Suzuki GSX-R 1000 Service Manual: 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 the oil seal and o-ring. If engine coolant is leaking, visually inspect the mechanical seal and seal washer. Refer to “water pump related parts inspection” . |
- Remove the left side cowling. Refer to “exterior parts removal and installation” in section 9d .
- Drain engine oil and coolant. Refer to “engine oil and filter replacement” in section 0b and “cooling system inspection” in section 0b .
- Disconnect the water bypass hose (1).
- Remove the water pump (2).
Installation
Install the water pump in the reverse order of removal.
Pay attention to the following points:
- apply grease to the o-ring.
| Caution replace the o-ring with the a new one. |
: Grease 99000–25010 (suzuki
super
grease “a” or equivalent)
- Install the water pump assembly with the slot of the pump shaft end “a” securely engaged with the flat “b” of the oil pump shaft.
- Tighten the water pump mounting bolts (1) to the specified torque.
Tightening torque water pump mounting bolt (a): 10 n·m (1.0 Kgfm, 7.0 Lbf-ft)
- Connect the water hoses securely. Refer to “water hose routing diagram” .
- Pour engine oil and coolant. Refer to “engine oil and filter replacement” in section 0b and “cooling system inspection” in section 0b (page 0b- 12).
- Bleed air from the cooling circuit. Refer to “cooling system inspection” in section 0b .
Water pump construction
Impeller
Mechanical seal
Oil seal
O-ring
O-ring
8
N·m (0.8 Kgf-m, 6.0 Lbf-ft)
10 N·m
(1.0 Kgf-m, 7.0 Lbf-ft)
Apply grease.
Apply engin ...
Water pump disassembly and assembly
Refer to “water pump removal and installation” .
Disassembly
Remove the air bleeder bolt (1) if necessary.
Remove the water pump case screws.
Remove the o-ring (2).
...
Other materials:
Steering components
Steering stem head nut
Steering stem upper bracket
Steering stem lock-nut
Washer
Steering stem nut
Dust seal cover
Dust seal
Steering stem upper bearing
Steering stem lower bearing
Lower seal
Steering stem lower bracket
Steering stem lo ...
Special tools and equipment
Recommended service material
Note
required service material is also described in the following.
“Rear lighting system construction”
Special tool
...
Wheel balance check and adjustment
Check and adjust the wheel balance in the following
procedures:
removal the wheel assembly. Refer to “front wheel assembly removal and
installation” and “rear wheel assembly removal and installation” .
Remove the mounting drum from the rear wheel.
(For rear wheel) ref ...