Written By: So-What

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.

- BradleyRAS

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!!!