Suzuki GSX-R 1000 Service Manual: Water pump disassembly and assembly

Refer to “water pump removal and installation” .

Disassembly

1. Remove the air bleeder bolt (1) if necessary.

2. Remove the water pump case screws.

3. Remove the o-ring (2).

4. Hold the impeller (3) with water pump pliers and remove the impeller securing bolt (4).
5. Remove the impeller (3).

6. Remove the mechanical seal ring (5) and rubber seal (6) from the impeller.

7. Remove the o-ring (7), impeller shaft (8) and washer (9) from the holder.

8. Remove the mechanical seal (10) with the special tool.

Special tool (a): 09921–20240 (bearing remover
set)

9. Remove the oil seal (11).

Assembly

1. Install the oil seal with the special tool.

Special tool (a): 09913–70210 (bearing
installing set (10 – 75 ö))

2. Apply a small quantity of the grease to the oil seal lip.

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

3. Install a new mechanical seal using a suitable size socket wrench.

4. Apply molybdenum solution to the impeller shaft (1) and washer (2).

M/o: molybdenum oil (molybdenum oil solution)

5. Install the impeller shaft (1) and washer (2) to the holder.

6. Install the rubber seal (3) into the impeller.
7.  After wiping off the oily or greasy matter from the mechanical seal ring (4), install it into the impeller.

8. Install the washer (5) and seal washer (6) onto the impeller securing bolt.

9. Install the impeller (7).
10. Hold the impeller with water pump pliers and tighten the impeller securing bolt to the specified torque.

Tightening torque impeller securing bolt (a): 8 n·m (0.8 Kgf-m, 6.0 Lbf-ft)

11. Install new o-ring (8) and apply engine coolant to it.

12. Tighten the water pump case screws to the specified torque.

Tightening torque water pump case screw: 6 n·m (0.6 Kgf-m, 4.5 Lbf-ft)

13. Tighten the water pump air bleeder bolt (9) to the specified torque.

Tightening torque water pump air bleeder bolt (b): 13 n·m (1.3 Kgfm, 9.5 Lbf-ft)