Water pump oil seal seat gouged - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

 
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post #1 of 5 Old 08-14-2016, 02:18 PM Thread Starter
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Join Date: Jul 2016
Location: East GTA
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Water pump oil seal seat gouged

So I went to do the water pump, since there was a bit of a leak, and after cleaning up in there it looks like someone did this before, and botched the oil seal while installing (maybe it was me pulling it, but I'm almost certain it isn't). So now theres some nice gouges in the oil seal seat area, and I'm wondering what I should do...maybe some permatex to fill in the gouge?

EDIT: Digging around a bit with a pick, feels like there might actually be a raised part -- guess I'll be pulling the cover, sanding it, and JB welding the seat...
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Last edited by drumstyx; 08-14-2016 at 02:43 PM.
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post #2 of 5 Old 08-14-2016, 05:15 PM Thread Starter
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Just an update on my plan... I've added some in weld, I'm letting it cure, then I'll be sanding it smooth. Next, I'll put a very thin layer of sealant around the outside of the seal. This means future seal removals won't be possible without removing the clutch cover to press it out and clean the surface, but I've concluded this is probably a better way to do it anyway.

Lesson learned: you'll probably save time by pressing out the seals rather than risking damage to the cover.
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post #3 of 5 Old 08-14-2016, 06:00 PM
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drumstyx,
I can see that you removed the Water Seal.
But the Oil Seal is the Black one at the back of the hole. Which one was leaking? Oil or Coolant?

If oil seal was leaking it is highly advised to remove the clutch cover to facilitated proper seal extraction. The water seal has to be removed/destroyed in order to replace the oil seal.
The 2 seals can be removed at the same time, from the back side. With a socket and press or socket and hammer.
Some people re-install the clutch cover before re-installing the seals. It reduces the chance of snagging the oil seal lip or rolling the lip inside-out and dislocating the little tension spring.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 84,000+ miles & counting
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post #4 of 5 Old 08-14-2016, 06:08 PM Thread Starter
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I believed it to be a bit of both, as it was oily but smelled like coolant. Didn't bother me to take the oil seal out, but I didn't want to pull the clutch cover as I didn't have a gasket for it. As it happens, the clutch cover came off easy and the gasket won't need replacing.

The picture might be a little crappy. But the oil seal is definitely removed there...the gouging is behind the weep hole there, where the oil seal seats. It's removed, dremeled, and has a dab of jb weld that will be sanded tomorrow after curing.
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post #5 of 5 Old 08-15-2016, 03:59 PM Thread Starter
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Join Date: Jul 2016
Location: East GTA
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Ground, JB welded, ground down again, and the new seal is in, with sealant around it setting up. Next time will be a bitch, but hopefully there won't be a next time!
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