Swapping an "H" right engine cover onto an "E"?

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TheRadBaron
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Swapping an "H" right engine cover onto an "E"?

Post by TheRadBaron »

My '89 is leaking coolant into the gearbox because the impeller shaft is badly worn where the seal contacts it. The shaft is NLA from Kawasaki and I can't find one for sale anywhere so I'm kind of stuck. I found some references to using an H-model water pump in a E-model and that's got me thinking.
First of all, does anyone know anything about this? I've been comparing the parts fiches between the E and H models and it looks like they both use the same cover gasket. The cover itself carries a different part number but they look similar enough that they might be fundamentally interchangeable. I'm sure that some swapping over of certain parts would be necessary as well but I'm thinking that this might be a viable swap. The H parts have better availability both from Kawasaki and on eBay and such.
I'll probably start doing a more comprehensive study of different part numbers next week but I thought I'd ask here and see if anyone had any insight. For that matter, does anyone have an H-model right side cover for sale?
TheRadBaron
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Swapping an "H" right engine cover onto an "E"?

Post by TheRadBaron »

Wait a minute. I think this is a no-go. The pictures of the covers looked very similar in the fiche diagram but they look a lot different in real life. Comparing photos of the E and H it is evident that the KIPS shaft comes out of the cover at a very different angle between the two. I guess this isn't going to work.
But the water pump parts may still be interchangeable to an extent I suppose. Probably a long shot but I'm exploring any options at this point. I'd really like to get this bike back into good health.
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Re: Swapping an "H" right engine cover onto an "E"?

Post by 6 Riders »

The H cover will not work. The mechanics of the E's & H's power valves are completely different, making the swap nearly impossible w/o changing to an H cylinder also. The reason that they use the same gasket is because the bottom end of the engine is the same. Unfortunately you are going to have to sorce E bike parts. I guess the good news is that all year E bike parts will work, as long as you use the water pump seals from the year of the side cover.
newbbewb wrote:^what he said.
masterblaster wrote:Man 6 riders you rock.
*side note...I'm drunk, so try to read what I'm trying to say, instead of what I actually type
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Re: Swapping an "H" right engine cover onto an "E"?

Post by 6 Riders »

Also, if you go to RMATV, they still list the impeller shaft from 93 & 94 bikes as available. They are $50 for just the shaft. I ordered a complete new water pump assembly for mine 2 years ago. Again, you will need the seals from the 93/4 bike to seal it up correctly, if you go this route.
newbbewb wrote:^what he said.
masterblaster wrote:Man 6 riders you rock.
*side note...I'm drunk, so try to read what I'm trying to say, instead of what I actually type
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Swapping an "H" right engine cover onto an "E"?

Post by Gotanubike »

Important! If you find a water pump gear shaft for your E, the 89-90 and 91-94 use two different shafts, 2 seals instead of 1 AND right side covers are different(to fit the new gear shaft). Check your parts fiche those years for right side cover and impeller shaft...You will need the shaft and/or cover corresponding to those to year groups. For instance, if your bike is an 89 or 90, then a 91-94 shaft wont work(unless you have the right side over to go with it)
1990 KDX200
Bike Profile -> http://www.kdxrider.net/forums/viewtopi ... 61#p136315
Suspension Overhaul(Shock+89-92 conventional forks) -> http://www.kdxrider.net/forums/viewtopi ... 15&t=15255
96'-98' RM125 Showa 49mm fork swap -> http://www.kdxrider.net/forums/viewtopi ... 04&t=16994
KDXrider world map! -> https://www.zeemaps.com/map?group=186158
TheRadBaron
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Re: Swapping an "H" right engine cover onto an "E"?

Post by TheRadBaron »

Thanks for all the tips, guys. I already knew about the differences in the shafts and side covers from when I researched all this stuff the first time around when I was rebuilding my motor.
I'm placing an order for the later shaft at RMATV right now. I'm a bit skeptical if it will show up or not but it's worth a shot. Then I'll just need to source the later clutch over but I figure that shouldn't be TOO hard. Hopefully I'm not wrong. Another option that might work is to have a machinist make up a spacer that will bring the later shaft to the dimensions of the earlier shaft. I think the only difference between the two designs is that the later part has a shorter shoulder on the outboard side of the gear than the earlier one. A simple spacer would probably work out alright, though I'd rather get the later cover and do it right.
Last edited by TheRadBaron on 09:42 pm Jul 16 2014, edited 1 time in total.
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Gotanubike
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Swapping an "H" right engine cover onto an "E"?

Post by Gotanubike »

You see those gear shafts pop up on ebay every now and then...I considered picking one up just so I have a spare...But how is your impeller shaft so badly worn that it's unusable?? When did you last change the seals?

Oh and I found the thread where we had discussed this already..


http://www.kdxrider.net/forums/viewtopi ... 15&t=15604
1990 KDX200
Bike Profile -> http://www.kdxrider.net/forums/viewtopi ... 61#p136315
Suspension Overhaul(Shock+89-92 conventional forks) -> http://www.kdxrider.net/forums/viewtopi ... 15&t=15255
96'-98' RM125 Showa 49mm fork swap -> http://www.kdxrider.net/forums/viewtopi ... 04&t=16994
KDXrider world map! -> https://www.zeemaps.com/map?group=186158
TheRadBaron
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Swapping an "H" right engine cover onto an "E"?

Post by TheRadBaron »

I just recently bought the bike. It looked good but the motor was pretty knackered internally. I rebuilt the top end and did a bunch of other stuff. The motor showed signs of coolant leaking into the gearbox when I tore it down and the impeller shaft was badly worn when I took it out. It looks like the bearing may have failed in the past and the metal bits scored up the rotating shaft. The bearing looked okay when I took it apart so maybe it had been repaired in the past without changing the shaft. I tried to dress the damage and I installed a new bearing and seal when I put the motor back together but after a few hours of riding today the gearbox was full of white foam.
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