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 components
Clutch pressure plate
Clutch push piece
No. 1 Drive plate (8 pcs.)
No. 3 Driven plate (0 – 2 pcs.)
No. 1 Driven plate (5 – 7 pcs.)
No. 2 Driven plate (1 pc.)
No. 2 Drive plate (1 pc.)
Spring washer
Spring washer seat
Clutch sleeve hub
Seat ...
Rear wheel components
Rear axel nut
Collar
Dust seal
Bearing
Retainer
Rear sprocket
Sprocket mounting drum
Wheel damper
Bearing
Spacer
Air valve
Rear wheel
Wheel balancer
Rear tire
Dust seal
Collar
Rear brake disc
Rear axle
1 ...
Air bleeding from brake fluid circuit
Air trapped in the brake fluid circuit acts like a cushion to
absorb a large proportion of the pressure developed by
the master cylinder and thus interferes with the full
braking performance of the brake caliper. The presence
of air is indicated by “sponginess” of the brake lever and
also by la ...