mechanic looking for advice
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ippielb
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Can't be done. Water pump is between the cooler and the motor. It's a pain to do the seals, Arctic cat says you need a seal installer tool but you just need a 6 point socket that fits snug around the seal and can fit on the steel collar.
Removal:
pull the motor, put it on the bench, remove the water pump cover with the retaining bolts. Gently remove the cover. Try not to use a sharp tool to pry the cover off as it is the sealing surface. There is an o-ring in the edge, and if my memory is right that's a $50 touch. you also cannot tap the cover down or up because there's two alignment pins that go into the case. I usually stick my finger inside the house outlet and wiggle back and forth if it's really stuck.
once you got the cover off you'll see the impeller it is held on with one bolt. A small black steel washer, and a rubber washer to create the seal. remove the bolt and two washers, once they're off you will be able to remove the impeller. Depending on if it's seized to the shaft or not you may need to wiggle it back and forth and spray some penetrating fluid on it. Do not try to pry the impeller off as its plastic and WILL shatter. Speaking from experience here.
once the impeller is off you will need to go to the front of the motor. Remove the oil pump, it is held on with two Allen head cap screws. It comes off easy just don't lose the o-ring that seals the oil pump to the spacer/cup. Remove the alignment/spacer cup from inside the block, make sure the o-ring that is sealing the cup to the case stays around the barrel of the cup.
after that is removed you can take the water/oil pump shaft out. There is a thrust washer that goes between the aluminum alignment cup and the steel shaft. DO NOT LOSE THIS, it's really slippery.
flip the motor to the back again. Take a large punch and stick it in the water pump seal. Gently pry to the side, without hitting the case, and lift up, if you have a seal puller be gentle not to scar up the inner sealing surface as it is a press fit seal.
once the mechanical water pump seal is out, there's may be a bunch of junk/crud in there, take a pick and clean it out. Make sure to not get crud in the motor itself.
Next step is to get your snap ring pliers and remove the snap ring so you can take out the oil seal. Remove the oil seal with a pick. It is not pressed in, just stab it and pull it out. Thoroughly clean the water pump area now.
Installation:
take your oil seal, gently rub 2-stroke oil around the outer edge of the seal, and some white lithium grease along the inside sealing surface. Put the seal in the shaft hole, and press it down with a socket the appropriate size.
insert the snap ring back in place to hold the oil seal in.
take your mechanical water pump seal and find a socket that fits snug around the inner part of the seal with the spring, and will press on the outer steel collar. I usually put a little smear of gasket maker on the seal that touches the case itself, not very much just a hair.
Start the seal seal with the socket and a short extension so when you tap with your hammer it will evenly disperse the force all the way around. Make sure you start it flat, if the seal starts to waunder you need to correct it immediately. Keep tapping it down until the metal collar is flush with the case, give it one more good tap to really seal it.
flip the motor over and you can start putting the oil pump and shaft back in.
Take the shaft, with a piece of Emory cloth touch up the end of the shaft so it feels smooth to the touch so it will not catch and scratch the oil seal. Clean it off to get rid of debris, then apply some white lithium grease to the shaft. Don't get grease in the threads of the shaft.
apply white lithium grease to the thrust washer and install it on the shaft. Insert the shaft threads first, gently into and through the oil seal until it stops. Apply white lithium grease to the oring around the barrel of the cup/spacer and install, same with the oilpump o ring and then bolt the oilpump back on. Apply a dab of blue loctite onto the screws.
flip the motor around and we can start finishing the water pump side.
take the impeller and remove the ceramic disk and the rubber insulator. Install the new insulator and the ceramic disk. Apply white lithium grease to the ceramic. And put the impeller back onto the shaft.
Take the new rubber coated washer and install with the rubber of the washer facing the impeller, then the little black washer, and the bolt through them both. I usually put a tiny drop of red loctite on the bolt to bolt it to the shaft permanently, dont want that coming loose and burning a hole in the cover.
Before you slap the cover back onto the case to finish up. Take a little bit of RTV gasket maker and put a light smear on the mating surface where the two halves of the case meet. Make sure you do not get any RTV gasket maker in the tiny little hole that bleeds the air out of the pump.
Now you can finish up, install the pump cover, and install the bolts with a dab of blue loctite. And you're done.
Removal:
pull the motor, put it on the bench, remove the water pump cover with the retaining bolts. Gently remove the cover. Try not to use a sharp tool to pry the cover off as it is the sealing surface. There is an o-ring in the edge, and if my memory is right that's a $50 touch. you also cannot tap the cover down or up because there's two alignment pins that go into the case. I usually stick my finger inside the house outlet and wiggle back and forth if it's really stuck.
once you got the cover off you'll see the impeller it is held on with one bolt. A small black steel washer, and a rubber washer to create the seal. remove the bolt and two washers, once they're off you will be able to remove the impeller. Depending on if it's seized to the shaft or not you may need to wiggle it back and forth and spray some penetrating fluid on it. Do not try to pry the impeller off as its plastic and WILL shatter. Speaking from experience here.
once the impeller is off you will need to go to the front of the motor. Remove the oil pump, it is held on with two Allen head cap screws. It comes off easy just don't lose the o-ring that seals the oil pump to the spacer/cup. Remove the alignment/spacer cup from inside the block, make sure the o-ring that is sealing the cup to the case stays around the barrel of the cup.
after that is removed you can take the water/oil pump shaft out. There is a thrust washer that goes between the aluminum alignment cup and the steel shaft. DO NOT LOSE THIS, it's really slippery.
flip the motor to the back again. Take a large punch and stick it in the water pump seal. Gently pry to the side, without hitting the case, and lift up, if you have a seal puller be gentle not to scar up the inner sealing surface as it is a press fit seal.
once the mechanical water pump seal is out, there's may be a bunch of junk/crud in there, take a pick and clean it out. Make sure to not get crud in the motor itself.
Next step is to get your snap ring pliers and remove the snap ring so you can take out the oil seal. Remove the oil seal with a pick. It is not pressed in, just stab it and pull it out. Thoroughly clean the water pump area now.
Installation:
take your oil seal, gently rub 2-stroke oil around the outer edge of the seal, and some white lithium grease along the inside sealing surface. Put the seal in the shaft hole, and press it down with a socket the appropriate size.
insert the snap ring back in place to hold the oil seal in.
take your mechanical water pump seal and find a socket that fits snug around the inner part of the seal with the spring, and will press on the outer steel collar. I usually put a little smear of gasket maker on the seal that touches the case itself, not very much just a hair.
Start the seal seal with the socket and a short extension so when you tap with your hammer it will evenly disperse the force all the way around. Make sure you start it flat, if the seal starts to waunder you need to correct it immediately. Keep tapping it down until the metal collar is flush with the case, give it one more good tap to really seal it.
flip the motor over and you can start putting the oil pump and shaft back in.
Take the shaft, with a piece of Emory cloth touch up the end of the shaft so it feels smooth to the touch so it will not catch and scratch the oil seal. Clean it off to get rid of debris, then apply some white lithium grease to the shaft. Don't get grease in the threads of the shaft.
apply white lithium grease to the thrust washer and install it on the shaft. Insert the shaft threads first, gently into and through the oil seal until it stops. Apply white lithium grease to the oring around the barrel of the cup/spacer and install, same with the oilpump o ring and then bolt the oilpump back on. Apply a dab of blue loctite onto the screws.
flip the motor around and we can start finishing the water pump side.
take the impeller and remove the ceramic disk and the rubber insulator. Install the new insulator and the ceramic disk. Apply white lithium grease to the ceramic. And put the impeller back onto the shaft.
Take the new rubber coated washer and install with the rubber of the washer facing the impeller, then the little black washer, and the bolt through them both. I usually put a tiny drop of red loctite on the bolt to bolt it to the shaft permanently, dont want that coming loose and burning a hole in the cover.
Before you slap the cover back onto the case to finish up. Take a little bit of RTV gasket maker and put a light smear on the mating surface where the two halves of the case meet. Make sure you do not get any RTV gasket maker in the tiny little hole that bleeds the air out of the pump.
Now you can finish up, install the pump cover, and install the bolts with a dab of blue loctite. And you're done.
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