I have an 88 LT250R, rebuilt the water pump, lasted about an hour, rebuilt it again, new everything including the shaft, lasted through practice and warm ups, i am pretty sure it is put together correctly or else it would leak right away. I am looking for ideas as to why this is happening.

 

I am assuming you have a manual and if you don't, it would be wise if you did. Where did it leak?, around the egdes, inside the pump itself?

 

yes I have both the suzuki and clymer manuals, it leaks out the little hole in the bottom.

First time I changed the ceramic seal under the empeller.

Second time I changed everything, brought it to a guy who knows how to do this just in case I was wrong. Put it back together, started it, no leaks, ran warm ups, no leaks, came back from the first heat, water running out the little hole. Took the clutch cover and water pump cover off today, so far everything looks fine. Will pull out the water pump pieces this week and see if anything there looks bad. Will put it back together with new seals and stuff and hopefully it wont leak again.

 

I have had the same problem with my 91. I got to the point I just gave up and added Bars leak to the antifreeze. That seem to solve the problem. I was told that this was a problem that all the quadracers had. You may want to talk to Duncan racing they may be able to help you since they have built alot of lt500r and lt250r. They my have a better solution than adding Bars leak. Let us know what you end up doing to solve the problem.

 

my brother had a similar problem on his '90, we replaced the seal as deascribed by mr dune on ORC. we used gaskacinch anyplace we could(between the seal and the clutch cover, on the grommet on the back of the impeller, and between the ceramic washer and that gropmmet) and used RTV blue on the impeller screw washer. no leaks yet in almost a year...

 

The Clymer manual I have say's the they require Bar's leak preventer from the factory, Check it out in the Cooling section