I have a 04 sportsman 500 H.O. and have never had problems with overheating. However, this past weekend I was out mud riding and it started to overheat. The fan was still working fine. I got home and cleaned the radiator and it still ran hot. I then checked my coolant level and ended up filling the radiator with about 3/4 gallon of antifreeze. when I hit the trail after that, my son was riding behind me and noticed a lot of fluid coming from under the engine. I stopped and crawled under it and noticed a little weep hole behind the water pump and it was just poring fluid out. before I got back home it was running hot again. I checked the impeller in the water pump and it was working fine. Now, I can start the engine when it is cold and radiator fluid automatically starts running out of the little weep hole behind the water pump. Anybody have any suggestions as to what might be causing this?

 

There are two sealing washers and a mechanical seal under the water pump cover. It has to be one or more of those parts that is causing your leak.

 

Thanks, I'll check that out. Does it take any special tools, from Polaris to replace those seals?

 

Yes, but I don't have the manual in front of me at the moment to tell you the part number.

You might just order the mechanical seal, call the dealer and make an appointment, then bring in the ATV to have the seal replaced. If you tear down the ATV so that the seal is exposed and ready to pull out, you would probably save yourself most if not all the labor cost involved, as well as the cost of the tool. Having a good relationship with your dealer comes into play here.

Or you could just wait until I get home from work and I'll post the name of the tool and part number for you.

 

It,s your mechanical seal, and yes it does require a special tool to pull it. Its about 75-100 bucks for the tool or you can do like sheepdog suggested and tear everything down and take it to your local dealer, shouldn't take them about 20 mins. to replace it. Ask them to check youre oil seal also while you have it apart .I just recently had the same problem and if you do alot of mudding use a small piece of stainless tubing and some windshield wiper hose and snorkle it....itll keep the sand and grit off the seals and maybe last longer...good luck

 

Water Pump Mechanical Seal Puller: (PN 2872105)

Replacement T-Handle: (PN 2872106)

In the manual, there are specific instructions AND diagrams (illustrations) that seem to be critical to the proper removal and replacement of this seal. I wouldn't want to tackle this job without having the manual in front of me, using the diagrams for reference.

Good luck.

 

just dont bend the shaft that the seal rides on...or youll have big problems!!

 

sheep dog, is there any detail instructions or good web site how to change the mech. seal yourself?