Water Pump On 680 Triple - Snowmobile World : Your #1 Snowmobile Forum

gibbydad · 12-02-2004, 09:24 AM

I purchased a 1996 680 Ultra last year. It ran great. On my first outing this year it overheated. It was losing fluid. I checked it and it was hot on the engine side and cold on the radiator side. The Polaris dealer said to check the impeller. I removed the front of the water pump and the impeller looks good. I can, however, turn the impeller with my hand and the gear makes a clicking noise like it is not fully engaged with the engine. Is this normal, or do I have a water pump failure with the gear? Also, I have removed all the bolts attaching the water pump to the engine block, but cannot get the pump off. Is there some trick to removing the pump or is it just stuck and I need to keep working at it to get it off?

tifa_5_2000 · 12-03-2004, 01:58 PM

im not sure but is it just stuck? mike

michahicks · 12-04-2004, 10:52 PM

Ouch!
It's been a while, but thinking if you have the 4 bolts out, it's stuck. When you have it apart, make sure you do the bearings/seals while you are at it. Do you remember it making a whining noise while running? The bearings will let go on occasion, taking out the gear. Can normally be heard prior to letting go.

UltraGN · 12-05-2004, 02:04 PM

You shouldn't be able to turn the impeller with your fingers while the pump is still on the engine. The crank turns that gear which turns the impeller. The only way the impeller should turn is if the crank is turning over. You probably chewed a bearing or the water pump gear.

Make sure all 4 bolts are out of the pump prior to removal...then it might need a little prying.

Canadian UltraRMK · 12-06-2004, 12:17 PM

I had the same happen to my waterpump about 3 years ago. It overheated, and that was it. Polaris was good enough to send me a new one free, even though it was one year over warranty. The removal was straight forward I think, and I remember using high temp silicone I think to re-seal it (or whatever they recommend). There is a small inspection window in the unit, and you should just see coolant (green) not oil, which was the case with mine, as the seal went. Good luck!

gibbydad · 12-06-2004, 06:43 PM

Thanks for the responses. I got the water pump off and the nylon gear on the pump was completely stripped. I've ordered a new one. I didn't have any coolant in the gear casing (as observed through the window). Is there any idea what causes that gear to strip? It costs $85 to get a new one (which is still a heck of a lot cheaper than a new water pump).

michahicks · 12-06-2004, 07:22 PM

<<<<Is there any idea what causes that gear to strip?>>>>

Ummmm, bearings. That's why I suggested you consider replacing both those, and the seals.

That's also why I said Ouch! Been here.

If you aren't in too much of a hurry, you might want to try and cross those bearings to something other than those supplied by Polaris. I hear they are getting about 30. each for them. Thinking you should be able to get both for that or less with a little patience.

UltraGN · 12-07-2004, 05:43 AM

CanadianUltraRMK-

I think you've got it backwards. You don't want to see coolant in the sight window.....you should see oil. The seal is in there to keep antifreeze out. And I believe only the '96's had the sight glass.

Canadian UltraRMK · 12-07-2004, 10:59 AM

Quote:

Originally posted by UltraGN@Dec 7 2004, 07:05 AM
CanadianUltraRMK-

I think you've got it backwards.* You don't want to see coolant in the sight window.....you should see oil.* The seal is in there to keep antifreeze out.* And I believe only the '96's had the sight glass.

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OOPS, I think you're right! You should be able to tell when you have the pump off, from which side the window is on, oil or coolant. Anyhow, when the bearings go, the seal in between goes too I guess, and the cooland and oil get mixed. I replaced the whold pump unit with bearings and all, as shipped from Polaris, and I think the cost of it should have been somewhere around $400 Canadian. Anyhow, it was a fairly easy fix, and removing the pipes was the biggest part. I believe Polaris had special oil for the unit also. Seem to recall it might have been Polaris 4-stroke oil made for quads...

gibbydad · 12-07-2004, 01:19 PM

I can see oil in the site glass, but no antifreeze so it appears the seal didn't fail. The shaft seems to turn okay (but maybe it didn't at 5000 rpm). The new gear should be here on Friday and then I will tear the pump housing open and see what else might have gone wrong. You are right on the bearing and seal. If you buy the Polaris parts they are pricey.