2002 sportsman 500ho oil leak - Polaris ATV Forum
ATV Repair and Maintenance Having problems? Doing a rebuild? All Repair/Maintenance Discussions here.

LinkBack Thread Tools Display Modes
post #1 of 6 (permalink) Old 03-21-2010, 08:47 AM Thread Starter
Junior Member
dattlerb's Avatar
Join Date: Feb 2010
Location: west monroe
Posts: 9
2002 sportsman 500ho oil leak

hey everyone, have another addition to the boards, i have a 2002 sportsman 500ho, yellow, has around 540 miles on it now (sat around a lot) i recently got a bad oil leak in it, would leave huge puddles on the floor where it sat, after looking at it several times to try to see where the leak was coming from i found a seep hole below the water pump housing, it was seeping from the hole very slowly but was enough to leave puddles if is sat a few weeks, after checking with local parts place i got (3) seal that go to the water pump assembly and got them replaced using a special tool (parts place rented it to me) was fairly easy to replace, i'm not an amateur mechanic, shady tree maybe but most mechanics are common sense, after removing the gaskets i noticed the water pump shaft was rusty (probably from the machine sitting alot) so i turned the motor over while holding fine sand paper on the shaft to remove the rust. got it all back together now and no oil leak! wooohooo! hopefully it will hold up, doesn't seem to be to good of a design to me. hope this helps someone. happy 4-wheelin!
dattlerb is offline  
Sponsored Links
post #2 of 6 (permalink) Old 03-21-2010, 09:08 AM
Extreme ATV Enthusiast
The Kid's Avatar
Join Date: Mar 2010
Location: texas
Posts: 348
glade you fixed it and yes it is a poor setup on the pump seal

The Kid
2001 500 H.O. Sportsman "Hoggwaller"
2in. lift,with HD ranger springs up front w/stock axles,2in. in the back
heel clicker
Warn 2500 puller outter
29.5's Laws skinny/fat
rubber down custom intake
homemade exhaust snorkel
rad. relocated up top
chains on front & rear A arms
swaybar removed
working on quads for 12 yrs let me know if i can help
"Hold my beer and let me show you how to really f#%* shit up"
The Kid is offline  
post #3 of 6 (permalink) Old 11-11-2010, 12:21 PM
Junior Member
alohman's Avatar
Join Date: Dec 2009
Location: colorado
Posts: 3
could you get to it by just taking the cover off of the water pump and removeing the pump.And was it a atv repair place that rented the tools.My 1997 sportsman 500 is leaking in the same place.Any help would be great.Thanks AL
alohman is offline  
Sponsored Links
post #4 of 6 (permalink) Old 11-11-2010, 03:02 PM
ATV Enthusiast
spongecop's Avatar
Join Date: Oct 2010
Location: Dallas, TX
Posts: 54
The water seal is an easy fix with the tools. You can purchase it for around 60$. The oil seal behind it is easy to pull out and reinstall - no special tools required. The most important thing is to snorkle the weep hole to prevent muddy water from getting up behind the seal and trashing it. I went through three seals before finding out that little tip. Also snorkle the overflow bottle cap to prevent muddy water from getting into coolant and trashing waterpump seal as well.

Taking the cover off the waterpump will expose the impeller. Once that is removed you pull the seal out. It can be done without the special tool, but extreme care must be taken not to bent the shaft. If that happens then the motor comes out, cases get split and your wallet empties
spongecop is offline  
post #5 of 6 (permalink) Old 11-13-2010, 11:30 AM
Junior Member
alohman's Avatar
Join Date: Dec 2009
Location: colorado
Posts: 3
IM assuming the water pump mechanical seal has to be removed first as the oil seal is behind it.And can the mechanical seal be removed and replaced without the special tool.I should probably order a new mechanical seal as well as the oil seal right?
alohman is offline  
post #6 of 6 (permalink) Old 11-13-2010, 02:25 PM
ATV Enthusiast
spongecop's Avatar
Join Date: Oct 2010
Location: Dallas, TX
Posts: 54
Yes, the oil seal is behind the mech. seal. There are lots of people who pull the mech. seal without the special tool. The risk you run is bending the shaft if you get too aggressive with it. The tool-less method is to run at least two self-tapping screws into the face of the seal and use a slide hammer to slowly pull it out. Done with some patience it will work fine. Once its out you can grab the oil seal with a pick..it comes out real easy. The mech. seal can be tapped in with a socket of the appropriate size.. I would also replace the water pump impeller and the self locking cap nut when you do this.

Tip: make sure you snorkle the weep hole. Typical method is to tap the hole and run a hollowed out grease zerk which then attaches to clear tubing run up higher than the air filter. this will extend the life of the mech. seal for years by keeping muddy water out of the cavity behind the seal. Also snorkle the overflow bottle.
spongecop is offline  

  Lower Navigation
Go Back   Polaris ATV Forum > Polaris ATV Technical Discussions > ATV Repair and Maintenance

Quick Reply

Register Now

In order to be able to post messages on the Polaris ATV Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Please enter a password for your user account. Note that passwords are case-sensitive.


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:


Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.

Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode

Similar Threads
Thread Thread Starter Forum Replies Last Post
2002 magnum 325 4x4 Transmission leak dude ATV New Members 1 12-16-2009 05:36 PM
sportsman oil leak alohman Polaris Sportsman 1 12-01-2009 07:59 PM
01 Sportsman 500HO KYBruce ATV New Members 3 10-25-2009 03:50 AM
Oil Change on 2002 Sportman 500HO Bud Man ATV Repair and Maintenance 6 10-19-2009 08:14 PM
01 Sportsman Gas Leak revman08 ATV Repair and Maintenance 8 10-15-2009 09:28 PM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

For the best viewing experience please update your browser to Google Chrome