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May 3rd, 2008, 08:05 AM   #21
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Ok, I´ll lift this excellent thread!

Today I was trying to replace the waterpumpseal... and (exactly as an earlier writer) messed the new seal up...

When I bought the new seal the owner of the shop asked me if I didn´t want to buy two seals.... I hesitated a moment... and bought one!!!

Now I can´t wait for Monday to come!

Now my question...

How do I fit the new seal in the sidecover without ruining it!?

Could I change the two o-rings and then put the sidecover on and then fit the seal from the outside on Monday... or is it easier to fit the seal with the sidecover free?

Many thanks!

/Rikard
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May 3rd, 2008, 08:32 AM   #22
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if you are naturally cack handed i suugest that you fit the cover without the seal in it at all and then fit the seal by hand after you're happy that the whole issue is a good fit etc.

regards

Taffy
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May 3rd, 2008, 11:48 AM   #23
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Originally Posted by Taffy
if you are naturally cack handed i suugest that you fit the cover without the seal in it at all and then fit the seal by hand after you're happy that the whole issue is a good fit etc.

regards

Taffy
A answer typical for Taffy... (thanks... love ya´!)

but I don´t know what cack handed means...

Which means I don´t know if I´m happier not knowing what "cackhanded" means....

I didn´t destroy the seal while trying to fit the sidecover though, it was when I tried to fit the seal into the sidecover....

/Rikard
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May 3rd, 2008, 12:07 PM   #24
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Hey B,

Welcome to the wonderful world of the metal ringed seals!! I destroyed a few before I got it right.

I bought a 25mm piece of aluminum round stock about 8" long and had it cut off square and use that as a drift to push the water pump seal in, that way it can't turn sideways on you. The new seals have some kind of blue coating on them to help them slide in easier.

I also just fitted an Orangeberg kit, this seal kit looks like the end of the oil leak problem past the little O ring on the water pump shaft. As just recently I had that little O ring go bad and start leaking oil out the weep hole.

Dale
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May 4th, 2008, 01:27 AM   #25
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Thanks again!

Now, that leaves me with two alternatives....

1, As Taffy said, mount the sidecover first and then afterwards the wpseal... how do you fit the seal afterwards? Ain´t it hard to get the space needed to knock the seal in?

To me it seems to be harder to fit the seal once the sidecover is on....

2, Wait until I get the new seal, mount that into the sidecover and then fit the sidecover...

/Rikard
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May 4th, 2008, 03:49 AM   #26
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i would choose the second one
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May 4th, 2008, 06:50 AM   #27
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Hi folks
Seems that the weepy hole seal is the bain of many Berg owners .I learned from past experience the hard way . The first 650 i owned i took to the IOM tt races for a full week of bonding , with you guessed it a weepy hole from day one . Not wanting to let that ruin my holiday a Swan Vesta was rammed in said hole for the duration.. (SV by the way is a match stick for our non UK res.) You Guessed right Nothing but problems after that until i decided to be brave and get my mits dirty..Can probably do both seals now with eyes closed, however touch wood not needed to remove side case for a while (0h 0h maybe tempting fate) ....Have only once tried to do the water seal without removing sidecase and was unsuccessful , my problem was i was concerned about damage to the case when removing the old seal ...One point i would like to make change the oil seal every time the case is off .Its a O ring that cost pennies (very small amount) and smear some grease ,Vaseline or KY on it before you re-ass. it .You Know shafts slide in better when lubricated . The number of times i have put a new O ring on Dry .only to find it weep straight away and realize its summat really trivial like a bit o grease ...AHH !!!


Good Luck
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March 23rd, 2010, 07:07 PM   #28
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Re: Weep hole leaking oil

Hey guys,

I'm looking to simplify this by making a list of "must change" and "should change" parts. I'm going to start a new tread but I think the moderators can decide whether to keep it or erase it.

KISS (Keep It Simple Stupid)

I need to do the fix ASAP since my baby is now puking coolant with the oil and I can't enjoy her the way I want.

I want to make one order so I can do the fix in one sitting and fumble around like a moron having to order more parts and wait a week or so for delivery. The local KTM dealer doesn't have and says he can't get the water pump gasket because it's "discontinued" so my closest 'Berg dealers are four and six hours away. This should be two days shipping but it took my rear master cylinder two weeks vs their claimed three days.

Part numbers are for '08 FE 650.

My impression of "must changes:"
- Bearing - Orangeberg weep hole fix kit is optimal
- Water pump gasket #80035053000 (Possibly two, just in case and good to have spare)
- Clutch cover gasket #80030025000 (Possibly two, just in case and good to have spare)
- O'ring for Drive Shaft of Water Pump (Don't know number or page it's on would like help here)
- and ?

My impression of "should change or may have to change:"
- Shaft Seal Ring #0760101844 Possibly two
- Water pump Gear #80035055000
- and ?

Are there any other recommendations for fixes/preventive maintenance while that side of the engine is off?

Those more informed please edit my post accordingly. If using the Queen's English or any island variation, including Oceana , please keep it clear. Your slang/jargon is quite entertaining but can confuse those of us educated in the new world where the government may have been more successful at dumbing us down.

Thanks for the contributions and help.

Cheers!
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March 23rd, 2010, 10:26 PM   #29
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Re: Weep hole leaking oil

Originally Posted by K2Berg
Hey guys,

I'm looking to simplify this by making a list of "must change" and "should change" parts. I'm going to start a new tread but I think the moderators can decide whether to keep it or erase it.

KISS (Keep It Simple Stupid)

I need to do the fix ASAP since my baby is now puking coolant with the oil and I can't enjoy her the way I want.

I want to make one order so I can do the fix in one sitting and fumble around like a moron having to order more parts and wait a week or so for delivery. The local KTM dealer doesn't have and says he can't get the water pump gasket because it's "discontinued" so my closest 'Berg dealers are four and six hours away. This should be two days shipping but it took my rear master cylinder two weeks vs their claimed three days.

Part numbers are for '08 FE 650.

My impression of "must changes:"
- Bearing - Orangeberg weep hole fix kit is optimal
- Water pump gasket #80035053000 (Possibly two, just in case and good to have spare)
- Clutch cover gasket #80030025000 (Possibly two, just in case and good to have spare)
- O'ring for Drive Shaft of Water Pump (Don't know number or page it's on would like help here)
- and ?

My impression of "should change or may have to change:"
- Shaft Seal Ring #0760101844 Possibly two
- Water pump Gear #80035055000
- and ?

Are there any other recommendations for fixes/preventive maintenance while that side of the engine is off?

Those more informed please edit my post accordingly. If using the Queen's English or any island variation, including Oceana , please keep it clear. Your slang/jargon is quite entertaining but can confuse those of us educated in the new world where the government may have been more successful at dumbing us down.

Thanks for the contributions and help.

Cheers!
You will want to get the o-ring for the clutch cover (or 2).
If it's leaking oil and coolant replace the bearing as well.
Waterpump gear? Should not need replaceing.
Get extra seals as you will likely bugger up the first one you do. I use a nut and bolt combination with 2 flat washers. I use that set up to press the seal into the case as opposed to driving it in.
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March 24th, 2010, 02:43 AM   #30
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Re: Weep hole leaking oil

very few people have probelms with the waterpump weeping. IMHO it's 100% man-made. you just need to put it together dead proper.

regards

Taffy
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