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2009 Kawasaki mule trans 4x4 water pump

3.9K views 1 reply 2 participants last post by  imported_cookie_monster  
#1 ·
Changing the water pump and need help. There is a bottom bolt that is hitting and can’t be pulled out all the way. Is there a step by step to removing water pump out there.
 
#2 ·
yeah

drain coolant and oil completely
remove outer belt cover
remove left rear shock absorber
remove front clutch
remove rear clutch
remove inner belt cover
remove the engine brace
remove water pump
remove the shifter cable bracket (top of transmission)-it is also bolted to the engine
loosen the two right side engine mounting bolts
remove the two left side engine mounting bolts
remove the crankcase cover
scrape all gasket residue from the crankcase cover & install new gasket
reinstall crankcase cover
install new water pump with new gasket
install newe water pump cover gasket
install all of the bolts with anti-sneeze on them and torque them per the shop manual
reinstall inner belt cover
reinstall rear clutch
reinstall front clutch and belt
reinstall outer belt cover
add oil & replace oil filter
remove coolant bleeder bolt from intake manifold
fill coolant through the radiator until it comes out of the intake bleed hole
reinstall bleeder bolt in the intake
remove bleed bolt from coolant pipe near the carburetor intake box
continue filling coolant thru radiator until it comes out of the pipe bleeder bolt
replace bleeder bolt in the pipe
continue filling the radiator until it's full
start engine with the radiator cap off
watch for bubbles to stop if they don't you have a leaking head gasket (doesn't take much more than a minute or so to stop)
stop the engine
top off the radiator and put the cap back on
fill the coolant reservoir until it's about half full (not a the full hot mark, about half full)
go drive around for a while then stop the engine
let engine cool overnight
in the morning look at your coolant tank, should be near the cold fill, if it is, leave it alone. If it's empty you didn't bleed it properly and you get to do it again

I hope I didnt' miss a step if I did sorry

u don't need to take the exhaust off but it does make it a little easier, slows the process down though and you will need 4 gaskets 2 on the heads and two at the back

Yes I said take the crankcase cover off because when you loosen the water pump bolts, which sandwiches the upper part of the crankcase cover against the block, they'll almost always leak oil and/or coolant. Replace that gasket! Or live with an oil leak, your choice. It takes literally 5 minutes to replace it once you're there.

let's see how quick you can do it, I've done them in 58 minutes before but that's working as fast as one man wants to ever work on a new-ish mule so the gaskets weren't too terribly stuck