Removal and disassembly
Drain the engine coolant. (2-18)
Drain the engine oil. (2-13)
Disconnect the water hoses (1), (2).
Remove the water pump case and clutch cover. (3-27)
Note: Before draining engine oil and engine coolant, inspect engine oil and coolant leakage between the water pump and clutch cover. 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 ring. (6-16)
Remove the snap ring and water pump driven gear (3).
Remove the pin (4) and washer (5).
Remove the water pump (6) from the clutch cover.
Remove the screws and separate the water pump.
Remove the O-rings (7).
Remove the E-ring from the impeller shaft.
Remove the impeller from the other side.
Remove the mechanical seal ring (5) and rubber seal (6) from the impeller.
Remove the bearings with the special tool.
- 09921-20240: Bearing remover set (10 mm)
Note: If there is no abnormal noise, bearings removal is not necessary.
Caution! The removed bearings must be replaced with the new ones.
Remove the mechanical seal and oil seal with the special tool.
- 09913-70210: Bearing installer set (∅20 mm)
Note: If there is no abnormal condition, the mechanical seal and the oil seal removal is not necessary.
Caution! The removed mechanical seal and oil seal must be replaced with a new one.
Inspection
Bearing
Inspect the play of the bearing by hand while it is in the water pump case.
Rotate the inner race by hand to inspect for abnormal noise and smooth rotation.
Replace the bearing if there is anything unusual.
Mechanical seal
Visually inspect the mechanical seal for damage, with particular attention given to the sealing face.
Replace the mechanical seal that shows indications of leakage. Also replace the seal ring if necessary.
Oil seal
Visually inspect the oil seal for damage, with particular attention given to the lip.
Replace the oil seal that shows indications of oil leakage.
Bearing case
Visually inspect the bearing case for damage.
Replace the water pump body if necessary.
Reassembly and installation
Install the oil seal with the special tool.
- 09913-70210: Bearing installer set (∅22 mm)
Note: The stamped mark on the oil seal faces impeller side.
Apply a small quantity of the SUZUKI SUPER GREASE to the oil seal lip.
- 99000-25030: SUZUKI SUPER GREASE "A" (USA)
- 99000-25010: SUZUKI SUPER GREASE "A" (Others)
Install the new mechanical seal with the special tool.
- 09913-70210: Bearing installer set (∅25 mm)
Install the new bearings with the special tool.
- 09913-70210: Bearing installer set (∅25 mm)
Note: The stamped mark on the bearing faces to the crankcase side.
Install the rubber seal (1) into the impeller.
After wiping off the oily or greasy matter from the mechanical seal ring, install it into the impeller.
Note: The paint marked side (A) of the mechanical seal ring faces to the impeller.
Apply SUZUKI SUPER GREASE to the impeller shaft.
- 99000-25030: SUZUKI SUPER GREASE "A" (USA)
- 99000-25010: SUZUKI SUPER GREASE "A" (Others)
Install the impeller to the water pump body.
Fix the impeller shaft with the E-ring (2).
Apply SUZUKI SUPER GREASE to the O-rings.
- 99000-25030: SUZUKI SUPER GREASE "A" (USA)
- 99000-25010: SUZUKI SUPER GREASE "A" (Others)
Install new O-rings (3).
Fill the bearing with engine oil until engine oil comes out from the hole of the be bearing housing.
Apply engine coolant to the O-ring (4).
Install a new O-ring.
Caution! Use a new O-ring to prevent engine coolant leakage.
Connect the water hoses.
Pour engine coolant. (2-18)
Pour engine oil. (2-14)