Kawasaki J300 - Service manual > Water Pump

Water Pump Cover Removal

• Drain the coolant (see Coolant Change in the Periodic Maintenance chapter).
• Remove:
  Right Lower Fairing (see Lower Fairing Removal in the Frame chapter)
  Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top chapter)
• Loosen the water hose clamp screw and disconnect the water hose [A].
• Open the water hose clamp and disconnect the water bypass hose [B].
• Remove:
  Water Pump Cover Bolts [C]
  Water Pump Cover [D] and Gasket

Water Pump Cover Installation

• Replace the water pump cover gasket with a new one.
• Install the dowel pins [A] and new gasket are in place.
• Install the water pump cover and tighten its bolts.
• Install the water hoses.
• Tighten:
  Torque - Water Hose Clamp Screw: 4.4 N*m (0.45 kgf*m, 39 in*lb)
• Install the removed parts (see appropriate chapters).
• Fill the cooling system with the coolant (see Coolant Change in the Periodic Maintenance chapter).

Impeller Removal/Installation

• Remove:
  Water Pump Cover (see Water Pump Cover Removal)
  Water Pump Impeller [A] and Washer

NOTE

• Water Pump Impeller is left-hand threads.

• If necessary, hold the alternator rotor bolt [A] to remove the water pump impeller.
  • When the alternator cover center cap is removed, replace the O-ring of the cap with a new one.
• Installation is the reverse of removal.

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

Water Pump Inspection

• Check the drainage outlet passage [A] at the bottom of the water pump housing for coolant leaks.

• If a coolant leak or ooze is found, start the engine and check if the coolant leaks continuously.
  • When coolant does not continuously leak, it is normal.

If the mechanical seal is damaged, the coolant continuously leaks through the drainage outlet passage. Replace the mechanical seal unit.

If the oil seal is damaged, engine oil leaks through the drainage outlet passage. Replace the oil seal.

Water Pump Impeller Disassembly/Assembly

• Remove the water pump impeller (see Water Pump Impeller Removal/Installation).
• The sealing seat [A] and rubber seal [B] may be removed easily by hand.
• Apply water around the surfaces of the rubber seal and sealing seat.
• 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.
• Install the water pump impeller (see Water Pump Impeller Removal/Installation).

Water Pump Impeller Inspection

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

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

Mechanical Seal Inspection

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

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

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

Mechanical Seal Removal

• Remove:
  Alternator Cover (see Alternator Cover Removal in the Electrical System chapter)
  Water Pump Impeller (see Water Pump Impeller Removal/ Installation)
  Circlip [A] and Washer
  Water Pump Shaft [B]

Special Tool - Outside Circlip Pliers: 57001-144

• Remove the mechanical seal and oil seal using a suitable tool [A].

Mechanical Seal Installation

• Press the new oil seal until it is bottomed.
  • Apply a high-temperature grease to the oil seal lips.

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 37.5: 57001-1660

See also: