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After some winter maintenance, I started the bike up for a short test drive. When I came back, coolant was leaking pretty badly from the weep hole under the water pump. Guess its time for a rebuild... After searching the forums last night, I haven't seen a complete parts lists or technical aid anywhere, so thought I'd try to document it all in one place. A couple questions: 1. I found in another post that P/N: 1FK-12450-00-00 is the newer metal impeller and that the plastic one was only used on MKI 1st gens. Can anyone (or a few people) confirm that this is indeed the metal replacement? I went through several years of bikes on Part Shark and they all listed this same P/N, but didn't indicate it as a replacement for obsolete part, which raised some suspicion. 2. Should I replace the thermostat too? 3. How do I get the water pump housing off without breaking the 90 degree plastic elbow joint between the thermostat and pump housing? Does it just slide/press in with the O-ring? Is it best to pull it out of the thermostat housing when pulling the pump housing off the case? Does it come easily or is there a safe method to pry/pull on it? 4. Is it necessary to replace the plastic gear (item 4)? I assume its worth $14 since I'll have it all apart, but just checking. 5. Will oil come out (do I need to drain oil) when I pull the water pump housing off the case? 6. What is item 3's purpose (Pin, dowel)? Should I replace that? Is it pressed in? 7. I'm planning to replace all the parts below. Am I missing anything? 8. I've read that success rate on a rebuild is not good. What are common mistakes or causes for this? What do I need to watch out for? Thanks in advance, everyone! Rebuild Parts List: 1FK-12450-00-00 – Qty 1 IMPELLER SHAFT ASY for 1984 YAMAHA XV 1200D Item 2 – this is supposedly the metal version, original was plastic $39.72 11H-12438-10-00 – Qty 1 SEAL, MECHANICAL for 1984 YAMAHA XV 1200D Item 8 – ceramic water tight seal $19.54 93101-10090-00 – Qty 1 OIL SEAL,S-TYPE for 1984 YAMAHA XV 1200D Item 7 $2.52 93306-00004-00 – Qty 1 BEARING for 1984 YAMAHA XV 1200D Item 6 $13.05 99009-10400-00 – Qty 2 CIRCLIP for 1984 YAMAHA XV 1200D Item 5, 2 places $1.18 26H-12459-00-00 GEAR, IMPELLER SHAFT Item 4 $13.86 ----------------------------------- 93211-16591-00 – Qty 1 O-RING for 1984 YAMAHA XV 1200D (Outer Impeller Case Cover O-ring gasket) Item 9 $5.05 214-11198-01-00 – Qty 1 GASKET for 1984 YAMAHA XV 1200D (Drain Plug O-ring) Item 12 $1.25 3JP-12449-02-00 – Qty 1 GASKET,WATER PUMP for 1984 YAMAHA XV 1200D (Gasket for main case housing) Item 14 $5.02 93210-27778-00 – Qty 2 O-RING for 1984 YAMAHA XV 1200D (O-ring seals for elbow joint between Pump housing and T-stat) Item 19 $1.45
