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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
Removal Note before draining engine oil and engine coolant, inspect engine oil and coolant leakage between the water pump and crankcase. If engine oil is leaking, visually inspect t ...

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:

Starter motor components
O-ring Housing end (inside) O-ring Starter motor case Armature Housing end (outside) 10 Nm (1.0 Kgf-m, 7.0 Lbf-ft) 4 Nm (0.4 Kgf-m, 3.0 Lbf-ft) 5 Nm (0.5 Kgf-m, 3.5 Lbf-ft) Apply grease to sliding surface Apply moly ...

Tp sensor adjustment
Inspect the tp sensor setting position and adjust it if necessary in the following procedures:  connect the special tool (mode select switch) to the dealer mode coupler. Refer to self-diagnostic procedures in section 1a . Special tool : 0993082720 (mode selection switch) Warn ...

Engine components removable with the engine in place
Engine components which can be removed while the engine is installed on the frame are as follows. For the installing and removing procedures, refer to respective paragraphs describing each component. Center of engine Item Removal Inspection Installation ...

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