Waterpump shaft with a broken gear

eprovenzano · Post by **eprovenzano** » 09:14 am Mar 10 2016

On my 91 basket case I have a noise in the bottom end. The crank rolled smoothly, and knowing the previous owner recently put new clutch plates in I was thinking something was amiss with the idler gear. So I pulled the clutch side cover and found the kickstart return spring was not in its little hole, it was rubbing on the clutch gear... hence the noise I could here...

I reinstalled everything to only to now hear a clunking noise... So I pull it apart again and find a broken tooth on the water pump shaft

This happens when you try to force the side case on without getting the gears to mesh properly... (ask me how I know, as I learned that valuable expensive lesson before). No this one came to me this way...

I looked up part number for the shaft, 13234-1092. The only shaft I've found (so far) is for a H series KDX part number 13234-1091... Does anyone know if they are the same, or did Kawi change the design a little in the H series KDX... Better yet, does anyone have a spare water pump shaft they'd be willing to part with.

eprovenzano · Post by **eprovenzano** » 11:30 am Mar 10 2016

I did some digging and compared pictures. I found they are different. From my research, there's a difference the following years, 89-90, 91-94, and 95+ Damn....

I'm struggling to find one for my 91.

eprovenzano · Post by **eprovenzano** » 01:00 pm Mar 10 2016

I'm thinking I "may" be able to have the H series machined to match the E series shaft.

Here are pics of both the H and E series shafts. As you can see the shaft of the H series that connects to the impeller is larger than the E series, also the connection of the impeller to the shaft is different... The part of the shaft that would lie in the bearing to me look very similar. As long as the H series shafts are longer and or wider, I'm good... Are the gears the same?

Pic of an H series water pump shaft

Pic of an E series water pump shaft

Davenay67 · Post by **Davenay67** » 02:55 pm Mar 10 2016

This might be a long shot, but did you try motorcycle salvage yards. I know there are a number of resources online now for sourcing used parts for motorcycles.

Not a comprehensive list by any mean, but a bit of a start....

http://www.uneedapart.com/used-motorcycle-parts/

http://www.usedmotorcyclesandparts.com/

http://www.cannibalcycle.com/

I used to spend many a happy hour scrounging through my local salvage yards looking for cheap parts to keep my beaters going. That type of operation seems long gone now, but the reach of the internet has broadened the capacity to find parts.

Davenay67 · Post by **Davenay67** » 02:57 pm Mar 10 2016

Is this any use..??

http://www.ebay.co.uk/itm/381510474366? ... rmvSB=true

david · Post by **david** » 03:01 pm Mar 10 2016

How about just the gear. Found this on ebay
http://www.ebay.com/itm/1991-KAWASAKI-K ... yP&vxp=mtr

eprovenzano · Post by **eprovenzano** » 03:04 pm Mar 10 2016

david wrote:How about just the gear. Found this on ebay
http://www.ebay.com/itm/1991-KAWASAKI-K ... yP&vxp=mtr

The gear is what goes onto the crankshaft. I need the opposing shaft that turns the impeller... Thanks though...

The part number I need is 13234 1092

Davenay67 · Post by **Davenay67** » 03:09 pm Mar 10 2016

Looks like Ron Ayers has them in stock....

http://www.ronayers.com/oemparts/p/kawa ... -comp-pump

eprovenzano · Post by **eprovenzano** » 03:16 pm Mar 10 2016

Davenay67 wrote:Looks like Ron Ayers has them in stock....

http://www.ronayers.com/oemparts/p/kawa ... -comp-pump

I looked at their site earlier and while it shows it available, I "ASSUMED" it was not... I just placed an order so we see if it available...

Thanks

david · Post by **david** » 03:22 pm Mar 10 2016

Service Honda's site shows the shaft as 'no longer available'.

eprovenzano · Post by **eprovenzano** » 03:23 pm Mar 10 2016

david wrote:Service Honda's site shows the shaft as 'no longer available'.

Most of the sites I've looked at show the item is no longer available... But I keep trying...

Post by **Julien D** » 04:42 pm Mar 10 2016

I have wondered in the past. I THINK it may be possible to use the H series shaft if you also use the H series impeller. You may also need H series seals / bearings. Hard to say for sure as I dont know of anyone who actually tried.

david · Post by **david** » 04:57 pm Mar 10 2016

Well the H uses a typical carbon/ceramic water pump seal, where the E uses a conventional rubber lip seal(s). I would think the seal locations are different sizes and not interchangeable.

eprovenzano · Post by **eprovenzano** » 05:01 pm Mar 10 2016

I agree, but I'm thinking as a last resort, can have an "H" shaft machined down to match an "E" series. For a machinist with a good lath it shouldn't be too difficult. Of course this is the shafts are at least the same diameter (if not bigger), the length can be made to work, and of course the gear has to be the the same.

david · Post by **david** » 05:18 pm Mar 10 2016

Surly you should be able to find someone on here that has one. The other thing you can do is find a seller on eBay with some other parts for the same year your looking at, and message them to ask if they have the water pump shaft.

eprovenzano · Post by **eprovenzano** » 05:22 pm Mar 10 2016

I put out quite a few emails looking for the shaft. The salvage yards I called don't have any

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david · Post by **david** » 05:24 pm Mar 10 2016

Sounds like your on it. Good luck, wish I had one for you.

eprovenzano · Post by **eprovenzano** » 09:48 am Mar 11 2016

Taking the advice from the forum, I went through the part listing for 91 - 94 KDX's on ebay and asked those selling parts if they have a water pump shaft. I sent off quite a lot of emails, so hopefully someone, somewhere has to have one available.

Edit: I've already received a few responses... sorry no we don't have one...

As I look at the pics of the H series and E series pump, I believe I can have the H series machined to match the E series... but I'll hold off on going down that path until we have no other choice.

eprovenzano · Post by **eprovenzano** » 03:07 pm Mar 11 2016

The majority of the vendors I've contacted have responded and state they do not have the water pump shaft I need, most state they've sold them. So just in case I need it, I purchased an H series water pump shaft for $10... If the gear is the same, as a last resort I'll have it machined to match the E series shaft.

eprovenzano · Post by **eprovenzano** » 06:01 pm Mar 11 2016

So far no luck... So I'm staring to look at plan "B". I did find the water pump bearing, and the water pump drive gear on the end of the crankshaft are the same between the E and H series. So this leads me to believe the gear is the same... Now If the shafts (as I hope) on the H series are at least the same if not longer, and are the same diameter or bigger... We can make this work.

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