SCREEN
PUMP
BEDPLATE
DRIVE GEAR
SNAP RING
(CHAMFER
FACES OUT)
RETAINING CAP
O--RINGS
OUTER ROTOR
INNER ROTOR
TIMING ROTOR
ENGINE DISASSEMBLY / ASSEMBLY
4.66
2004 Four Stroke PWC Service Manual
Crankcase Ven t ilatio n
Engine blow--by is recovered via the oil separator or cyclone. The oil separator is located on the oil storage tank.
Engine oil and fuel vapors are collected in the top housing of the oil storage tank. These vapors are routed to
the separator. Heavy elements such as oil and unburned fuel are collected at the bottom of the separator and
are routed back to the crankcase sump. The remaining vapors are collected at the top of the separator and routed
to the air intake flame arrestor where they are drawn into the intake air stream and burned.
Crankcase Ven t ilatio n Circuit
OIL STORAGE
TANK
OIL
SEPARATOR
CRANKCASE
SUMP
FLAME ARRESTOR
Low Pressure Pump Removal / Installation
NOTE: The engine must be removed to access the low pressure pump.
1. Remove the crankcase bedplate from the lower
crankcase.
2. Remove the fasteners securing the screen to the
bedplate and pump.
3. Remove the pump from the bedplate.
NOTE: The low pressure pump is not serviceable
and must be replaced as one component is when
operation is suspect.
High Pressure Pump Removal / Installation
NOTE: The engine must be removed to access the high pressure pump.
1. Remove snap ring. Carefully extract rotor cover from
crankcase.
2. Extract outer and inner rotors from bore. Remove
timing rotor from shaft.
3. Carefully remove timing key.
NOTE: Always use a new timing key and o rings
during pump assembly.
NOTE: V erify snap ring bevel faces outward.
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