Oil pump and pressure relief valve — removal, inspection and installation (Honda XRV750 Africa Twin)

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Note: To access the oil pump the engine must be removed from the frame and the crankcases separated.

Removal

1. Separate the crankcase halves (Section 23).

2. Unscrew the bolt securing the pressure relief valve cover to the pump, then remove the cover from the end of the relief valve (see illustrations). If required, withdraw the valve from the pump (see illustration). Discard the valve O-ring as a new one must be used. Refer to Step 12 for relief valve checks.








3. Unscrew the remaining two bolts securing the pump assembly to the crankcase, then remove the pump along with its oil pipe (see illustrations). Remove the two oil passage collars from the crankcase and discard their O-rings as new ones must be used (see Illustration). Remove the pump dowel if it is loose - it could be in either the pump or the crankcase (see illustration).

Inspection

4. Remove the oil pipe from the pump and discard its O-rings as new ones must be used (see illustration).



5. Remove the oil strainer from the pump, noting how it fits (see illustration). Discard the seal as a new one must be used.




6. Unscrew the three bolts and separate the rotor housing from the pump body (see Illustration). Remove the dowels from either the housing or the body if they are loose (see illustration).








7. Withdraw the pump drive shaft and remove the thrust washer and the drive pin, noting how it locates in the shaft and in the notches in the inner rotor. Remove the inner and outer rotors from the pump body. Note whether the punch mark on the outer rotor in or out of the housing so it can be installed the same way round. Clean all the components in solvent.

8. Inspect the pump body and rotors for scoring and wear (see illustration). If any damage, scoring or uneven or excessive wear is evident, replace the pump with a new one (individual components are not available).



9. Measure the clearance between the inner rotor tip and the outer rotor with a feeler gauge and compare it to the maximum clearance listed in the specifications at the beginning of the Chapter (see illustration). If the clearance measured is greater than the maximum listed, replace the pump with a new one.



10. Measure the clearance between the outer rotor and the pump body with a feeler gauge and compare it to the maximum clearance listed in the specifications at the beginning of the Chapter (see illustration). If the clearance measured is greater than the maximum listed, replace the pump with a new one.



11. Lay a straightedge across the rotors and the pump body and, using a feeler gauge, measure the rotor end float (the gap between the rotors and the straightedge) (see illustration). If the clearance measured is greater than the maximum listed, replace the pump with a new one.



12. If not already done, withdraw the relief valve from the pump (see illustration). Discard its O-ring. Press down on the plunger and check that it moves freely in the body and returns under spring pressure (see illustration). Remove the circlip from the end of the relief valve body and withdraw the washer, spring and valve plunger (see illustrations). Clean all the components in solvent. Check that the plunger moves freely in the body and inspect it for wear or damage. If the valve is good, install the plunger into the body, followed by the spring and the washer, and secure them in place with the circlip (seillustrations). Note that apart from the O-ring, none of the relief valve components are available separately. Fit a new O-ring onto the valve (see illustration), and if required now, fit the valve into the pump (see illustration 25.12a).















13. Check the pump drive chain and sprockets for wear or damage, and replace them as a set if necessary.

14. If the pump Is good, make sure all the components are clean, then lubricate them with new engine oil. Fit the outer rotor into the housing with the punch mark facing the same way as noted on removal (see illustration). Fit the inner rotor into the outer rotor so that its notches face out (see illustration) Slide the thick-tabbed end of the shaft into the inner rotor, then fit the drive pin into the shaft (see illustrations). Slide the shaft fully home so that the drive pin ends fit into the notches in the inner rotor (see illustration). Fit the thrust washer over the shaft and onto the inner rotor (see illustration).













15. Fit the doweis into the pump body if they were removed (see illustration 25.6c). Fit the rotor housing, making sure the dowels locate correctly (see illustration). Fit the three bolts into the pump body and tighten them securely (see illustration).





16. Smear a new seal for the strainer with clean oil and fit it into the pump (see illustration). Make sure the strainer is clean and free of any debris, then fit it into the seal, on models with an oval (as opposed to round) strainer making sure its rim locates correctly (see illustrations).







17. Fit new O-rings, smeared with clean engine oil and with their tapered side facing out, to each end of the pump oil pipe, then fit the pipe into the pump (see illustrations).

Installation

18. Fit the oil passage collars into the crankcase and fit new O-rings around them (see illustration 25.3c). If removed, also fit the pump dowel (see illustration 25.3d)

19. Before installing the pump, prime It by pouring oil into the outlet and turning the shaft by hand This ensures that oil is being pumped as soon as the engine is turned over.

20 Install the pump with its oil pipe onto the crankcase, making sure the pump locates correctly onto the dowel and collars and the pipe is properly inserted into its hole (see illustration 25.3b). Install the pump bolts and tighten them securely (see illustration 25.3a).

21. If not already done, fit a new O-ring onto the pressure relief valve, then fit the valve into the pump (see illustrations 25.12a and 25.2c). Fit the cover over the end of the valve and secure It with its bolt (see illustrations 25.2b and a).

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Article about repair motorcycles «Honda Africa Twin XRV 750» (1989-2003): «Oil pump and pressure relief valve — removal, inspection and installation»: https://motoinstruction.ru/en/Honda/Africa-Twin/XRV750/engine/repair/115064 <a href="https://motoinstruction.ru/en/Honda/Africa-Twin/XRV750/engine/repair/115064">Oil pump and pressure relief valve — removal, inspection and installation</a> - article about repair motorcycles «Honda Africa Twin XRV 750» (1989-2003) from section «Engine repair». [url=https://motoinstruction.ru/en/Honda/Africa-Twin/XRV750/engine/repair/115064]Oil pump and pressure relief valve — removal, inspection and installation[/url] - article about repair motorcycles «Honda Africa Twin XRV 750» (1989-2003) from section «Engine repair».