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Removal
Drain the coolant. See the Coolant topic for more information.
Remove the coolant reserve tank. See the Coolant Reserve Tank topic for more information.
Loosen the radiator hose clamp with a flat blade screwdriver and slide off the coolant hose.
Slide off the hose clamp using pliers and remove the coolant hose. Also remove the telltale catch container.
If the telltale container has coolant in it the mechanical seal has failed and needs to be replaced.
Remove the four water pump cover bolts with an 8 mm socket.
Use a pry point to free the water pump cover.
Remove the water pump cover.
Note: On 2002 – 2003 models remove the recoil starter and hold the recoil starter pulley with a hook wrench while loosening the impeller. See the Recoil Starter topic for more information.
Special Tool-
Hook Wrench: 57001-1101
Remove the impeller using a socket. Inspect the impeller for corrosion or damage. Replace as needed.
Remove the two dowel pins.
Seal Replacement
If the bear, oil seal, or mechanical seal is removed they must be replaced as a set.
Remove the alternator cover. See the Alternator topic for more information.
Turn the water pump bearing with a finger. If the bearing is rough it must be replaced.
Remove the bearing from the alternator cover with a suitable bearing puller.
Special Tools-
Bearing Remover Shaft Dia. 9: 57001-1265
Bearing Remover Head Dia. 10 x 12: 57001-1266
Remove the oil seal.
Drive the mechanical seal out of the alternator cover from the inside.
Special Tools- Bearing Driver Set: 57001-1129
Drive in the new oil seal until the driver bottoms against the alternator cover. Coat the lips of the oil seal in a high temperature grease.
Drive in the bearing from the inside of the alternator cover. Use a suitable driver that is the same outside diameter as the bearing. Make sure the bearing’s markings are facing out and the bearing is fully seated in the cover.
Use a socket that is the same outside diameter of the mechanical seal to drive it into the alternator cover from the outside.
Replace the rubber seal and sealing seat on the back of the impeller. Push these new seals into place by hand.
Installation
Install the two dowel pins.
Apply coolant to the mechanical seal and sealing seat sliding surfaces.
Note: On 2002 – 2003 models hold the recoil starter pulley with a hook wrench while tightening the impeller. Install the recoil starter. See the Recoil Starter topic for more information.
Special Tool-
Hook Wrench: 57001-1101
Install the impeller and tighten to specification using a socket.
| Fastener | Torque | ||
| N-m | kgf-m | ft-lb | |
| Water pump impeller | 7.9 | 0.8 | 69 in-lb |
Install a new gasket.
Install the water pump cover.
Install the four water pump cover bolts and tighten with an 8 mm socket.
| Fastener | Torque | ||
| N-m | kgf-m | ft-lb | |
| Water pump cover bolts | 8.8 | 0.9 | 78 in-lb |
Install the coolant hose and slide on the hose clamp using pliers.
Install the coolant hose and slide the radiator hose clamp on. Tighten the clamp with a flat blade screwdriver.
Install the coolant reserve tank. See the Coolant Reserve Tank topic for more information.
Fill with coolant. See the Coolant topic for more information.