I would recommend getting a factory service manual. There are two for our bike. A "generic" (85-90 EN400/EN450) and a "specific" (1994-2009 Ninja 500/GPZ500S). Look first in the specific and it frequently refers to the generic for stuff that has not changed.
The most I have gotten into mine is adjusting the valves.
I can look up something for you if you wish, but I'm about to call it a night.
Right, I have the water pump impeller off, so the shaft is just screwed on as well? I tried unscrewing it, but something turns on the other side of the disc the shaft is connected to, how do I stop it turning so I can unscrew it?
I have the housing removed already. The shaft is revealed, but I cannot figure out how to remove the shaft.
The parts breakdown makes it look like it is screwed in, but I cannot unscrew it.
The reason I am trying to remove the shaft is that its threads broke off into the impeller, so I need a new one. I want to take this one out an install another. I asked my the parts department at my dealer how to do it, and they said they had never done it before on an EX 500, but it is probably held in by clips. However, there are no clips on the exterior surface where I can see the shaft.
Here's the pic i mentioned, RED arrow pointing at your impeller shaft.
I'm woundering if the crankcase has to be split to remove the balancer shaft complete with gear before you can remove the impeller shaft or maybe removing the oil pan will enable you to hold that gear whilst undoing the shaft. (Holding it present a new problem of it's own)
I will further investigate the method of fixing later at work.
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