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  • 3 Post By epajet
  • 1 Post By jon andersson
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January 19th, 2016, 06:28 AM   #1
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Joined: Oct 2015
From: Albany, NY

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2009 Fe390 water pump seals

G'day all. Just changed out both water pump seals, oil/coolant, on my 2009 Fe390. The coolant seal was straight forward but it wasn't quite clear as to wether the oil seal could be replaced without removing the housing. It can be done. Carefully. The oil seal is backed by a bearing so there is no danger of pushing the seal into the motor as some suggested. The coolant seal was, as widely mentioned on this forum, back to front, hence the leak. I started by cutting a little rubber away from the centre of the seal to reveal the metal washer like structure under the rubber and then inserted a very small flat head screwdriver under it. Using gentle leverage both seals popped out. The oil seal being further in took more coaxing. A pick, much like what dentists use would be perfect as there is plenty of room and flex from the seal around the shaft. Do not try to remove either by prying the oustide of the seals, this will inevitably damage the surrounding metal.
There was a little dirt inbetween the seals so I also made the weep hole mod, this is easily done with the water pump cover off.
Good luck.
Attached Thumbnails
2009 Fe390 water pump seals-old-oil-seal.jpg   2009 Fe390 water pump seals-correct-face-face-position.jpg   2009 Fe390 water pump seals-bearing.jpg   2009 Fe390 water pump seals-weep-mod.jpg  

Last edited by epajet; January 19th, 2016 at 06:34 AM.
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January 19th, 2016, 07:32 AM   #2
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Joined: Nov 2011
From: Nordic countries

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Yes it's normal that the water coolant seal is the wrong way. It was that way on both my 570s and it's that way in the official workshop manual. So KTM/Husaberg has made an error there. The lip should be towards the water side.

I had problems removing the impeller on both my engines, so I laid the bikes on the side and removed the right side cover. Then I carefully knocked out the impeller shaft (it's even in the workshop manual to do it that way if the impeller doesn't come off). So if people struggle with the impeller, don't be afraid of opening up the side. Easy. No need to remove the clutch cover but the brake pedal must be removed. Torque the bolts back with 10Nm.
Thanks from Rainerio
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June 20th, 2016, 10:25 AM   #3
Joined: Jul 2013
From: Höör: South Sweden

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I Ride: FS650 2006 & FE390 2010
on the first pic, is the green seal for the waterpump mounter correct or wrong, dont get it, mine is mounted the other way, seen from teh outside.
will swop thisone late this week after a leak this weekend during a endurotrip to poland.
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June 23rd, 2016, 11:51 PM   #4
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