Suzuki DR-Z400 Water Pump Fix


I did the fix last night and took some pics and notes to make this easy on people that haven't done it and want more detail. Please chime in if you think I've missed something.

Required Tools:

Set of Allen wrenches

#3 Phillips screwdriver

small flat head screwdriver

8 & 10 mm sockets

13 mm open end wrench (I needed this to remove my skid plate)

snap ring pliers

gasket scraper

compressed air

Required Parts:

New clutch cover gasket, Suzuki Part # 11482-29F00

Tube or can of RTV sealant

Oil filter and oil (if you plan to change the oil)

1. Remove your skid plate (if you have one). I have a Tonn's skid plate and it was in the way.

2. Remove right side radiator cover.

3. Unbolt the rear brake lever. This will require removing a cotter pin on the backside of the bolt, and then the bolt itself. I was able to swing the lever far enough out of the way without completely removing it from the bike (see pic).


4. Drain the coolant. This requires removing the radiator cap and the small bolt on the water pump, which has an aluminum washer on it. I rocked the bike from side to side to get most of the coolant out of the bike.

5. The oil, two options here. You can either drain the oil and remove the oil filter or you can do what I did which is lay the bike on its left side to keep the oil from pouring out of the engine when you remove the clutch cover. I still removed the oil filter so I could clean the clutch cover with brake clean after scraping the old gasket off.

6. Loosen the hose clamp on the coolant hose that attaches to the top of the water pump and fold the hose out of the way.

7. Remove the water pump cover and the clutch cover by removing the bolts holding them on. Note that some of the bolts are of different sizes so keep track of which hole you pulled them from. Also, not all of the bolts need be removed, see the pic below.


8. Remove the old gasket from the clutch cover and/or the engine with your gasket scraper. I then cleaned the clutch cover with brake cleaner as it was fairly oily.

9. With your snap ring pliers, remove the snap ring from the plastic gear on the clutch cover seen here:


10. Remove the plastic gear.

11. Push out the metal pin and remove the washer underneath as seen here:


12. With a screwdriver or whatever your preferred tool, remove the “E” clip as seen here:


13. After removing the “E” clip push the water pump shaft out of the clutch cover.

14. You will now have the part in your hand that needs fixing. Remove the porcelain gasket at the bottom of the shaft by blowing it with compressed air. Don’t not pry it with a screwdriver as it could damage the gasket. Mine was stuck fairly well so I sprayed some WD-40 on first to loosen it up.

15. If you used WD-40 clean the shaft and gasket with some brake cleaner and then apply the RTV sealant to this area (I reused this pic as its perfect):


16. Push the gasket back down flush on the shaft wiping away any excess RTV that may flow out.

17. Reassemble the shaft into the clutch cover in reverse order as listed in steps 9-13.

18. Place your new clutch cover gasket on the engine and then place the cover back onto the bike.

19. Put the bolts back into the clutch and water pump cover and tighten equally. I could not find a torque setting for these in the manual so I snugged them evenly.

20. Put the oil filter or a new one in the bike and put the oil filter cover back on.

21. Re-attach the brake lever and tighten the bolt to 21 ft lbs. Be sure to install a new cotter pin on the backside of the bolt.

22. If you drained your oil, refill the crankcase with the proper amount. If you didn’t drain the oil be sure you have enough in the crankcase from oil lost from removing the clutch cover.

23. Let bike sit for 24 hours to let the RTV set up before adding coolant.

24. Re-attach the coolant hose to the top of the water pump and tighten the hose clamp.

25. Fill the radiator with a “Silicate Free” anti-freeze and put the radiator cap back on and tighten the radiator cap screw.

26. Put the radiator cover and your skid plate back on the bike.

27. You are done, go ride!

User Feedback

I noticed that you cannot get the porcelain part separate. It is not even shown on the parts list. I expect it comes with the water pump shaft.


The small oil seal shown in the parts diagram seems to behind an aluminum cap which is behind the mechanical seal. That seems to be one that should be replaced as well. No mention in the service manual how to do that. How would you get the aluminum cap off without damaging it?

Share this comment

Link to comment
Share on other sites

Create an account or sign in to comment

You need to be a member in order to leave a comment

Reply with:

  • Similar Content

    • By zoeposit
      Hi All
      Selling the motor from my 00 Lc4e with only 5,014 miles on the clock !
      Posting it minus the water pump, covers, stator, tensioner,  in order to keep the price down - figuring you would have that stuff anyway.                                                                                        Does included thermostat housing and full clutch.
      The roller bearing upgrade was done by me with a puller that everyone shared back in the old days.
      Bike ran great, no issues or leaks.
      It can ship UPS for approx $100-$140 depending on location - contact me for an exact price.                                                                                                                                                     
      I'm located in NE PA about 2 hrs from NYC. 18415. Pickup is an option.
      I accept PayPal, but other conventional payments are fine too.
      Anything you need to know - let me know. Available by PM, Email, or Phone.

      Price $900

    • By Bryan Bosch

      Rockstar Energy Husqvarna Factory Rider Starts his Quest to Defend Cross-Country Rallies World Championship
      March 15, 2018 – (Motor Sports Newswire) – Rockstar Energy Husqvarna Factory Racing’s Pablo Quintanilla will re-start his 2018 international rally racing campaign on March 24 to 29 at the Abu Dhabi Desert Challenge in the United Arab Emirates. Working hard towards returning to full competitive fitness following a foot injury sustained during the closing stages of the Dakar Rally, Pablo’s teammate Andrew Short is expected to join the Rockstar Energy Husqvarna Factory Racing squad at the 2018 Merzouga Rally in mid-April.

      With the Abu Dhabi Desert Challenge playing host to the opening round of the 2018 FIM Cross-Country Rallies World Championship, the event in the UAE will see Pablo Quintanilla begin the defence of his FIM Cross-Country World Championship title. Securing eighth overall at the 2018 Dakar Rally in January, the Chilean rally star is already looking forward to a solid return to racing aboard his FR 450 Rally machine.
      Successfully wrapping up his debut participation at the prestigious Dakar Rally with a top 20 result, Andrew Short has been recuperating from a fractured tibia and fibula on his lower right leg. Resuming his training sessions in the middle of March, the American has his eyes set on making a return to racing at the Merzouga Rally on April 15/20, in the dunes of Morocco.
      Celebrating its 28th edition in 2018, the Abu Dhabi Desert Challenge is a six-stage-long rally taking place in the southern part of the United Arab Emirates. Kicking off with the traditional Super Special Stage on Saturday, March 24, the event will continue with five more days of racing in the Liwa Desert before competitors reach the finish line inside the Yas Marina circuit on March 29, 2018.

      Pablo Quintanilla: “Abu Dhabi will be our first race after the Dakar and I’m really looking forward to it. It’d be good to start the season carrying the #1 plate on my Husqvarna as the reigning champion. With it being the first race for the new season, it is important for everybody. My goal is to get a good race pace from the beginning in order to be inside the group of leading riders. The season will be long and my plan is to continue improving my pace as the racing goes on. I want to get back my racing speed and also remain strong throughout the event in Abu Dhabi. Taking place in deep sandy dunes, the Desert Challenge is always a tough event and it is also highly probable that we will have to race in high temperatures. It’s going to be a challenge but I’m looking forward to it.”
      Husqvarna Motorcycles. Tradition on two wheels since 1903.
      Husqvarna Motorcycles are widely known and respected in the off-road world for a heritage of competition and numerous motocross and enduro world championships. Originally founded in Sweden in 1903, Husqvarna Motorcycles have been designed and manufactured in Mattighofen, Austria since 2013.
      Rockstar Energy Drink
      Rockstar Energy Drink is designed for those who lead active lifestyles – from Athletes to Rockstars. Available in over 20 flavors at convenience and grocery outlets in over 30 countries, Rockstar supports the Rockstar lifestyle across the globe through Action Sports, Motor Sports, and Live Music. For more information visit:
      Source: Husqvarna Motorcycles GmbH

    • By Zach440
      Selling my 2009 Drz400sm. Been a great bike but it’s time to let go . Not looking for any trades - spring is just around the corner ! Located in northern Virginia . Cash only $4200- willing to negotiate I have some wolfman luggage options available as well. Love to make a package deal for someone 

      -11640 miles . Mild off-road never wrecked.
      -Oil / filter changed every 1500 miles
      -New did chain , brake pads , front sprocket at 10400 miles .
      - valves checked and within spec at 10,000
      - jetted with JD kit and 3x3 mod
      -doubletake mirrors
      -waterproof usb wired and located next to Speedo
      - drc large foot pegs , barkbusters with integrated turn signals . 12oclocklabs tall delete with upgraded circuit board
      -thumpertalk case savers
      -sergeant seat (amazing) and Clarke 3.9 tank (190mile range )
      - fog lights wired in so they shut off with high beams
      -Shorai lithium battery
      -led headlight

      - stock gas tank and seat will be included

      The bike is dirty in photos and I apologize my water is currently disabled outside due to freezing temps . Radiator guards and skid plate NOT included but can be for some extra $$. Rear tire could be replaced but front is fine .
    • By SendIt
      Was wondering if a newer model exhaust can fit on my 05 RMZ-250. My stock exhaust is rusted out and I prefer the look of the new ones and have seen great reviews on some, as I also want more weight savings. I have been unable to find out if a newer model can fit on my bike, was wondering if anyone could help me out.
    • By ThomasM.
      hotcams shim kit that will fit most 450's.
      I used 3x 1.75mm and 2x 1.7mm shims. the rest is still there
      part# HCSHIM02
      $60 shipped
      will fit:
      2002 - 2017 Honda CRF 450R BIKE,2005 - 2017 Honda CRF 450X BIKE,2003 - 2004 Kawasaki KLX 400 BIKE,2008 - 2009 Kawasaki KLX 450R BIKE,2008 - 2017 Kawasaki KX 450F BIKE,2000 - 2016 Suzuki DRZ 400 BIKE,2005 - 2015 Suzuki DRZ 400S BIKE,2016 - 2017 Suzuki DRZ 400SM BIKE,2005 - 2017 Suzuki RMZ 450 BIKE,2014 - 2017 Yamaha WR 250F BIKE,2003 - 2016 Yamaha WR 450F BIKE,2014 - 2017 Yamaha YZ 250F BIKE,1998 - 1999 Yamaha YZ 400 F BIKE,2000 - 2002 Yamaha YZ 426 F BIKE,2003 - 2017 Yamaha YZ 450F