1999 Polaris 500 xc Chain case leak help

B

bigred_tr

New member
I have had this sled for its entire life. I do regular maintenance on this sled.

For the past 5 years or so I have been losing chain chase oil on this sled. I have replaced the seals and bearings and still leaks. It appears to be the cover or may be some out the dip stick.

I have replaced the cover gasket several times and make sure everything goes on straight to get the best seal possible.

The past 2 years I have to use a silicone gasket that appears to help a lot but I seem to have to add some oil every few runs.

Could cover or case warp or something?

Any idea's or suggestions appreciated.

TX

Big Red

PS..Looks like last year for the sled. Think'n to give'n it to the son in Laws....I'm done dink'n wif it. :)
 
B

bigred_tr

New member
mmmmmmmm well thanks for the information. Yes we have been using synthetic. It has been what the dealer recommends.

I did have one year that we where having this issue and we could only find boat grease/lube for the lower end of out boards. We squeezed a bunch into the case and never had to add any more on that trip.

I will pull the cover AGAIN, gonna use an RTV gasket stuff on the cover and give the regular gear lube a try. May be a graphite kind be best?

TX again, It is really appreciated. I need idea's !!!!

Big Red
 
X

xcr440

Well-known member
I have always run synthetic in my chain cases and never had an issue with that fluid.

Make sure the seal seam is at the top of the case, and RTV it up good is about all you should have to do, as long as the bearing seal isn’t leaking on the inside of the tunnel.
 
G

garageguy

Well-known member
Older sleds dont have a proper seal on the other side of the shaft bearing, synthetic lube will crawl right through the bearing seal and leak out.
 
D

Duffy

New member
After 10 years your seals need to be changed. The real issue is that the OEM seals are not synthetic oil compatible. The OEM seals are made of Buna rubber and when using synthetic oils you need to use Viton seals.
 
R

raceinsnow

New member
take the cover off, take the gears and chain out and clean the case good. You will find a crack at the bottom of the case because the chain jumped
 
K

koolmg1962

New member
Agree with "raceinsnow" Had same sled with same symptoms over multiple years. Replace seal and cover - finally replaced case - problem fix.
 
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