Section 11 LUBRICATION SYSTEM (2-STROKE)
Subsection 02 (OIL INJECTION SYSTEM)
11-02-4 SMR2003-033_11_02A.FM
GENERAL
Whenever repairing the oil injection system, al-
ways verify for water infiltration in reservoir.
Also pressure test the oil injection system.
All Models except the XP DI
Clamp and Hose
Verify oil filler neck hose no. 2 for damage. Always
ensure that clamps no. 1 are well positioned and
tightened. Torque clamps to 3.5 N•m (31 lbf•in).
All Models
Check Valve
Black side of the one-way check valve no. 3 is the
valve outlet. It allows air to get in reservoir.
Oil Filter
Oil filter no. 4 should be replaced annually.
OIL SYSTEM PRESSURIZATION
Pressure Test
Proceed as follows:
– Fill up oil reservoir.
– Install a hose pincher to rotary valve shaft oil
supply hose (except 947 engines).
– Install a hose pincher to rotary valve shaft oil
return hose (except 947 engines).
– Install a hose pincher to oil injection pump sup-
ply hose.
DI Models
Install a hose pincher to compressor return line air.
Disconnect oil tank vent line on PTO side throttle
body.
Carburetor-Equipped Models
Connect pump gauge tester (P/N 529 021 800) to
oil injection reservoir vent check valve.
DI Models
Connect pump gauge tester (P/N 529 021 800) to
disconnected tube at throttle body.
All Models
NOTE: Use the same pump included in the EN-
GINE LEAK TESTER KIT (P/N 295 500 352).
TYPICAL
1. Connect pump to check valve
– Pressurize oil system to 21 kPa (3 PSI).
All Models
– If pressure is not maintained, locate leak and
repair/replace component leaking. To ease leak
search spray a solution of soapy water on compo-
nents, bubbles will indicate leak location.
DI Models
Verify check valve inside filler neck (inside vent
adapter on XP DI) if pressure does not hold. Also
ensure air can enter through check valve in the
opposite direction.
All Models
NOTE: The system must maintain a pressure of
21 kPa (3 PSI) for at least 10 minutes. Never pres-
surize over 21 kPa (3 PSI).
CAUTION: If any leak is found, do not start the
engine and wipe off any oil leakage.
Disconnect pump gauge tester and remove hose
pinchers. On DI models, reconnect line at throttle
body.
WARNING
Whenever oil system components are dis-
connected or replaced, a pressure test must
be done before starting engine. Ensure to ver-
ify oil line ends for damage. Always cut dam-
aged end before reinstallation.
1
F01G0IA
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