Radiator sludge

[vamr]

Cool, glad to hear it wasn't head gasket. What about the little flakes though? Could that be explained by the water pump seal too?

I believe it's just the corrosion of the radiator but will know for sure tomorrow.

[vamr]

I apologies for the barrage of questions but...

Got the cover off, after picking up a new gasket and seal. The metal inside looks like it was hit by shrapnel. Any idea of what would cause such damage and if I need to replace that wheel?

Thank you!

[Sketchy_Racer]

dunno whats happened there, but that impeller is still fine to use. Replace the seal, CLEAN everything. get it spick'n'span...

go from there

[vamr]

dunno whats happened there, but that impeller is still fine to use. Replace the seal, CLEAN everything. get it spick'n'span...

go from there

Cheers, will do once I pick up waterpump pliers (once again, lack of manual hurts).

I can only assume that either someone dropped a piece of soft metal into the radiator that has been subsequently disintegrated by the impeller and destroyed the seal in the process or the radiator has corroded and chipped.

Should I be worried about subsequent damage to the head by debris?

[Sketchy_Racer]

I wouldnt worry about the head....

The water flowing out of the pump isnt moving at a huge velocity... so HIGHLY unlikely to do any damage... And at a guess, i would say that crap was the cause of the water pump seal faliure...

[vamr]

After some trial and error (with some good advice from a few members here) got the right side engine cover off and have to say am not any further with the search for the cause of the said leak... just more confusion.

There is obvious evidence of coolant in the gearbox oil however the seals appear to be perfectly fine and recently replaced (I have no previous history of the bike). If anything, the impeller side mechanical seal is a little bit soft but that wouldn't explain the leak as the oil seal is ok.

My only conclusion of where all went wrong is the gasket, in particular around the water channel to the head, is a bit chewed up and off centre by around 2mm.

There is no other places where the coolant can meet gearbox oil so with any luck, replacing the seals (just in case) and the gasket will solve the problem.

There was in fact no damage to the impeller, just appeared to be at first look. I'm pretty sure it was the sealant used during the last installation of the gaskets (over-eager application) that ended up sticking to the blades (strangely enough, texture and colour wise it resembles something akin to Liquid Nails). On the waterpump case there is deep scoring but it doesn't really look like anything done by debris, more like someone's attempt to scrape off antifreeze residue with a screwdriver.

Live and learn I guess, at least I ended up with a better understanding of the bike (such as that there is nothing behind the clutchplate"cover" except for some dampening rubber and that for some unknown reason the nut of the powervalve activation shaft is countersunk).

Am still perplexed as to why Kawasaki tends to use quite soft metal for key bolts and nuts that hold the engine together.

[replicator]

yep. that milky white stuff means the presence of oil in the cooling system. that or someone is pulling a prank on you and putting yogurt in it or something

[Sketchy_Racer]

Even if the seal that is on the water impeller shaft looks good, does not mean it is sealing.

So replacing it is good

Keep us updated

Good on you for getting your hands dirty and sorting this out