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Water pump rebuilding service.

R. J. Jan 20, 2015

  1. R. J.

    R. J. Senior Member

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    Rebuilding ZL 1000 Water Pump

    :hello: I'm learning as I go. This is my first rebuild. Water Pump OEM part # 49044-1083. This water pump fits the following Models. 85 & 86 ZL 900 / ZX 900. 87 ZL 1000, ZG 1000 & ZX 1000. 88 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 which is the smaller one. Water pump cover O ring part # 92055-1271 which is the larger one with one square corner. Bearing OEM supplier part # NSK JAPAN 6001DU. NSK is the manufacture, 6001 is the part # & DU tells you that it has rubber dust cover seals. Do not use a bearing having metal 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 a water pump is $30 labor, $80 for parts & $15 for shipping with $150 of insurance. That's a total of $125. 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/
     

    Attached Files:

    Last edited: Sep 24, 2018
  2. R. J.

    R. J. Senior Member

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    Re: Rebuilding ZL 1000 Water Pump

    :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
     
    Last edited: Apr 25, 2017
  3. R. J.

    R. J. Senior Member

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    Re: Rebuilding ZL 1000 Water Pump

    :hello: I was at my friend Ron's in Daytona yesterday & asked him about the mechanical ceramic seal for the water pump. He said that some pluming supply stores sells mechanical seals that to take an old one & match them up. Ron rebuilds water pumps. He also said sometimes the mech seals cup can crush that the seal sits in that sometimes it's tricky to install. What he does is he puts the water pump in his oven at his shop at @ 200*F for @ 20 minutes in order to press the ceramic seals cup side in the pump's housing so that the cup does not crush. So I left the water pump with him. He could not do it right then. He is swamped with work.
     
    Last edited: Nov 27, 2018
  4. R. J.

    R. J. Senior Member

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    Re: Rebuilding ZL 1000 Water Pump

    :hello: I jarred my friend Ron's memory last night. He called me awhile ago & said he remembers that the mechanical seal from a 1981 Honda CR 250 R will work in the ZL 1000 water pump. Honda OEM part # is 19217-657-023. This is for the 32 MM & not the 35 MM water pump housing.
     
    Last edited: Nov 27, 2018
  5. R. J.

    R. J. Senior Member

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    Re: Rebuilding ZL 1000 Water Pump

    :hello: After redoing the valves on Madman Jr. motor & putting it all together I just left the water pump with Ron to finish up. I did not want to use my wife's oven. If you are very careful you do not need to use an oven to seat the mechanical seals cup into the water pumps housing. Use a large socket the same size as the O. D. of the mech seal 32 or 35 mm. Put a thin coat of gasket maker around the rim of the mech seal that is if the factory did not. Press the seal in with a press or a really wide opening bench vice. IMG_0132.jpg
     
    Last edited: Nov 27, 2018
  6. R. J.

    R. J. Senior Member

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    Re: Rebuilding ZL 1000 Water Pump

    :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
     
    Last edited: Apr 25, 2017
  7. R. J.

    R. J. Senior Member

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    Re: Rebuilding ZL 1000 Water Pump

    :hello: I received the Honda mechanical seal yesterday. It is the 32 mm O.D. unit. Cost $35. The Kawasaki one is much cheaper. Refere to post # 1 for KAW part #. The 32 mm one will fit some of our water pumps but I've found that most use the 35 mm O.D. ceramic mechanical seal. IMG_0180.jpg IMG_0181.jpg IMG_0183.jpg
     
    Last edited: Nov 29, 2017
  8. R. J.

    R. J. Senior Member

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    Re: Rebuilding ZL 1000 Water Pump

    :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
     
    Last edited: Nov 29, 2017
  9. rkerg

    rkerg Senior Member

    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.
     
  10. R. J.

    R. J. Senior Member

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    Re: Rebuilding ZL 1000 Water Pump

    :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.
     
    Last edited: Nov 29, 2017
  11. rkerg

    rkerg Senior Member

    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.
     
    Last edited: Jan 30, 2015
  12. kawboy

    kawboy Supporting Member Technical Author

    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.
     
  13. Jarney

    Jarney Strip Warrior Staff Member Administrator Super Moderator Supporting Member

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    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.
     
  14. rkerg

    rkerg Senior Member

    Re: Rebuilding ZL 1000 Water Pump

     
  15. R. J.

    R. J. Senior Member

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    Re: Rebuilding ZL 1000 Water Pump

    :hello: rkeg: Your water pump needs bearings & oil seal that is on the side of the shaft that goes into the engine case. The mechanical seal is good. Do you want me to rebulid it. The bearing are $40 for JAPAN or $20 for CHINA. The seal is around $3.00 depending if you want OEM or after market.
     
    Last edited: Oct 25, 2015
  16. rkerg

    rkerg Senior Member

    Re: Rebuilding ZL 1000 Water Pump

    Sure, go for it. Use the best parts you can get.
     
  17. rkerg

    rkerg Senior Member

    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.
     
  18. R. J.

    R. J. Senior Member

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    Re: Rebuilding ZL 1000 Water Pump

    :hello: You was my first. :laughing7: Did you check out the old bearings I sent. The one looks OK but the dust covers are bad. I just happen to have extra OEM parts so I just added them in. If you go with the JAPAN bearing & just the OEM water pump seal it runs just right at $80.0 for parts.
     
    Last edited: Nov 27, 2018
  19. mikemerriam

    mikemerriam Active Member

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    Do any members offer Waterpump rebuilding service?
    Please PM me if intrested and how much $$$
     
  20. R. J.

    R. J. Senior Member

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    :hello: I have done a few. I can get to it sometime in the middle of the month. I need the money up front for the parts @ $ 80. That includes 2 bearing, 1 oil seal, 3 O-rings & one ceramic mechanical seal. Also shipping with $150 of insurance is @ $14.95. My labor rate is $30 per pump. PM me sometime around the 16 th of this month.
     
    Last edited: Sep 24, 2018

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