Correct way to install water pump seal and o-ring

swinny91 · April 25th, 2020, 12:12 PM

Hi everyone,

I recently purchased a husaberg fe400e 2002 model.

there's a bit of a water leak coming from the wheep hole.
The guy before me had done a lot of work to the bike and had actually put a new water pump seal and in, after reading quite a few threads on here I'm a bit confused as to whether hes fit it correctly or if it needs to be the other way around, also is the rubber seal supposed to sit flush on the casing or be sunken in, it was sat a little bit skuwif but when I tried push one side in it just all push in... 🤦*♂️
any information would be really greatly appreciated!

I've attached a picture to show whatnot currently looks like, can somebody please tell me what I need to buy and do to make it right?

Thanks,

Ash.

Taffy · April 26th, 2020, 01:57 AM

Hi Ash

from mwhat I can see in this very pooor photo, you have the spring side towards the camers = which is correct.

however, that seal doesn't appear to be Brown and only the OEM metal-backed seal works.

just press it in with a vice and something flat. don't tap it in as they tend to fold in half like a conch.

cheers

Taffy

swinny91 · April 26th, 2020, 02:18 AM

Thank you taffy,

At the minute the seal is pressed into the hole, should this sit flush on the casing?

also if this seal isn't sufficient are you able to send me a price for the correct part please?

And apologies for the rubbish picture my camera is terrible I can take a clearer one this afternoon...
Many Thanks,

Ash.

Taffy · April 26th, 2020, 04:34 AM

well if it's a standard soft rubber seal it's shit. no good at all, that is why it is at the bottom of the hole because it FELL in.

they are 100100 on my webshop. £6.06 to a leper...

cheers

Taffy

Alfy · April 26th, 2020, 10:24 AM

On first years crf 450 a cavitation phenomenon caused the water pump seal to break. A simple modification eliminates the frequent breakages of this seal. It is important that the impeller shaft shows no signs of wear.

husabutt · April 26th, 2020, 11:41 AM

Taffy's kit has just about everything you could need.

Taffmeisters Water Pump Repair Kit 2001-2003

Its an excellent value.

I would take it apart first as you may break the impeller when you take it off. It gets brittle over time and stuck on. A new circlip that holds the impeller on is always a good idea. It tends to rust and loosen a bit every time you take it off. Also there is a very large O-ring that sits in the case that gets smashed down. You can easily match that up from a O-Ring assortment.

Purchase extra WP seals as you may go through a few before you get it right. It is a very very tight interference fit. I put the seal in the freezer overnight and then heat the case with a heat gun (or hair dryer if you don't have one. Press the seal in, don't bash it in with a socket and hammer. If you can't figure a way to press it in an independent auto mechanic in your neighborhood would probably do it for a six pack of craft beer.

When putting the side cover back on liberally coat the WP shaft and kick start shaft with grease. Husaberg sells a plastic cover for the WP shaft so that you don't nik the seal upon installation. You can also use a little thin tape around the shaft. Take you time and lay the bike on its side during removal and installation.

Coat the side cover gasket with a very light coat of grease so that it can be reused a few times.

When removing the side cover tap the kickstart shaft lightly with a plastic hammer to keep the kickstart assembly from popping out (one less thing you will have to deal with).

Keep in mind that more damage is probably done to the WP seal during installation of the side cover than actual wear and tear so it may be worth it to purchase the plastic mounting sleeve if you are going to keep this bike for awhile.

swinny91 · April 26th, 2020, 01:59 PM

Thanks Guys, Taffy's sorted me out with what I needed, the advice from everybody has been fantastic.

I've managed to get the shitty old seal out carefully without removing the full side cover and am hoping that I may be able to carefully insert the new seal the same way, along with a new circlip and water pump gasket.

if this doesn't work I'll be sure to refer back to the extremely detailed and brilliant advice from you Husabutt

you've all been fantastic help!

thanks,

Ash.

Taffy · April 27th, 2020, 12:37 AM

couple of things here.
thanks Eric, nice support there, how I remember this place used to be all the time with DL at the head of it all. I didn't realise the 'fat' waterjacket O ring wasn't in the photos! But we do supply it anyway...

Swinny
that's two people who have now told you to press the seal in the cover yet you are leaving the cover on the engine. it's at times like this I need one of those popcorn-eating-emojis!!!

regards

Taffy

Taffy · April 27th, 2020, 12:39 AM

Originally Posted by Alfy

On first years crf 450 a cavitation phenomenon caused the water pump seal to break. A simple modification eliminates the frequent breakages of this seal. It is important that the impeller shaft shows no signs of wear.

so what is the modification Alfy?

Taffy

swinny91 · April 27th, 2020, 02:25 AM

Originally Posted by Taffy

couple of things here.
thanks Eric, nice support there, how I remember this place used to be all the time with DL at the head of it all. I didn't realise the 'fat' waterjacket O ring wasn't in the photos! But we do supply it anyway...

Swinny
that's two people who have now told you to press the seal in the cover yet you are leaving the cover on the engine. it's at times like this I need one of those popcorn-eating-emojis!!!

regards

Taffy

When i look at the diagram i can't see an o ring that sits inside the water pump casing, unless you mean the one inside the engine casing at the top, part 20?

I know you think I'm been daft for trying to push the seal in without removing the case but I'm just a bit concerned from reading on here how some people have had a big struggle trying to get it back on correctly.

On the plus side for you taffy, if it doesn't work and I bust the new seal... I'll have to order another one off you, then I'll take the whole casing off, and buy a press to put it in with.

Thanks guys.