Kawasaki Z1000SX - Service manual > Water Pump

Water Pump Removal

• Drain:
  Coolant (see Coolant Change in the Periodic Maintenance chapter)
  Engine Oil (see Engine Oil Change in the Periodic Maintenance chapter)
• Remove:
  Left Lower Fairing (see Lower Fairing Removal in the Frame chapter)
  Engine Sprocket Cover (see Engine Sprocket Cover Removal in the Final Drive chapter)
• Remove the water pipe bolts [A] to pull out the water pipes [B] from the water pump cover.
• Disconnect the neutral switch connector [C].
• Loosen the clamp bolt [D] to remove the water hose [E].

• Remove:
  Water Pump Cover Bolts [A]
  Water Pump Cover [B]

• Remove:
  Water Pump Impeller Bolt [A] and Washer
  Water Pump Impeller [B]
  Water Pump Housing [C]

Water Pump Installation

• Replace the O-ring [A] with a new one, and install it.

• Be sure to install the dowel pins [A].

• Install:
  Water Pump Housing [A]
  Water Pump Impeller [B]
• Tighten:
  Torque - Water Pump Impeller Bolt [C]: 9.8 N*m (1.0 kgf*m, 87 in*lb)
• Be sure to install the dowel pins [D].

• Replace the O-ring [A] with a new one, and install it.

• Install the water pump cover [A].
• Tighten:
  Torque - Water Pump Cover Bolts [B]: 11 N*m (1.1 kgf*m, 97 in*lb)
• Replace the O-ring [C] with new ones.

• Install the water pipes [A] to the water pump cover.
• Apply a non-parmanent locking agent to the threads of the water pipe bolts [B], and tighten them.

  Torque - Water Pipe Bolts: 12 N*m (1.2 kgf*m, 106 in*lb)

• Install the water hose [C].
• Tighten:
  Torque - Water Hose Clamp Screw [D]: 2.9 N*m (0.30 kgf*m, 26 in*lb)
• Connect the neutral switch connector [E].

Water Pump Inspection

• Remove the left lower fairing (see Lower Fairing Removal in the Frame chapter).
• Check the drainage outlet passage [A] at the bottom of the water pump body for coolant leaks.

  If the mechanical seal is damaged, the coolant leaks through the seal and drains through the passage. Replace the mechanical seal un

Water Pump Impeller Disassembly/Assembly

• Remove the water pump impeller (see Water Pump Removal).
• The sealing seat and rubber seal may be removed easily by hand.
• Apply coolant around the surfaces of the rubber seal and sealing seat.
• Install the rubber seal [A] and sealing seat [B] into the impeller by pressing them by hand until the seat stops at the bottom of the hole.
• Install the water pump impeller (see Water Pump Installation).

Water Pump Impeller Inspection

• Remove the water pump cover (see Water Pump Removal).
• Visually inspect the water pump impeller [A].

  If the surface is corroded or if the blades are damaged, replace the impeller.

Water Pump Housing Disassembly

NOTICE Do not damage the hole wall of the water pump housing.

• Insert a bar [A] into the pump housing [B], and hammer evenly around the circumference of the mechanical seal bottom [C].

• Take the oil seal [A] out of the housing [B] with a hook [C].

Water Pump Housing Assembly

NOTICE Do not reuse the mechanical seal and oil seal.

• Apply high-temperature grease to the oil seal lips [A].
• Press the new oil seal into the housing with a bearing driver [B] until it stops at the bottom surface [C] of the housing.

  Special Tool - Bearing Driver Set: 57001-1129

NOTICE Be careful not to damage the sealing surface of the mechanical seal.

• Press the new mechanical seal into the housing with the oil seal driver [A] until its flange [B] touches the surface [C] of the housing.

  Special Tool - Oil Seal Driver: 57001-1660

Mechanical Seal Inspection

• Remove the water pump impeller (see Water Pump Removal).
• Visually inspect the mechanical seal.

  If any one of the parts is damaged, replace the mechanical seal as a unit.

  Impeller Sealing Seat Surface [A]
  Rubber Seal [B]
  Mechanical Seal [C]

See also: