How do you get a water pump cover off an EX500?

Fixion · 12-29-2004

I have an 1989 EX500 which needs its water pump cover replaced (bought the bike damaged). I took off the bottom fairing and took out all 4 screws, but the water pump cover just won't come off, it wiggles, but doesn't come off. There is a hard line going into the engine block from the pump cover, will that just slide out?

It looks like its two pieces, the water pump cover (what I need to replace) and the water pump base, I can't get the two apart. Do I just pry them apart with a screwdriver? Can that damage it?

QKENUF4U · 12-29-2004

been here done this lol
its a O-RING on the water pump line and its a real PITA to get out. you will have to PRY it out, just be careful to not bend/kink/collapse the line.
good luck

Fixion · 12-29-2004

On the end thats in the engine block, water pump cover, or both?

Fixion · 12-29-2004

I'm having trouble separating the water pump cover and the back. They just wont come apart. The entire thing (front and back) moves as one piece. I have all 4 bolts out, and the bolt fromthe bottom to let the water out. I can't get the two apart.

QKENUF4U · 12-29-2004

http://houseofmotorcycles.bikebandit...500A3%29US.asp

which part ya talkin about ? if its the same parts i had to pull off then they are VERY TGHT since they are held in with a o-ring and it gets corroded in.

Fixion · 12-30-2004

Got it apart and changed the cover. The part that I had trouble separating the water pump cover from (the water pump back) isn't on the diagram. They were held together with some screw guides which were very tight. I had to pry the cover off the back with two screwdrivers. Surprisingly, the orings on mine weren't hard to remove. Thanks for the help

.

Anyways, its done, the new pump cover is on my bike

gen.confusion · 09-10-2007

I have what I think is a different problem from Fixion. The water pump cover is loose, but it really seems the hardline is holding it in there. Does the hard line come out of the end thats in the engine block, water pump cover, or both?

Basically, what should I pry?

GREENISBEST · 09-10-2007

Quote:

Originally Posted by gen.confusion

I have what I think is a different problem from Fixion. The water pump cover is loose, but it really seems the hardline is holding it in there. Does the hard line come out of the end thats in the engine block, water pump cover, or both?

Basically, what should I pry?

Blimey mate you dug this one up from a while back..

The Hard line will come away from the Engine side, There is an 'O' ring that does hold it in there quite tightly when it's got corrosion around it..

Prying anywhere you can get in but as QWENUF4Y said beware you don't damage anything especially the casing in the process.

The Locating Dowels are what ultimately get corroded and hold the cover on and they are a right PIG to get off

gen.confusion · 09-10-2007

Digging up old threads is always better than making a new one. Also avoids the "do a f#$%ing search" replies

Thanks for your help, I'll give it a shot tonight. I still need to source a new part or find a buddy with a TIG welder. Any suggestions?

GREENISBEST · 09-11-2007

Quote:

Originally Posted by gen.confusion

Digging up old threads is always better than making a new one. Also avoids the "do a f#$%ing search" replies

Thanks for your help, I'll give it a shot tonight. I still need to source a new part or find a buddy with a TIG welder. Any suggestions?

I would source New as Tig welding up your old one raises the issue with it being perfectly flat to form a good fit..

New are resonably priced as its not a hugely complicated part..

12-29-2004	#1 (permalink)
Fixion Sit speling cheker BTK Expert Join Date: Dec 2004 Location: SWMO Posts: 423	How do you get a water pump cover off an EX500? I have an 1989 EX500 which needs its water pump cover replaced (bought the bike damaged). I took off the bottom fairing and took out all 4 screws, but the water pump cover just won't come off, it wiggles, but doesn't come off. There is a hard line going into the engine block from the pump cover, will that just slide out? It looks like its two pieces, the water pump cover (what I need to replace) and the water pump base, I can't get the two apart. Do I just pry them apart with a screwdriver? Can that damage it?

12-29-2004	#2 (permalink)
QKENUF4U AZ's Official Mechanic BTK Expert Join Date: Sep 2004 Location: lake havasu city arizona Posts: 4,551	been here done this lol its a O-RING on the water pump line and its a real PITA to get out. you will have to PRY it out, just be careful to not bend/kink/collapse the line. good luck

12-29-2004	#3 (permalink)
Fixion Sit speling cheker BTK Expert Join Date: Dec 2004 Location: SWMO Posts: 423	On the end thats in the engine block, water pump cover, or both?

12-29-2004	#4 (permalink)
Fixion Sit speling cheker BTK Expert Join Date: Dec 2004 Location: SWMO Posts: 423	I'm having trouble separating the water pump cover and the back. They just wont come apart. The entire thing (front and back) moves as one piece. I have all 4 bolts out, and the bolt fromthe bottom to let the water out. I can't get the two apart.

12-29-2004	#5 (permalink)
QKENUF4U AZ's Official Mechanic BTK Expert Join Date: Sep 2004 Location: lake havasu city arizona Posts: 4,551	http://houseofmotorcycles.bikebandit...500A3%29US.asp which part ya talkin about ? if its the same parts i had to pull off then they are VERY TGHT since they are held in with a o-ring and it gets corroded in.

12-30-2004	#6 (permalink)
Fixion Sit speling cheker BTK Expert Join Date: Dec 2004 Location: SWMO Posts: 423	Got it apart and changed the cover. The part that I had trouble separating the water pump cover from (the water pump back) isn't on the diagram. They were held together with some screw guides which were very tight. I had to pry the cover off the back with two screwdrivers. Surprisingly, the orings on mine weren't hard to remove. Thanks for the help . Anyways, its done, the new pump cover is on my bike

09-10-2007	#7 (permalink)
gen.confusion Newbie Join Date: Sep 2007 Posts: 3	I have what I think is a different problem from Fixion. The water pump cover is loose, but it really seems the hardline is holding it in there. Does the hard line come out of the end thats in the engine block, water pump cover, or both? Basically, what should I pry?

09-10-2007	#9 (permalink)
gen.confusion Newbie Join Date: Sep 2007 Posts: 3	Digging up old threads is always better than making a new one. Also avoids the "do a f#$%ing search" replies Thanks for your help, I'll give it a shot tonight. I still need to source a new part or find a buddy with a TIG welder. Any suggestions?

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