Hey guys, I have an 02 500 sportsman 6×6 that all of a sudden has had a ton of different issues come up, none of which I can seem to get figured out. Machine has around 1300 miles on it. This machine is only used on my 5 acre property for chores and some light bird hunting in the fall. It’s not running for long periods daily. Here is a list of issues i’m having.
1. consuming oil
2. water pump leaking AGAIN after replacement
3. right side brake won’t bleed up and get firm
4. new belt just installed now hits cover on DECEL only
I bought it used, last fall i had the top end tore down because the base gasket was leaking and the water pump started dripping. I had both repaired. Tech said that rings, piston, clutches, etc…. looked fine when he was in there, so no further work was done. Well i noticed that the machine has started using oil it seems. I changed it in May and it is already under the add line. No idea where it’s going, no more leaks, no smoke. I did remove the plug and found some slight oil on the sealing ring but plug wasn’t all oily like a 2 stroke.
Water pump, no clue as to why i see drips out the weep hole again, doesn’t go through hardly any, but again i don’t ride it much.
Rear or right side brake lever was spongy and so i tried to bleed out the caliper and now it has no resistance whatsoever. I took apart the master cyl and cleaned it up, no change. Again i am at a loss…
Now i put on a new belt and now it slaps the clutch cover on decel once it’s almost stopped. I pulled the cover and revved it in idle and watched the belt flip around. Clutches seem to be moving fine. I installed a Gates G force belt from Napa with corresponding numbers from the OE belt. Sorry for posting so many issues, but this thing has me at my whits end. With almost dropping 1k on the engine last year, I didn’t want to have to dive into this many things again. Any help especially with the brake and belt issues would be great.
Hey guys, I have an 02 500 sportsman 6×6 that all of a sudden has had a ton of different issues come up, none of which I can seem to get figured out. Machine has around 1300 miles on it. This machine is only used on my 5 acre property for chores and some light bird hunting in the fall. It’s not running for long periods daily. Here is a list of issues i’m having.
1. consuming oil
2. water pump leaking AGAIN after replacement
3. right side brake won’t bleed up and get firm
4. new belt just installed now hits cover on DECEL only
I bought it used, last fall i had the top end tore down because the base gasket was leaking and the water pump started dripping. I had both repaired. Tech said that rings, piston, clutches, etc…. looked fine when he was in there, so no further work was done. Well i noticed that the machine has started using oil it seems. I changed it in May and it is already under the add line. No idea where it’s going, no more leaks, no smoke. I did remove the plug and found some slight oil on the sealing ring but plug wasn’t all oily like a 2 stroke.
Water pump, no clue as to why i see drips out the weep hole again, doesn’t go through hardly any, but again i don’t ride it much.
Rear or right side brake lever was spongy and so i tried to bleed out the caliper and now it has no resistance whatsoever. I took apart the master cyl and cleaned it up, no change. Again i am at a loss…
Now i put on a new belt and now it slaps the clutch cover on decel once it’s almost stopped. I pulled the cover and revved it in idle and watched the belt flip around. Clutches seem to be moving fine. I installed a Gates G force belt from Napa with corresponding numbers from the OE belt. Sorry for posting so many issues, but this thing has me at my whits end. With almost dropping 1k on the engine last year, I didn’t want to have to dive into this many things again. Any help especially with the brake and belt issues would be great.
