Hi Everyone.

I'm new to the site and am looking for someone that has changed a water pump mechanical seal on a 03 500 HO sportsman. I see in the manual that the engine case should be split to replace the both the water pump seal and the oil pump seal. Has anyone changed the seals without splitting the case? is the seal pressed in from the outside or is that why the case needs split because the seal is pressed in from the inside.

Thanks for any suggestions/input

 

Don't,I repeat,don't go by the so called "short cuts" that some have posted and on some videos on prying out this two piece seal.. It takes the w/p seal puller to do the job right. Once it's out the oil seal can be pulled out by simply inserting a 2" drywall screw and wigging the seal out. A deep socket the same size of the seal that can clear the shaft can be used to install the new oil seal if needed.Thew new w/p seal can be driven in with a similar type socket other than the seal installer. Either get the seal puller or load up the atv and let a dealer do it. At this cost,for a one time use,about as easy to just let the dealer pull the seal.Water Pump Mechanical Seal Puller Just a friendly warning on this because if you bend the impeller/oil pump shaft,the engine has to be split.. to replace it. I've had to do this several times and it ain't fun or cheap.It's not the cost of the shft but the labor involved. Item #15 is the shaft.Dirt Cheap Yamaha, Polaris, Suzuki & Kawasaki OEM Parts & Accessories – Cycle Parts Warehouse It so happens that someone posted today in the "other" forum on the same thing,but sounds like he's in a bit of trouble..


"Hey guys, I have been trying to get my 2004 polaris sportsman 400 to stop leaking coolant out of the weep hole behind the water impeller.

I replaced the oil seal and mechanical seal, started it up and the sucker still leaked out of the dang weep hole, but now it was water and oil. I replaced both again, but same situation. I was really extra super careful that last time because I didn't feel like buying another $80 worth of seals... What am I doing wrong??!?

Side note: the impeller shaft might be a little tweaked from me prying on the mechanical seal the first time trying to get it out. That might be what caused the seals to fail again. How hard is it to get a new shaft and replace it? Am I going to have to pull the motor? "

Don't be like this guy.. OPT

 

Thanks OPT

I did a little research as well and agree/and happy there is a tool for the removal of the w/p seal. I was not looking forward to the hours of engine removal/split.

thanks again for your reply

WD