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Discussion Starter #121
The minor scuff marks inside of the oil pump are totally normal. The pre-screen under the clutch only takes out chunks big enough to truly Hurt the pump. The paper oil filter is supposed to filter the finer particulates out. (As long as people don't throw away the by-pass pin.)

So back to solid dowel. Hummmmm. There is such a Kawasaki part number, #551A0408 Dowel pin, https://www.kawasakipartshouse.com/oemparts/partsearch/kawasaki?partsearch=551a0408 But not used any where on a KLR650.

Tom is correct, there are two, #610A0408 solid dowels used on ALL KLR650 water pump covers. https://www.kawasakipartshouse.com/oemparts/partsearch/kawasaki?partsearch=610a0408 Wonder why this part search shows 1996-1999 650? Guess that just tells us how Incomplete a search can be.

Also makes one wonder why 2 numbers for basically same part, 551A0408 & 610A0408? The left handed man forgot to look in the right hand drawer?
 

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The minor scuff marks inside of the oil pump are totally normal. The pre-screen under the clutch only takes out chunks big enough to truly Hurt the pump. The paper oil filter is supposed to filter the finer particulates out. (As long as people don't throw away the by-pass pin.)
OK good to know the wear is normal. Oil pump gasket is hopefully my last order before I button it all back up.

Thanks to both of you again, I discovered that 551 is 6mm diameter, and 610 is 4mm dia. This was, in fact, the culprit - apparently stayed in the case cover until i started maneuvering it around.
 
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