water pump install question

[Eddie]

OK I just got the new pump, I still need to see if i can get the old one out, but my question is, is there anything I need to know before installing the new pump? any tricks? do I coat the o-rings on the new pump with anything? (greese) also i would think that I not only have to drain the coolant but also the crank case fluid? I have not read the book on this yet so I thought I would ask you guys if there is any tricks or things I need to be careful of , ........

[Suzsmokeyallan]

Its best you drain the coolant and the transmission oil beforehand to keep things less messy, also make sure the bike is on the centre stand to ease work and gain space. You will have to remove the lower pipes and centre header as well before work commences.
You must lube the o-rings with oil or grease before assembly which helps prevent pinching them dry. Also there is a locator pin up at the top of the case that mates with a slot in the top of the pump body, these MUST be aligned to get the pump up far enough to expose the large snap ring slot.
If you look at the cartridge there are two little slots inside the lower edge opposite each other, you can make a tool from steel or alloy plate that fits into these like a flat key This way you can push up the cartridge with the key and then turn it slightly while pushing to find the locator pins slot.

Your first order of the day is to get the old cartridge out, to do this the impeller needs to be heated and a small two jaw puller used to get it off the shaft first while its hot. Don't break it or bend it as that will cost you heavily, once thats off the large snap ring comes out the crankcase and then the creativity starts.
Making up a slide hammer device or drilling the case from above are your two options to shift the cartridge. Both of these ways are posted here on this site in the required threads.

[tz375]

Grease or vaseline on the O rings helps. Be aware of the small bolt that has to match the keyway in the pump. Water drained, yes. Oil, not in my experience and I have changed a couple now by laying the bike on its side. Seriously, there is no need to drain the oil if the bike is either on its side or upright.

I use a pair of long levers to pry the pump out after the impeller is off and Snap ring is out..

[Eddie]

ok thanks for the info, I will probly just put some oil on the 0-rings, I took the bike for a 30 mile ride and came back and it didnt seem to be leaking as much as it did before, if I just go on a real short ride it leaks, also it looks like it leaks from the left side somewhere? (left side if you are sitting on the bike), I know it leaks from the weap hole in the water pump cover a little, but it seems to leak from somewhere else also, or maybe when riding the weap hole leaks and the wind takes it to that side? Im just afraid of trying to fix it and making it worse! but im also afraid of the coolant getting in the crankcase and screwing it up more.... also I was going to ask what screw does the pump line up with? do you mean inside the crankcase? I know there is a notch on the top of the housing , does that fit into a screw in the case?

[tz375]

Correct. That's what Suzuki Allan was describing also. There's a bolt for inside the transmission that protrudes into the water pump cavity, and as Allan mentioned, just push the pump in and rotate it until it drop deeper into place. It's all pretty much self evident when you do it.

I has to remove and replace the pump on this bike and a prior one, twice in both cases because a replacement seal didn't seal and no issues with water and oil mixing.

[Eddie]

ok, well I got the girl laying down on her side but she doesnt want to give it up, wow that didnt sound right i had hell just getting the cover off! then the snap ring that holds the impellar on broke!!! then I heated the impellar and was able to get it half way off then my wife decides to help, and she grabs a micro fiber towel that is dry and pulls the impellar off which melts the rag to the impellar, so i spent the next 2 hours with a dremmel tool and a wire wheel getting the towell off,,,I told her to get a damp rag and she insisted on the dry microfiber, i had no time to argue, but at least she decided to help she probly thought i was really screwing things up, (shes probly right) we went for a ride earlier and when we got back i just started taking things apart, cant stand the leak.. here are some pics..

[Eddie]

I was suppose to do laundry today sorry,,, but instead I tore the bike that I just rode with no problems, down to this, now im wondering if i did the right thing? my cat was falling asleep with boredom watching me for hours....