Email from our Honda rep:
Original reply from Honda:
"As we've concluded based on extensive unit evaluation. It is extremely probable, Mr. Johnson's Pioneer 500 is used in an excessive amount of water. Typically, in an off road recreational environment mud is associated with water. These conditions can lead to early wear and deterioration of drive train components including (but not limited to) seals and gasket.
In the interest of customer satisfaction and education. I am willing to provide the benefit of the doubt and repair the rear output shaft seal and rear engine cover sealant. This will also provide us the opportunity to verify the integrity of the output shaft sealing surface and associated parts. As this requires the removal of the engine, it provides easy access to address concerns at the front of the engine.
With regard to the front engine leaks:
If you see any debri were the front drive shaft mats to the output shaft take photos of this.
Regarding rear differential seepage:
Verify the oil height and condition
Verify his vent line extensions are free from clogging
Provided diff oil and height are in good condition, proper height and vent lines are not obstructed warranty will cover rear diff re seal.
Regarding front differential concerns:
Based on the after market vent line extension pinched at dash, this will be Mr. Johnson's responsibility if he would like it repaired
Replace throttle cable under warranty
Recommendations:
Prior to starting repairs, contact Mr. Johnson, advise his unit exhibits signs of use in excessive water. While you are willing to provide benefit of the doubt to address his current concerns, should discovery of additional problems with in the engine be discovered, the repair cost may be his responsibility...
Document current oil and height conditions (engine and diff) note also coolant level.
Would show customer jammed air filter bracket.
Customer will need to pay for the engine oil and filter based on current condition of oil and no maintenance records provided.
Please document on the Repair order that the unit exhibits signs of usage in excessive amount of water and mud, reference page 85 of your owner's manual regarding operation in water. As reflected in your warranty booklet. Misuse is not covered by Honda's express limited warranty."
