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R/R water pump instructions


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#1 mwmerrill

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Posted 10 November 2017 - 12:04 PM

How I changed the water pump on my 03 ace.

This is at a high level, please reference the manual for details and torques.

 

Note this is at your own risk and should take about 6 hours or so at a relaxed pace

Please feel free to edit if I missed something.

 

Have a magnet handy for any dropped nuts or bolts.  The collars are a pain to re install and I ended up using a telescoping magnet to hold the collar while I pushed the cross bolt back in.

1 drain oil and coolant

2 remove both seats and fuel tank. (for access to coolant re fill )

3 remove exhaust pipes

4 jack up bike remove bolts to kick stand and swing it out of the way

5. remove rear wheel,  undo swing arm and let swing arm rest on some wood blocks. ( I left the shocks on)

6 RE INSTALL swing arm bolt and nut to hold the motor but allow for sliding

7 remove rear motor mount bracket

8 unbolt and remove the collar spacers from the front upper and lower motor mount. Put bolts back in and hand tighten nuts

(see attached photos from manual)

9. remove the chrome cover from the left hand side that covers the sprocket and water pump

10. disconnect both water pump hoses

11 push the motor to the right hand side, it actually moves over quite a bit

12 remove bolts to water pump and remove

13 install new water pump per manual instructions

14 put everything back together

 

Its not a hard job, more annoying than anything.   While I had the exhaust off etc I did a lot of cleaning before I re installed. 

 

No more coolant leaks!

Attached Files


Matt

03' Ace 47K miles


#2 Vomio

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Posted 10 November 2017 - 11:10 PM

Congratulations on your accomplishment!

 

An annoying job maybe, but it would seem to be considerably less annoying than removing the engine from the bike as per the Service Manual.

I read of people doing this by moving and tipping the engine in the frame, but sliding it over on the swing arm bolt seems like a safer approach.

 

Thank you for taking the time to document this and post it.

Others are definitely going to benefit from this in the future.


Edited by Vomio, 10 November 2017 - 11:55 PM.
Edit: I linked to this from the FAQ