Water Pump seal(s) replacement - 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 12 Old 09-15-2009, 10:55 PM Thread Starter
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Water Pump seal(s) replacement

I checked the forums and can't find a How To for the water pump seal(s) replacement. I found one at MarkNet but I don't liek the idea of removing the right side cover. Does the right side cover have to be removed?

There are only two drops of coolant from the weep hole in 24 hours. I have a 1,500 mile trip that leaves in three days and would rather wait until after the trip for the repair. What are the chances that the water pump will hold its own during the trip?

Thanks in advance.

Tim

2005 KLR 685
2015 Yamaha Super Tenere ES, 5/23/2015
2012 Yamaha Super Tenere; Purchased 7/30/2011; Sold 5/23/2015
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post #2 of 12 Old 09-16-2009, 10:27 PM Thread Starter
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If I can get the gasket off I would be in the reinstall mode.

Any thoughts on how to remove the gasket that was installed with Permatex? Don't ask.
I am trying Goo Off with little help. I have many experiences with stuck gaskets though they were on cast iron and you can abuse the heck out of that.

Thoughts!!!

Tim

2005 KLR 685
2015 Yamaha Super Tenere ES, 5/23/2015
2012 Yamaha Super Tenere; Purchased 7/30/2011; Sold 5/23/2015
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post #3 of 12 Old 09-16-2009, 10:54 PM
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Tim -


Soak a rag in isopropyl alcohol and let it set on the Permatex. It should soften up. Rubbing briskly with a stiff finger nail type brush that is dipped in alcohol may allow you to do it faster.

I know you're in a time crunch - hope that helps.

Tom
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post #4 of 12 Old 09-16-2009, 11:30 PM Thread Starter
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Quote:
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Tim -


Soak a rag in isopropyl alcohol and let it set on the Permatex. It should soften up. Rubbing briskly with a stiff finger nail type brush that is dipped in alcohol may allow you to do it faster.

I know you're in a time crunch - hope that helps.

Tom

Thanks Tom,

I did get some Permatex Gasket Remover and it is cooking as we read. The directions say to leave it on at least 15 minutes. I also purchased some plastic scrapers to help protect the aluminum surface.

If this does not work I will give the IA a try.

If I get the gasket off tonight I will finish in the morning.

Tim

2005 KLR 685
2015 Yamaha Super Tenere ES, 5/23/2015
2012 Yamaha Super Tenere; Purchased 7/30/2011; Sold 5/23/2015
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post #5 of 12 Old 09-17-2009, 12:22 AM
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Tim -


I will have to look into this gasket remover stuff. I've always used the IA, 'cuz it's the solvent in Permatex.

Permatex is just about the only thing that will make a British 4 banger almost oil tight. Almost.

Son of a gun to get off, though...

Tom
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post #6 of 12 Old 09-17-2009, 01:32 AM Thread Starter
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Quote:
Originally Posted by Tom Schmitz View Post
Tim -


I will have to look into this gasket remover stuff. I've always used the IA, 'cuz it's the solvent in Permatex.

Permatex is just about the only thing that will make a British 4 banger almost oil tight. Almost.

Son of a gun to get off, though...

Tom
The Permatex Gasket Remover did the job though I used three applications. It is a foam and has a brush as the applicator. I used a metal scraper and surprisingly it did not ding the surface.

Tom are you going to the Julian KLR Tech Day on 10/10/2009? I will be there though most likely on my V-Strom DL1000. I will be riding in from San Diego and departing to Lake Elsinore.

What is the condition of Angeles Crest Highway? I plan on riding it on either the 5th or 12th.

Tim

2005 KLR 685
2015 Yamaha Super Tenere ES, 5/23/2015
2012 Yamaha Super Tenere; Purchased 7/30/2011; Sold 5/23/2015
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post #7 of 12 Old 09-17-2009, 06:33 PM
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Tim -

One of these days I want to go to a Julian tech day, but it won't be this upcoming one.

A friend and I are circumnavigating southern California that week and will be coming home from Whitney Portal that day.

We'll be leaving LA and heading generally up to Carmel, then through the valley over to Yosemite and straight through to Benton, then down 395 to LA again. There will be a handful of side trips thrown in.

When I do get to Julian, I'll hope I'll be bringing some suspension bits to install, as I think I need a guiding hand with that stuff.

As far as Angeles Crest goes - I think it is open now, and surely should be open by the first of October. I hadn't heard of any damage from the fire. Might be a bit spooky up there. I remember riding up Harris grade, the back way into Lompoc, 15 years ago after a fire. It was really eery.

Tom

Last edited by Tom Schmitz; 09-17-2009 at 06:40 PM.
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post #8 of 12 Old 09-17-2009, 07:08 PM Thread Starter
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Tim -

One of these days I want to go to a Julian tech day, but it won't be this upcoming one.

A friend and I are circumnavigating southern California that week and will be coming home from Whitney Portal that day.

We'll be leaving LA and heading generally up to Carmel, then through the valley over to Yosemite and straight through to Benton, then down 395 to LA again. There will be a handful of side trips thrown in.

When I do get to Julian, I'll hope I'll be bringing some suspension bits to install, as I think I need a guiding hand with that stuff.

As far as Angeles Crest goes - I think it is open now, and surely should be open by the first of October. I hadn't heard of any damage from the fire. Might be a bit spooky up there. I remember riding up Harris grade, the back way into Lompoc, 15 years ago after a fire. It was really eery.

Tom
Tom,

This will be the last Julian for the year and I not sure if they are doing another in San Diego this year.

What suspension parts? I have done everything but remove the rear shock and you could do any of these projects. I just install the Ricor Intiminator Fork Valves and that was a fun project. If you are doing the RaceTech Gold Valves you might need some assurance and a helping hand.

I am coming over Monitor Pass with an overnight in Bishop. Then to Lone Pine to Las Vegas then to Socal. I plan on visiting Mt Whitney Portal on the way home though will visit Randsburg before that. I will be taking Sonora Pass on the return trip though plan to stop at the Marine base for lunch.

Enjoy your journey and stop at Corbin's (Hollister) for lunch (excellent diner) and ride Hwy 25.

Tim

2005 KLR 685
2015 Yamaha Super Tenere ES, 5/23/2015
2012 Yamaha Super Tenere; Purchased 7/30/2011; Sold 5/23/2015
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post #9 of 12 Old 09-17-2009, 07:34 PM
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Tim -

The rear doesn't bother me too much as the plan is for a Moab shock. That should pretty much be an R&R.

On the front I'm thinking of progressively wound shocks and some emulators. From what I hear, setting up the emulators is where I could use some help. My experience with suspension has been limited to destroying it while on the bike.

All of this will likely take place next spring.

We'll be taking Carmel Valley road south out of Carmel and wiggle waggling south until we hit 25, then north to Hollister. From there we sweep through the valley and head in to Yosemite.

Tom
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post #10 of 12 Old 09-17-2009, 08:20 PM Thread Starter
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Quote:
Originally Posted by Tom Schmitz View Post
Tim -

The rear doesn't bother me too much as the plan is for a Moab shock. That should pretty much be an R&R.

On the front I'm thinking of progressively wound shocks and some emulators. From what I hear, setting up the emulators is where I could use some help. My experience with suspension has been limited to destroying it while on the bike.

All of this will likely take place next spring.

We'll be taking Carmel Valley road south out of Carmel and wiggle waggling south until we hit 25, then north to Hollister. From there we sweep through the valley and head in to Yosemite.

Tom
Consider the Ricor Intiminators. You can install them in two hours. Call Don and talk to him about the comparision.

The diner at Corbin's has excellent food and great diner atmosphere.

Tim

2005 KLR 685
2015 Yamaha Super Tenere ES, 5/23/2015
2012 Yamaha Super Tenere; Purchased 7/30/2011; Sold 5/23/2015
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