Tech doc discussion: Water Pump Seal/Bearing Replacement

[Jarney]

Just did a search for the part number Kawboy found and found this on a KLR site - a tech doc for their water pumps.

[FONT=Geneva, Arial, Helvetica, sans-serif]"B). Always install oil seal (92049) prior to installing the mechanical seal (49063).
Both seals fit into the same opening - back to back. You can remove and install the side case multiple times, but YOU CAN ONLY REMOVE the mechanical and oil seals from the case once and then they should be considered damaged. [/FONT]
[FONT=Geneva, Arial, Helvetica, sans-serif]The mechanical seal consists of three pieces and is listed as part - 49063. The first piece has blue waterproof sealer, a spring with rubber face and it fits into the case. It should be driven gently until the lip is seated flush into the case using an appropriately sized socket (after first installing the oil seal). The other two pieces of the mechanical seal fit in back of the impeller - namely the white ceramic disk and its mating rubber 'ring' into which is the holder for the ceramic ring. [/FONT]
[FONT=Geneva, Arial, Helvetica, sans-serif]Remember if you remove the mechanical seal, you MUST replace both the oil seal and the mechanical seal set. Don't forget the shims - one on each side of the impeller."[/FONT]

Here is the link for the quote above - there's a pic of the mechanical seal if you scroll down the page far enough. They don't give the size of it though so I don't know if it would work or not. Maybe they have a source for them if they are the right size. Maybe the concourse guys would have a source for them? Later.

http://www.klr650.marknet.us/wpump.html

 

[Jarney]

Ok, if you search the X-ref, it shows 2 water pumps for the ZL900
49044-1053 and 49044-1058

Depending on which pump you look up:

49044-1053

85-86 zl 900
84-86 zx 900
86 zx 1000


49044-1058

86-88, 90-95, 97-2000 ZG1000
87 zl1000
85-86 zl900
86-87 zx1000
84-86 zx900

 

[Jarney]

Ok, snagged a caliper and took some measurements and wrote down numbers from the .1

The 2 bearings and the seal are 28mm
Mech Seal - rubber part is 26mm, bottom of metal part is 30mm and the lip or flange of the metal piece is 35mm

Bearings say:
Japan NSK 6001DU 589

Seal says:
C7 SD 12 28 7-1 Then there's some sort of symbol on it that looks like ALS


The seal on the .2 is 25mm and says:
A20 S 12 25 7L NS and then that same symbol.

Not sure when I'll get the rest of the .2 apart but I'll post up when I get any info off the parts. Later.

 

[kawboy]

Jarney - in post #60, left-hand picture, is that an o-ring between the pump and the oil seal? I don't have that piece.

 

[SnakeDoctor]

Ok, if you search the X-ref, it shows 2 water pumps for the ZL900
49044-1053 and 49044-1058

Depending on which pump you look up:

49044-1053

85-86 zl 900
84-86 zx 900
86 zx 1000


49044-1058

86-88, 90-95, 97-2000 ZG1000
87 zl1000
85-86 zl900
86-87 zx1000
84-86 zx900

OK then, which of these has the c-clip on the shaft ( I have this type) and can anyone supply samples of the parts for the other one? Doesn't matter if they are used as long as my supplier can figure what they are and get correct measurements. Maybe someone has an old water pump that doesn't have the c-clip on it that I can take to my supplier. Just trying to help here guys as I think I can get everything here for both models.

 

[kawboy]

OK then, which of these has the c-clip on the shaft ( I have this type) and can anyone supply samples of the parts for the other one?

SD - from above

"The seal on the .2 is 25mm and says:
A20 S 12 25 7L NS and then that same symbol."

This is the oil seal - same as the .1, but 25 mm od.

I'm betting the mech seal will be the same in both pumps.

 

[kawboy]

I've sent the measurements of the mech seal to the KLR guy. Hopefully he will respond, and hopefully it'll be the same seal. If so, and if SD can't get it, we can get it from Kaw.

 

[hassethehen]

My eyes has went by this thread some time, without reading it.

Thats until i saw the waterpump in my import engine which shortly will go into my freshly painted frame. (It need some love before i put it all togehter.) Ah, i thought, i better buy a new one. "ONLY" 162US $ on Bikebandit. (The word "Bandit" has a different meaning for me after that...)
I will do the repairs myself and thanks to this thread it feels really doable although i don't have the hydraulic press in my garage.
Thanks, guys!

/H

 

[Jarney]

Kawboy: Sorry about that, should have taken that piece out of the pic - it's just the spring that goes in the oil seal. I agree that I think the mech seal will be the same size as will be the inner bearing in both pumps. It appears it's just the outer seal and bearing that are different.

SD: The 990 .1 has the snap ring or c-clip. The 990 .2 does not.

I should have the .2 apart tomorrow (my press guy wasn't home today) and will post up the other measurements, numbers, etc., what ever info I can find out once it's apart. Later.

 

[kawboy]

I should have the .2 apart tomorrow (my press guy wasn't home today) .

Jarney - I don't have a press either. I used a BFH.
Set the pump on 2 4x4 blocks, set a socket or something on the impeller shaft end, and hammered it out.

Once the impeller shaft is out, you can get a punch in there to tap around the edge of the outer bearing.

Then turn the pump over, repeat for the inner bearing, which pushes the mech seal out.

Probably not the best way, but it's a bad pump anyway, can't hurt it.

I got the seat (ceramic part) out of the impeller. Nothing holding it in but rust and corrosion. The seat itself measures 23 mm od, 14 mm id, 4 mm th. With the gasket installed it's 25 mm od, 5 mm th.

 

[Jarney]

Kawboy:
yeah, the .1's come apart pretty easy. I popped 2 of them apart with very little trouble. It's this .2 that is a freakin' nightmare.

I ended up getting the machinist to press apart the .2 today. He said it was a bear and couldn't believe how stuck in there it was. He used a hydraulic press and it made one heck of a pop when it broke free - I thought the housing busted, even then it struggled to come out. The bad thing is, the bearing is still on the shaft - they didn't have anything small enough to pull it off with and neither do I so I'll have to try and locate somebody at work tomorrow and see if I can get the bearing off.

And if you are real observant in the above paragraph - you read right - bearing - as in ONE. The mech seal appears to be the same measurements, the bearing is 24mm od and approx. 34 - 35 mm long. I won't know exact measurements until I can get the **** thing off the impeller shaft. Here's a pic:

Later.

 

[SnakeDoctor]

Can someone send me the parts for the number 2 pump (the one without the c-clip) so I can get these parts lined up here? Thanks

 

[kawboy]

And if you are real observant in the above paragraph - you read right - bearing - as in ONE. The mech seal appears to be the same measurements, the bearing is 24mm od and approx. 34 - 35 mm long. I won't know exact measurements until I can get the **** thing off the impeller shaft.

Now that's a bearing .

Do we know which one is newer? The .1 looks like a better design, but you'd think .2 would come AFTER .1 (?)

I replaced mine a few years ago and still have the box. It's the later p/n 49044-1058. Went out to the garage to look at the bike. Saw 990, but no .1 or .2 (it's dark, I'll look again in the daytime). What I did see is oil film on the bottom of the pump, so I need to get parts together I guess.

 

[Jarney]

Can someone send me the parts for the number 2 pump (the one without the c-clip) so I can get these parts lined up here? Thanks

Patience doc.....hahaha.....
I'm trying to get some info on the .2 parts but I still can't get the freakin' bearing off the impeller. I had a puller cranked down on it today - didn't budge - added some heat - didn't budge - banged on it with a hammer - didn't budge. I'm going to try and throw it in the freezer overnight just for giggles and see what happens. Man that thing is on there something awful. I'm going to hand it over to a guy I work with that has his own welding business on the side tomorrow and see what he can do with it if it doesn't pop off overnight. Maybe I'll just get ticked off and grab the die grinder and cut the stinkin' thing off - wouldn't do us much good that way though. Later.

 

[Jarney]

Now that's a bearing .

Do we know which one is newer? The .1 looks like a better design, but you'd think .2 would come AFTER .1 (?)

I replaced mine a few years ago and still have the box. It's the later p/n 49044-1058. Went out to the garage to look at the bike. Saw 990, but no .1 or .2 (it's dark, I'll look again in the daytime). What I did see is oil film on the bottom of the pump, so I need to get parts together I guess.

Yeah, that would make sense Kawboy.
.1 is definitely a better set up.
If or when you pull the pump, it may be stamped on the back, all 3 of mine were stamped on both sides. Later.
Later.

 

[kawboy]

Yeah, that would make sense Kawboy.
.1 is definitely a better set up.
If or when you pull the pump, it may be stamped on the back, all 3 of mine were stamped on both sides. Later.
Later.

Hope it's not a ".3"

 

[Jarney]

Ok, the .2 is apart - what a mess. Turns out the impeller shaft IS the inner race. You can see in the pic of the impeller shaft, 2 grooves where the ball bearings ride. No wonder it didn't want to come apart. I have no idea how they even put this thing together. So I'm going to check a few places and see what's available and see what can be done with it.

With the .2 bearing being such a small diameter, do you think a standard needle bearing would work ok? Might be able to find a needle bearing that would fit the shaft and have the same outer dimensions? That would eliminate this whole set up that way?

All I can say is I hope none of you have this set up in your water pumps. Here's a couple of **** poor pics. Later.

 

[kawboy]

That is a weird set-up.

Might be able to find a needle bearing that would fit the shaft and have the same outer dimensions?

That might work - or it may not be worth messin' with.

 

[Jarney]

Just found this on the zx forum. At least the seal is the same size so maybe the other parts are the same size too? Anybody a member of the zx forums that could ask around? This guy rides a 92 zx 11. Later.



"(P.S. - I called the Kawasaki shop today and all they said the only parts listed were the O-ring for the housing (mine is good) and the whole $170 water pump. He said no oil seal was listed. THAT SUCKS.)

Don't throw away your old pump,if the oilseal is the only problem.

I had the same answer fm my Kaw dealer,and they are right. They do not sell this pumps in loose parts.
But I managed to find replacement for both the Lip seal and the mechanical seal and the two ballbearings that sits on the shaft.
Just measure the old lip seal of yours,it should be 12-28-7,all in millimetre.( 12 is hole diameter,28 is diameter overall and 7 is thickness) Go to a shop that sells this seals,and You will find one.Cost almost nothing. Good luck"

 

[gosupes]

Just measure the old lip seal of yours,it should be 12-28-7,all in millimetre.( 12 is hole diameter,28 is diameter overall and 7 is thickness) Go to a shop that sells this seals,and You will find one.Cost almost nothing. Good luck"

There is also the seal type, TC, which is double lipped.