Buell 2003XB9S, Service Manual

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2003 Buell XB9S: Engine 3-81
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CLEANING AND INSPECTION
1. Clean all parts in cleaning solvent. Blow out holes and oil
passages with compressed air.
2. See Figure 3-120. Inspect both gerotor sets for wear.
a. Mesh pieces of each set together as shown.
b. Use a feeler gauge to determine clearance.
c. The SERVICE WEAR LIMIT between gerotors is
0.004 in. (0.102 mm). Replace gerotors as a set if
clearance exceeds this dimension.
d. Measure thickness of feed gerotors with a microme-
ter. Replace gerotors as a set if they are not the
same thickness.
3. See Figure 3-118. Check gear shaft teeth for damage or
wear. Replace if necessary.
ASSEMBLY/INSTALLATION
NOTE
Liberally coat all moving parts with clean engine oil to ensure
easy assembly and smooth operation at start-up.
1. See Figure 3-118. Install gear shaft through body. Posi-
tion thrust washer over end of shaft. Install new retaining
ring into groove in shaft.
2. Insert inner gerotor of the gerotor scavenge set over gear
shaft.
3. Place outer gerotor over inner gerotor to complete scav-
enge set.
4. See Figure 3-121. Install gerotor separator plate by lining
up slots on perimeter with tabs inside oil pump body.
5. Install a new O-ring into groove in pump body.
6. See Figure 3-118. Place gerotor feed set over gear shaft.
7. Place cover onto pump body. Install cover TORX screws.
Tighten to 70-80
in-lbs (8-9 Nm).
8. Place new mounting gasket in position.
NOTE
If fittings were removed, use TEFLON® PIPE SEALANT or
HYLOMAR® on fitting threads.
9. Secure pump to crankcase with mounting screws.
Tighten to 125-150
in-lbs (14-17 Nm).
10. See Figure 3-119. Attach return line connection.
11. Attach feed line connections to both sides of the oil
pump.
12. Install new oil filter and fill oil reservoir with proper oil.
See 1.6 ENGINE LUBRICATION SYSTEM.
Figure 3-120. Gerotor Wear Limits
b1070x3x
1. Outer gerotor
2. Inner gerotor
3. Wear limit
1
2
3
Figure 3-121. Separator Plate Slots
1
6620
2
3
1. Gerotor separator plate
2. Slot on separator plate
3. Tab on oil pump body
4. O-ring
4