Today I just changed my 3rd water pump seal. I'm guessing that mud just eats them son of a bitches up. My first one I sunk in a mud hole, second i was at about a 60 degree angle with the wife in a hole, third one I don't have a clue but there was grit and shit up behind the seal. After the first I realized these rzr's aren't honda foremans so I've tried to avoid it all costs, that's how I ended on the side in a hole with a buddy hanging on the side.
Anywho, I've had 3 people call me and about 20 others pm me because for some reason they think I'm know what i'm doing, haha, I just like to drink and ride. Anyhow, I've gotton tired of typing on the phone, on the computer and what not trying to help out and decided to do a little write-up with pics. I don't mind helping out at all, just this may reach more people and help a little bit more with pics. Blackbart did a great write up on this but it was with the engine pulled and taken apart, I have zero desire on doing that again.
First off a little common sence, Raise the rear of the rzr as high as you can get it and remove the rear tire. This will keep you from losing a lot of coolant. Then pull your tire off. Remove the coolant hose and jam a screwdriver handle into it then tie it off high up. This will keep the from losing too much coolant. Next remove the 7 bolts that hold the cover on and pull the cover off. You will lose coolant while doing these 2 steps so have a drain pan ready or let it run in the drive, doesn't matter too much to me either way. Go ahead and remove the cover and set it to the side.
The following pic is where you should be at. I have already removed it at this pic but there is a 7/16" nut that holds on the impellor there. You'll need to pull the impellor off.
After that you'll have a flat black seal to remove on the outside, just pull it off. Next there is a contraption with a spring on it, there will be a little resistance but just grag it with needle nose pliers and pull that sucker off.
Next I used a short handle screwdriver and slowly and carefully pried back the copper piece that is sealed to the block wall with a little blue stuff. Work the copper pice away all the way around, you'll need the edge of it to grab to pull the seal out. I'm sure a brass screwdriver would work great without scratching, but I guess I didn't have one.
I used a pair of needle nose vise grip pliers. You'll want to slowly work the copper seal out and work it a little at a time all the way around, be paitiet, it'll come out.
Once the seal is out clean all the crap out, I used wd-40 and a pic set like what you would find in a dental office to get in the tight spaces. Next step I've read about others using a grease zert and taking the ball out to hook a rubber hose to it to help keep crap out so I decided to do this. I used the smallest pushin type and used a drill to drill into the weep hole, just big enough to get the zert in. I also used a bit to waller out the zert to allow coolant/oil to flow out easier if it is needed. Then I just knocked it in with a hammer.
After cleaning out shaving and grime it was time to install the new seal. I used a 32mm socket and it fits perfect over the new water pump seal and slowly drove it in with a hammer. Use care to tap it in evenly to keep from damaging it.
When you drive it in you need to pull the flat black seal off. When you put the black piece in make sure you put the side with the grooves out. Your pump seal will leak if it is in backwards i've been told. This side out.
Next just put on the impellor with the blades visible and properly torque down the nut that holds it on. Then you're ready to put the cover back on.
Put the cover back on and do not grease or oil the seal. I think the torque for the cover bolts is 96 inch pounds but I won't swear to it though. Make sure to follow the torque sequencing pattern for the cover. In case you haven't made an effort to download a service manual here is a pic of the tightening pattern.
Once you are done with that just refill your coolant and bleed all air out of your system and hopefully you'll be ready for some cold beer and good hills again.
Thanks to Swingarm1 for giving me some guidance to my first pump seal. I may have left something out, if so or any suggestions please pipe in.
DISCLAIMER: This is how I did it on my RZR. It may or may not work on yours. I am not responsible for your ride if it breaks.