Water pump seals, possible infection. - 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 11 Old 02-03-2020, 05:56 PM Thread Starter
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Water pump seals, possible infection.

I'm half way through replacing the water pump seals.
I removed most of the seal paraphernalia apart from the seal embedded into the clutch cover housing that was rusted into place..
To do this I had to remove the clutch cover housing ( knocking off the gear change U spring in the process).
The replacement seals are coming from eBay via China, however due to the Corona Virus, my order, although they arrived in Spain a week ago, delivery will be apparently delayed.
I am no expert in viral diseases but mechanical seals should not pose any health threat.

As an aside I was looking at the oil distribution mods whilst I had the clutch cover off but decided against it. I usually ride at a steady 4000 RPM with the occasional increase for an overtake. The mods seem to be for riding at much higher revs.

BTW original Kawasaki oil filter costs $$, However I bought one locally for 5 Euros. Champion COF023.

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post #2 of 11 Old 02-03-2020, 07:07 PM
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The 3 banjo bolt replacements or drilling of existing banjo bolts can only improve the KLR engine lubrication system. Kawasaki did this themselves for the KLX series engines back in 1993!

The KLR series engines are the only ones to EVER use the tiny holed banjo bolts. The banjo bolt by the starter motor should at least have 2 holes to properly feed the other 2 holes, shouldn't it?

With more oil feed thru the oil pipe, the 4 camshaft bearings, 5 free-spinning gears, the bushing in the clutch hub, all transmission and upper rear balancer bearings receive more oil volume.

Simple, Cheap & Easy.

Sorry to hear about your parts delay.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #3 of 11 Old 02-03-2020, 07:30 PM
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Is there a forum topic on the banjo bolt mod?
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post #4 of 11 Old 02-03-2020, 08:29 PM
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Would you like the original version, https://www.klrforum.com/1987-2007-w...ch-ya-got.html

The condensed version, https://www.klrforum.com/1987-2007-w...mportance.html

Or the easiest to read, complete with videos by Tom Schmitz? https://www.souperdoo.com/stuff%20th...ht-oil-burning

Or Toms original full expose-ay, https://www.klrforum.com/2008-klr650...09-klr650.html

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post #5 of 11 Old 02-04-2020, 06:54 PM Thread Starter
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Quote:
Originally Posted by pdwestman View Post
The 3 banjo bolt replacements or drilling of existing banjo bolts can only improve the KLR engine lubrication system. Kawasaki did this themselves for the KLX series engines back in 1993!

The KLR series engines are the only ones to EVER use the tiny holed banjo bolts. The banjo bolt by the starter motor should at least have 2 holes to properly feed the other 2 holes, shouldn't it?

With more oil feed thru the oil pipe, the 4 camshaft bearings, 5 free-spinning gears, the bushing in the clutch hub, all transmission and upper rear balancer bearings receive more oil volume.

Simple, Cheap & Easy.

Sorry to hear about your parts delay.
That does seem like a quick and inexpensive mod.
I don't have any imperial 1/8" drill bits so I'll use a 3mm drill bit.

Still no parts delivery!!!
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post #6 of 11 Old 03-04-2020, 07:35 AM Thread Starter
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Wrong parts

After waiting for over two months for the water pump repair kit to arrive guess what?
They sent the wrong parts, the diameters of all sections are much too big. (see attached image)
An example, the old impeller seal diameter is around 11.60mm the replacement they sent is 15mm. so I don't know which KLR650 model has that dimension?

I'll now pay again but this time I'll order from Germany.
Attached Images
File Type: jpg Kawasaki KLR650 wpump seals.jpg (201.8 KB, 5 views)

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post #7 of 11 Old 03-04-2020, 03:25 PM
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All years of KLR650 use the same water pump seals, all parts.

They just plumb sent the wrong stuff.

Here in the US we are fortunate to have internet businesses like Partzilla that sell every OEM part that is still available. Some of these companies have Canadian branches so that our brothers to the north don't have to order from the US and pay for expensive and lengthy shipping with duty fees and such like that.

Are there similar businesses in the EU?

If there are, it makes me wonder what the effect will be on Brexit citizens. To be sorted, I suppose.

Tom [email protected]

I still held his automatic more or less pointed at him, but he swung on me just the same. It caught me flush on the chin. It was meant to be a hard one, but a pansy has no iron in his bones, whatever he looks like. -Philip Marlowe

'Why' and 'How' are words so important they cannot be too often used. -Napoleon Bonaparte

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post #8 of 11 Old 03-05-2020, 01:05 PM Thread Starter
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Thanks for that info Tom, and as you state this Brexit thing is still an unknown quantity!!

I've now ordered the mechanical seal from Germany but I still have to get the PN#92049 oil seal. I can buy oil seals locally but i need to know the ODxIDxheight/thickness.
If anyone has those measurements to hand I would be most grateful.
Many thanks,
James.

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post #9 of 11 Old 03-05-2020, 01:54 PM
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Description on this parts page, SC10227 tells my that 92049-1157 oil seal measures 10 x 22 x 7 mm.

https://www.kawasakipartshouse.com/o...b50/water-pump

My caliper agrees.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #10 of 11 Old 03-05-2020, 02:00 PM Thread Starter
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Quote:
Originally Posted by pdwestman View Post
Description on this parts page, SC10227 tells my that 92049-1157 oil seal measures 10 x 22 x 7 mm.

https://www.kawasakipartshouse.com/o...b50/water-pump

My caliper agrees.
Wow, that was a quick reply

Thanks so much for those measurements, I can now buy one from my local supplier without having to order and pay shipping for one.

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