TOPIC:

I have the engine block off the bike and on the bench. It is all stripped down except for the impeller shaft. The circlip is off but the impeller is stuck. Any tips in getting it off.
Maybe the machine shop can do the rebore with it in place- any suggestions gratefully acknowledged.
Cylinders 3 & 4 have bore surface rust. I'm trying one of those big bore kits from Japan.
Thanks.

It's not stuck too badly. Be careful the impeller is brittle. I took a chance and gripped the vanes with two needle nosed vise grips and worked it till it came loose all at once.

Bill

Had the same problem last month.

How to do it.

Remove metal gear from other end of shaft (the one that drives the nylon gear)

If you have the block off, then position the impellor facing upwards & give a good spray of WD40 or other penetrating oil & leave for an hour or so to sink in.

Get a metal rod or drift that is slightly smaller than the shaft itself where it goes through the impeller & tap it through slowly.

I assume you will be replacing mechanical seal anyway as it may damage it.

Worked for me................just be gentle !

Pete F

Well, that all worked out good. Thank-you both for your replies. The best method for me was to use a small steel hammer and tap lightly from the rear of the shaft, so the shaft and impeller came out together. - to the front of the engine. The attached photo is a reference for others as it shows why the shaft is so often difficult to get out - mainly because of rust. So with liberal doses of wd-40 and some patients it all worked.
When ordering the replacement mechanical seal, what is actually supplied. In this link from Kawasaki there shows 8 separate pieces making up part # 49063-1001

www.kawasakiepc.com/SystemSearch_Frames....322&CFTOKEN=37140530
LINK DOESN'T WORK

But the photo on zed-parts looks kind of meager.
Will also order oil seal behind the impeller # 92049-1028.

So the question is really , does part # 49063-1001 give me all that I need to put this all back together.

The mechanical seal kit has 2 parts

1 part is the seal face that sits in the rear of the impeller as seen in your photo

2 is the mechanical seal itself which fits ito the holder & head itself.

Be caresul removing & refitting the new mechanical seal as the holder is easily damaged,

The K manual covers the procedure pretty well

Pete F

P.S The BIG BOYS TONKA TOYS photo is brilliant !