Valve Closing Temperature (for reference)

Standard: 70°C (158°F) or more at 25 kPa (0.25 kgf/cm², 3.6 psi)

4-10 COOLING SYSTEM

Water Pump

Water Pump Removal

• Drain the coolant.

• Remove the engine guard (see Engine Guard Removal in the Frame chapter)

• Loosen the clamp and remove the radiator hose [A] from the water pump cover [B].

• Remove the four cover bolts [C].

• With the water pipe [D] attached, remove the water pump cover.

• Install the right footpeg assembly.

NOTE

○The impeller and water pump shaft have a left-handed thread, therefore they must be turned clockwise [A] to remove.

• Shift the transmission into 1st gear. While applying the rear brake, remove the impeller [B].

• Pull the water pump housing [A] and gasket out of the right crankcase. Turn the water pump shaft [B] clockwise, and remove it.

Water Pump Installation

• When installing the water pump shaft or impeller, shift the transmission into 1st gear and apply the rear brake.

• Apply silicone sealant to the area [A] where the mating surface of the crankcase contacts the water pump hous­ing gasket.

Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

• Apply high temperature grease to the lips of the water pump housing oil seal.

• Turn the water pump shaft or impeller counterclockwise, and tighten them.

Torque -Water Pump Shaft: 25 N-m (2.5 kgf-m, 18 ft-lb)

Water Pump Impeller: 9.8 N-m (1.0 kgf-m, 87 in-lb)

COOLING SYSTEM 4-11

Water Pump

• 

  Be sure to install the water pipe O-rings [A], and apply high temperature grease to them.

• Install the water pump cover with the water pipe, being careful of the two knock pins [B].

Torque-Water Pump Cover Bolts: 11 N-m (1.1 kgf-m, 95 in-lb)

Mechanical Seal Inspection

• Visually inspect the mechanical seal.

• If any one of the parts is damaged, replace the mechani­cal seal as a unit.

OThe sealing seat and rubber seal may be removed easily by hand.

1. Impeller Sealing Seat Surface

2. Rubber Seal

3. Mechanical Seal Diaphragm

Water Pump Housing Disassembly

Caution

Be careful not to damage the sealing surface of the mechanical seal.

Take the oil seal [A] out of the housing [B] with a hook [C].

• Press the mechanical seal [A] out of the housing with a bearing driver [B].

Special Tool - Bearing Driver Set: 57001-1129

Water Pump Housing Assembly

• Apply a high temperature grease [A] to the oil seal [B].

• Press the oil seal into the housing with a bearing driver until it stops at the bottom surface of the housing [C].

• Press the mechanical seal into the housing with a bearing driver [D] until its flange [E] touches the surface [F] of the housing.

Special Tool - Bearing Driver Set: 57001-1129

4-12 COOLING SYSTEM

Water Pump

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.

Pump Impeller Inspection

• Visually check the impeller [A].

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

COOLING SYSTEM 4-13

Radiator, Radiator Fan

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WARNING

The radiator fan is connected directly to the bat­tery. The radiator fan may start even if the ignition switch is off. NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN CONNECTOR IS DIS­CONNECTED. TOUCHING THE FAN BEFORE THE CONNECTOR IS DISCONNECTED COULD CAUSE INJURY FROM THE FAN BLADES.

Radiator Removal

• Drain the coolant.

• Remove:

Both Lower Fairing (see Lower Fairing Removal in the

Frame chapter)

Both Radiator Cover Screws [A] and Radiator Covers [B]

• Disconnect:

Radiator Fan Connector Radiator Fan Switch Connector [A] Radiator Hoses [B]

• Unscrew the radiator mounting bolts [C] and remove the radiator taking care not to damage the radiator core.