I just got back from riding and noticed that there was coolant leaking from my 03 sportsman 500.After inspecting it closer it looks like its coming from a manufactured hole in the bottem of the coolant pump.If it is the mechanical seal,do I have to take the engine off the frame to replace it?????Thats what this clymer repair book says! Please tell me a better way! Thanks for any help

 

You do not have to remove the engine. There is a special tool though, it has fingers that grab the seal to pull it out!

 

where would I find this tool i keep hearing/reading about?

 

Not sure on the location of one, my buddy (works at a dealer) was going to swing by the house to do mine on my '01 500, but I traded it in before it was repaired. I believe it is a pretty complicated piece, maybe you could check with your dealer and have them do the seal, and you do all the tearing down/putting back together!

 

Probably a good idea.

I checked the service manual for my '06 500 and found the following part numbers.

1. Water pump mechanical seal puller: (PN 2872105)
2. Replacement T-handle: (PN 2872106)
3. Water pump install kit: (PN 5131135)
4. Crankshaft/water pump seal installation kit: (PN 2871283)

So, to remove the seal you need #1 and #2.

To install the seal you need #3 OR #4, as #4 has #3 in it. LOL!!

This assumes that the parts on your '03 are the same as an '06.

Hope this helps.

 

Thanks for the help guys Im just going to take it to a mech and let them tear it up!

 

Sometimes that's the best thing to do. It hurts the wallet, but you know it'll be done right(hopefully)!

 

Cost me about 90$ last time I had it done with no headaches.

 

Took it to a dealer today,gonna cost $180 plus parts to change the mechanical seal and the oil seal behind it......ouch....I hope this bike doesnt cost me this much everytime I ride!..............ps I know the price is high but believe it or not they were the cheapest quote i got and i called about 10 different places!