This how to is for the KDX 200 H series. It also applies the the H series 220.
Obviously we're going to need parts, so order up the mechanical seal, and oil seal. They can be found in the link below. Also included with the mechanical seal is the black and white part that sits inside the back of the impeller, and the metal cup the sits inside the water pump hole. These pieces make up the mechanical seal. Here are the part numbers
Note: Pay no mind to how the diagram has the parts in order...It's wrong.
http://www.bikebandit.com/oem-parts/199 ... 6#sch63173
Water pump mechanical seal: P/N 49063
Oil seal: P/N 92049B
Also, you'll need the right side engine cover gasket. P/N 11009A
Now I'm just doing the the mechanical seal and oil seal, But all the parts and part number are on that page if you need any other parts for the water pump.
So, let's get started.
I had already removed everything and had everything on my table, so I just put everything back together with 1 or 2 screws for the sake of this How To. So don't be scared when you only see 1 or 2 screws holding my right side together, haha.
First thing you'll need to do is drain the oil and coolant. Next you can remove the clutch cover. Pay attention to the longer screw on the top right. It'd be bad news if you put that anywhere else besides where it belongs.
Once you got that off, you can go ahead and take the clutch spring bolts out. Loosen them in a cross pattern, this way you're not putting too much pressure on one side.
Remove the springs, rod, ect and set them aside.
Next comes the nut that holds the clutch on. I usually put the bike in 6th gear and apply the brakes. It helps to have a long wrench for leverage.
Pay attention to the washer right behind that nut. Don't lose it.
Once that nut comes off, the clutch basket, ect, will slide right out. Make sure that the shim, and the washer behind the shim don't fall off as you're taking the clutch off.
Now you'll need to remove the kick start lever bolt and kick starter.
Now you're left with this
Remove the water pump cover and kips cover
Remove all of the engine cover screws, and slide it off.
You're bike should look like this now
Ok, guys. Here is where a lot of people (including myself) get confused. In this picture, we have the oil seal, mechanical seal, bearing, impeller, and shaft. Remeber, the mechanical seal consists of the metal cup, the little seal that sits inside of it, and the seal that sits inside of the impeller.
Take the mechanical seal (metal cup), and press it into the engine cover from the outside, so that the edges of the seal touch the step inside of the engine cover.
Next, take your oil seal and press it onto the back of the mechanical seal. Do this from the INSIDE of the engine cover. Make sure the flat surface of the oil seal is facing the outside of the engine cover.
Next, press the bearing into the the water pump hole from the INSIDE of the engine cover. Make sure it's flush.
Next, slide the shaft into the back of the bearing like so
Now we have the impeller and the other half of the mechanical seal. Just press it into the impeller, with the white part showing
It's also a good idea to put some coolant on these parts as you're installing them. Gives it a little lubrication.
Next just tighten the impeller nut down to factory spec, put it all back on the bike and go ride!
I think I covered everything. Let me know if I left something out.
