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660 Water pump AAARRGGHHH!!

This is a discussion on 660 Water pump AAARRGGHHH!! within the Engine forums, part of the Technical category; this is too much!! First, the water pump removal on an '06 660 ranks up top with all-time crappy jobs. Can't see it, cramped space. ...


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Old 08-06-2011, 11:23 PM
WRR WRR is offline
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Pissed 660 Water pump AAARRGGHHH!!

this is too much!! First, the water pump removal on an '06 660 ranks up top with all-time crappy jobs. Can't see it, cramped space. Smacked my head. Crap dripping on my face. Many tools swaps to find the right combo that might work. Skid plate is welded and can't be removed to make this simple and easy. I think Polaris helped in the engineering on this.

I finally got it out and it looked iffy on the pitted impeller shaft and a nick on the housing near the o-ring seal, so I took it to Yamaha. Mechanic said it was fine, but since it was so ugy to take apart, i decided to pay him to rebuild it so I didn't screw it up. definitely didn't want to repeat this job.

Put it back together and the lower tube with the hex/allen key leaked. BECAUSE I didn't put the o-ring in!! DOH!! My own stupidity.

Get the thrill of doing that worst part again, and then fill it, bleed air, and run it. IT STILL WHIZZES out the exact same clear tube that started this whole job in the first place. Mechanic said this is where it leaks when the seal is done. But this is a brand new seal!!WTF????

Anyone else ever encounter this? Any other things that cause that tube to whiz coolant? I'm leaning to complete pump replacement from ebay, chinese thing for $99 shipped. How could it be any worse that this OEM POS?

To ice the cake, I got lots of crap in my eyes and went to rinse with saline. NOPE!! It was my wife's contact lense cleaner, so the stinging will hopefully vanish...eventually???

THEN, I typed a long, funny story describing this disaster, and when I hit "submit", my internet cut out and lost my entire thread. NO WAY I was going to let this crap job get the better of me. so i still decided to share it. I know I'm whining, but entire, full day wasted, and now another 3 hours to do another re&re, since I know all the tricks and short cuts now. JOY!
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Old 08-07-2011, 05:10 AM
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Which tube are you talking about that leaks..........
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Old 08-07-2011, 06:03 AM
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bummer!!! lol.

1. wear safety glasses

2. is it coming out of the weep hole? you replaced the shaft and bearings?
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Old 08-07-2011, 07:44 AM
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I can sell you a complete all assembled water pump...housing and all for 120.00 oem....I wouldnt use china!!!
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Old 08-07-2011, 12:30 PM
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it is leaking out the smaller diameter, clear plastic "overflow" tube (the one on the side of the waterpump that is routed to the skid plate hole). only leaks when running.

never replaced bearing as Yamaha mechanic said it was fine, and I thought so too. Shaft had some pitting in the middle/upper area (closer to the impeller). mechanic said to take some eery cloth to it, and it was okay. At that point I handed him all the parts and let him assemble it, and clean the impeller shaft.

WV Rhino.... I PM'ed you.
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Old 08-07-2011, 12:39 PM
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forgot to ask..... is there ANY other reason (blockage somewhere else??) that causes this tube to whiz coolant while running? I'm still thinking it only leaks there if there is a seal issue.

guess I have to waste more money on oil and coolant too!!
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Old 08-07-2011, 03:45 PM
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that would only weep if the seal is bad. thats why it's there....maybe in backwards? or got pinched?

iv neve seen a rhino water pump yet, but I have done a ton quads and dirtbikes at my shop. usually seals and bearing.
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Old 08-07-2011, 03:48 PM
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Quote: Originally Posted by WRR View Post
it is leaking out the smaller diameter, clear plastic "overflow" tube (the one on the side of the waterpump that is routed to the skid plate hole). only leaks when running.

never replaced bearing as Yamaha mechanic said it was fine, and I thought so too. Shaft had some pitting in the middle/upper area (closer to the impeller). mechanic said to take some eery cloth to it, and it was okay. At that point I handed him all the parts and let him assemble it, and clean the impeller shaft.

WV Rhino.... I PM'ed you.
got it....
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Old 08-15-2011, 08:05 AM
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just to give this some closure:

Took it out again and back to Yamaha dealer. They replaced the seal again, and now it seems good. So I guess even the experts can pinch a seal.

A few helpful hints: the 2 hoses below; one is held on by a spring loaded clamp. I slid that off using 45 degree, long handled needle nose pliers.

The second hose uses an allen/hex head screw. Way too hard to reach from the underside. remove this hose half way up the motor near the cylinder jug/head (the other place where it connects). this way you don't even have to remove the allen head screw as it stays connected to the water pump cover. IF you do remove this, make sure you re-install the rubber o-ring or it will leak (yours truly....mr. stoopid did that on reassembly and it leaked!!).

LAST... you only need to remove 2 bolts to take this off the motor. the 9 o'clock & 3 o'clock position bolts have to be removed. 6 & 12 just hold the cover on the pump. The only way I could reach 9 was with a wrench, too tight for a socket. 3 is easy to reach.

what started as almost all day, i now have down to .5 hours, including adding coolant and motor oil.
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Old 08-15-2011, 08:11 AM
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Quote: Originally Posted by WRR View Post
what started as almost all day, i now have down to .5 hours, including adding coolant and motor oil.
I find that's the ONLY benefit to having to do ****ty jobs... you get better at it each time.
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Old 08-15-2011, 08:55 AM
WRR WRR is offline
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OMG!!! where'd you get that handle? that's my handle on most any website I join. I only used "WRR", because i originally joined this site when i didn't own a rhino and my friend did, and it is his nickname.

you should be flamehead or oilerhead.
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Old 08-15-2011, 09:08 AM
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Ahh the OTHER canucklehead. I use this handle on every forum too. Calgary Flames fan, but use the 'canuck' part to refer to Canada, not those filthy loser Vancouver Canucks.
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Old 08-15-2011, 09:19 AM
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haha!! as much of a die hard fan as i am.... Luongo was painful to watch blow our only ever legitimate chance at winning the Cup. so ya, they were filthy losers in the end. at least i called you flamehead, instead of Flamer!!
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