Derbi ATV DXR 200, Workshop Manual

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4-2-1. Engine oil (4-stroke engine oil only) -- refer to part 3-04
4-2-2- Oil Pump/Oil Filter Rotor Removal: (Fig. 4-13) (option) remove the kick lever --- if this
engine has kick
01. disconnect the clutch cable.
02. remove the right crankcase cover bolts and crankcase cover.
03. check any oil leaks or damage from the cover gasket, oil seal, and o-ring, replace the new one if
necessary.
04. remove the 3 screws on oil filter rotor cover Fig. 4-14.
05. remove the washer and oil filter rotor Fig. 4-15.
06. remove the 2 oil pump mounting bolts and oil pump body Fig. 4-16.
07. remove the 2 o-rings Fig. 4-17.
08. check any deformation or damage on o-ring, if so replace it.
CAUTION
BE SURE TO USE THE NEW GASKET WHEN RE-ASSEMBLY.
4-2-3. Oil-pump disassembly and inspection
01. remove the 2 screws Fig. 4-18.
02. measure the clearance of pump body to outer rotor Fig. 4-19.
*service limit: 0.20mm
03. measure the clearance of inner rotor to outer rotor Fig- 4-20.
* service limit: 0.02mm
04, Measure the clearance of rotor end to pump body Fig. 4-21.
*service limit: 0.15mm
4-2-4. Oil-pump reassembly and installation(Fig. 4-22)
The procedure reverses the removal steps:
01. install the outer and inner rotors into pump body Fig. 4-22.
02. put pump shaft by aligning the flat on shaft to inner rotor.
03. put the gasket and pump cover (2). Tighten the screw (3).
04. install the 2 o-rings and tighten the 2 mounting bolts.
05. install the oil pump gear and cover.
06. tighten the 2 bolts.
* torque: 4.0-5.0 kg-m
07. install the oil filter rotor.
08, install the R. crankcase cover.
CAUTION
1. MAKE SURE TO PUT SOME ENGINE OIL BEFORE INSTALL O-RING.
2. MAKE SURE THE WASHER WITH THE MARK “OUTSIDE” FACING UP.