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:
Cam chain tension adjuster inspection
The cam chain tension adjuster is maintained to proper
tension automatically.
Remove the cam chain tension adjuster. Refer to “engine top side
disassembly” .
Holding the cam chain tension adjuster as shown in
the figure, compress the plunger by turning the
adjuster body unt ...
Gearshift shaft oil seal / bearing removal and installation
Removal
Remove the gearshift shaft. Refer to “gearshift shaft / gearshift cam
plate removal and installation” .
Remove the gearshift shaft oil seal (1).
Remove the bearings (2) and (3) with the special
tools.
Special tool
(a): 09921–20210 (bearing remover
(12
mm))
...
Side-stand construction
Frame
Side-stand bracket
Washer
Side-stand
50 N·m (5.0 Kgf-m,
36.0 Lbf-ft)
40 N·m
(4.0 Kgf-m, 29.0 Lbf-ft)
Apply grease to sliding
surface.
...