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:
Crankcase breather (pcv) cover inspection
Inspect the crankcase breather (pcv) cover in the
following procedures:
remove the crankcase breather (pcv) cover. Refer to “crankcase breather
(pcv) hose / reed valve / cover removal and installation” .
Inspect the crankcase breather (pcv) cover for
carbon deposit. If carbon ...
Throttle body construction
Intake pipe
Evap system purge control solenoid valve
(e-33 only)
Evap canister (e-33 only)
Iat sensor
Isc valve hose
Ho2 sensor
Face
the clamp end left side.
Yellow
marking should face upward.
Face the
end of clamps upward and ke ...
Ecm removal and installation
Removal
Remove the frame covers. Refer to “exterior parts
removal and installation” in section 9d (page 9d-
6).
Disconnect the battery (–) lead wire.
Remove the tool set (1) and prop stay (2).
Disconnect the hose clamp (3) (e-33 only) and
starter relay (4).
Remo ...