Section 03 ENGINE

Subsection 05 (LUBRICATION SYSTEM)

LUBRICATION SYSTEM
SERVICE TOOLS
Description Part Number Page
adapter hose......................................................................... 529 035 652 ........................................... 50
pressure gauge..................................................................... 529 035 709 ........................................... 50

SERVICE PRODUCTS
Description Part Number Page
XP-S 5W30 4-stroke oil......................................................... 219 700 706 ........................................... 47
XP-S 5W40 synthetic oil ....................................................... 293 600 039 ........................................... 47
Loctite 243 (blue).................................................................. 293 800 060 ........................................... 51

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Section 03 ENGINE
Subsection 05 (LUBRICATION SYSTEM)

Engine oil

2
NEW

10 N•m
(89 lbf•in)
13
NEW
Engine oil 12 N•m 5
Engine oil (106 lbf•in) Loctite
Engine 243
10 N•m oil
(89 lbf•in) 7

9
6
30 N•m 4 NEW
(22 lbf•ft) 3 10 12
8

M18 x 1.5
11

Engine oil

10 N•m
(89 lbf•in)

vmr2008-124-001_a

46 vmr2008-124
 Section 03 ENGINE
Subsection 05 (LUBRICATION SYSTEM)

GENERAL Engine Oil Viscosity Chart

During assembly/installation, use the torque val-
ues and service products as in the exploded SAE 0W30
views. SAE 5W30 (XP-S 5W30 Mineral Oil)
Clean threads before applying a threadlocker. Re-
SAE 10W30
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for SAE 5W40 (XP-S 5W40 Synthetic Oil)
complete procedure.
SAE 10W40 (XP-S 10W40 Mineral Oil)
 WARNING SAE 15W40
Torque wrench tightening specifications
must be strictly adhered to. SAE 20W50
Locking devices (e.g.: locking tabs, elastic TEMPERATURE RANGE
stop nuts, self-locking fasteners, cotter pin, 50°C (122°F)
etc.) must be installed or replaced with new 40°C (104°F)
ones where specified. If the efficiency of 30°C (86°F)
a locking device is impaired, it must be re- 20°C (68°F)
newed. 10°C (50°F)
0°C (32°F)
- 10°C (14°F)
MAINTENANCE - 20°C (- 4°F)
- 30°C (- 22°F)
ENGINE OIL
Oil Level Verification
Recommended Oil
CAUTION: Check level frequently and refill
Use 4-stroke SAE 5W30 engine oil that meets or if necessary. Do not overfill. Operating the
exceeds the requirements for API service classifi- engine/transmission with an improper level
cation SM, SL or SJ. Always check the API service may severely damage engine/transmission.
label certification on the oil container it must con- Wipe off any spillage.
tain at least one of the above standards.
The XP-S 5W30 4-stroke oil (P/N 219 700 706) is
recommended.
For improved overall performance and all season
application, use XP-S 5W40 synthetic oil (P/N 293
600 039).

V07C24A

RH SIDE OF ENGINE
1. Dipstick

With vehicle on a level surface and engine cold,

not running, check the oil level as follows:
1. Unscrew dipstick no. 1 then remove it and
wipe clean.
2. Reinstall dipstick, screw in it completely.

vmr2008-124 47
Section 03 ENGINE
Subsection 05 (LUBRICATION SYSTEM)

3. Remove and check oil level. It should be near

or equal to the upper mark.

vmr2008-124-101_a

vmr2008-124-100_a
1. Dipstick
2. O-ring
1. Full
2. Add Unscrew drain plug no. 3.
3. Operating range

To add oil, remove the dipstick. Place a funnel into

the dipstick tube to avoid spillage.
Add a small amount of recommended oil and
recheck oil level.
Repeat the above procedures until oil level reach-
es the dipstick's upper mark. Do not overfill.
Properly tighten dipstick.

Engine Oil Replacement

Prior to change the oil, ensure vehicle is on a level
surface.
Oil and oil filter no. 2 must be replaced at the same
time. Oil change and oil filter replacement should
vmr2008-124-102_a
be done with a warm engine.
SEEN FROM RH SIDE, UNDERNEATH VEHICLE
 WARNING
Allow oil to drain completely from crankcase.
The engine oil can be very hot. Wait until en-
gine oil is warm. Clean the magnetic drain plug from metal shav-
ings and residue. Presence of debris gives an in-
dication of failure inside the engine.
Place a drain pan under the engine drain plug area.
Install a new gasket ring no. 4 on drain plug.
Clean the drain plug area.
Remove dipstick. CAUTION: Never use the gasket ring a second
time. Always replace by a new one.
CAUTION: Pay attention not to lose the O-ring Torque drain plug to 30 N•m (22 lbf•ft).
on dipstick.
Replace the oil filter.
Refill engine with recommended engine oil. Oil
change capacity with filter is 3 L (3.17 qt).
After filling, check the oil level with the dipstick.
Refer to OIL LEVEL CHECK above.
NOTE: Run engine to ensure oil filter and drain
plug areas are not leaking.

48 vmr2008-124
 Section 03 ENGINE
Subsection 05 (LUBRICATION SYSTEM)

Dispose oil and filter as per your local environmen-

tal regulations.

OIL FILTER
Oil Filter Removal
Remove:
– Engine cover

R400motr112A 2 1
1. Inlet bore from the oil pump to the oil filter
2. Outlet bore to the engine oil providing system

Oil Filter Installation

The installation is the opposite of the removal pro-
cedure. Pay attention to the following details.
vmr2008-123-100_a
Apply oil on rubber seal of oil filter to ensure proper
installation.
– Oil filter screws Install O-ring on oil filter cover.
– Oil filter cover with O-ring
– Oil filter.

R400motr113A
R400motr111A 4 3 2 1
1. O-ring in place
1. Oil filter screws
2. Oil filter cover
3. O-ring
4. Oil filter
INSPECTION
Oil Filter Inspection ENGINE OIL PRESSURE TEST
Check oil filter cover O-ring, change it if necessary. NOTE: The engine oil pressure test should be
Check and clean the oil filter inlet and outlet area done with a warm engine and the recommended
for dirt and other contaminations. oil.
Remove the oil pressure switch no. 5.

vmr2008-124 49
Section 03 ENGINE
Subsection 05 (LUBRICATION SYSTEM)

vmr2008-124-103_A
vmr2008-124-105_a

Install the pressure gauge (P/N 529 035 709) and

Start engine and measure oil pressure as per fol-
the adapter hose (P/N 529 035 652) to the switch
lowing table.
hole.
The engine oil pressure should be within the fol-
lowing values.

PRESSION/
1300 RPM 6000 RPM
RPM
Minimal 70 kPa (10 PSI) 350 kPa (51 PSI)
529 035 709
Nominal 350 kPa (51 PSI) 500 kPa (73 PSI)
Maximal 550 kPa (80 PSI) 700 kPa (102 PSI)

If the engine oil pressure is out of specifications,

check the points described in TECHNICAL GUIDE-
LINES (TROUBLESHOOTING) section.

PROCEDURES
529 035 652 OIL PRESSURE SWITCH

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50 vmr2008-124
 Section 03 ENGINE
Subsection 05 (LUBRICATION SYSTEM)

Oil Pressure Switch Activation OPS CIRCUIT MEASUREMENT

Oil pressure switch is normally closed and it opens RESISTANCE
when engine runs and pressure reaches 30 and OPS PIN ECM PIN
@ 20°C (68°F)
60 kPa (4.4 and 8.7 PSI). So, when engine runs,
switch is open and if pressure goes to low, the 1 E2 Close to 0
switches closes.
To check the function of the oil pressure switch,
an oil pressure test has to be performed. Refer to
ENGINE OIL PRESSURE.
If the engine oil pressure is good, check the resis-
tance of the oil pressure switch while engine is off
and while engine is running.

Oil Pressure Switch Resistance Test

Disconnect the connector from the oil pressure
switch.
Use a multimeter and select to check the resis-
tance as shown.

OPS ENGINE NOT ENGINE

CONNECTOR RUNNING RUNNING vmr2008-124-104_b

PIN RESISTANCE
Oil Pressure Switch Removal
Infinitely
Unplug and unscrew the oil pressure switch no. 5.
Close to 0 high when
Engine
1 (normally pressure reaches
ground
closed switch) 30 - 60 kPa
(4.4 - 8.7 PSI)

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Oil Pressure Switch Installation

vmr2008-124-104_a
If resistance values are incorrect, replace the oil
pressure switch.
If the values are correct, check the continuity of
the wiring harness.
Disconnect the ECM connector and check conti-
nuity of circuit between switch and ECM.
Apply Loctite 243 (blue) (P/N 293 800 060) and
torque switch to 12 N•m (106 lbf•in).
Plug switch connector.
OIL STRAINER
Oil Strainer Removal
Engine must be lifted or removed to access the
oil strainer. Refer to the ENGINE REMOVAL/IN-
STALLATION.

vmr2008-124 51
Section 03 ENGINE
Subsection 05 (LUBRICATION SYSTEM)

Drain engine oil, refer to OIL CHANGE in this sec- Inspect O-ring on the oil collector and rubber ring
tion. on the oil strainer cover.
Remove screws retaining oil strainer cover. If O-ring and/or rubber ring is (are) brittle, cracked
or hard, replace the defective part(s).
2
Clean both contact surfaces of oil strainer cover.
Check and clean the oil inlet and outlet area for dirt
and other contaminations.

R400motr114A 2 1
1. Oil strainer cover
2. 5 screws
R400motr116A 2 1 3
Remove oil collector with O-ring and oil strainer.
1. Oil inlet to the oil pump
2. Oil return from the oil pressure regulator system
1 2 3. Oil return from the engine oil circulation

Oil Strainer Installation

For installation, reverse the removal procedure.
Torque oil strainer cover screws as per following
sequence.

4
R400motr115A
3
1. Oil collector with O-ring
2. Oil strainer
2

Oil Strainer Cleaning and Inspection

Clean oil strainer with a part cleaner then use an
R400motr114B
air gun to dry it.

 WARNING
Always wear eye protector. Chemicals can
cause a rash break out in and an injury to your
eyes.
Reinstall engine in vehicle. Refill engine at the
proper level with the recommended oil.
Start engine and let idle for a few minutes. Ensure
oil filter and magnetic drain plug areas are not leak-
ing.

52 vmr2008-124
 Section 03 ENGINE
Subsection 05 (LUBRICATION SYSTEM)

Stop engine. Wait a while to allow oil to flow
down to crankcase then check oil level. Refill as
necessary.
ENGINE OIL PRESSURE
REGULATOR
The oil pressure regulator is located in the oil pump
housing (engine MAG side, behind magneto cov-
er).
Oil Pressure Regulator Inspection
Inspect valve piston for scoring or other damages.
Check compression spring for free length.
COMPRESSION SPRING FREE LENGTH
NEW NOMINAL 64 mm (2.519 in)
SERVICE LIMIT 62 mm (2.441 in)
Replace both parts if important wear or damage
are present.
Clean bore and threads in the oil pump housing
from metal shavings and other contaminations.

Oil Pressure Regulator Installation

For installation, reverse the removal procedure.

OIL PUMP
The oil pump is located on the engine MAG side
(refer to ENGINE OIL PRESSURE REGULATOR).

Oil Pump Removal

1 2
vmr2006-054-003_a
1. Oil pressure regulator plug
2. Oil pump housing
NOTE: The oil pressure regulator system works
when the oil pressure exceeds 500 kPa (73 PSI).
Oil Pressure Regulator Removal
Remove:
– Engine from vehicle (refer to ENGINE RE-
MOVAL/INSTALLATION)
– Water pump cover (refer to COOLING SYSTEM)
– Magneto cover (refer to MAGNETO/STARTER)
– Oil pressure regulator plug, compression spring
and valve piston.
Remove:
– Engine from vehicle (refer to ENGINE RE-
MOVAL/INSTALLATION)
– Water pump cover (refer to COOLING SYSTEM )
– Magneto cover (refer to MAGNETO/STARTER).
NOTE: The following steps to remove the drive
gear no. 6 and the intermediate gear no. 7 are not
necessary to replace only the oil pump.
Remove retaining ring no. 8 then drive gear no. 6
and needle pin no. 9.
CAUTION: Never use the retaining ring a sec-
ond time. Always replace by a new one.
NOTE: Drive gear is snapped on a needle pin. This
needle pin passes through the balancing shaft.
Remove pin and intermediate gear.

 WARNING
Oil pressure regulator plug on oil pump hous-
ing is spring loaded.

R400motr117A 3 2 1
1. Valve piston
2. Compression spring
3. Oil pressure regulator plug

vmr2008-124 53
Section 03 ENGINE
Subsection 05 (LUBRICATION SYSTEM)

1 2

1
vmr2006-054-004

1. Dowel pins

R400motr118A
Remove oil pump gear no. 11.
1. Intermediate gear
2. Pin
NOTE: Oil pump gear is snapped on needle pin.
This needle pin passes through the oil pump shaft.
Remove oil pump cover screws and oil pump cov- Use screwdrivers to remove this gear.
er.
4 2 3
1

R400motr119A 1
1. 4 oil pump cover screws R400motr122A
2. Oil from the pump to the oil filter in the magneto cover
3. Oil pump cover
1. Flat screwdrivers
4. Oil seal to crankcase MAG side

NOTE: To remove oil pump system, lift the dowel 2

pins no. 10 a bit. The oil pump housing with oil 3
pump shaft assembly will be easier to remove.
CAUTION: Pay attention not to drop the dowel 2
pins inside the engine.

4
1

1
R400motr123A

1. Oil pump gear

2. Dowel pins
R400motr120A
3. Suction side of the oil pump
4. Outlet from the engine oil pressure regulator valve
1. Oil pump system

Remove needle pin no. 12, oil pump shaft assem-

bly and oil pump housing.
54 vmr2008-124
 Section 03 ENGINE
Subsection 05 (LUBRICATION SYSTEM)

1
R400motr126A

1. Pittings on the teeth

1 Using a feeler gauge, measure the clearance be-

R400motr125A tween inner and outer rotor.
1. Oil pump shaft assembly
2. Oil pump housing

C
1

R400motr127A

1. Outer rotor
2. Inner rotor

vmr2008-124-002_a
OUTER AND INNER ROTOR CLEARANCE
1. Bore for dowel pin support SERVICE LIMIT
2. Oil return from the oil pressure regulator system
3. Oil inlet to the oil pump (leads to strainer on engine bottom) A
B 0.25 mm (.009 in)
Oil Pump Inspection C
Inspect oil pump shaft assembly, housing and cov-
er for marks or other damages. If clearance between inner and outer rotor ex-
ceeds the tolerance, replace oil pump shaft
Replace O-ring no. 13 if brittle or hard. This O-ring
assembly. Ensure to also check oil pump housing
is located on the oil pump housing.
and cover. If damaged, replace the complete oil
Check inner rotor for corroded pin holes or other pump assembly.
damages. If so, replace oil pump shaft assembly.
If clearance between outer rotor and its bore in
Check the inside of oil pump housing and its cover oil pump exceeds the tolerance, replace the com-
for scoring or other damages. If so, change the plete oil pump assembly.
complete oil pump assembly.
Using a dial indicator, measure side wear as
shown.

vmr2008-124 55
Section 03 ENGINE
Subsection 05 (LUBRICATION SYSTEM)

1 4

2 2
3

R400motr119B

NOTE: After tightening the oil pump housing

screws check for smooth operation of the oil
1
R400motr128B
pump assembly.
1. Oil pump housing surface
Install the O-ring no. 13 on oil pump cover.
2. Dial indicator After engine is completely reassembled, start en-
gine and make sure oil pressure is within specifi-
cations (refer to ENGINE OIL PRESSURE TEST at
the beginning of this section).

1
R400motr128B

1. Oil pump outer rotor surface

2. Dial indicator

Difference between pump housing and outer rotor

should not exceed 0.1 mm (.004 in). If so, replace
the complete oil pump assembly.
NOTE: When the axial clearance of the oil pump
shaft assembly increases, the oil pressure de-
creases.

Oil Pump Installation

For installation, reverse the removal procedure.
CAUTION: Never apply any sealing compound
on split surfaces of oil pump.
Tightening oil pump housing screws as per follow-
ing sequence.

56 vmr2008-124