13
Pump Clappet Valves
1. Disconnect the spark plug cap from the spark plug (page3).
2. Turn the fuel valve lever to the OFF position (page 3).
3. Flush the pump chamber (page 12).
4. Lift the suction side of the pump and allow all the water to drain out
the discharge fitting.
5. Use a 19 mm wrench and remove the nuts and flat washers from
both the suction and discharge ports.
6. Remove both ports. The clappet valves are directional, so when
removing the valves, note the water flow direction.
7. Inspect the ports, case sealing surfaces, and clappets for damage.
If the clappets are worn, torn, or damaged, replace them. If the
case sealing surface is damaged and cannot be cleaned, an
optional wear plate and gasket is available from your Honda water
pump dealer (page 20).
8. Install the clappet valves over the studs. On the discharge side,
install the flat side of the valve facing the pump housing. On the
suction side, install the flat side of the valve facing the port.
9. Install both ports, making sure all clappet valve tabs are
positioned correctly.
10. Apply several drops of Hondalock 2 or equivalent thread lock to
the stud threads. Hand tighten the nuts, then torque evenly.
TORQUE: 20 ft-lb (27 N•m)
11. After tightening the nuts, insert a screwdriver into each port and
check clappet valve operation. Clappets should operate freely
and should seal when released. If a clappet does not operate
properly, reinstall the clappet and recheck.
12. Run the pump and check for leaks.
Pump Diaphragm Disassembly
1. Disconnect the spark plug cap from the spark plug (page3).
2. Drain the fuel tank (page 16). Flush the pump chamber (page 12).
3. Remove the plastic connecting rod cover (page12 ).
Pull the starter grip to rotate the connecting rod to the down
position.
4. Remove the 4 nuts, washers, bolts, and the upper pump assembly
using a 19 mm wrench. Place the upper pump and engine
assembly to the side.
5. Use a 17 mm wrench and remove the bolt securing the
connecting rod to the crank arm. Wipe the rod surface clean and
use a felt tip marker to mark the outside of the connecting rod for
reassembly.
CLAPPET VALVE
(suction side)
FLAT
WASHER (4)
NUT (4)
CLAPPET VALVE
(discharge side)
CLAPPET
VALVE
TABS
PORT
DISCHARGE
PORT
SUCTION
PORT
CLAPPETVALVE
(flat side facing the
pump housing)
CLAPPETVALVE
(flatside facing
the port)
LOWER CASE
UPPERPUMP
ASSEMBLY
DIAPHRAGM
ASSEMBLY
CRANK ARM
12 x 50 mm
BOLT (4)
12 mm
WASHER (8)
12 mm
NUT (4)
NYLON
WASHER
WASHER
10mm LOCK WASHER
10x20mm
BOLT
CRANK
ARM
CONNECTING ROD