Oil and Coolant Pump - Removal

Warning - General - Stabilise Motorcycle

warning
Make sure the motorcycle is stabilised and adequately supported.A correctly supported motorcycle will help prevent it from falling.An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.

Warning - Cooling - Cap Removal (scalding)

warning
Do not remove the coolant pressure cap when the engine is hot. When the engine is hot, the coolant inside the radiator is hot and also under pressure. Contact with hot coolant will cause scalds and skin damage.

Warning - Hot Engine oil

warning
If the engine has recently been running, the engine oil will be hot to the touch. Contact with the hot oils may cause damage to exposed skin. To avoid skin damage, do not touch hot oil.

Warning - General - Prolonged or repeated contact with engine oil

warning
Prolonged or repeated contact with engine oil can lead to skin dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contamination which can cause cancer. Wear suitable clothing and avoid skin contact.The engine oil and filter must be replaced in accordance with scheduled maintenance requirements.

Caution - General - Do not pour engine oil - pollution

caution
Do not pour engine oil on the ground, down sewers or drains, or into watercourses. To prevent pollution of watercourses etc., dispose of used oil sensibly. If in doubt contact your local authority.
note
The oil pump and water pump are supplied as an assembly and cannot be separated. This procedure covers the removal of the oil and water pump assembly.

Perform the following operations

Perform the following operations:

Seat - Remove L Series

Battery - Remove L Series

Radiator - Remove L Series

Exhaust - Removal L Series

Clutch - Remove L Series

Sump - Removal L Series

  1. Release and discard the two fixings and remove the oil transfer pipe. Remove and discard the two O-ring seals.
    2. Oil transfer pipe (chyf_1)

    1. Oil transfer pipe

    2. Fixings

  2. Release and discard the two fixings and remove the oil pick-up. Remove and discard the O-ring seal.
    3. Oil Pick Up (chyc_1)

    1. Oil pick-up

    2. Fixings

  3. Remove and discard the bolt securing the coolant outlet pipe to the crankcase and withdraw the pipe. Remove and discard the O-rings from the elbow.
    4. Coolant Outlet Pipe (cdph_3)

    1. Coolant outlet pipe

    2. Fixing

  4. Remove and discard the bolt securing the coolant inlet elbow to the crankcase and withdraw the elbow. Remove and discard the O-ring from the elbow.
    5. Coolant inlet elbow cdpg_1

    1. Coolant inlet pipe

    2. Fixing

  5. Release the fixings securing the drive chain guide to the crankcase and remove the guide.
    6. Oil pump chain guide cdpk

    1. Oil pump drive chain guide (engine shown inverted)

    2. Fixings

  6. Slide the oil pump drive sprocket gently backwards and forwards to dislodge the inner needle roller bearing.
    7. Oil pump drive sprocket bearing cdwf

    1. Oil pump drive sprocket (engine shown inverted)

    2. Needle roller bearing

  7. Carefully remove the bearing while supporting the oil pump drive sprocket.
    8. Remove needle roller bearing cdwg

    1. Needle roller bearing (engine shown inverted)

    2. Oil pump drive sprocket

    note
    Note the position of the washer under the oil pump fixing for the oil pump dowel for installation.
  8. Release the fixings securing the oil pump. Remove the fixings and collect the washer.
    9. Oil Pump fixings (B00533_1)

    1. Oil pump

    2. Fixings

    3. Washer

  9. Using a suitable tool, slide the dowel upwards to release the oil pump from the crankcase. It is not necessary to remove the dowel completely from the oil pump.
    10. Oil Pump Dowel (B00534_1)

    1. Oil pump

    2. Dowel

  10. Detach the drive chain from the oil pump.
    11. Oil Pump Drive Chain (B00536_1)

    1. Oil pump

    2. Drive chain

  11. Carefully withdraw the oil pump from the crankcase.
  12. Remove and discard the O-ring from the inlet sleeve on the water pump body.