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)