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Kdx 200 h3 1997 cooling system

Posted: 11:18 am Dec 28 2024
by Spud66
Hi all

Just put inner clutchcase and associated bit back on bike, including clutch case, oil, kick starter etc.

Got great spark, 150+ psi with new piston, but filling up radiators found I had leak thought at first it was from Coolant bleed bolt so changed crush washer and still leaking, but not from bleed bolt.
But from this hole next to bleed bolt, so not sure looking at drawings what is missing or what that hole is even for?
On the old broken inner clutch case where water impeller is it's the same as new one I have put on so at a bit of a loss any info from the site gurus on this before jb weld comes out??

Re: Kdx 200 h3 1997 cooling system

Posted: 05:29 pm Dec 28 2024
by SS109
That is the coolant weep hole. It is supposed to leak coolant if your water pump seal has failed. You need to replace your water pump seal.

Re: Kdx 200 h3 1997 cooling system

Posted: 03:35 am Dec 29 2024
by Spud66
Bloody hell it's a new seal that's failed then and also means I have to strip it all apart again aaaarrrrgghh

Ok thanks for info.

Any idea what the part number is???

Re: Kdx 200 h3 1997 cooling system

Posted: 08:40 pm Dec 30 2024
by SS109
Spud66 wrote: 03:35 am Dec 29 2024 Any idea what the part number is???
Mechanical seal is 49063-1055, inner seal is 92049-1259, and the o-ring is 670B1506.

So, you have already replaced all of those and it's still leaking? I do know you have to be real careful when installing the mechanical seal or it will fail.