Water Pump Removal
- Drain the coolant (See Coolant Change in the Periodic Maintenance chapter).
Remove:
- Radiator Hose [A]
- Water Pump Cover Bolts [B]
- Right Lower Fairing Bracket [C]
- Water Pump Cover [D]
![](https://motoinstruction.ru/img/kawasaki/23/128401.jpg)
- Shift the transmission into 1st gear.
- While applying the rear brake, remove the water pump impeller bolt [A].
Remove:
- Impeller [B]
- Water Pump Housing [C]
![](https://motoinstruction.ru/img/kawasaki/23/128402.jpg)
Water Pump Installation
- Replace the O-rings [A] on the water pump housing with new ones and apply grease them.
- Apply high-temperature grease to the lips of the water pump housing oil seal [B].
![](https://motoinstruction.ru/img/kawasaki/23/128403.jpg)
- Be sure that the dowel pin [A] is in position.
- Install the water pump housing.
- When installing the water pump impeller bolt, shift the transmission into 1st gear and apply the rear brake.
Tighten:
Torque - Water Pump Impeller Bolt: 9.8 Nm (1.0 kgf·m, 87 in·lb)
![](https://motoinstruction.ru/img/kawasaki/23/128404.jpg)
- Replace the O-ring [A] on the water pump cover with a new one and grease it.
![](https://motoinstruction.ru/img/kawasaki/23/128405.jpg)
- Install the water pump cover, being careful of the two dowel pins [A].
- Install the right lower fairing bracket and tighten the water pump cover bolts.
Torque - Water Pump Cover Bolts: 9.8 Nm (1.0 kgf·m 87 in·lb)
![](https://motoinstruction.ru/img/kawasaki/23/128406.jpg)
Mechanical Seal Inspection
- Remove the 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.
The sealing seat and rubber seal may be removed easily by hand.
- Impeller Sealing Seat Surface [A]
- Rubber Seal [B]
- Mechanical Seal Diaphragm [C]
- Align the line [A] of the water pump cover and the red mark [B] of the radiator hose [C].
![](https://motoinstruction.ru/img/kawasaki/23/128407.jpg)
![](https://motoinstruction.ru/img/kawasaki/23/128408.jpg)
- Install the radiator hose clamp [A] as shown.
Tighten:
Torque - Radiator Hose Clamp Screws: 2.0 N·m (0.20 kgf·m, 18 in·lb)
- Fill the radiator with the coolant (See Coolant Change in the Periodic Maintenance chapter).
![](https://motoinstruction.ru/img/kawasaki/23/128409.jpg)
Water Pump Housing Disassembly
Caution: Be careful not to damage the sealing surface of the mechanical seal.
- Remove the water pump housing (See Water Pump Removal).
- Take the oil seal [A] out of the housing [B] with a hook [C].
![](https://motoinstruction.ru/img/kawasaki/23/128410.jpg)
- Press the mechanical seal [A] out of the housing with a bearing driver [B].
Special Tool - Bearing Driver Set: 57001-1129
![](https://motoinstruction.ru/img/kawasaki/23/128411.jpg)
Water Pump Housing Assembly
- Apply high-temperature grease [A] to the new oil seal [B].
- Press the oil seal into the housing with a bearing driver so that the seal surface is flush [C] with the end of the hole.
Apply a soap and water solution or rubber lubricant to the outer circumference [D] of the oil seal so that it will go into place smoothly.
- Press the new mechanical seal into the housing with the oil seal driver [E] until its flange [F] touches the surface [G] of the housing.
Special Tool - Oil Seal Driver: 57001-1660
![](https://motoinstruction.ru/img/kawasaki/23/128412.jpg)
Impeller Assembly
- Clean the sliding surface of the mechanical seal with a high-flash point solvent, and apply a little coolant to the sliding surface to give the mechanical seal initial lubrication.
- Apply coolant to the surfaces of the rubber seal [A] and sealing seat [B], and install the rubber seal and sealing seat into the impeller by pressing them by hand until the seat stops at the bottom of the hole.
![](https://motoinstruction.ru/img/kawasaki/23/128413.jpg)
Pump Impeller Inspection
- Remove the water pump cover (See Water Pump Removal).
- Visually check the impeller [A].
If the surface is corroded, or if the blades are damaged, replace the impeller (See Water Pump Removal).
![](https://motoinstruction.ru/img/kawasaki/23/128414.jpg)