Hi Stew, Thanks for the post! That is some great information.
I have a 2005 Sportsman 800, so my water seal is a little different. The manual strongly suggests that I take the whole gear/stator cover off for fear of damaging the shaft, which looks like a pain in the butt. So I was wondering if you know if your method of using the screw and puller would work on the '05 800 machine?
I don't think you'll get any response from AKstew. I haven't seen him on here in a very long time.
Your water pump seal is not any different than anyone else's. Most all liquid cooled Polaris engines except for the newer ones use the same type mechanical seal and they ALL tell you to open the case to change it. In fact, the 600, 700 and 800 engines all use the exact same seal from 2004-2017 no matter if its a Sportsman, RZR, Ranger and even the 800 Indy sleds!
I have no doubt Stew's method will work just fine but I was always leery of pulling against the pump shaft and if you don't intend to change the oil seal behind it drilling and putting screws in to pull without damaging the oil seal would be tricky.
I prefer to just carefully peel the old seal out with a screwdriver and/or small pry bar as shown in the attached video. You just have to take your time and be very careful not to bugger up the aluminum case. The seal cup you're trying to get out is fairly soft brass and once you get it started pealing up around the lip you just keep working around it till you get it out. I've done a bunch of them that way and never had a problem.
There's a bunch of Youtube videos (some good some not so much) on the subject. Just search "800 Polaris water pump seal video" or something similar. Here's a couple. In the first video at around 2:55
the guy shows you what I mean about pealing the seal out.
In the second video, the guy is working on a 800 RZR but its the same engine/same seal. He already has the seal out but he shows the installation of the new seal. Start watching at around 1:55
I think. I too use a 32mm twelve point socket to install
the seal like he does but some folks use pieces of PVC or other pipe of the appropriate size. Some ebay seal kits come with what they call a seal installation tool which is basically a piece of PVC with a machine lip on it at a premium price lol. Part of the seal is ceramic material and you must be very careful putting it in or you will destroy your new seal and have to start over with another new one!!!
Good luck no matter which method you choose. If you have any other questions don't hesitate to ask and make sure to let us know how it goes.