coolant leak left side case????

[loopedr1]

hey guys....i love the site and i know someone can fix my problem.....i just purchased a 1994 bayou 400 and i have a coolant leak near the water pump...thought it was the gasket and i changed it BUT it seams to be leaking out of a small check hole at the bottom of water pump housing???? i figured the water pump shaft seal is bad...but how do you get to it.....how do you remove the water pump shaft to get to the seal...and did i figure right???? any help would be great.................

[86klf300guy]

yeap open the cover to hte water pump there shold be a seal that just needs replaces itll look kinda like a rubber seal with a spring on it.just replace that seal and you back in good shape-corey-

[99prairie400]

Purchase a service manual. They aren't that expensive for a KLF400B and they'll save you TONS of time and headache.

When you remove the water pump cover, the impeller is exposed. A 10mm wrench counter-clockwise will remove the impeller unless the bolt is extremely tight. If the bolt is tightened down beyond the compression holding the engine from turning over, use an impact gun to pop the bolt loose fast. You need to check out the water pump bearings as well. My KLF400B6 had a leaking mechanical seal and when I went to remove the impeller the shaft was moving a full 1/8" side to side. The outer bearing was completely gone. There were no balls left in the bearing, only the inner race on the shaft and the outer race in the housing. I couldn't believe it was only leaking as much as it was after seeing how bad everything was worn out. A new bearing and two new seals later, not a drop!

[loopedr1]

thank you guys sooooo much....i figured that was the problem.....i have ordered the manual but haven't gotten it yet....i just love the forum. i think i will be here all the time with stupid questions.. ::

[99prairie400]

I have found that the manual sometimes leaves things to be desired (and guessed at!) but it's the best source for general process disassembly, assembly, and inspection.

The good news is, for us old torque-monster riders, that Kawasaki still fully supports factory replacement parts. I ordered water pump bearings, seals, and cover gasket and they were in the next week.

Also, get familiar with the parts micro-fiche. Kawasaki.com has one but it's a little hard to use... babbitt's online has an easier diagram to use (and to cross-reference part numbers with model)

[loopedr1]

ok guys......need more help.....i got the cover off....got the impeller off.....got the mechanical seal off.....and sure enough the bearing is bad too...BUT now i have the shaft sticking out of the motor and the bearing races stuck in side...how do you get the shaft out????? do you use some kind of puller to get the shaft and bearings out???? do i need to take the whole engine side cover off and get to them from the back side??..the shaft moves free like it catches some kind of key way...or do you just pull the shaft out hard and the bearings come to??? any help would be great>>>>

[99prairie400]

Is the outer bearing bad? If it is, the shaft and inner bearings have to come out from the inside. The shaft is keyed to the balancer shaft under the stator cover. Once you undo all the bolts it still won't come off, the flywheel and stator are magnetically attracted. Make sure that you have all of the bolts out and then tap it off gently.

[okieduc104]

Originally Posted by loopedr1

hey guys....i love the site and i know someone can fix my problem.....i just purchased a 1994 bayou 400 and i have a coolant leak near the water pump...thought it was the gasket and i changed it BUT it seams to be leaking out of a small check hole at the bottom of water pump housing???? i figured the water pump shaft seal is bad...but how do you get to it.....how do you remove the water pump shaft to get to the seal...and did i figure right???? any help would be great.................

Boy Howdy, I am sure glad we have this site and all the knowledgable guys to help us keep our stuff in repair
I don't know but suspect you will need a new water pump, but then maybe not!.
I don't know about you, but for me these Kawasakis are another breed from the usual John Deere or Ford tractor or a Briggs or Kohlor Johnson- Evinrude or Harly built engine. I wouldn't attempt much beyond adding oil and gas without having a service or repair manual for the machine and have gone thru it from stem to stern before I tried to disassemble much of the beast.

[loopedr1]

damn......figured the cover would have to come off..DAMN....also the drive shaft going to the front diff goes right across the bottom of the engine cover. i think i will need to loosen the front diff and pull the unit forward enough to clear the output shaft of the trans...the shaft is just to close to pull the cover off the engine. OK i'll let you guys know what happends.....

[loopedr1]

OK here we go...........loosened the front diff and it wouldn't move enough forward to get the shaft free......then noticed that there was a spring clip on the front shaft........OK...removed the clip and the shaft colar on the mid shaft moved back releasing it from the front diff. didnt need to loosen the front diff after all.....removed the shaft and could get to all the bolts....sure enough the stator magnets had a hold of it but the cover came loose with a small tug...now i need the cover gasket and found that the water pump shaft was rusted and damaged too....as for the stuck outer bearing race....i used a dremel to make a grab spot on the race and removed that SO...just need new parts and reassembly should go smooth......thanks you guys for great help.

[99prairie400]

I went through the same thing about a month ago. Go ahead while you're at it and purchase a manual, factory, clymer's, haynes, something. Maybe you can tell the next KLF400 rider how to rebuild his water pump from memory

[loopedr1]

sure...i'll help when ever i can....i check the boards all most everyday..i'm just not use to working on a kawasaki...i just sold my 1987 honda big red to buy this klf 400. i could work on the honda with my eyes closed...thank you for all the help...by the way i see you live in north carolina. how far from charlotte..would love to meet up...

[99prairie400]

an 87 ATC 250es? I have an '83 ATC 200 and my dad has an '81 185S. Are you sure it was an '87? I thought they only made them up to '86 in North America..

Not a bad trade up I'd say though... 4x4, liquid cooled, and not THAT much more complicated.

I live just north of Raleigh but we're going to be in Goldsboro in the spring at Busco beach. Ever been?

[loopedr1]

YEP it was a low vin # 1987....i sold it on ebay for 1200. hoped to get more but needed to buy this kawasaki before they sold it. here is a pic of the vin

http://i609.photobucket.com/albums/t...dr1/small1.jpg

http://i609.photobucket.com/albums/t...dr1/small2.jpg

didn't want to sell in but needed to get a four wheeler.

north carolina will allow 3 wheelers in state parks BUT my boys ( 8-12 ) can't ride their 4 wheelers in the park due to age

south carolina will allow my boys to ride their 4 wheelers in the state parks BUT they don't allow 3 wheelers......so the 3 wheeler had to go..

.may be this winter i can come up and you can show me the mods you did to your bike....it looks awsome!!!

[99prairie400]

What size quad's do you have for your boys? NC has age restrictions but they aren't as ridiculous as some make them out to be... I think it's 50cc up to 5 years of age, 90cc up to 9 years of age, and 150cc up to 16 years of age.

I don't particularly agree with big brother telling everyone what to do but I can understand why they did it. I was at Busco one time and saw a 4 year old riding a 420 Rancher... he was so small that he couldn't shift, it was put in 2nd gear and all he had to do was hit the gas or brake. Not to say that it wasn't cute to see (or an oddity to most) but he ended up running the 4 wheeler into the lake because he couldn't reach the left brake handle and the parking brake lever at the same time...

[loopedr1]

thats why they passed the crazy laws they do...my 8 yr old rides a china 110cc but it looks like a 50cc and my 12 yr old rides a polaris 90. here is a pic of them

http://i609.photobucket.com/albums/t...1/100_0099.jpg

i took the time to teach them the right way to ride.....they ride better than most adults ive seen.....i was always afraid to take them to busco or uwharrie for fear of a ranger giving us a ticket or taking the 4 wheeler away...better safe than sorry...thats why ill go to adventure world in sc when i get mine up and running..i want to paint it because its blue with white wheels. it looks like a barbie car. i hate it.. i love the color of yours and im going to home depot to get some fusor camo paint . cant wait until im finished.

[99prairie400]

Uwharrie national forest you do have to worry about rangers checking ID's and things. It's a state park and they're strict on underage riders simply because of the risk of someone getting hurt on some of those trails...

Busco beach is privately owned and almost all mud and trails. The state laws still apply but if your children are not acting up I don't think Jack is going to even question EXACTLY what cc their quad is or which month they were born in. In other words, enforcement of the age rule isn't strict but the helmet law is. I have seen them ask people to leave the park for refusing to wear their helmet.

[loopedr1]

cool.....i should check it out then......

[99prairie400]

If you like mud, it's the place to be. Also, there are basically no restrictions because it's private land. Loudest pipe and biggest tires you can find are ok. Sometimes on a pretty Saturday afternoon the quads out on the dragstrip can get a little aggrevating, but you shouldn't be beside the dragstrip anyway, you should be buried in a mudhole somewhere.