Ok I'm trying to replace the water pump seal and need advice on how to remove it from the shaft. I also plan on replacing the oil seal also since I'm already in there unless told otherwise! It's a 04.5 sportsman 700 efi

 

Pull the outer cover!! Don't do as some have and pried out w/p seal and oil seals. Too risky and can bend the shaft,then it gets costly!!Pull the flywheel and stator,just move the stator out of the way.Pull the w/p impeller and hose. Remove the remaining cover bolts,pull the cover off. Expect oil to drain out unless you have it leaning inwards. Take the cover to the work bench. Pull the oil seal from the rear,from the rear knock the w/p seal out of the case.Install the new w/p seal with a socket that fits it's diameter. Oil seal the same way. Clean up the cover and the engine case.Install a new cover gasket. Install the cover,stator and flywheel,impeller,w/p gasket and cover. Hook up the hoses,fill the radiator,leave the radiator cap off,jack up the front end a little,run the engine until the fan cycles on and off a few times to remove any air pockets.Top off radiator and coolant bottle. #13 is the gasket needed along with the w/p cover gasket and seals. #14 is the outer cover.
Dirt Cheap Yamaha, Polaris, Suzuki & Kawasaki OEM Parts & Accessories – Cycle Parts Warehouse

 

Ok so to get the fly wheel off I gotta have a puller huh ? Will a automotive type puller work or is something special for polaris ? Do I need to mark the flywheel so it goes back the same way or what ? Jus what all entails in this job ?

 

Flywheel is keyed. Harmonic puller is best to use on the flywheel or a heavy duty steering wheel puller. Three 8mm bolts screw into the flywheel and it will pop off. Be careful not to damage the crank shaft threads. You can "borrow" these at most auto stores with just a refundable deposit. Here's a good video on this. 700 engine in a dune buggy.Video is mainly for upgrading the ignition system but at approx 3:50 shows on pulling the flywheel. Sometimes heat is needed on these flywheels also.Impact tools are a must!

 

What do you mean when u say the flywheel is keyed ? Only certain way it'll go on ?

 

Can only go one way. Woodruff key is on the crank shaft. Cutout slot on the flywheel lines up on it. Woodruff key on the crank shaft is #26.Dirt Cheap Yamaha, Polaris, Suzuki & Kawasaki OEM Parts & Accessories – Cycle Parts Warehouse The manual goes into good detail on this and replacing seals.http://polaris-atv.brssm.com/2005-Po...ce-Manual.html If you have the efi model,they have the manual for this one also.

 

Ok so what's the best way to remove the gasket material off the engine side of the cover , with out getting debris all in the gears ?

 

Very easy,most of the gasket may stay with the outer cover. Just use cheap old blue shop towels to cover the gear area,plus a plain old razor blade scraper or the handle type scraper. I always used just used a tad of 1104/1194 Three Bond sealant on the inner side to hold the gasket in place. From the factory the gasket is assembled dry.

 

Yea I was thinking about using a scraper with razor blades but was kinda worried bout gouging in the block ,! The whole gasket stayed on the block !

 

Just scape her off. Don't get scared now,your past the hard part already on this job..