Water pump broke down

[KrekerisLV]

Hello, riders, I'm once again asking for your help / opinion.

I went for a ride to city center to run some errands. Came back to my X9, started it up and as I was about to get back on road, i heard loud knocking in water pump cover. As i had disassembled it before, i knew that the thing going wild in there most likely is one of the water pump drive pins. I had no choice but to keep going, because I couldn't afford to get someone with trailer to come get it and pushing it home was out of question (tunnels, bridges etc.). Got home (with multiple stops to cool down engine) and drained cooling fluid, took of the cover and saw the massacre that the pin had caused.




I don't remember exactly how i removed the broken pins from flywheel last time one of them broke, however, i remember it having something to do with dark magic. So my question to you all is, does anyone have any tips to remove the broken bolts?
In the fourth picture you can see that the hole, where the water pump drive pin screws are, is messed up (that's probably why it fell out). No idea how the hole became like that tho. Would it be okay to replace only 2 pins? Any idea how to fix the stretched out hole?

Thanks!
Krišs

[Dave Milnes]

I wouldn't repair, I would replace all the damaged parts. Solo is the 125 expert who has tackled this before.
I would suggest when assembling these pumps that less torque when tightening the studs and use a thread lock. Overtightening causes stresses to form where the threaded part enlarges into the stud body as there isn't enough radius at the fillet.
Have a google around and see if anyone has produced any improvement kits of parts for these engines as this is a common problem.

[KrekerisLV]

Thank you for your reply. I took your advice and bought new parts. A piece of the magnet in rotor had also broken off so repairing it was completely out of question. Million years later parts arrived. I got myself a new rotor, 3 new studs and water pump wheel. I also ordered gasket but it didn't arrive ):
Now i have an issue - i need to safely disassemble the water pump so i can replace the wheel, however, i can't see an obvious way of taking it apart. I inspected the new water pump wheel and came to conclusion that it's pressed on the shaft. Does anyone have any tips on removing it? Worst case scenario - I'll splash some more cash and buy full repair kit with new bearings and everything (which i probably should've began with).
Thanks!

[Dave Milnes]

Sorry I don't know about the 125 pump. Have alook on the exploded diagrams on www.easyparts.nl website.