Announcement

Collapse
No announcement yet.

So-What's How To Replace a ZZR1200 Water Pump

Collapse
This is a sticky topic.
X
X
 
  • Filter
  • Time
  • Show
Clear All
new posts

  • So-What's How To Replace a ZZR1200 Water Pump

    Replacing the water pump is easier than one would think. Below is a how to guide from member SO-WHAT (Tony Calloway, Chicago IL). Tony replaced his water pump and coolant at 58,841 miles after a slight leak was detected, coming from the water pump 'weep' hole:

    To begin, remove the left side inner and side fairing as well as the right side inner fairing panel.



    Next, remove the coolant resevoir bottle


    After draining the coolant from the resevoir bottle, locate the coolant drain plug on the lower coolant tube


    remove the coolant drain plug and allow the coolant to drain


    next, unplug the neutral indicator sensor wire


    after all of the coolant has drained, remove the upper coolant tube from the water pump


    remove the lower coolant tube


    allow excess coolant to drain from both the lower and upper tubes




    next remove the TWO bolts that mount the water pump to the motor, (look at the new water pump and you will see the TWO bolt holes at the top and bottom of the pump, the three bolts that are IN the water pump hold the pump together, do not remove them)


    This is what your ZZR will look like with the water pump removed, note the position of the water pump drive cam, you will need to match the water pump shaft to the position of the cam before installing the new water pump









    BEFORE installing the new water pump, note that the NEW water pump comes with a new O-ring installed on the shaft housing, however you will need to replace the O-rings on BOTH upper and lower coolant tubes. This is very important!! You may need a drop of oil to help get the new O-ring onto the coolant tubes.




    next, install the new pump, if the cam and the shaft do not mate, use a screw driver to gently turn the water pump fins until the shaft drops into the cam gear


    After torqueing the 2 water pump mounting bolts, and installing the upper and lower coolant tubes, we are now ready to re-install and fill the coolant resevoir bottle and radiator. BE SURE TO USE AN APPROVED ALUMINUM FRIENDLY COOLANT!!!










    Start the motor & add the new coolant while allowing air escape thru the radiator cap. When all of the air has escaped, fill the resevoir bottle.

    Wipe down tools to ensure removal of toxic coolant.


    Last but not least....TEST RIDE!!!

  • #2
    good job with the How to !!
    mod need to keep as sticky !!
    *

    Comment


    • #3
      Thanks Loic!

      Comment


      • #4
        Originally posted by loic
        good job with the How to !!
        mod need to keep as sticky !!
        +1...great documentation!

        Comment


        • #5
          Thanks John, nice meeting you!!

          Comment


          • #6
            Good job fellas!!!!Nice meeting all of you!!!!!

            Ducky
            "Fat, Drunk, and Stupid is no way to go thru life son" Dean Vernon Wormer,Faber College

            Comment


            • #7
              Originally posted by So-What
              Thanks Loic!
              you're welcome ! we need to "see"you more here !!
              *

              Comment


              • #8
                Here is my maintenance chart, also found on page 11 in the members gallery


                Comment


                • #9
                  Originally posted by So-What
                  Thanks John, nice meeting you!!
                  Originally posted by Ducky149
                  Good job fellas!!!!Nice meeting all of you!!!!!

                  Ducky
                  It was also great meeting both of you…We’ll have to ride soon!

                  Comment


                  • #10
                    Great Job Tony. You are truely an inspiration to us all. Ride safe my friend.
                    A veteran is someone who, at one point in his life wrote a blank check Made payable to "The United States of America " for an amount of "up toand includinghis life." That is Honor.

                    Comment


                    • #11
                      Way to go Tony!

                      http://www.cyclepathic.com/

                      Comment


                      • #12
                        Top job Tony. Keep riding safe
                        It takes more love to share the saddle than it does to share the bed. ~Author Unknown

                        Comment


                        • #13
                          Awesome Bud!!!!!!!!!!!

                          Good to see you on here!!

                          Nice Jacket also! When did you get that??

                          Hope to see you at T.W.O.!!!

                          Comment


                          • #14
                            This should be put into the How-To section. Great write-up and directions Tony!!!!
                            They laugh at me because I am different. I laugh at them because they're all the same!----KJ

                            For those who ride, no explanation is necessary. For those who don't, no explanation is possible!!!---KRA(My Twin)

                            Comment


                            • #15
                              Great write-up, Tony


                              While I am master of my sword, I shall never think any man greater than myself.
                              ~Eumenes of Cardia

                              I'd rather wake up in the middle of nowhere than in any city on earth. ~Steve McQueen

                              I work over by worlds of fun. ~JimmyMac

                              My photo album - http://zzrbikes.com/gallery2/main.php?g2_itemId=146333

                              Comment

                              Working...
                              X