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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” .

  1. Remove the left side cowling. Refer to “exterior parts removal and installation” in section 9d .
  2.  Drain engine oil and coolant. Refer to “engine oil and filter replacement” in section 0b  and “cooling system inspection” in section 0b .
  3.  Disconnect the water bypass hose (1).
  4. Remove the water pump (2).

Suzuki GSX-R. Removal


Installation

Install the water pump in the reverse order of removal.

Pay attention to the following points:

Caution

replace the o-ring with the a new one.

: Grease 99000–25010 (suzuki
super grease “a” or equivalent)

Suzuki GSX-R. Installation


Tightening torque water pump mounting bolt (a): 10 n·m (1.0 Kgfm, 7.0 Lbf-ft)

Suzuki GSX-R. Installation


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 ...

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 that shows indications of leakage. Oil seal Visually inspect the oil seal for damage, with p ...

Engine top side assembly
Assemble the engine top side in the reverse order of disassembly. Pay attention to the following points: Cylinder head Install the dowel pins and a new cylinder head gasket (1) to the cylinder. Caution use a new gasket to prevent gas leakage. Place the cylinder head ...

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