I have a 2003 600 Sportsman that is dumping antifreeze into the base somehow. I replaced the head and base gaskets but didn't solve the problem. A dealer in my area is telling me that he has seen the waterpump gasket fail and cause the symptoms that I am seeing. By my manual this doesn't look possible. Has anyone else had this happen and if so, what was the fix? One thing I did notice was that while torqing the head bolts down one didn't feel the same as the rest. I managed to reach the specified torque but it felt soft where the others were firm. I didn't overtorque. Any help would be great.
Thanks

 

Your dealer should know that the '02-03 twins need the original plastic water pump cover to be replaced with a metal one, they all eventually warp and leak.
Find another dealer.

Jim

 

Monitor your oil level closely. If you see it rising on the stick most likely the inner seal (seperating the oil from the water is defective. It happened on my 03 700. Had the seal replaced and the WP completely rebuilt ( already had the WP cover changed ) and that fixed the problem. Also, dont do like I did. Make sure you check your oil level by following the instructions in the manual!!!!

 

Biggator, when you check your oil this way how does it read on the stick?