Water pump seals for dummies

[nicmartim]

All, I have looked and looked for a comprehensive how-to on replacing the pump seals on my 91 kdx 200. I have the water pump cover off and impeller removed. The washer on the backside of the impeller was rusted and rough, thankfully I ordered the replacement. I have also ordered and received 2 replacement seals and the bearing for the shaft.

Ok, my question is.... How do I get into this pump? Do I have to remove the entire right side of the engine? The clutch housing cover as well or will they come off as a unit? I do not have a manual (yet), still working on finding one that doesnt cost more than I paid for the bike. In looking at the right side of the engine it looks like i'll have to remove the kick stater, KIPS actuator, and maybe the brake pedal. Is this all correct? How easy is it to remove the KIPS actuator and more importantly how easy is it to get back together? I seem to be able to take anything apart, but getting it back together is usually another (longer) story. Any help or links that could point me in the right direction? Thanks all!

[6 Riders]

Yes the inner clutch cover must come off. So, remove the upper KiPS cover, unbolt the activator arm (left hand thread), remove kicker and brake pedal. The clutch cable needs to come off as well, however, you do not need to remove the outer clutch cover from the inner.
I do mine with the bike laying on it's side. First time you do it, you need to take your time and pay close attention how everything (including the seals) comes out/off. After the first time, it's a breeze. Takes me a couple hours total to replace the seals.

[nicmartim]

6 Riders, thanks for the heads up. Got the cover off, shaft out, bearing popped out and both seals removed. A couple more easy questions for now. The inner most seal looks to have a sort of spring inside it. Kind of circles around inside between the inner wall and outer wall. Also one side is hexagon shaped on the inside. When the old one popped out I did not make note of the orientation of this. Should the seal be mounted with the spring-like device inboard or out? Also, when the cover came off a very thin flat washer fell off from the area of the kickstarter. Where does this go? It is not small in diameter, bet it could fit on my pinky finger.

The shaft has some very slight grooves. I dont thing it is deep enough to cause issue and a new on is $56. BTW, getting that cover off was simple except for the one bolt that sits behind the mount point for the return spring for the rear brake lever. That thing is a PITA to get out. Thanks again!

[6 Riders]

It's been a long time since I've done mine, but IIRC, the spring faces out word.. You'll notice a very slight taper in the seals, the larger side goes out on both. I'll have o look to see where the washer goes, but I think it's from the kickstart assembly.