is as same as old one. |
(4) |
Apply clean engine oil to the gasket of
a new oil filter. |
(5) |
Lightly screw the oil filter into place,
and tighten it until the gasket contacts the
seat. |
(6) |
Tighten it an additional 3/4
turn. | |
3. |
Refill with engine oil filter.
A. |
Clean and install the oil drain plug
with a new gasket.
Tightening torque
34.3 ~ 44.1Nm (3.5 ~ 4.5kgf.m,
25.3 ~ 32.5lb-ft)
| |
B. |
Fill with fresh engine oil
Capacity
Total : 4.8L (5.07 US qts, 4.22
lmp qts)
Oil pan : 4.2 L (4.44 US qts, 3.70
lmp qts)
Drain and refill including oil
filter :
4.5 L (4.76 US qts, 3.96 lmp
qts)
Oil quality : Above API SJ/SL or
SAE 5W-20
| |
C. |
Install the oil filler
cap. | |
4. |
Start engine and check for oil
leaks. |
5. |
Recheck engine oil
level. |
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
7.8 ~ 11.8Nm (0.8 ~ 1.2kgf.m, 5.8
~ 8.7lb-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
11.8 ~ 14.7Nm (1.2 ~ 1.5kgf.m, 8.7
~ 10.8lbf.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 upper oil pan.
(1) |
Using a razor blade and gasket scraper,
remove all the old packing material from the gasket
surfaces.
Check that the mating surfaces are
clean and dry before applying liquid
gasket. | |
(2) |
Install the oil pan(A) with the
17bolts.
Uniformly tighten the bolts in several
passes. |
Tightening
torque
18.6 ~ 23.5Nm (1.9 ~ 2.4kgf.m, 13.7 ~
17.4lb-ft) : (1 ~ 15)
4.9 ~ 6.9Nm (0.5 ~ 0.7kgf.m, 3.6 ~
5.1lb-ft) : (16,17)
|


•
|
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. | | |
7. |
Install oil screen.
Install a new gasket and oil screen(A) with
2bolts(B).
Tightening
torque
14.7 ~ 21.6Nm (1.5 ~ 2.2kgf.m, 10.8 ~
15.9lb-ft)
|

|
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.
• |
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. | | |
(2) |
Install the lower oil pan
10bolts.
Uniformly tighten the bolts serveral
passes |
Tightening torque
9.8 ~11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~
8.7lb-ft)
|

|
9. |
Install the timing belt. (Refer to Timing
system in this group.) |
10. |
Install the drive
belt |
11. |
Install the alternator. (Refer to Alternator
in EE Group) |
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. |
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
39.2 ~ 49.0Nm (4.0 ~ 5.0kgf.m, 28.9 ~
36.2lb-ft)
|

|
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. | |