Kawasaki Z400 - Service manual > Water Pump

Water Pump Cover Removal

• Drain the coolant (see Coolant Change in the Periodic Maintenance chapter).
• Remove: 1 Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) Clutch Cover Bolts [A]
• Disconnect the water hose [B].

Remove: Water Pump Cover Bolts [A]

Water Pump Cover [B]

Water Pump Cover Installation

Replace the O-ring [A] with a new one.

Apply grease to the O-ring.

Be sure to install the dowel pins [A] in position.

Install the water pump cover [A].

Tighten: Toque -Wafer Pump Cover Bolts [B]: 9.8 N.m (1.0 kgf-m,87 in*lb)

• Install e removed parts (see appropriate chapters).

Water Pump Removal

• Shift the transmission into 1st gear.
• Remove the water pump cover (see Water Pump Cover Removal).
• While applying the rear brake, remove the water pump impeller [A].
• Remove: Lower Fairing Bracket Bolts [B] Bracket [C] Water Pump Housing [D]

Water Pump Installation

• Replace the O-rings [A] with new ones.
• Apply grease to the O-rings.

• Be sure to install the dowel pins [A] in position.
• Install: Water Pump Housing

• Install the bracket [A].
• Tighten: Toque - Lower Fairing Bracket Bolts [B]: 9.8 Nm (1.0 kgf-m, 87 in-lb) Water Pump Impeller [C]: 9.8 Nm (1.0 kgf-m, 8- in-lb)
• Install the removal parts (see appropriate chapters).:

Water Pump Inspection

• Remove the right lower fairing (see Lower Fairing Removal in the Frame chapter).
• 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 dl seal is damaged, engine oil leaks through the drainage outlet passage. Replace the water pump.

Mechanical Seal Inspection

• Remove the impeller (see Water Pump Removal).
• Visually inspect the mechanical seal

*If any of the parts is damaged, replace the mechanical seal with a new one (see Mechanical Seal Removal/Installation).

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

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

Mechanical Seal Removal

• Remove: Water Pump Housing (see Water Pump Removal) Water Pump Shaft
• Using a suitable tool, remove the following parts from the water pump housing.

  Ball Bering [A] Oil Seal [B] Mechanical Seal [C]

Mechanical Seal Installation

• Using a suitable tool or pipe with the dimension as shown, install the mechanical seal [A] until the flange [B] on the mechanical seal is bottomed.

  30 - 33 mm (1.2 - 1.3 in.) [C] 26 - 29 mm (1.0 - 1.1 in.) [D]

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.

Water Pump Impeller Inspection

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

*If the surface is corroded, or if the blades are damaged, replace the impeller with a new one (see Water Pump Removal/Installation).

See also: