ISC/IAC motor o-ring install - HELP!!

[stevenk2]

Stupid question #101 - how do you reinstall the rubber o-ring on the ISC stepper motor? We are replacing our ISC motor to fix the low idle stalling issue, and everything was going smoothly until we went to install the o-ring. I removed the old one and saw exactly how it fit on the old ISC motor, but now when I go to reinstall it, it's like it's just an eighth of an inch too large and won't fit the channel on the motor housing anymore. I'm going to run up to our local Kawasaki dealer tomorrow to see if they have a new o-ring in stock to see if that's maybe the issue, but I'm concerned it takes a special tool or something to get it back into the channel again.

Any help or advice would be GREATLY appreciated!

[Rescue1]

Stupid question #101 - how do you reinstall the rubber o-ring on the ISC stepper motor? We are replacing our ISC motor to fix the low idle stalling issue, and everything was going smoothly until we went to install the o-ring. I removed the old one and saw exactly how it fit on the old ISC motor, but now when I go to reinstall it, it's like it's just an eighth of an inch too large and won't fit the channel on the motor housing anymore. I'm going to run up to our local Kawasaki dealer tomorrow to see if they have a new o-ring in stock to see if that's maybe the issue, but I'm concerned it takes a special tool or something to get it back into the channel again.

Any help or advice would be GREATLY appreciated!

When it gets taken out it swells up, and gets even worse if gets in contact with carb/brake cleaner if you are cleaning the surface.

You can try using grease to stick it back into the groove which sometimes works but what it really needs is a new seal. You can also slice a piece out to shorten it a bit so it fits better but a new one is the permanent fix.

[stevenk2]

Thanks, Rescue1! I figured a new o-ring would probably be the solution - my son is running the ISC and original seal up to the dealer today to see if they have a new one in stock and/or if they can get the original back into the groove. We had considered cutting out a small slice of the original yesterday when we were working on it, but I'd heard that you want to make sure the ISC is airtight, otherwise you might get spurious readings with the ECU that could cause additional issues at idle (and otherwise). Best case scenario sounds like getting a new o-ring, so that's what we'll go for.

[stevenk2]

My son just got back from the dealership, and they don't have the o-ring, but gave him a part number to look up. Unfortunately, it looks like the number they gave him is actually for the throttle body o-ring and not the one for the IAC o-ring (P/N 92055-3773). I looked up a couple of exploded parts diagrams online, and none of them appear to have the ISC o-ring pictured. I'm thinking that I may just need to try to reuse the one I have and just make it work somehow. Kinda silly how a little 25-cent piece of rubber is holding up getting the thing put back together and running again.

If I'm unable to get the original to work again, is there any other option but to cut it to fit? Can you seal it with some kind of form-a-gasket from a tube or RTV or something like that?

[Rescue1]

My son just got back from the dealership, and they don't have the o-ring, but gave him a part number to look up. Unfortunately, it looks like the number they gave him is actually for the throttle body o-ring and not the one for the IAC o-ring (P/N 92055-3773). I looked up a couple of exploded parts diagrams online, and none of them appear to have the ISC o-ring pictured. I'm thinking that I may just need to try to reuse the one I have and just make it work somehow. Kinda silly how a little 25-cent piece of rubber is holding up getting the thing put back together and running again.

If I'm unable to get the original to work again, is there any other option but to cut it to fit? Can you seal it with some kind of form-a-gasket from a tube or RTV or something like that?

Did you try using grease in the grooves to help ÔÇ£stickÔÇØ it in?

Some ultra gray may work but at that point slicing a piece off or each length will be less messy and get ya up and running. Then go through the greenhulk store or I use Riva and order the part then change it another time.

[stevenk2]

I'll try some grease first to see if I can get that to work. Is there any special kind I need to use in this application, or really any automotive-grade stuff will work?

Then go through the greenhulk store or I use Riva and order the part then change it another time.

The issue is that even in the exploded parts diagrams I am seeing online (including on Riva's site), none of them have an o-ring pictured as a separate part with a part number. The only thing I can figure is that when you purchase the ISC new directly from Kawasaki, the o-ring comes preinstalled with it. This particular replacement ISC I purchased was used, so it did not come with the o-ring.

[stevenk2]

Quick update on all of this - we were wholly unsuccessful in locating a replacement o-ring, nobody seems to even have a part number for it. I went ahead and tried some of the suggestions for getting the original to fit, but in the end I ended up trimming the excess length (slowly & carefully, only trimming very tiny pieces until it fit perfectly with no gap) to get it to fit properly. Reinstalled the ISC and plugged it back into the wiring harness, engine fired right up and settled right down to normal idle speed with no issues. We'll likely be out on the water tomorrow to fully test it under normal operating loads, but I expect it's fixed now and we won't have any further issues.

Thanks to everyone for all of the advice and suggestions!!

[Rescue1]

Your fix should work fine, But if you still want to swap out the O-Ring it's easy and cheap enough. Here is a link with the part number in the description...

https://www.partzilla.com/product/kawasaki/92055-3773?gclid=CjwKCAjwsIbpBRBNEiwAZF8-z1E2S9a7Ji-qLtpgWhjS6E9871q2upfnX-L_zQyBWuLAzzqo8ykS3hoCdzEQAvD_BwE

[stevenk2]

Thanks again, Rescue1 - I'll continue to search for the o-ring replacement, but be aware that 92055-3773 is not the correct part number for this. Here's an exploded parts diagram from Kawasaki - the ISC/IAC motor is p/n 21174, and the o-ring fits into a channel on the body/flange of the ISC that seats to the metal housing that's bolted to the throttle body. Part number 92055A (as shown in the diagram, likely the same p/n as 92055-3773 that you referenced) is the throttle body gasket that the entire assembled ISC sits on to seal it to the throttle body. The ISC o-ring is a simple circular flat rubber gasket.



I'm hoping that our fix works, since it appears to be impossible to purchase just the o-ring as a separate part, and I really didn't want to spend nearly $200 for a brand-new ISC with the o-ring pre-installed (assuming that's what the deal is, anyways). Plan B would be to try to hunt down a generic flat-style o-ring with the proper diameter; Plan C would be to run a bead of Permatex (or RTV or something similar) in that channel on the ISC and just seal it up that way. I would assume that the end game is to just find something that creates an air-tight seal to prevent air leaks under load that could give the ECU false readings and affect the engine running properly at idle (or otherwise).

[Rescue1]

Apologies sir, I thought you meant the other gasket which does the same thing. I had a spare, likely non working solenoid in my parts bin and took it out before in hopes of sending you a working rubber O-ring, but as soon as I pulled it out it expanded..

But really I think cutting a small section out is the way to go and you shouldn't have any issues.

[Rescue1]

I found this though. I'll try and see if it works..

https://thepeasantblog.wordpress.com/2016/03/26/how-to-shrink-a-o-ring-or-gasket/

[stevenk2]

Interesting..........I never would have thought to boil the gasket, but it makes some sense. If I run into the situation again, I'll have to give that method a try. At this point, I've kinda committed to the trimming method, so if this ISC ever fails, it seems as though the only recourse I'll have will be to either make my existing (trimmed) o-ring work, or I'll have to purchase a brand-new ISC that (hopefully) has the o-ring preinstalled from the factory. Just seems a little silly that the o-ring isn't available from Kawasaki as a separate purchaseable part, especially since it looks like all of the other o-rings/gaskets in the engine are.

I suppose I could use RTV to form a seal as well (in place of the o-ring), but that seems a bit messier of a solution. The end game is to make an airtight seal against the throttle body, so in theory that should do the trick though.

Another thought I had was that somewhere I'd heard that these are the same motors they use on their Ninja bikes. I wonder if I may have any luck searching for the replacement ISC o-ring from a Ninja parts catalog? Somehow I think not, since they're entirely different applications, but who knows?

[macGruber]

This WILL Work

I know this thread is 3 years old but I'm going to put an answer anyway for future searches. This 100% will work to restore the size of that IAC or any other Oring on a Kawasaki Jet ski.

Boil it for 10 minutes to help remove impurities. Then soak it in carburetor cleaner for 3 hours submerged. It will expand to almost twice its original size. Remove it and let it sit in the Sun for a day... And at the end it doesn't hurt to hit it very lightly with a hair dryer or even a heat gun for 30 seconds from a respectable distance of about eight to 12 in. Then I even hit mine with an upside down can of compressed air to spread it down with a puddle of liquid nitrogen for 4 seconds and basically freeze it. It worked perfectly and returned it to the exact OEM size. I'll guarantee it. Something about the carburetor cleaner expanding the O-ring must allow final stage impurities to escape and be cleaned out but it does not ruin the O-ring at all. It reduces back to its normal size when all of the carburetor cleaner evaporates from the material. It remains supple and seals perfectly.

Why bother with this you ask? Try getting an oem ANYTHING right now. Have to get creative during supply chain delays like this and this works. Hope it helps somebody in the future when they search for it.