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:
Clutch parts inspection
Refer to “clutch removal” and “clutch installation” .
Clutch drive and driven plate
Note
wipe off the engine oil from the drive and
driven plates with a clean rag.
Measure the thickness of drive plates with a vernier
calipers. If the drive plate thickness is found to have ...
Front brake disc inspection
Brake disc thickness
Check the brake disc for damage or cracks and measure
the thickness using the micrometer.
Replace the brake disc if the thickness is less than the
service limit or if defect is found.
Special tool
(a): 09900–20205 (micrometer (0 –
25 mm))
Brake disc thickness
service ...
Fuel tank cap
To open the fuel tank cap, insert
the ignition key into the lock and
turn it clockwise. With the key
inserted, lift up with the key and
open the fuel tank cap. To close
the fuel tank cap, push the cap
down firmly with the key in the cap
lock.
Fuel level
Fi ller neck
Wa ...