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filterx

03 E leaking rad fluid from weep hole - must replace parts? - SOLVED

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I posted about this back in the spring but hasn't big a huge issue but I'm going to fix over the winter and have a Clymer manual,

03 E - Leaking rad fluid from weep hole - What are the must replace parts ?

So far I figure min are numbers 9,3,4,7,14 & (17/18 just cus) + outer right case gasket 11482-29F00.

Clipboard02.thumb.jpg.5f3858b7e5a6f68a4f1c247f2413157d.jpg

Is it worth also replacing both bearings number 5 and anything else?

Am I missing anything?

Thanks!

 

Edited by filterx

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I posted about this back in the spring but hasn't big a huge issue but I'm going to fix over the winter and have a Clymer manual,
03 E - Leaking rad fluid from weep hole - What are the must replace parts ?
So far I figure min are numbers 9,3,4,7,14 & (17/18 just cus) + outer right case gasket 11482-29F00.
Is it worth also replacing both bearings number 5 and anything else?
Am I missing anything?
Thanks!
 

Either try the known fix with the ceramic disc moves sometimes called the “RTV fix “
Oh replace the pump assembly

More times than not people that don’t have the specific drivers needed to install the sales make a mess of it and end up having to replace the entire unit anyway

If you order the pump do it for a 2003 Kawasaki KLX 400 SR same exact part just in a different plastic bag

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7 minutes ago, Erik Marquez said:


Either try the known fix with the ceramic disc moves sometimes called the “RTV fix “
Oh replace the pump assembly

More times than not people that don’t have the specific drivers needed to install the sales make a mess of it and end up having to replace the entire unit anyway

If you order the pump do it for a 2003 Kawasaki KLX 400 SR same exact part just in a different plastic bag

Sorry I just edit and added the microfiche.

So you are the main dude in this forum and I'd like to hear your options and money is really not an issue.

Once I have the assembly off the bike I have access to a full shop to do the rebuild and I thought the leak was caused by part 3/4 failing and am assuming you mean the correct driver to install 3 and now that just looked at the manual I think you're right about just replacing part 1 and being done with it :)

I can could order part 1 and I'm assuming you are recommending ordering the same thing for the KLX cus checking OEM 49044-S004 looks like its 90US vs the E one which is like 120US and to confirm the KLX 400 SR one is an EXACT replacement for the 2003 DRZ-400E cus it looks like it?

I'm in Canada and would have to order OEM parts through local shop so thanks in for your help

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12 hours ago, filterx said:

Sorry I just edit and added the microfiche.

So you are the main dude in this forum and I'd like to hear your options and money is really not an issue.

Once I have the assembly off the bike I have access to a full shop to do the rebuild and I thought the leak was caused by part 3/4 failing and am assuming you mean the correct driver to install 3 and now that just looked at the manual I think you're right about just replacing part 1 and being done with it :)

I can could order part 1 and I'm assuming you are recommending ordering the same thing for the KLX cus checking OEM 49044-S004 looks like its 90US vs the E one which is like 120US and to confirm the KLX 400 SR one is an EXACT replacement for the 2003 DRZ-400E cus it looks like it?

I'm in Canada and would have to order OEM parts through local shop so thanks in for your help

Suzuki part 

PUMP ASSY, WATER 

17400-29F00

Should be somewhere around $121 USD price

same exact Suzuki part with a Kawasaki part number label slapped on top of the Suzuki one
PUMP-WATER

49044-S004
Should be somewhere around $94 USD price
 

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10 hours ago, Erik Marquez said:

Suzuki part 

PUMP ASSY, WATER 

17400-29F00

Should be somewhere around $121 USD price

same exact Suzuki part with a Kawasaki part number label slapped on top of the Suzuki one
PUMP-WATER

49044-S004
Should be somewhere around $94 USD price
 

I'm ordering the right side case gasket, clutch cover o-ring and Kawi water pump and thanks very much :)

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Sorry I just edit and added the microfiche.
So you are the main dude in this forum and I'd like to hear your options and money is really not an issue.
Once I have the assembly off the bike I have access to a full shop to do the rebuild and I thought the leak was caused by part 3/4 failing and am assuming you mean the correct driver to install 3 and now that just looked at the manual I think you're right about just replacing part 1 and being done with it
I can could order part 1 and I'm assuming you are recommending ordering the same thing for the KLX cus checking OEM 49044-S004 looks like its 90US vs the E one which is like 120US and to confirm the KLX 400 SR one is an EXACT replacement for the 2003 DRZ-400E cus it looks like it?
I'm in Canada and would have to order OEM parts through local shop so thanks in for your help
Ya Phil, Erik is a great help to alot of guys on this forum.
I haven't had to do my water pump yet, so i can't be of any help, but i have next week off, could you show me some of the cool rides around Squamish ? Maybe next thurs. ?

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14 minutes ago, bucket list said:

Ya Phil, Erik is a great help to alot of guys on this forum.
I haven't had to do my water pump yet, so i can't be of any help, but i have next week off, could you show me some of the cool rides around Squamish ? Maybe next thurs. ?

Ya dude, my insurance is up on the DRZ on the 13th but if you want to ride some off road stuff give me a call Wednesday night and we can see what the weather etc looks like and I have to take time off work but NP. PM me if you don't have my cell #

Edited by filterx

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11 hours ago, filterx said:

I'm ordering the right side case gasket, clutch cover o-ring and Kawi water pump and thanks very much :)

Don’t need to remove clutch cover , and even if you do , o ring is reusable. 

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13 hours ago, habs said:

Don’t need to remove clutch cover , and even if you do , o ring is reusable. 

Ya I didn't think so BUT for whatever reason my Clymer manual said to and at this point I don't mind spending the $$ on an o-ring and need it and not have it.

Thanks for the input

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On 10/12/2018 at 7:16 PM, filterx said:

Ya I didn't think so BUT for whatever reason my Clymer manual

The right side engine covers... Clutch cover inner, clutch cover outer...the inner cover needs to come off so you can remove the circlip, water pump drive gear and indexing pin..  the manual was referring to removing the inner cover, and that would take a new gasket to reinstall. the outer cover which only gets you access to the clutch assembly itself uses the O ring.

image.png.ae1970021fd654858cd38914f7fc356c.png

Might want to pick up a OEM service manual.., new, used, digital ....

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Drained the oil (it was do for a oil/filter change anyway), drained the rad and yes you do not need to remove the clutch cover outer but IMO you need to remove the rear brake pedal (which needs a lube) so all I can think is that the Clymer Manual (which came with the bike) says to remove the clutch cover outer so you don't have to remove the brake pedal but you do have to remove at least 2 clutch case outer bolts to remove the inner case. Bought the parts from a local shop and should be able to return the o-ring but I've been busy and should have had at removing the case before ordering the parts :)

Took about 20 mins should be a pretty easy reassembly once I get the new water pump, clean off old gasket etc etc etc.

Thanks again for the suggestions and help.

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