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Old 06-13-2012, 07:33 PM
mwestwood800HO's Avatar
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Water Pump Seal Replacement

Hey guys, need to replace my water pump seal on my 2008 Sportsman 800 H.O and was wondering if anyone knows how hard it is to replace and has any step by step instructions on how to do it properly with no issues?
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Old 06-13-2012, 07:38 PM
87CYCLONE's Avatar
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Location: Central Wisconsin
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Ideally there is a special tool you should have to pull the old mechanical seal out. It can be done without it but you really need to be careful not to damage the case or shaft. I would recommend taking it to an experienced mechanic or else purchasing the tool and a service manual!

1987 250-X Cyclone

1987 250 Trail Boss 4x4
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Old 06-13-2012, 09:08 PM
AKStew's Avatar
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Location: Westerville, Ohio
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Try reading this it may help.

Water Pump Seal and Oil Seal Replacement on 2006 Sportsman 700 - Pics Inside

2011 Sportsman 500 HO Touring: Polaris 3500 lb. Winch, Kimpex Adventure XL Trunk, 7" Passenger Foot Risers, UNI Foam Filter
2006 Sportsman 500 X2 EFI: Superwinch Terra 25 w/Synthetic Rope, Kolpin 4 gal Gas Pack, 3" Passenger Foot Risers, 3-Headlight Mod, K&N Filter

SOLD 2010 Sportsman 300: Polaris 2500 lb. Winch, Kolpin Rear Seat (for the dog), UNI Foam Filter
SOLD 2006 Sportsman 700 Twin EFI: 27" Mud-Lite XTR, Superwinch Terra 35 w/Synthetic Rope, Polaris HD Front Springs, OEM Front Bumper Guard, WES Rear Seat, Kimpex Fender Guards w/Footpegs, 3-Headlight Mod, K&N Filter, Symtec Heated Grips
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Old 06-14-2012, 02:57 AM
KICKER431's Avatar
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Location: Chaumont NY
Posts: 2,069
Yeah, AKStew's post is a recommended reading. Even if you don't mock up his tool, it will still give you a great frame of reference for when you start tearing into yours. I am stilll looking at doing this on both of my machines some day.
MINE:2015 Sportsman SP 800 Sunset Red
completely stock FOR NOW

HERS:2007 Sportsman 700 EFI Black Metallic
Tamarack Cargo Seat, Fender Guards with footpegs from Thor, UNI air filter, Symtec heated grips
Warn 2500 with synthetic rope, ThermoTec exhaust wrap, Reverse Override, 3 Headlight Mod
26" Maxxis Bighorn 2.0

RIP Sarge (2004 Sportsman 700 EFI killed on trail 32, Rock House, Hatfield-McCoy)
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Old 06-14-2012, 03:49 AM
nicks500HO's Avatar
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Join Date: Apr 2010
Location: toronto
Posts: 25
I just had mine done at polaris for $290 that's including mechanical seal, oil seal, water pump gasket and labour. I tried to find the tool for cheap but it was more than the repair $300+. I didn't want to risk ruining the shaft or anything. Happy searching.
2004.5 Sportsman 500 HO
SS 108's wrapped in 26" XTR'S
K&N Filter
SPX Hand/Thumb Warmers
2500# Warn
Engine Ice
Awaiting Install....
RDC Rad Relocate kit
Custom Snorks
More RDC To Come....

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