I am replacing the water pump seals and bearing on a 96 400 express -- I was wondering if there was any tips to remove the water pump bearing??

Thanks!

 

Here's a video on the 350,basically the same engine. The hard part as the guy finds out in the video is getting the counter balancer cover off because the fill neck hits the frame! Had the same problem and you just have to work with it. Sometimes you have to knock out the large crank bearing in the co0ver to have room to wiggle. Once you have the cover off,the seals just pop off and knock the bearing out from the back of the w/p housing. Special attention need on the inner seal and bearing that the small hole is NOT blocked in the housing. Hope this helps. IF you need further help,this cheap 5 buck pdf service manual shows you step by step with illustrations on the water pump.DOWNLOAD 1996-1998 Polaris ATV Repair Manual ALL MODELS - Download ...

 

Thanks for the quick reply. My issue is that I have pulled everything apart but the water pump bearing has stayed on the counter balance shaft. That shaft seems much too small for me to comfortably use a bearing puller to remove.

 

One way is to use a small 3 jaw gear puller that's small enough that won't mushroom out the shaft end or bend it.These you can rent or buy at any auto supply.You can always install the nut on the shaft first and thread it off after the you get the bearing up enough to take it off to clean the threads.Another way is to use penetrating oil on the shaft and bearing along with heat from a heat gun. Then you can use pliers to gently twist the bearing off.

 

Ok I'll keep at it.

How far does the bearing go onto the shaft -- the manual I have says nothing about that part. Only about checking the clearance with modeling clay...

Really appreciate the help!

 

Manual doesn't say how far the bearing goes on the shaft because it's supposed to stay in the water pump housing. The housing fits fairly close to the c/b gear as you've probably noticed.

 

Got the bearing off -- shaft is in decent shape.

Is the bearing supposed to just slide on the shaft -- no resistance at all really.

 

The bearing,seals are to be installed into the w/p housing, the housing then slips on the shaft and housing stud nuts are tightened after the cover is fully installed.If in doubt about assembly the cheap manual can help on this and plenty of other service/repair related issues. Yes I push manuals because they really do help..

 

Thanks for the assistance so far!!

I do have the manual (pages 152-15 are printed out laying by the project ) Just never done a water pump before and the manual is rather vague in the particulars.

I need to order a crank bearing and seal as well -- I will update the post once completed for future reference.

 

I do agree on some repairs the manual writers think that you already should know what to do on specific repairs without them having to go into every possible detail,but that's their job to go into details imo or let someone else write the blame things..