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EAS00468
WATER PUMP
WATER PUMP
COOL J C lyJ2| 10 4i , /
10Nm(1.0m« kg, 7.2 ft* lb) d r ^ ®
Order Job/Part
Removing the water pump
Front cover
Side cover(left and right)
Single seat/Trunk
Footrest board
Coolant
5
6
7
8
9
1
2
3
4
Breather hose
Thermostat inlet hose
Water pump outlet hose
Radiator outlet hose
Water pump housing cover
Gasket
Water pump housing
Plate
Impeller shaft
6-7
Q’ty
Remarks
Remove the parts in the order listed.
Refer to”COVER AND PANEL”in chapter 3.
1
1
1
1
1
1
1
1
1
Drain.
Refer to”CHANGING THE COOLANT”in chapter 3.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
WATER PUMP
COOL J C
6
Order
10
11
12
Oil seal
Bearing
Gasket
Job/Part
® ^ ^ ®
10Nm(1.0m • kg, 7.2 ft* lb)
Remarks
Q’ty
1
1
1
For installation, reverse the removal procedure.
6-8
WATER PUMP
COOL J C
EAS00471
DISASSEMBLING THE WATER PUMP
1. Remove:
8water pump housing c o v e r 1
8dowel pin
8gasket
2. Remove:
8plate 2
8impeller shaft 3
8gasket
8oil seal
(with a thin, flat-head screwdriver)
8bearing
NOTE:
8 Remove the oil seal from the inside of the water pump housing.
8 Remove the bearing from the inside of the water pump housing.
EAS00474
CHECKING THE WATER PUMP
1. Check:
• water pump housing cover
• water pump housing
• impeller ©
Cracks/damage/wear -» Replace.
6-9
2. Check:
• water pump seal (T)
Cracks/damage/wear -» Replace.
3. Check:
• bearing
Rough movement -» Replace.
4. Check:
• radiator outlet hose
Cracks/damage/wear -» Replace.
1
6-10
WATER PUMP
COOL J C
EAS00475
ASSEMBLING THE WATER PUMP
1. Install:
8bearing1
NOTE:
8 Before installing the oil seal, apply tap water or coolant onto its out surface.
8 Install the oil seal with a socket that matches its outside diameter.
2. Install:
8water pump seal New 1
(into the water pump housing 2 ) c C
Never lubricate the water pump seal surface with oil or grease.
NOTE:
8 Install the water pump seal with the special tools.
8 Press in depth of water pump and oil seal is 5.5~6.0mm a .
^
Mechanical seal installer
90890-04145 3
Middle driven shaft bearing driver
90890-04058 4
YM-04058
3. Measure:
8 impeller shaft tilt
Out of specification -» Replace the impeller shaft .
Impeller shaft tilt limit
0.15mm(0.0059in)
1 Straightedge
2 Impeller
4. Install:
8impeller s h a f t 1
8 p l a t e 2 c C
After installation, check that the impeller shaft rotates smoothly.
WATER PUMP
COOL J C
5. Install:
8gasket New
8water pump housing c o v e r 1
• water pump assembly (T)
M§
Iae EAS00478
INSTALLING THE WATER PUMP
1. Install:
X | 10Nm(1.0m
* kg, 7.2ft
* lb)
NOTE: b//
Align the slit a on the impeller shaft with
^ bolt.
2. Install:
• breather hose
• thermostat inlet hose
• water pump outlet hose
• radiator outlet hose
3. Fill:
• cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT” in chapter 3.
4. Check:
• cooling system
Leaks -» Repair or replace the faulty part.
5. Measure:
• radiator cap opening pressure
Below the specified pressure -» Replace the radiator cap.
Refer to “CHECKING THE RADIATOR”.
6-11
FI ifl
CHAPTER 7
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM 7-1
WIRING DIAGRAM 7-2
ECU’S SELF-DIAGNOSTIC FUNCTION 7-4
CHECKING FOR A DEFECTIVE ENGINE TROUBLE WARNING
LIGHT BULB 7-5
SELF-DIAGNOSTIC FANCTION TABLE 7-5
Self-diagnostic fanction table 7-5
TROUBLESHOOTING CHART 7-7
DIAGNOSTIC MODE 7-8
TROUBLESHOOTING DETAILS 7-12
THROTTLE BODY AND FUEL INJECTOR 7-26
THROTTLE BODY 7-26
FUEL INJECTOR AND FUEL HOSE 7-27
FUEL TANK 7-28
REMOVING THE FUEL HOSE 7-29
REMOVING THE FUEL PUMP 7-29
CHECKING THE THROTTLE BODY 7-30
INSTALLING THE FUEL PUMP 7-31
INSTALLING THE FUEL HOSE 7-31
CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OP-
ERATION 7-32
CHECKING THE THROTTLE POSITION SENSOR 7-32
CHECKING THE ISC (IDLE SPEED CONTROL) VALVE 7-34
AIR INDUCTION SYSTEM 7-35
AIR INJECTION 7-35
AIR CUT-OFF VALVE 7-35
AIR INDUCTION SYSTEM DIAGRAMS 7-36
AIR CUT-OFF VALVE AND AIR FILTER CASE 7-37
CHECKING THE AIR INDUCTION SYSTEM 7-38
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