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I finished buttoning the bike up tonight after installing the new (Honda, OEM) water pump. I filled the radiator with distilled water, intending to flush it out....and it immediately started leaking out the weep hole.

When I took the old water pump out, it was wedged in there VERY tight - I had to whack it out with a dead blow hammer to get it to come out.

When I put the two new O-rings on the new pump, it slid in there very easily.

Looking at the parts diagrams, the primary candidate for the leak is the large O-ring. I'm pretty sure this did not fold over or kink when I put the new pump in.

Has anyone experienced this? Does the O-ring look undersized in the pictures below?

I guess I will be taking the whole thing apart again tomorrow to try and figure out what is going on. I'm too frustrated and disgusted to do any more with it tonight.


 

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did you change the gasket in back of the water pump?
or you may have bent it when you put it back in
 

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Which gasket are you referring too?

two O rings and 3 aluminum crush washers.

I checked a water pump that I had taken out, the groove measured 2.4mm and the O ring 2.4mm which is what the fiche says.

Did you lube the O rings on install, I use Vaseline or Crisco on O rings to allow them to slide in.
 

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I changed all the gaskets and O-rings, but if the gasket was damaged, it would be leaking from between the water pump cover and the engine front cover. This is definitely leaking out the weep hole. So either water is getting past the large O-ring, or the pump is faulty and it is getting past the front seal and going through the interior of the pump and out its hole. From what I can tell, anyway. I looked at the old pump (I still have it - the bearings on it are shot, no wonder it was leaking) and the large O-ring doesn't protrude any more than the new one does. My hopes are that I twisted the O-ring somehow when inserting it.

I'm tempted to just squirt a ton of RTV in there and be done with it. But I won't, I want it done right. :)
 

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I did lube them (you can see in the picture, I had done the small one, not the large one yet).

I'm going to attempt to pull the cover off tomorrow without hauling the radiator and assorted minutia off. I'm REALLY tired of taking that radiator off and putting it back on, it's one of my most hated tasks on that bike. I'm thinking that if I pull the lower hose off, I might have enough clearance to get it out - perhaps with only unbolting the bottom of the radiator and pulling it forward.
 

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I hate it when this happens to me as wellbut sleep on it anduse your better judgement tomorrow. Do it right even if it means pulling the blasted radiator again.

I pulled on a rad hose once and cracked the fitting so had to take it out again anyway. :X
 

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When I did my 1100 pump, there was no problem getting the cover off with the rad in place...I actually just unbolted the lower hose connector from the cover & let it hang...

Should come off pretty easy since you've just been there, and knowing what you've already been through makes me feel your pain!
 

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I'd run it for a bit I had the same problem..a slight leak after a new pump after running it for a week it stopped..I think the mechanical seal at the back of the impeller was seating itself..but just a guess..

Most likely issue is as you said a kinked, nicked o ring..if it is it won't hurt any the run it for a few days like that and if it's the seal..it may seat itself in a few days..

Just my .02 of experience with this..
 

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I had the same issue 20yrs ago with the oem gasket set from Honda. The big o ring was a smaller gauge and it took me 3 itterations of front engine coverremoval before I figured the problem out. I wasn't that smart back then because every time I'd get her back together I'd pour in antifreeze instead of distilled water and it leaked out all over.. I ended up using the old o ring and it lasted until I did the front trans cover paint this winter. Don't you know the new after market japan gasket set works fine so for with 5+ k miles so far this season. Go figure! looks like mother Honda hasn't got that o ring right yet.
 

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In my case it leaked just as fast as I filled it.
 

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I didn't have any problem when I replaced the pump on my 84 aspy. I put grease around the o rings before installing and it went in slick. The pump on the 84 looks just like your pic so I'm sure they are very similar. Did you also replace the pump shaft seal that the pump drive shaft goes into? On mine, the pump bearings were so worn out that all of the play in the shaft ruined the seal and water was being pumped into the crankcase, what a gooey mess.
Probably if you grease it up it will seal fine. If not, you may have to get a larger diameter o ring. Good luck, I hope it works out well for you.
Jim(inSC)
 

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Oh, btw, I bought the water pump seal kit from JC Whitney when I did mine. It had all of the needed gaskets and o rings in it, but, the thermostat o ring was too large in diameter so I used the original. I think the kit was about 26 bucks. Good luck again.
Jim(inSC)
 

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I used the same water pump seal kit (tons of O rings, gaskets, etc.) and yes, I did replace the mechanical seal even though it looked fine.

I called around a few shops today looking for the O-rings (just in case) but of course nobody has them. I'll pull the blasted thing out tonight when I get home and see if I can see any obvious problem. Then I'll try again - if it still leaks, I guess I'll order a new O-ring. Sigh.

Fortunately I did use distilled water to test (I was planning to flush it out) - but unfortunately I had just finished filling the crankcase with brand new oil when I noticed the water leaking out!!!

I wonder if I tip the bike backwards before I pull the cover off, if I can manage to keep all the oil in there?
 

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GSMacLean wrote:
I wonder if I tip the bike backwards before I pull the cover off, if I can manage to keep all the oil in there?
:? you would probably have to tie onto the forks andhang it from the rafters. just drain it in a clean pan and put it back in.The bright side is you dont have to take out the radiator on a 1100 if you have a 1/4 inch swivel.JB
 
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Hope you gt it goin soon GS.
Its a shame to loose all this great riding weather.Good Luck with it.
Tommy
 

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I think you might have undersized O-rings. I've changed three pumps and they all took a bit of pushing to get them in. I used a rubber mallet and a piece of wood to tap them into the cover. I also lube them well withgrease.
 

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Visually from here speaking as a plumber, that large o-ring looks too small. I would say next size up would be correct.
 

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Sounds like you have water leaking into the oil..Duh..so maybe the smaller o ring on the back of the pump is fouled too??? I think that is only way water can get into the oil from the things you have messed with.although at the "ears" of the front case I believe those are water ports and there is an oil galley close by if the o rings in those ports were pinched, they do tend to fall out of place I guess water could get into the oil as well..but it would also be leaking at those ports as well..just thinking out loud...
 
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