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2004 Polaris 500 ATV. Changed water pump Now it leaks out weep hole. Any answers

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  • Polaris Master
  • 9,324 Answers

The new pump shaft seal is no good. Get another pump.

Posted on Jan 04, 2017

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Posted on Jan 02, 2017

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How do I replace a starter on a 2004 500 Polaris ATP


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Spark plug gap for a Polaris sportmans 500 a 2010 year


0.028

http://www.polarisatvforums.com/forums/atv-repair-maintenance/14769-spark-plug-gap.html

BKR6ES(STOCK#6364) regular, or IRIDIUM BKR6EIX(STOCK#6418).Gap setting is .028.
That plug is used on all 500 HO from 2000-2011 Sportsman Models.

http://www.polarisatvforums.com/forums/atv-repair-maintenance/40754-500ho-ngk-spark-plug-number.html

http://www.ngksparkplugs.ca/results-motorcycles.cfm?model=empty&enginesize=500&make=POLARIS&apptype=ATV

Here is your manual. Spark Plug page 93. Page 123 says
Spark Plug / Gap NGK BKR6E / .035 in. (0.9 mm)

Different plug (E rather than ES) and gap. check the plug that came out.

http://cdn.polarisindustries.com/polaris/common/parts-manuals/9923420r01_lo_res.pdf

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Just bought this bike had no manuals with it I need to know about checking and changing oil


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Signs bad water pump


Water in the oil which would look like chocolate milk. Oil in the cooling system which would look like tar or black dots floating in the coolent. Or a visible leak of coolent on the floor or ground. After checking the hoses and related gaskets for leaks look at the weep hole on the water pump. If there is coolant around the hole then the pump seal is bad.

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