At the bottom of the motor under the water pump there is a hole approx 1/4" dia, this is the weep hole to let the coolant escape if/when the mechanical seal leaks. Your problem sounds like the mechanical seal or the gasket. If it is the mechanical seal don't repair this yourself unless you know what your doing and you have the special extraction tool. A word of caution, if you try to remove the seal with out the special tool you run a high risk of bending the pump shaft and that would mean splitting the crankcase to replace it.

 

yes I have finally pinpointed the leak. It IS coming from the gasket behind the waterpump. You guys are good! All the way on the bottom. Is this what everyone is saying that Polaris is having trouble with or is this a different problem all together? Is it worth a try just tightening up the bolts a little? I am leaking a drop every 10 seconds or so but it is a little more when im actually on the gas. Thanks.

Chris

 

You could try torquing them down a bit but I would be VERY careful. Those bolts are going into aluminum so you have to be caeful. The manual shows them to be torqued to 9-10 ft. lbs. (the water pump cover bolts).

 

another spot to pinpoint the leak is the hose coming off the water pump, mine leaks and runs down and makes it look like it is coming out of the waterpump seal but it is not...only does it after sittting for a long time though..dont know why for sure...

 

Does anyone know the part numberor cost for the extraction tool Traildog mentioned. My 2002 700 is leaking coolant again and I think it is the seal. I have already replaced the water pump cover last year with the new aluminum one. I have no visible drips comming from the quad. I have been racing harescrambles and I am using about one overflow bottle of coolant per two hour race. Does anyone have any tips or good directions on how to replace this seal?

 

I don't know of any extraction tool you need when replacing the seal. You will need a flywheel puller though. You can get away with a generic type but be careful.

 

Polaridoo, you may becorrect in saying that you can pull the seal with a regular puller. My 2001 Sportsman 500 HO needs the special puller for sure and my assumption was that they would be the same. I could be wrong.
For my 01 500
The special tool part# is PN 2872105
If you would like a couple of scanned pages explaining the replacement send me an email and I will send them to you.

 

I sure need some help getting this LEAK taken care of now that I have pulled the water pump open and see the the MS needs to be Pulled ..? I would like any help if possible to finding the cost of a puller and were I might find on I live in Goose Creek SC .