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Suzuki GSX-R 1000 Service Manual: Water pump disassembly and assembly

Refer to water pump removal and installation .

Disassembly

  1. Remove the air bleeder bolt (1) if necessary.

Suzuki GSX-R. Disassembly


  1. Remove the water pump case screws.

Suzuki GSX-R. Disassembly


  1. Remove the o-ring (2).

Suzuki GSX-R. Disassembly


  1. Hold the impeller (3) with water pump pliers and remove the impeller securing bolt (4).
  2. Remove the impeller (3).

Suzuki GSX-R. Disassembly


  1. Remove the mechanical seal ring (5) and rubber seal (6) from the impeller.

Suzuki GSX-R. Disassembly


  1. Remove the o-ring (7), impeller shaft (8) and washer (9) from the holder.

Suzuki GSX-R. Disassembly


  1. Remove the mechanical seal (10) with the special tool.
Note

if there is no abnormal condition, the mechanical seal removal is not necessary.

Special tool (a): 0992120240 (bearing remover
set)

Suzuki GSX-R. Disassembly


  1. Remove the oil seal (11).
Note

if there is no abnormal condition, the oil seal removal is not necessary.

Suzuki GSX-R. Disassembly


Assembly

  1. Install the oil seal with the special tool.
Caution

the removed oil seal must be replaced with a new one.

 

Note

the stamped mark on the oil seal should face mechanical seal side.

Special tool (a): 0991370210 (bearing
installing set (10 75 ö))

Suzuki GSX-R. Assembly


  1. Apply a small quantity of the grease to the oil seal lip.

: Grease 9900025010 (suzuki
super grease a or equivalent)

Suzuki GSX-R. Assembly


  1. Install a new mechanical seal using a suitable size socket wrench.
Caution

the removed mechanical seal must be replaced with a new one.

 

Note

on new mechanical seals, the sealer a has been applied.

Suzuki GSX-R. Assembly


Suzuki GSX-R. Assembly


  1. Apply molybdenum solution to the impeller shaft (1) and washer (2).

M/o: molybdenum oil (molybdenum oil solution)

  1. Install the impeller shaft (1) and washer (2) to the holder.

Suzuki GSX-R. Assembly


  1. Install the rubber seal (3) into the impeller.
  2.  After wiping off the oily or greasy matter from the mechanical seal ring (4), install it into the impeller.
Note

the paint marked side b of mechanical seal ring faces the rubber seal.

Suzuki GSX-R. Assembly


  1. Install the washer (5) and seal washer (6) onto the impeller securing bolt.
Note

the metal side c of seal washer and the curved side d of washer face the impeller securing bolt head.

Suzuki GSX-R. Assembly


  1. Install the impeller (7).
  2. Hold the impeller with water pump pliers and tighten the impeller securing bolt to the specified torque.

Tightening torque impeller securing bolt (a): 8 nm (0.8 Kgf-m, 6.0 Lbf-ft)

Suzuki GSX-R. Assembly


  1. Install new o-ring (8) and apply engine coolant to it.
Caution

use a new o-ring to prevent engine coolant leakage.

  1. Tighten the water pump case screws to the specified torque.

Tightening torque water pump case screw: 6 nm (0.6 Kgf-m, 4.5 Lbf-ft)

Suzuki GSX-R. Assembly


  1. Tighten the water pump air bleeder bolt (9) to the specified torque.
Caution

use a new gasket washer to prevent engine coolant leakage.

Tightening torque water pump air bleeder bolt (b): 13 nm (1.3 Kgfm, 9.5 Lbf-ft)

Suzuki GSX-R. Assembly


Water pump removal and installation
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Water pump related parts inspection
Refer to water pump disassembly and assembly . Mechanical seal Visually inspect the mechanical seal for damage, with particular attention given to the sealing face. Replace the mechanical seal ...

Other materials:

Oil cooler / oil cooler hose inspection and cleaning
Refer to exterior parts removal and installation in section 9d . Oil cooler hose inspection Inspect the oil cooler hoses for any damage and oil leakage. If any defects are found, replace the oil cooler hose with a new one. Oil cooler inspection Remove the oil cooler guard (1). ...

Rear brake light switch inspection
Inspect the rear brake light switch in the following procedures:  lift and support the fuel tank. Refer to fuel tank removal and installation in section 1g (page 1g- 9).  Disconnect the rear brake light switch lead wire coupler (1). Inspect the rear brake light swi ...

Serial number location
You need to know the frame and engine serial numbers to get title documents for your motorcycle. You also need these numbers to help your dealer when you order parts. The frame number 1 is stamped on the steering head as shown in the illustration. The engine serial number 2 Is stamped ...

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