Crankcase Assembly; Water Pump Mechanical Seal Installation; Water Pump Mechanical Seal Removal - Engine Installed - Polaris 2007 Sportsman 500 EF Service Manual

Crankcase Assembly

1. Apply Crankcase Sealant (PN 2871557) to the crankcase
mating surfaces. Be sure the alignment pins are in place.
2. Set the crankcase in position carefully to avoid damaging
the pump shaft seal, and install the magneto end crankshaft
installation tool (follow instructions provided with the
Crankshaft/Water Pump Installation Kit (PN 2871283).
Draw the crankcase halves together by tightening the nut
on the tool and tapping lightly in the pump shaft area with
a soft faced hammer to maintain alignment. Continually
check alignment of the cases during installation, closing the
gap equally until the surfaces are tightly seated.
3. Remove the tool.
4. Install the crankcase flange bolts and tighten in 3 steps
following the pattern to specified torque.
Crankcase Bolt Torque:
14 ft. lbs. (19 Nm)
Crankcase Sealant:
(PN 2871557)

Water Pump Mechanical Seal Installation

5. Clean the seal cavity to remove all traces of old sealer.
6. Place a new mechanical seal in the seal drive collar, and
install on the pump shaft.
7. Screw the guide onto the end of the pump shaft.
8. Install the washer and nut and tighten to draw seal into place
until fully seated.
9. Remove the guide adaptor using the additional nut as a jam
nut if necessary.
Water Pump Mechanical Seal Removal -
Engine Installed
Water Pump Mechanical Seal
Puller: (PN 2872105)
Replacement T-Handle:
(PN 2872106)
This tool allows a technician to replace the mechanical
water pump seal on EH50PL engines without removing
the engine and splitting the cases.
CAUTION
Improper or careless use of this tool or procedure
can result in a bent water pump shaft.Pump shaft
replacement requires engine removal and
crankcase separation. Use caution while performing
this procedure. Make sure that the puller is parallel
to the shaft at all times. Do not place side loads on
the water pump shaft or strike the puller or shaft in
any way.
1. After the coolant has been drained, remove the water pump
cover, impeller and the sealing washer. (Ill. 1).
Sealing Washer
(Copper or Aluminium)
Coolant Drain
Bolt
III. 1
ENGINE
Sealing Washer
Oil
Seal
Impeller
Mechanical Seal
3.41
3