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NUMBER: 08 DD15-10 S.M. REF.: 3.2 ENGINE: DD15 DATE: September 2008 SUBJECT: 3.2 OIL PAN PUBLICATION: DDC-SVC-MAN-0002 Oil pan section 3.2 has been updated. Section Change 3.2 Oil Pan Call-outs have been updated. 3.2.1 Removal of Oil Pan Step 1: Open the oil ﬁlter and cap. 188.8.131.52 Cleaning of Oil Pan Step 1: Clean the oil pan and attaching hardware with clean fuel oil or solvent. 3.2.2 Removal of Threaded Insert Section 3.2.2 has been added. 3.2.3 Installation of Threaded Insert Section 3.2.3 has been added. 3.2.4 Installation of Oil Pan Section 3.2.4 has been changed. 3.2 OIL PAN Depending on the manufacturer, the oil pan (2) consists either of glass ﬁber reinforced plastic or aluminum. Sealing of the oil pan (2) takes place using a metal elastomer pre-formed gasket (3) for the aluminum pan or an elastomer gasket for the plastic pan. The oil pan seal has high sealing reliability and noise reduction. The oil pan (2) holds 40 liters of engine oil. In order to determine the engine oil level, there is a conventional oil dipstick. See Figure 1. 1. Bolt and Isolator 12. Bracket 2. Oil Pan 13. Dipstick and Dipstick Tube 3. Gasket 14. Clamp 4. Bolt 15. Adapter 5. Bolt 16. Seal 6. Nut 17. Threaded Insert Connecting Nut 7. Bracket 18. Seal Ring 8. Clamp 19. Threaded Insert 20. Seal Ring 9. Bolt 10. Bolt 21. Drain Plug 11. Bracket
If you're a thrifty soul like I am (notice I didn't say cheap), you'll want to save some dough by doing your oil change yourself. It's really easy, doesn't take a lot of muscle or time, and you can spend what you save by doing it yourself on some toys for your bike. Having previously purchased the Honda Service Manual (I figured it oughta come in handy for more than just an oil change), I purchased my supplies to do my own oil change at 4000 miles. I bought the Honda oil filter wrench because you can put a 3/8" drive ratchet on it to loosen or tighten the filter. It's not cheap, but it's a good one-time investment for your bike. If you've ever changed the oil and filter in a 4-wheel vehicle, it's the same concept, everything's just in a different place. Following the Service Manual, here's what I did. All sections italicized are direct quotes from the Honda Service Manual. NOTE: Change the engine oil with the engine warm and the motorcycle on its side stand to assure complete and rapid draining. Start the engine and let it idle for a few minutes to warm the oil. Remove the oil dipstick. This provides an air gap for the oil to flow freely while draining. Locate the oil drain plug. It is on the left side, at the bottom of the engine. There is not enough space to use a ratchet, so I used a 17mm combination wrench. The open end included in your bike's toolkit will work fine. Loosen the drain plug, then place a drain pan under the drain plug. Remove the drain plug. Let the oil drain into the drain pan. Now the manual states: With the engine stop switch "OFF", push the starter button for a few seconds to drain any oil which may be left in the engine. NOTE: Do not operate the motor for more than a few seconds.
Motor Oil Place the bike on the center stand (not the kick stand) The Drain Plug and the Dipstick for the motor oil are located on the right side of the bike. Place a drain pan under the Drain Plug and remove the plug with a 17mm socket or wrench. Lancepowersports.com A small spring and Screen Type Oil Filter will also pop out. Place these two items off to the side and wash them clean by flushing them with new 10W-40 motor oil. (If you keep the dipstick out of the motor, it will drain the oil faster) Let the motor oil drain until only a few drops fall every few seconds. Put the cleaned Oil Filter and the spring back into the engine as shown to the left. If done incorrectly, the filter will not be efficient in collecting dirt and sludge from the engine. Screw back on the drain plug using a torque wrench. The recommended torque for this bolt is 15 lbs/ft. Lancepowersports.com Using a funnel, pour 0.75 quarts of 10W-40 Motor Oil into the engine. We recommend using non-synthetic oil for the first oil change to help the engine break in properly. After the first oil change, feel free to use synthetic oil. Check the oil with the dipstick. Place the dipstick in the motor but do not screw it in. Pull it out and make sure that the oil reading is within the hash-marks, then add or drain oil accordingly until it is. Screw in the dipstick and run the bike for a minute or two and check the level to make sure that you have the proper level. Lancepowersports.com
e-mail: email@example.com SALES TEAM STOCKS ARE LIMITED GERSON EXT 213/214 PLEASE PHONE (011)334-1031 SHERAZ EXT 212/202 FOR BEST PRICING ANDRE EXT 216 FAX (011)334-0921 KEN EXT 215 101.001 SLEEVE SEALS BLACK 1.9/2.1 101.004 CAMSHAFT OIL SEAL GOLF/ JETTA 101.005 REAR MAIN OIL SEAL FLANGE MK1/2 101.007 GOLF 4 SEAL FLANGE CRANKSHAFT 101.021 REAR OIL SEAL + FLANGE MK1/2/3/POLO 102.035 THERMOSWITCH GOLF2 103.035 F/INJ BREATHER PIPE GROMMET GOLF/ JETTA 103.039 GOLF/ JETTA CYL.HEAD GASKET 1.6/1.8 103.041 CYL HEAD GASK -T/PORTER 2.5 - 103.042 GOLF 3/POLO RUBBER T/GASKET 103.046 SUMP GASKET RUBBER MK 1/2/3/POLO 103.048 GOLF/ JETTA TAPPET COVER GASKET 103.054 UNIVERSAL WALSH PLUG 36.6MM 103.065 POLO BARE CYCLINDER HEAD 103.072 1.9 TDI /POLO RUBBER TAP.GASKET 103.073 GOLF 4 1.9 TDI TAPPET GASKET EARLY 103.074 POLO 1.4 TAPPET COVER GASKET 103.076 GOLF 2.0 CYL HEAD GASKET METAL 103.663 AUDI A4 DIPSTICK FUNNEL GUIDE LONG 103.664 MK4 POLO CRANKSHAFT GEAR 103.666 D/STICK GUIDE LONG 104.057 GOLF OIL CAP 104.062 OIL FILTER W/ RELIEF VALVE - GOLF 104.063 DIPSTICK - GOLF 105.067 GOLF SUMP PLUG BOLT 105.902 GOLF 4 TDI /GTI OIL SUMP W/SENSOR HOLE 106.073 CRANKSHAFT TIMING GEAR GOLF/ JETTA/ AUDI 106.074 GOLF 1/2/3 TAPPET COVER 107.084 AUDI 500 / A6 TENSIONER 107.085 GOLF 4/AUDI A3/A4 1.6 & 2L TENSIONER 107.087 FAN BELT TENSIONER GOLF 3 107.088 UPPER CAMBELT COVER GOLF/ JETTA 107.089 LOWER CAMBELT COVER GOLF/ JETTA 107.094 CAMBELT TENSIONER MK 4/PASSAT 1.9TDI (AFN MOTORS ONLY) 107.096 TENSIONER ALT. PWR ST. BELT POLO 1.4/1.6 / CADDY 107.098 VR6 TENSIONER DAMPER 107.100 GOLF 4/POLO ROLLER TIMING BELT 107.101 POWER STEERING PUMP PULLEY GOLF 2 107.103 CAMBELT VIBRATION DAMPER EARLY 107.104 AUDI A4/A6 CAMBELT TENSIONER V6 MULTI VALVE 97 UP 107.105 AUDI A4 VIBRATION DAMPER 107.106 ROLLER CAMBELT GOLF MK 4/PASSAT 1.9TDI (AFN MOTORS ONLY) 107.900 ROLLER + BRACKET TOP POLO 1.4 16 VALVE TOP 107.902 CAMBELT TENSIONER AUDI A4 107.903 TENSIONER AUDI A4 ENGINE CODE AEB 107.907 TDI ALL TEN.ROLLER LATE 107.908 POLO 1.4 DAMPER TENSIONER 107.909 AUDI A4 TEN.ROLLER 109.103 1800 KOMBI OIL PUMP 109.104 OIL PUMP GOLF 8 VALVE (ROP83030/OP250) 109.109 KOMBI 2.5 OIL PUMP (ROP83048) 109.200 AUDI A3 CHAIN TENSIONER 111.112 MK3 FLANGE BLOCK OFF 111.114 WATER METAL PIPE FUEL INJ. MK3 111.117 GOLF THERMOSTAT 111.118 MK.3 CYL.HEAD FLANGE 111.118x WATER FLANGE GOLF3/ GOLF 4 & POLO (MILLENIUM) 111.119 MK 1/2 CYL HEAD FLANGE 111.121 WATER BOTTLE CAP KOMBI W/PIPE
PLASTIC RADIATOR FAN SHROUD: The fan will hit the lower portion of the fan shroud. Before starting installation, Remove the 4 screws that hold the fan shroud to the radiator allowing the fan shroud to be lowered once body lift is completed. Make sure fan is clear of fan shroud before beginning. See instruction No. 12. 2. Loosen body mount bolts on one side of vehicle and remove bolts from opposite side using a 5/8” socket for positions 1,5 and 6 (ref. Fig.1 on page 2) and a ¾” socket for positions 2, 3 and 4. Use a long extension to remove mounts next to gas tank. Place 2x4 between jack and body to spread out load and jack up body on the side you have removed the bolts from just far enough to remove mounts. The bolts on the opposite side will help ensure that the body does not shift. CAUTION: Open Hood while jacking up the body to make sure that the fan doesn’t hit the shroud. Also, watch that hoses and wires are not stretched. The dip-stick head can be B pinched so remove dipstick while doing installation. When lifting the side of the vehicle that the fuel filler is on, keep a close eye not to stretch, tear or pull too far on the hose connection.) Remove factory mounts one at a time and remove stock steel insert. View A. Insert stock steel inserts inside top portion of body lift spacer in positions 2-6. (Note:If it fits tight, you may have to use a vise.) See View B. Insert 7/8” OD x 1” long tube (Part No S10281 Included in kit) into lower portion of body lift spacer in positions 2-6 and insert steel sleeve (Part No. S10012 Included in kit) in position #1. (This tube/sleeve is a crush sleeve to eliminate over-torque of polyurethane mounts) Jack up the body using a 2x4 under one side of the body for support just high enough to insert...
TROUBLESHOOTING CONDITION Low oil warning light stays on: ACTION Check oil level. Check for leaks. If the problem persists, visit your Toyota Dealer Service Department for diagnosis and repair. DO NOT DRIVE THE VEHICLE IF NO OIL IS VISIBLE ON THE DIPSTICK OR IF THE OIL WARNING LIGHT STAYS ON. There is an odor of hot motor oil: The "Check Engine" light comes on: Check for oil leaks or spills. Some oil may have spilled on the engine or exhaust. Wait until the engine or exhaust cools, then wipe off the excess oil with a rag. The remaining damp area should dry as the engine or exhaust warms up and the oil evaporates. If the oil spot or oil spill reappears, oil is leaking and other maintenance or repair is needed. Take the vehicle to your Toyota Dealer Service Department for diagnosis and repair. Please refer to the following sources for additional information: • • • • Your vehicle’s Owner’s Manual Your vehicle’s Repair Manual Genuine Toyota Motor Oil Brochure Genuine Toyota Oil Filter Brochure
Engine Oil Level This single cylinder engine is a wet-sump engine, meaning the oil is contained in the bottom of the crankcase. To check the oil level follow the procedure listed below: 8. Unscrew and remove dipstick and check to see that the oil level is in the SAFE ( XX) range. Add oil as indicated by the level on the dipstick. Do not overfill (see NOTE below!). 1. Position vehicle on a level surface. 2. Place the transmission in Park (P). 3. Be sure engine OFF has not been run for at lease 3 minutes. IMPORTANT: Do not run the machine and then immediately check the dipstick. 4. Locate the engine oil dipstick: • RZR 570 - Located on the RH side of the engine case; accessible through the RH rear wheel well area. Maintain Oil Level In SAFE Range DO NOT Overfill the Engine NOTE: A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase. If the oil level is over the full mark, change the oil immediately. 9. Reinstall the dipstick and hand tighten. Engine Oil and Filter Service Always change engine oil and filter at the intervals outlined in the Periodic Maintenance Chart. Always change the oil filter whenever changing the engine oil. IMPORTANT: Thoroughly clean engine around the oil drain plug, oil filter and oil dipstick to prevent contamination from entering the engine. WARNING 5. Be sure to clean area around dipstick to ensure no dirt / debris falls into the dip stick hole. 6. Unscrew and remove dipstick and wipe dry with a clean cloth. 7. Reinstall the dipstick completely. NOTE: Make certain the dipstick is threaded all the way into the engine case. Personal injury can occur when handling used oil. Hot oil can cause burns or skin damage. Recommended Engine Oil: PS-4 Plus Synthetic 4-Cycle Engine Oil (PN 2876244) (Quart) 1. Position vehicle on a level surface. 2. Place the transmission in PARK (P). 3. Start the engine. Allow it to idle for two to three minutes until warm. Stop the engine. NOTE: Drain plug is accessed through...
Draining Oil S Start engine and run until warm. Stop engine. Disconnect spark plug wires to prevent accidental starting. S Remove oil drainplug and capture waste oil in an approved container. Dispose of waste oil properly, see Fig. 1, when completed, tighten plug. S Replace oil filter every 100 hours of operation. Before installing new oil filter, lightly oil filter gasket with fresh, clean engine oil. Screw filter on by hand until gasket contacts filter adapter. Tighten 1/2 to 3/4 turn, see, Fig. 2. Replace and Install Foam Pre-Cleaner if equipped and Paper Cartridge Air Filter S Clean air filter assembly parts. If your kit contains Briggs & Stratton paper cartridge part #693141. You can extend the replacement of the air cleaner cartridge to 100 hours of operation, unless operating under dusty conditions. A precleaner is not required for use with this paper cartridge. S Make sure cover is properly installed before starting engine. S Use Briggs & Stratton certified SAE 30 oil, part number 100028, 48 oz. (1.418 liters) or 100005, 20 oz. (.6 liters). A S Start engine and run for five minutes. Shut down engine and recheck oil level on dipstick after engine cools for five minutes. (Wipe dipstick before checking oil.)
This document is protected by copyright and may not, in whole or part be stored in a retrieval system, or transmitted in any form or by any means, copied, photocopied, translated or reduced to any machine-readable form without prior consent in writing from Triumph Motorcycles Limited. No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible. Triumph Motorcycles Limited reserves the right to make changes and alter specifications without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your authorised Triumph dealer for the latest information on product improvements incorporated after this publication. All information contained in this publication is based on the latest product information available at the time of publication. Illustrations in this publication are intended for reference use only and may not depict actual model component parts. Engine and Lubrication Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Semi or fully synthetic 10W/40 or 10W/50 engine oil which meets specification API SH (or higher) and JASO MA. Triumph recommends Castrol Power 1 Racing 4T 10W/40 or 10W/50 (fully synthetic) engine oil, sold as Castrol Power RS Racing 4T 10W/40 or 10W/50 (fully synthetic) in some countries Fill quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 litres (oil and filter change). Always refer to the dipstick/filler cap markings for correct level
Tools and Materials As far as tools go, you will need an assortment of flat and Philips-head screwdrivers, a clean rag, a 14mm socket and suitable ratchet and extension bar (if you plan to remove a front seat), a pair of wire cutters and strippers, a drill, a jigsaw, a rotary tool (commonly referred to as a “Dremel”) with a cylindrical sanding attachment and small grinding attachment, and a long stiff piece of wire or a narrow rod such as a straightened-out coat-hanger or an old dipstick. Other household tools like a knife and pliers are also handy. The materials you will need include a sheet of 5mm MDF board (at least 40cm x 20cm), a pair of 6.5” x 15mm MDF speaker spacer rings from your local Figure 3 – My aftermarket 6.5” woofer, 1” tweeter, and car audio shop (or a sheet of 15mm MDF to make crossover across the top row, and stock tweeter and your own rings, at least 40cm x 20cm), some woofer below on the bottom row. contact cement, speaker wire, and a can of cheap spray-paint (colour doesn’t matter, but I used matt black). The amount of speaker wire depends on whether you intend to re-use any of the existing factory speaker wire, and where you intend to install your Crossovers and Amplifier. I purchased about 15m of oxygen-free speaker wire from Dick Smith (at about AU$1.55/m) which has a considerably thicker core than the thin wire supplied with the New Speakers, yet isn’t so thick that it’s expensive or difficult to work with. I don’t want to start a debate on the merits of various speaker wires though, so you choose whatever you feel happy with. I found 15m to be just about the right total length of wire for my install, but it’s worth being careful before cutting it (i.e. don’t just cut it into 4 equal lengths, remember that the wiring will likely be longer on one side of the car than the other and measure first).