DIY waterpump rebuild (proper thread). Published from old zzr-international.co.uk site by dirtdoggle

DIY waterpump rebuild (proper thread)
Postby dirtdoogle » Tue Aug 21, 2012 11:43 am

I apologise in advance for my poor pics, nerve damage in my right wrist makes me shake a wee bit 😉

What you need:
A ZZR4/600/K/D, haven’t done one on the N/E but I think they’re the same
10 and 8mm spanners
Many hammers
Cigarettes
Socket set
Assortment of decent screw drivers
Circlip pliers
Extensive knowledge of grunting and swearing
Bearing puller really, really helps

Parts: Loctite sealant or similar
A wee bit of grease (if pedantic like myself)
Bearings: Two 12x28x8 stainless steel and must be 2RS sealed type (these cost me a grand total of $5NZ)
12 x 28 x 7mm radius oil seal
12mm external circlip
Rear water pump o-ring http://www.ronayers.com/ProductDetails/ … KU/1088282
Front water pump housing seal http://www.ronayers.com/ProductDetails/ … KU/1088281

Righto what you want to do:
Remove your bottom fairing (no pics, my bike obviously hasn’t got one, fairings are silly)
Drain the coolant, if unsure of how to do this, step away from the bike and go have a coffee.
Remove both hoses to the water pump
Un do the top and bottom 10mm bolts on the front of the pump
Ease the pump out

Now the fun begins.
Remove the remaining bolts from the pump cover and open ‘er up
Should look like this, hopefully…
Image
Now flip it over so you’re looking at the back
In theory, you’ll be looking at an oil seal
Image
Pop this wee fellow out and you’ll be able to see a circlip on the shaft holding the bearing in
Whip that out with the previously mentioned circlip pliers (or get real handy with a flat blade screw driver…)

Now you can grab you hammer assortment! Yay!
Place the pump on blocks of wood, impeller facing down and make sure it’s not hitting the wood
Gently drive the pump shaft out, this may require the grunting and/or swearing you got yourslef before starting this job.

Once you’ve managed to get the impeller and shaft out, flip it over and you should see this
Image
I didn’t need to replace this seal on mine, but do note how it sits on yours (this seal causes a lot of drag, I’m currently trying to think of a mod to get rid of it)
Ease it off and you’ll see this
Image
If not, you’ve started working on the wrong bike and it’s not my problem
Now, select your favourite long screw driver (unless you have a bearing puller, then you win) and drive the bearing on the engine side out, heat can help here, I’m a sucker for making shit hot, so I put it in the oven for half an hour at 150 celcius, made life superbly easy!

Once that bearing is out, flip the pump, burn your hands (oops!) and gently tap the other side out, I used a socket and wooden mallet for this one and being heated, they popped right out (the pump I did before hand wasn’t heated and was a prick to do)

Now you’ll have a completely empty water pump! The end.

No not really…
I’m sorry for the lack of pictures, most of the ones I took are too blurry to make sense 😆

Clean everything, I cannot stress this enough, if you’re spending time doing something like this, make it perfect
Is it clean yet?
Good.
Insert the new impeller side bearing and gently drive it in, makes life easier yet again if the pump is a bit warm, and I always put bearing in the freezer before installation, easier than peeling a potato with a gun.
It should look like this Image
If not, you’re a womble and should stop sniffing glue
Clean this wee thingy Image I used brake cleaner and a razor blade, but I’m slightly pedantic.
Apply a very thin smear of the loctite sealant stuff, or whatever is on hand (blood, feces etc)
It’ll push right in if you freeze it… otherwise, get a socket (I think 16mm was about right) and very gently tap it in
Once that’s nice and snug, fit that odd little spring loaded washer/seal, making sure it’s alligned correctly on the little dimples.
I think fitting a teflon washer between that and the impeller will get rid of the ridiculous drag it causes

Now, find the impeller, put a thin smear of grease on it and push it through (yet again, heat/cold parts help, but hammers work too)
Once you have that in, insert the new bearing in the engine side, double check that the impeller has clearance on the housing too, otherwise you’ll have a big mess
Fit the circlip
Apply a tiny smear of the sealant rubbish on the outside of that new oil seal and push it firmly in to place.

Don’t forget that new rear O-ring!
Flip it over again, check you’ve still got clearance on the impeller
Mount the housing on the motor and turn the impeller until you feel the shaft slip in to place of it’s drive
Clean the mating surfaces on the housing, fit new seal (or just use more sealant, not my problem)
Fit the from cover and bolt ‘er up

Polished front is optional and not worth doing on a faired bike
Image
I hope this helps someone, it’s long stupid and rambling, but you’ve made it this far and good luck to you

Will update once I have found a decent alternative to the inside seal 🙂

———-
Green Magic Man (me) add this to the post:

I thought I should pass along this research. An Italian at the German zzr site said he did his ZZR600 D model water pump with this Honda part which is the same seal for the oil seal in the Kawi.
Part # 91201-mf2-003
I looked it up and it shows up indeed as:
Honda 91201-MF2-003 OIL SEAL (12X28X7) — OIL SEAL ( 12X28X7) (Honda Code 2073054), OIL SEAL …
For US $3.50 at partzilla, US $4.50 at local Kawi dealer.
I will order one and try to confirm this fits in my ZZR600 water pump. I think that enables me to source all the parts at this point.
This was the post:
http://www.zzr-rg.co.uk/forum/viewtopic.php?t=5163

Also, cross referenced another part, this one is a Kawasaki part a forum poster says fits too:
92049 1416 said this fits but is not common knowledge it fits most Kawasakis.
And same guys says this for the mechanical seal part: 49063 1055
Here is my source thread for this: http://www.kiwibiker.co.nz/forums/showt … -weep-hole
—

I can indeed confirm this Honda oil seal part fits the ZX6E / ZZR600 model :clap: :
Honda part #: 91201-MF2-003
description: OIL SEAL (12X28X7)
price: US Dollars $4.99

I had to special order the part and installed it today. Very nice fit. This is the oil seal that goes around the impeller shaft at the very end (not the wider O Ring that goes around the water pump impeller housing.


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