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Just bought a 91 Kawisaki KDX200 and took the water pump cover off to inspect, and a big surprise, the impeller falls out along with the impeller bolt head, with the remaining bolt lodged inside the gear shaft. Who knows how long this has been running without any circulating water. Luckily I've only used it once since I bought it.

My question is, how does something like that happen? My brother says bad bearings but they seem fine when I took the engine cover off to remove the impeller gear shaft. My guess was someone left water in it for the winter and tried to startwith frozen water in the impeller housing and just snapped it off...any ideas?

Probably fatigue from over-tightening. Be extra careful trying to get the broken bolt out of the shaft, as the shaft is apparently discontinued and no longer available from most suppliers.

My bro took it into work today and got it out! Soo happy...so now just a matter of ordering a new bolt...

Also, note the washer was on the outside of the impeller but the schematics diagram says the washer goes inside, against the seal??

Hello...

Broke one electrical discharge on the water pump impeller lodging of a 1989 9.9 hp. ..,
So, please tell me Would I be able to get by with three bolts....?

Hello. Please start a new thread. Welcome to kdxrider.