I have a 700 that has 2700 miles I have replaced the waterpump seal 4 times. If coolant is near the little hole in bottom of waterpump area of motor the weep hole is doing its job-- the water pump impellor and seal need to be replaced about 50$ and an hour or 2

 

I went to my PoPo dealer today and asked questions about the leak. The tech told me 99 times out of 100 the water pump seal is the culprit. I bought the $50 seal and will replace this week. As for the cover, he said just reseal it with some rtv gasket sealant and I'm good to go.

As always, Thanks for all of the input. I'll update again when it's fixed.

 

ItStillRuns: Question on replaceing the water pump seal on my 600 Polaris. You replaced yours 4 times you stated, any hints or special tools that would help me to replace mine? Any information from you on this would be of great help, I try to do all my own repair.

Thanks Very Much--DennyM

 

its pretty easy really. I used a big nail instead of a seal puller to pry the seal off the shaft it seals to. Just becareful not to scratch the shaft . For a nice parts breakdown go to bikebandit.com and find the oem parts area and click your machines # its got the entire Polaris parts catalog on line. (I also have the shop manual ). Hope that helps. Jeff

 

Itstillsruns, Thanks for reply on my water pump leak. I contacted BikeBandit.com and have a catalog coming, will be doing repair when it gets above zero here in Minnesota, 10 below tonight, but spring is coming. Thanks DennyM

 

Alrighty then...............here is the final verdict!!

I did NOT replace the seal. I was certain the leak was from the cover and was right. I resealed the cover yesterday with grey high temp rtv. Today I filled the radiator and cranked her up and ..........NO LEAK!!!! The weap hole is dry. let it run for 30 minutes. When it leaked it would drip out in a few minutes so I think I got it. Taking back the $50 seal tomorrow for a refund and will spend it on some budweiser!!!!

Thanks everyone.

 

Hey Beertruck: I just bought a 2002 Sportsman 700 from a friend who never used it. It has 44 original miles, and is in mint condition. I noticed the coolant leak you and others talked about. I went to Polaris dealer today, and the fella there told me that the plastic covers, and in rare cases, the mechanical seal was the culprit. I picked up the aluminum cover to replace the plastic one. I am hopinbg this is the correct fix. I did not check to see if it cam with new seal/o ring etc. Do you think the one in the quad can be reused? Any advice would be greatly appreciated. Thanks Mountain Joe.

 

The original plastic cover would warp like they stated earlier. Polaris actually made a steel cover to go over the plastic one to fix this, then later, it was all aluminum. my advidce. Get the new cover and o-ring and try it before messing with the mechanical seal. WAY cheaper and easier. Give it a shot first.

 

Thanks 94 Harley: I am going to do just that. I did not check to see if o ring/seal came with the new aluminum cover I picked up. I will be disappointed if the dealer did not include it with cover. I explained the problem to the dealer, and he said he was familiar with the problem and gave me what I needed. I left the cover in the back of my car. I will check in the am before I head out to work.
Thanks Mountain Joe.