Remove and Replace the Waterpump

The water pump on the Concours can leak oil as well as coolant. There is a weep hole on the bottom of the pump, if the oil or coolant seal leaks it will drip onto the exhaust system. This can cause smoke rise up from the area near the water pump when the exhaust pipe warms up, particularly if it hasn't been started in a while. Other symptoms of a bad water pump might include overheating or noise.

Weep Hole
Looking straight up from underneath, we can see the weep hole clearly in this picture. Wipe the area clean and if you can see oil or coolant coming from this hole, you'll have to remove the water pump.

Remove Plastic
Remove the lower fairing, left middle fairing and the left fairing cover. Remove left side radiator duct and heat shield.
Drain the engine oil and the coolant. Alternatively, you might be able to find a way to support the bike leaned over to the right enough that the oil does not need to be drained, and you may find this position makes working on the bike much easier. Just be sure the bike is securely supported if you decide to go this route. Either way, you'll need to clean the are well to prevent the possibility of dirt entering the motor when the pump is removed. However if an oil change is due, this is a good time to do it.


Remove Clutch Slave
Warning: Do not allow the clutch lever to be pulled while the clutch slave cylinder is removed!
There are three bolts, outlined in red in the photo, that attach the clutch slave cylinder to the motor. Remove them and pull the clutch slave cylinder out. Note the plastic spacer behind it, and its orientation.

Remove Shifter Bracket
Next remove the shift lever, and it's mounting bracket. The location of the three bolts holding the bracket in place are outlined in red.

Remove Cover Bolts
Remove the hose clamp and hose connected to the water pump. You may find it easier to remove the elbow of hose at the radiator first. Cut the zip tie holding this pipe (ref#39102) to the other pipe (ref#39192). Then you can remove the two pieces of hose with a short metal pipe between them as one assembly. (ref#'s 39062B, 32102, 39052E) Now you can remove the two bolts, outlined in the photo, and pull the cover off the pump. (See discussion: Leave the pump cover on?)
Remove the Pipe and Coolant Hose
Now that the cover is off, there is one more bolt to remove. It holds the metal pipe (ref#39192) to the pump. In the photo, you can see the bracket the bolt goes through. Once you have removed the bolt, pull the pipe out of the pump and pull the pump out of the motor.

If Your Pump Is Leaking Oil
If your pump is leaking oil from the weep hole, but otherwise good, you can replace the oil seal. The seal does not show up on an older parts fiche, but it is part number 92049-1416. Use a punch or a small screwdriver to dent the old seal and carefully pry it out. Do not scratch the pump shaft or the pump body. Use a little Loctite 271 or equivalent to insure the new seal stays in place. Be sure and orient the seal properly, the flat side goes in first. This might seem wrong, most seals go in with the flat side visible, but the pump goes on the motor with oil on the side of the pump the seal goes on. Think of the flat side of the seal as the dry side. The side with the lip is the wet side and needs to go into the motor. Press the seal in with a socket, tapping lightly with a small hammer.


Inspect the O-rings and Mating Surfaces
First make sure the bore into which the pump installs is clean and smooth. Inspect the o-ring in the cover and on the neck of the pump that goes into the motor. The o-ring on the neck is a standard metric o-ring, (listed as 33.2x2.4) but the one in the cover is not. Clean the o-ring grooves, the mating surfaces, the bore that the metal pipe goes into and the nipple the hose fits onto. Check the cover to be sure it is flat.

O-Ring on the Pipe
Check the o-ring on the end of pipe (ref#39192). Make sure the end of the pipe is clean and smooth and the o-ring is not cut, abraded, hardened or cracked. If it is, replace it with a new one. This is a standard metric o-ring, (25mm) you can get one at a hydraulics shop. Put a thin smear of grease on the o-ring and in the bore where the pump goes.

Smear a little grease on the o-ring (ref#920550) on the pump. Take a look at the shaft the pump mates to in the motor, and note the alignment of the tab. Align the pump shaft the same way, and slide the pump into the bore. You will likely have to turn the impeller slightly to get it to fit in all the way. Once the pump is all the way into the motor, carefully insert the metal pipe with the o-ring on it into the pump, and bolt it in place.

O-Ring In Cover
Now put the o-ring (ref#92055A) in the cover. Use small amount of grease is used to hold it in place. Put the cover on the pump. Insert and tighten the two bolts that hold the cover on. Then reinstall the radiator hose. Before you tighten the hose clamps, use a zip tie (ref#92072A)to pull the pipe (ref#32102) away from the exhaust pipe by pulling it to the other pipe (ref#39192). Hose clamps can be purchased at any auto parts or hardware store, 1.5 inch clamps are recommended. Reinstall the shifter bracket and shifter. Reinstall the clutch slave. Pay attention to the orientation of the plastic spacer, and tighten the bolts for the clutch slave evenly. Refill the engine oil and coolant. Don't forget to bleed the pump! And there is also a bleed at the thermostat housing too. (needed: link to an article about filling and bleeding the cooling system) Check for leaks, replace the fairing and your done!
Cooling System Reference numbers in this article refer to this image:

Great video from Steve in Sunny Fla:

Photos:


01-removeClutchSlave.jpg, 02-removeBracket.jpg, 03-removeBolts.jpg: WillyP
overallWaterPump_Zorlac.jpg: Zorlac
More photos

04-coverOff.jpg, 05-oringInCover.jpg: WillyP
weepHole.jpg: Zorlac
radiator.gif: Brock Delp's '99 Kawasaki Concours Microfiche
I see no need to remove the cover off the water pump.
I just adds to the workload and in most cases necessitates the need to replace the cover o-ring.
My suggestion is remove the pump as a single item. -- Colin P.

I think for a first-timer removing the cover is a good idea. I first tried to remove the pump with the cover on but, IIRC pulled it off to get just that little bit extra clearance. I also think the o-ring should be inspected and replaced if needed. If I did it again I probably would leave the cover on, if i was replacing the pump with another. If I was planning on putting the pump back on I would want to inspect the o-ring and impeller. Also, removing the cover will make it easier to get the pump on as you can turn the impeller to line up the tab and slot. -- WillyP
With the bike on the center stand you I don't believe you need to drain the oil unless it's filled (this needs checking)
However if an oil change is due, this is a good time to do it

There is a 2nd bleed point on the thermostat.

Need to add the replacement of the slave clutch cylinder and that the bolts need to be done up evenly so you don't break the plastic washer. -- Colin P.

edited article -- WillyP
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