2010 EC 300 Water pump shaft snapped & bearing collapsed

[cladoo]

Originally Posted by Cberg

WOW!! Awesome Clay, Mark, and Glenn!!

Does this offer apply to all 2010+ bikes outside the USA as well?

I will try to get some from Gas Gas Pacific and have them for us Albertans!

[Cberg]

Originally Posted by cladoo

I will try to get some from Gas Gas Pacific and have them for us Albertans!

Thanks Claude !!

[Neil E.]

2011 250, my plastic impeller was just slightly rubbing on the cover. I just got the engine back from dealer and he had installed an alloy impeller as I requested (cover not installed for better access to engine mount). When I check the clearance with the cover sitting against the impeller (no gasket), there is ~.020" space. This would require two stock gaskets minimum.

I have some .060" cork so I'll try that as I expect it to compress to about .045" for a gap of .025". I've never had any cooling issues and my engine temperature stays low.

[GMP]

Check your cover in the center around the hole. There may be rough casting there that the alloy impeller hits that the plastic would not. You can work this out and smooth the area if needed. I had to do this once fitting an LTR impeller to a GG125 with an older cover.

This is not surprising, look at the kit from MotocrossCenter. Their plate is quite thick, and the impeller appers only slightly deeper than the Checkpoint part. The cover is a sand casting with only limited machine work, so lots of room for improvement there. Getting a close fit with the alloy part is going to be a custom job as described.

Neil,

So you are approx .5mm. A 1mm gasket or spacer plate would set you up fine.

[Neil E.]

The cover is quite good inside and would only take a bit of polishing to clear the plastic impeller.

I should remove the alloy impeller and machine the back side, but I'll leave it alone since it's already mounted. No point in taking a chance on damaging the plastic gears if some bolt torque transfers into the shaft. Cutting a new gasket is easy enough. I have some stiffer .040" gasket material that may be ideal for this job.

Measuring some stock gaskets shows that they start out at .020" and compress down to ~.015" after assembly.

[adv rider]

I got some sheet gasket from NAPA, it measures 1.5mm thick. So i imagine even after torquing it should be at least .5mm thicker than the oem one.
I plan to make the gasket today, i will torque and measure

[Vindicator]

MotocrossCenter water pump kit arrived yesterday:



The 2 gaskets are 0,5mm each and the aluminum spacer is 5mm



The old impeller is ~13,5mm and the new one is 18mm height . This leaves a gap of 0,5mm on the spacer. Because we need to use 2 gaskets (1mm) , I would say that when torqued adequately we might end-up with ~1mm of extra gap.
Preliminary testing shows no contact with the cover. I'll see if I can find some shims to put between the shaft and the impeller to measure overall gap.

The new seal on the left, the housing has 1mm more than the old one:


But this is what's really troubles me:


The used one is at the center, the others are new but none of then is correctly centered... There's small differences that will make it wobble like in previous video . This should not be like this... Any alternatives ?

[gasgasman]

The gears are "self centering". They basically float on the shaft.
That means they will wobble when spun without another gear to mesh with it.

[Vindicator]

The new impeller, shaft, bearing and retainer in place . Also a new plastic gear on the other end.





I used a 1,5mm shim (don't have any lower) between the impeller and the shaft and I could hear it gently scratching the cover. I added another and with 3mm I couldn't even close the cover. My best guess is there's at least 1mm gap with this setup. Just to be on the safe side, I will throw another gasket on the cover.

[desertgasser300]

I really dont want to open the pump cover on the 12', im afraid I might find this!

It also looks like McMaster and Carr has a listing for the spring seal. Just don't know the size of it?

http://www.mcmaster.com/#mechanical-seals/=mlwmby