7-7
7-7
7-7
7-8
7-8
7-8
7-10
7-10
7-10
7-10
7-11
7-11
7-11
7-12
7-13
7-13
7-13
7-14
7-14
7-14
7-16
7-16
7-17
7-17
7-17

7

7-2 ENGINE LUBRICATION SYSTEM
Exploded View

ENGINE LUBRICATION SYSTEM 7-3
Exploded View
No.
1
2
3
4
5
6
7
8
9
10
11
12

Fastener
Oil Pump Drive Chain Guide Bolt
Oil Cooler Mounting Bolts
Oil Pressure Switch
Oil Pressure Switch Terminal Bolt
Oil Pump Drive Gear Bolt
Oil Passage Plugs (Tapered)
Oil Pipe Holder Bolt
Oil Pressure Relief Valve
Oil Filter
Oil Filter Holder Bolt
Oil Pan Bolts
Engine Oil Drain Bolt

N·m
10
12
15
1.5
10
20
10
15
17
35
10
29

Torque
kgf·m
1.0
1.2
1.5
0.15
1.0
2.0
1.0
1.5
1.7
3.6
1.0
3.0

ft·lb
89 in·lb
106 in·lb
11
13 in·lb
89 in·lb
15
89 in·lb
11
13
26
89 in·lb
21

EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
LG: Apply liquid gasket.
Lh: Left-hand Threads
M: Apply molybdenum disulfied grease.
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1)
R: Replacement Parts
S: Follow the specified tightening sequence.

Remarks
L
L, S
LG
G
L, Lh
L
L
L
G, R
L
S

7-4 ENGINE LUBRICATION SYSTEM
Engine Oil Flow Chart

1. Camshaft Oil Passages
2. Oil Pressure Switch
3. Drive Shaft Oil Passage
4. Output Shaft Oil Passage
5. Starter Clutch Oil Passage
6. Oil Pump
7. Oil Cooler

8. Balancer Oil Passage
9. Oil Pipe
10. Oil Filter
11. Oil Pressure Relief Valve
12. Oil Screen
13. Blowby Gas

ENGINE LUBRICATION SYSTEM 7-5
Specifications
Item
Engine Oil
Type
Viscosity
Capacity

Level
Oil Pressure Measurement
Oil Pressure

Standard
API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2
SAE 10W-40
2.9 L (3.1 US qt) (when filter is not removed)
3.3 L (3.5 US qt) (when filter is removed)
3.7 L (3.9 US qt) (when engine is completely dry)
Between upper and lower level lines
(Wait several minutes after idling or running)
About 90 kPa (0.92 kgf/cm², 13 psi) @4 000 r/min (rpm), Oil
Temperature 90°C (194°F)

7-6 ENGINE LUBRICATION SYSTEM
Special Tools and Sealant
Oil Pressure Gauge, 10 kgf/cm²:
57001-164

Outside Circlip Pliers:
57001-144

Oil Pressure Gauge Adapter, PT3/8:
57001-1233

Liquid Gasket, TB1211F:
92104-0004

ENGINE LUBRICATION SYSTEM 7-7
Engine Oil and Oil Filter
WARNING
Vehicle operation with insufficient, deteriorated,
or contaminated engine oil will cause accelerated
wear and may result in engine seizure, accident,
and injury. Check the oil level before each use and
change the oil and filter according to the periodic
maintenance chart.

Oil Level Inspection

that the engine oil level is between the upper [A]
• Check
and lower [B] levels in the oil level inspection window.

NOTE

○Situate the motorcycle so that it is perpendicular to the
ground.
○If the motorcycle has just been used, wait several minutes for all the oil to drain down.
○If the oil has just been changed, start the engine and
run it for several minutes at idle speed. This fills the oil
filter with oil. Stop the engine, then wait several minutes
until the oil settles.
NOTICE
Racing the engine before the oil reaches every part
can cause engine seizure.
If the engine oil gets extremely low or if the oil
pump or oil passages clog up or otherwise do not
function properly, the warning indicator light (LED)
and oil pressure warning indicator will light. If this
light stays on when the engine is running above
idle speed, stop the engine immediately and find
the cause.
If the oil level is too high, remove the excess oil, using a
syringe or some other suitable device.
If the oil level is too low, add the correct amount of oil
through the oil filler opening. Use the same type and
make of oil that is already in the engine.

NOTE

○If the engine oil type and make are unknown, use any
brand of the specified oil to top off the level in preference
to running the engine with the oil level low. Then at your
earliest convenience, change the oil completely.

Engine Oil Change

to the Engine Oil Change in the Periodic Mainte• Refer
nance chapter.

Oil Filter Replacement

to the Oil Filter Replacement in the Periodic Main• Refer
tenance chapter.

7-8 ENGINE LUBRICATION SYSTEM
Oil Pan
Oil Pan Removal

the engine oil (see Engine Oil Change in the Peri• Drain
odic Maintenance chapter).
• Remove:
Exhaust Pipe (see Exhaust Pipe Removal in the Engine
Top End chapter)
Oil Filter (see Oil Filter Replacement in the Periodic
Maintenance chapter)
Oil Pan Bolts [A]
Clamp [B]
Oil Pan [C]
Front [D]

Oil Pan Installation
If the oil filter holder bolt [A] was removed, tighten it.

○Apply a non-permanent locking agent to the threads of
the oil filter holder bolt.
Torque - Oil Filter Holder Bolt: 35 N·m (3.6 kgf·m, 26 ft·lb)

the O-rings [B] with new ones, and apply grease
• Replace
to them.
• Install the O-rings to the oil pipe [C].

• Install:
Oil Pressure Relief Valve (see Oil Pressure Relief Valve
•
•

Installation)
Oil Pipe [A]
Oil Pipe Holder [B]
Apply a non-permanent locking agent to the oil pipe holder
bolt [C].
Tighten:
Torque - Oil Pipe Holder Bolt: 10 N·m (1.0 kgf·m, 89 in·lb)

the oil screen [A] with a high flash-point solvent and
• Clean
remove any particles stuck to them.

○Blow away the particles by applying compressed air [B]
from the inside to the outside (from the clean side to the
dirty side).

WARNING
Gasoline and low flash-point solvents can be
flammable and/or explosive and cause severe
burns. Clean the screen in a well-ventilated area,
and take care that there are no sparks or flame
anywhere near the working area; this includes any
appliance with a pilot light. Do not use gasoline or
a low flash-point solvent to clean the screen.

NOTE

○While cleaning the oil screen, check for any metal particles that might indicate internal engine damage.
the screen carefully for any damage, holes, broken
• Check
wires.
If the screen is damaged, replace it.

ENGINE LUBRICATION SYSTEM 7-9
Oil Pan
the fitting [A] until it is bottomed.
•○Install
Face the flanged side [B] to the bottom.
Lower Crankcase [C]
Install the hose [D] and the clamp [E].
○Face the knob of the clamp [F] inward as shown.
Viewed from Bottom [G]

•

the O-rings [A] [B] with new ones, and apply
• Replace
grease to them.
the O-rings.
•○Install
Face the chamfered side [C] downward.
the oil screen [D].
•○Install
Fit the claws [E] to the crankcase rib [F].

the oil pan gasket [A] with a new one.
• Replace
Install
the
[B] as shown.
• Tighten theclamp
oil pan bolts [C] as shown sequence [1  18].
•
Torque - Oil Pan Bolts: 10 N·m (1.0 kgf·m, 89 in·lb)

•

Front [D]
Install the removed parts (see appropriate chapters).

7-10 ENGINE LUBRICATION SYSTEM
Oil Pressure Relief Valve
Oil Pressure Relief Valve Removal

• Remove:
Oil Pan (see Oil Pan Removal)
Oil Pressure Relief Valve [A]

Oil Pressure Relief Valve Installation

a non-permanent locking agent to the threads of
• Apply
the oil pressure relief valve, and tighten it.

NOTICE
Do not apply too much non-permanent locking
agent to the threads. This may block the oil passage.
Torque - Oil Pressure Relief Valve: 15 N·m (1.5 kgf·m, 11
ft·lb)

Oil Pressure Relief Valve Inspection

the oil pressure relief valve (see Oil Pressure
• Remove
Relief Valve Removal).
to see if the valve [A] slides smoothly when push• Check
ing it in with a wooden or other soft rod, and see if it comes
back to its seat by spring [B] pressure.

NOTE

○Inspect the valve in its assembled state.

Disassembly
and assembly may change the valve performance.

If any rough spots are found during above inspection,
wash the valve clean with a high flash-point solvent and
blow out any foreign particles that may be in the valve with
compressed air.

WARNING
Gasoline and low flash-point solvents can be
flammable and/or explosive and cause severe
burns. Clean the relief valve in a well-ventilated
area, and take care that there is no spark or flame
anywhere near the working areas. Do not use
gasoline or low flash-point solvents to clean the
relief valve.
If cleaning does not solve the problem, replace the oil
pressure relief valve as an assembly. The oil pressure
relief valve is precision made with no allowance for replacement of individual parts.

ENGINE LUBRICATION SYSTEM 7-11
Oil Pump
Oil Pump Removal

• Drain:
Coolant (see Coolant Change in the Periodic Maintenance chapter)
Engine Oil (see Engine Oil Change in the Periodic Maintenance chapter)
the water hose clamp screw [A] and disconnect
• Loosen
the water hose [B].
the water pipe mounting bolt [C] and disconnect
• Remove
the water pipe [D].
• Remove:
Water Pump Cover Bolts [E]
Water Pump Cover [F]

the impeller bolt [A].
• Loosen
Remove
the oil (water) pump body [B] together with the
• impeller [C]
and the outer rotor [D].
• Remove the impeller bolt, washer and impeller.

• Remove:
Pin [A]
Inner Rotor [B]
Oil (Water) Pump Shaft [C]

Oil Pump Installation

the outer rotor [A] into the crankcase.
• Install
• Assemble:
Oil (Water) Pump Shaft [B]
Pin [C]
Inner Rotor [D]
○To prevent dropping, apply grease to the pin.
Install the inner rotor assembly into the crankcase.
○Fit the slot [E] onto the projection [F].

•

7-12 ENGINE LUBRICATION SYSTEM
Oil Pump
the O-ring [A] with a new one.
• Replace
Apply
grease
to the O-ring.
• Install the oil (water)
pump body [B].
•

coolant to the surface of the rubber seal [A] on the
• Apply
impeller.
the impeller, washer and impeller bolt.
• Install
Tighten:
•
Torque - Impeller Bolt: 10 N·m (1.0 kgf·m, 89 in·lb)

the O-ring [A] with a new one.
• Replace
Apply
liquid
gasket to any positions of the O-ring to pre• vent it from coming
off.
Sealant - Liquid Gasket, TB1211F: 92104-0004

the dowel pins [B] and water pump cover [C].
• Install
Apply
a
non-permanent locking agent to the water pump
• cover bolts
(L = 40 mm, 1.6 in.) and tighten them.

○Insert the bolt (L = 25 mm, 1.0 in.) to the upper bolt hole.
Torque - Water Pump Cover Bolts: 10 N·m (1.0 kgf·m, 89
in·lb)

the water pipe and hoses (see Cable, Wire, and
• Install
Hose Routing section in the Appendix chapter).
the O-ring [A] with a new one.
• Replace
soap and water solution to the O-ring.
• Apply
Apply
a non-permanent locking agent to the water pipe
• mounting
bolt.
Tighten:
•
Torque - Water Pipe Mounting Bolt: 10 N·m (1.0 kgf·m, 89
in·lb)
Water Hose Clamp Screw: 3.0 N·m (0.31 kgf·m, 27
in·lb)

Oil Pump Drive Gear Removal/Installation

• Remove:
Clutch (see Clutch Removal in the Clutch chapter)
Oil Pump Drive Chain Guide Bolt [A]
Oil Pump Drive Chain Guide [B]
Oil Pump Drive Gear Bolt [C]
Oil Pump Drive Gear [D]
Oil Pump Sprocket [E]
Oil Pump Drive Chain [F]
Collar [G]
○The oil pump drive gear bolt is left-hand threads.

ENGINE LUBRICATION SYSTEM 7-13
Oil Pump
Oil Pump Drive Gear Installation

• Install the collar [A] to the oil pump drive gear shaft.

the oil pump drive chain [A] to the gears, and then
• Engage
install the oil pump drive gear [B].

○Face the “OUT” mark [C] to outside.

a non-permanent locking agent to the oil pump drive
• Apply
chain guide bolt and the oil pump drive gear bolt [D].
the oil pump drive gear bolt temporary.
•○Tighten
The oil pump drive gear bolt is left-hand threads.
• Install the oil pump drive chain guide and tighten its bolt.
Torque - Oil Pump Drive Chain Guide Bolt: 10 N·m (1.0
kgf·m, 89 in·lb)

the clutch (see Clutch Installation in the Clutch
• Install
chapter).
• Tighten:
Torque - Oil Pump Drive Gear Bolt: 10 N·m (1.0 kgf·m, 89
in·lb)

• Install the removed parts (see appropriate chapters).
Oil Pump Drive Gear Shaft Removal

• Remove:
Oil Pump Drive Gear (see Oil Pump Drive Gear Removal)
Oil Pan (see Oil Pan Removal)
Circlip [A]
Washers [B]
Oil Pump Drive Gear Shaft [C]
Special Tool - Outside Circlip Pliers: 57001-144

Oil Pump Drive Gear Shaft Installation

molybdenum disulfide grease [A] to the oil pump
• Apply
drive gear shaft.
molybdenum disulfide oil solution to the followings.
• Apply
Transmission Case [B]

•
•
•

Crankcase [C]
Install the oil pump drive gear shaft and washers [D] as
shown.
Replace the circlip [E] with a new one.
Install the circlip into the groove of the oil pump drive gear
shaft.
Special Tool - Outside Circlip Pliers: 57001-144

• Install the removed parts (see appropriate chapters).

7-14 ENGINE LUBRICATION SYSTEM
Oil Cooler
Oil Cooler Removal

• Drain:
Engine Oil (see Engine Oil Change in the Periodic Main•
•

tenance chapter)
Coolant (see Coolant Change in the Periodic Maintenance chapter)
Remove:
Lower Fairings (see Lower Fairing Removal in the Frame
chapter)
Slide the clamps [A] and disconnect the water hoses [B].

• Remove:
Oil Cooler Mounting Bolts [A]
•

Oil Cooler [B]
Take the water hoses off the oil cooler.

Oil Cooler Installation