Oil Pump, Clutch and Water Pump

OIL PUMP AND OIL PAN

 

1   Chain cover
2   Oil pump sprocket
3   Oil pump drive sprocket 
4   Oil pump cover
5   Inner rotor
6   Spring
7   Relief valve
8   Shaft
9    Dowel pin
10   Outer rotor
11   Dowel pin

12   O-ring

1. Install:
• O-ring 1 onto the oil pump assembly
• Chain
• Oil pump assembly
• Chain cover

Oil Pump: 12 Nm (1.2 m-kg, 8.7 ft-lb)

2. Install: 
• Oil pan    
• Wire clamps 1
• Bolts
• Oil level switch 2   

Oil Pan: 12 Nm (1.2 mkg,  .7 ft-lb)
Oil Level Switch: 8 Nm (0.8m-kg, 5.8 ft-lb)

CLUTCH

1    Plate washer
2    Oil seal
3    Bearing
4    Pinion gear
5    Plate washer
6    Circlip
7    Lock washer
8    Friction plate
9    Clutch plate
10    Wire clip
11    Clutch plate
12   
Clutch boss spring
13   Spring seat
14    Thrust plate
15   Spacer
16   Bearing (15-28)
17   Oil pump drive sprocket
18  Collar
19  Thrust plate
20   Pull rod
21   Bearing
22   Water pump drive shaft
23   Spacer
24   Water pump drive gear

Note:
The outermost friction plate has a V-cut in it. Give some identifying mark to the corresponding dog in the clutch housing.

 

CLUTCH AND OIL PUMP DRIVE SPROCKET

1. Install: 
• Thrust plate 1  
• Oil pump drive sprocket 2

12 Nm (1.2m-kg, 8.7 ft-lb)

2. Hook the drive chain on the drive sprocket.

3 Install:
• Collar 3

4. Install:
• Water pump drive shaft 1
• Clutch housing

CAUTION: 
Be sure that the oil pump drive gear tabs engage the clutch housing grooves on its back or the tabs will be damaged when tightening the clutch boss securing nut
.

5. Install: 
• Bearing 1
• Spacer 2
• Thrust plate 3
• Clutch boss 4
• Lock washer (New) 5

• Nut 6

Clutch Boss: 70 Nm (7.0 m kg, 50 ft lb)

6.  Bend lock washer tabs against the nut flats.

7.  Install: 
• Friction plates
• Clutch plates

8. Install: 
• Friction plate (with V-cut 1 in tab)

NOTE:
Install the friction plate so that the V-cut tab is in the identified dog 2 . If you forget to identify the position with a mark, measure the width of each dog. 13.8 mm (0.543 in) width is for that position. The other width are 14 mm (0.551 in).

9. Install:
• Plate washer 2
• Thrust bearing 3 onto the pull rod 4

• Pull rod 4 
into the pressure plate 1

10. Install:
• Pressure plate

NOTE:
Align a dot on the clutch boss with a dot on the pressure plate.

• Clutch springs

Clutch Spring: 8 Nm (0.8 m-kg, 5.8 ft-lb)

11. Install:
• Oil baffle plate
• Dowel pins
• Gasket
• Clutch cover

NOTE:
Set the gear of the clutch pull rod facing approximately 45° from horizontal toward the rear.

• Set the clutch lever 1 on the right crankcase cover parallel to the gasket surface. 
• Make sure that the punch mark on the lever 2 align with the mark on the crankcase cover 3 when pushing the lever towards the front by hand.

Clutch Cover: 1 2 Nm(1.2m-kg,8.7ft-lb)

12. Install: 
• Spacer 1
• Water pump drive gear 2
• Water pump drive gear cover.

Water Pump Drive Gear: 12 Nm (1.2 m-kg, 8.7 ft-lb) LOCTITE®

Cover: 8Nm(0.8m-kg, 5.8ft-lb)