Guys I need a little advice...I have a 1996 400 Polaris Sport 2 stroke. I found water in the counterbalance and oil in the recoil starter cover. I assume the crankshaft and water pump seals are shot. I've done alot of work on smaller yamaha's in the past but I relize that Polaris is a whole different animal. How difficult is this, what do I need to look for,and what special tools am I going to need?
Thanks Kernal

 

its not bad at all the only toll you will need is a countr ballence puller there about $15

 

you dont even need that..i just did this on a bike just like yours just have to replace 2 seals and 2 gaskets. dont have to pull the counterbalancer its very very easy.
o the only thing you will need is a span socket. there is a nut on the crank that is slotted. that has to come off to get the stator cover off the engine. its LEFT HAND THREAD. we didnt know that and used a flat head screw driver and a hammer to try to take it off.. ended up tighting it so much that we couldnt get it to turn the other way. had to cut it off and buy a new one. anyways, the task at hand is not that hard at all. the water pump doesnt have anything to it. like i said there are two seals in the water pump housing make sure you pay attention to which way they are facing. one is facing one way and the other is facing the opposite way. then there is a gasket that goes between the water pump housing and the rotor cover and then theres a rotor cover gasket. the oil in the recoil housing wont be too bad to fix either because you will already have what you need apart to fix it. right behind that slotted nut on the crank is a seal. thats the only thing seperating the recoil from the counterbalancer gears. good luck

 

oh yeah you only need the counter balance puller if your counter balance is bad from not being lubed right.

 

Great information guys....Thanks
Kernal

 

Great information...Eggenz7...would you advise that I purchase a span socket rather than try to drive the nut off with a screw driver?
Thanks Kernal

 

as long as you dont tighten it up by going the wrong way the nut should come off. the cheapest ive been able to find that socket is 45 bucks. ive also heard stories of people being able to goto their dealership and borrow special tools like that, so you might want to try if you have one close enough to you.

 

Zach, You were nice enough to reply to my post a while back, I hope I can pick your brain one more time.
I started this project the other day; ofcourse I got pulled off it by the old lady before I got too far. My question: do you have to pull the engine to remove the rotor cover and waterpump cover. My Haynes manual isn't very clear on this.
Thanks Kernal

 

nope should only have to remove the brake cover and the exhaust shield. we also pulled the exhaust system off to give us a little bit more room