1999 Polaris 500 XC Chain chase question

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bigred_tr

New member
I have been dealing with a oil leak from my chain chase area. After trying a few things I am replacing the chain case and in the process of doing that now.
While looking at diagrams and then taking apart the chain case. Where the 2 shafts fit into the case, there is what they call a seal and a O ring. It appears the seal is tapered.
Being sure...the taper goes towards the case then O ring then case. ?

Any help be appreciated.

TX

BR
 
T

Tracker

Guest
bigred_tr said:
I have been dealing with a oil leak from my chain chase area. After trying a few things I am replacing the chain case and in the process of doing that now.
While looking at diagrams and then taking apart the chain case. Where the 2 shafts fit into the case, there is what they call a seal and a O ring. It appears the seal is tapered.
Being sure...the taper goes towards the case then O ring then case. ?

Any help be appreciated.

TX

BR
Click to expand...

I had same issue on me firecat....before you do all that....check the case half mounted to engine for a crack...hairline...really hard to see....not the cover part....had to do it twice due to this and doing what your doing first
 
M

mikedrh

Member
There is a "seal sleeve" on the shafts where the seal rides. Make sure the seal sleeve is all the way on and seated against the shoulder on the shaft. Slide the o-ring on the shaft and up against the seal sleeve. Install seals (lip side facing the chain) and bearings in the chaincase. Slide the chaincase over the shafts without damaging the new seals. We see many machines where the o-ring is either missing or installed in the wrong spot.
 
T

Tracker

Guest
good advice mike but BR...its a 1999....and if ya have pounded that drive shaft a lot...then looks for cracks in the case whilst its clean...mine only showed up upon tightening...then the crack widened...especially if you have 10,000 miles on that thing
 
M

mikedrh

Member
Tracker said:
good advice mike but BR...its a 1999....and if ya have pounded that drive shaft a lot...then looks for cracks in the case whilst its clean...mine only showed up upon tightening...then the crack widened...especially if you have 10,000 miles on that thing
Click to expand...

I agree but it says he is replacing it. I assumed that meant with a new chaincase.

Install the rubber gasket on the chaincase and then install the cover. You absolutely, positively have to put a generous dab of silicone where the rubber gasket for the cover meets. It should be CLEAN of all oil or the silicone is useless.
 
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bigred_tr

New member
You are correct Mike. I am replacing the case.

I think my problem is with the seal and O ring on the 2 shafts. It appears the O ring on the upper shaft was missing.

I have ordered 2 new O rings and 1 seal for the bottom for SnGs.

Gasket, silicone 10-4 Mike !

Keep all posted and thanks for the notes. !

PS..I bought a 2016 last year...1999 Po has 17500 miles on it..One motor rebuild 2 years ago. Otherwise it's hang'n in there and will be my 2nd rider sled. :)

BR
 
B

bigred_tr

New member
Pics of seal and O ring

Phone pics 2018 012.jpg Phone pics 2018 013.jpg


Help Mike :)........So here is the seal and O ring.

The O ring will go into the groove side of the seal.( It fits in there pic #2 ). then that will press to the chain case.

Is this correct ??

TX Again

BR
 
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B

bigred_tr

New member
I think I got it but if you look closely at my 2 pictures, pic #1 the seal has a lip that goes up. ( O - ring doesn't fit around that? )
or pic #2 where the O- ring fits into the seal in a groove. I think this is the way I want to put it on as you described.

TX

BR
 
M

mikedrh

Member
bigred_tr said:
I think I got it but if you look closely at my 2 pictures, pic #1 the seal has a lip that goes up. ( O - ring doesn't fit around that? )
or pic #2 where the O- ring fits into the seal in a groove. I think this is the way I want to put it on as you described.

TX

BR
Click to expand...

The o-ring goes inside the seal sleeve. Picture #2.

The o-ring when installed in the sleeve and on the shaft would face the chaincase. When you tighten the bolts (nut on the upper) that hold the sprockets on it pushes the sprockets against the bearings. The bearings push up against the o-ring completing the seal around the shaft.
 
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B

bigred_tr

New member
I just wanted to close out the thread and TX for any replies and reads.

Sled is all back together and waits for snow.

So far no leaks.

So all along I think the issue with my sled was that the 2 seals and 2 O-rings that are between the Jack&drive shaft ends.

There was NO O-ring present on the Drive shaft end. Seal was good.

The jack shaft end the seal was so worn away, the groove that you put the O-ring into was gone.

Added O- ring on top and new seal and O-ring below.

replaced all 4 bearings and seals on the chain case so good for 5 K more !!!!

4 year learning experience for me. I know this area now pretty good.

:)

BR
 
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