Water pump rebuilding service.

R. J.

R. J.

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Rebuilding ZG/ZL/ZX 900/1000 Water Pumps. I am able to rebuild water pumps for all JAPAN bikes. IMG_0088.jpg IMG_0077.jpg IMG_0079.jpg IMG_0093.jpg IMG_0094.jpg IMG_0095.jpg IMG_0096.jpg IMG_0097.jpg IMG_0098.jpg IMG_0100.jpg IMG_0101.jpg IMG_0106.jpg IMG_0108.jpg

:hello: To repuild one water pump is $220 plus return shipping. Water Pump OEM part # 49044-1058 and 49044-1083. A new OEM water pump from KAWASAKI costs $320. See KAWASAKI fitment chart. AS OF 5/15/23 THE WATER PUMPS ARE DISCONTINUED. https://www.partzilla.com/product/kawasaki/49044-1058?ref=c4069a80a23227b131ab384b74e7ed758d54428e. https://www.partzilla.com/product/kawasaki/49044-1077 The ZL 600 water pump part # 49044-1077 is also discontinued . The water pump in the pics above fits the following Models. 85/86 ZL 900, 84/86 ZX 900, 87 ZL 1000, 86/87 ZX 1000 and 87 to 06 ZG 1000. 32 mm mechanical ceramic seal part # 49063-1055, oil seal OEM part # 92049-1416. Water pipe O-ring 25 mm OEM part # 671B2525. Water pump inside rear O-ring part # 92055-1266 33 mm. Water pump cover O ring part # 92055-1271 which is the larger one with one square corner. Bearings OEM supplier part # NSK JAPAN 6001DU. NSK is the manufacture, 6001 is the part #. DU tells you that it has rubber/plastic dust seals. Do not use bearings having metal dust seals. They will let in water/coolant. If you want to go with an aftermarket water pump oil seal the dementions are 12mmx28mmx7mm. For water pumps that use a 35 mm mechanical ceramic seal I'm using one that is made in the UK by AESSEAL. Manufacturer part # N-B03-ABZ1-0127B. For me to rebuild your water pump labor is $60, $160 for parts & $18 for return shipping with $220 of insurance. That's a total of $238. I put a thin coat of permatex ultra gray/black gasket maker to hold the water pumps cover O ring in place when installing it on the pump. Here are two other threads on water pump rebuilding. Started by ZL Mark. http://www.zl-oa.com/community/threads/tech-doc-discussion-water-pump-seal-bearing-replacement.6862/ ZL Mark & Wuputt. http://www.zl-oa.com/community/threads/water-pump-seal-bearing-replacement.6861/ My cell # is 386-837-7793. The best time to call me is 7 AM to 10 AM 7 days a Week. If I don't answer my cell phone please leave me a detailed message or TEXT me. My E-mail address is r[email protected] . ________________________________________________________________________ 20230307_205426[1].jpg
 
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Rebuilding ZG/ZL/ZX 900/1000 Water Pumps

:hello: In order to get the bearing off the shaft I had to make a makeshift jig. I used an old set of bike brake pads & clamped them to the Press fixture. Later on I'm going to make a better set up. The bearings I'm using are TIMKEN. They are marked FAFNIR part # 9101 PP JAPAN. I used a 19 MM 1/2 drive socket & hammer to install the new bearings. I use this method because I can get a feel for when the bearing is completely seated in. IMG_0109.jpg IMG_0111.jpg IMG_0112.jpg IMG_0117.jpg IMG_0120.jpg
 
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Rebuilding ZG/ZL/ZX 900/1000 Water Pumps

:hello: Installed my water pump today. As far as the front oil seal goes Ron my go to Tech said to use OEM & not the ribbed aftermarket ones. I put a very thin coat of wheel bearing grease on the external O ring so that the water pump slides into the engine case without tearing. IMG_0160.jpg IMG_0163.jpg
 
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Rebuilding ZG/ZL/ZX 900/1000 Water Pumps

:hello: I read in the manual that you should not let the white disk of the mechanical seal come in contact with your skin/fingers. IMG_0183.jpg
 
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Re: Rebuilding ZL 1000 Water Pump

Its the same part. #49044. Maybe as the years went by Kaw changed it a bit to improve it but it will fit either bike. It fits both of my bikes, and a lot more Kaw models. Thats how they roll.
 
Rebuilding ZG/ZL/ZX 900/1000 Water Pumps

:hello: Guys one pump that I'm rebuilding has no notch for a retainer C-clip near the end of the shaft under the oil seal.
 
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Re: Rebuilding ZL 1000 Water Pump

I don't doubt that, but think it prob just a design improvement of the same part because its the same part # or maybe its an after market part. Don't know if the one I sent you is an original part or a replacement but it was on my 900 back in 07 when I bought it.
 
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Re: Rebuilding ZL 1000 Water Pump

From what I remember when Jarney and I were looking into this, there didn't seem to be any rhyme or reason as to the internal configuration of the pumps i.e. year and model was irrelevant. You just can't tell until it's disassembled. It's as if Kaw was getting them from different vendors and installing whatever they had on hand at the time.
 
Re: Rebuilding ZL 1000 Water Pump

Yeah, it was a random crap shoot as to what came out of each one. There are no identifying marks on the outsides of them that make any difference either - some have some numbers on the outsides of them, but it didn't make a difference as to what was inside them. Later.
 
Re: Rebuilding ZL 1000 Water Pump

I got my rebuilt water pump from RJ yesterday and it looks good. He not only replaced the bearings & seal but also all of the O rings & included everything you might need for an installation. My only disappointment was that he did not have it delivered by one of those scantily clad babes that he is always hanging with in Fla. Thanks to RJ I have a spare WP for about half the price of a brand new one.
 
:hello: Raining out so I figured I'd do some water pump rebuilding. When installing the cover on a water pump I put a thin coat of permatex ultra gray or black gasket maker on the O-ring to hold it in place. Also I polish the shafts. ____________________________________IMG_1596.jpg IMG_1597.jpg IMG_6694.JPG
 
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:hello: Seals & C clips removed. I have one pump & cover in the Ultra sonic cleaner. Locally I found JAPAN NSK bearings part # 6001D0UCM NS7S. which are OEM. Cost $25 each._______________________________________________________________________________ IMG_1598.jpg IMG_1599.jpg IMG_1602.jpg
 
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Mine must be the ugly one on the left. So glad I sent it to you.
Doing this bike the right way is the only way to fly !
Wiring harness has checked out with very minor repairs.
 
:hello: It is the one on the right next to the cover. The bearing is spinning in the housing so It is trash. So I'll be sending you a different pump. Also your mechanical ceramic seal is bad. I installed a good used one. PM me your name & address.
 
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:hello: Polished the shafts. Removed old bearings. Installed new bearings & ceramic mechanical seal. Installed shaft in housing then the C retainer clip. Last but not least installed new oil seal. _____________________________________________________________________ IMG_1604.jpg IMG_1606.jpg IMG_1610.jpg IMG_1615.jpg IMG_1616.jpg IMG_1617.jpg IMG_1618.jpg IMG_1621.jpg IMG_1622.jpg IMG_1626.jpg IMG_1628.jpg IMG_1629.jpg _______The last pic is of my new bearing remover for when the inner bearing gets stuck on the shaft.
 
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Good pics RJ. Now all you need is a little powdercoating set-up.
 
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