1999 Polaris 500 xc

[bigred_tr]

Have 2 issues I wanted to see if there are any suggestions. And yeah I know one of them is to buy a new sled, so don't start...LOL

1. Other than buying a new cover exhaust. Not available to order. Have to hunt. Is there a way to stop the orange/rust dust from slowly covering the inside of my sled hood?
I know it's not good for my clutch either but dealing with almost an antique.

2. I have replaced my 2 chain case bearings several times over the many years and as of late I seem to have a leak in this area. We think it maybe the seal behind the bottom bearing but we believe we are installing them back in correctly. I also have started to use RTV silicone seal along with a new rubber gasket for the cover. All screws are tight.

TX for any suggestions in advance.

Big Red

 

[mikedrh]

If you see oil inside the tub it's probably the cover gasket or that rare occasion the cover or case is cracked. Always silicone where the ends of the gasket meet.

If it's leaking under around the shaft area it could be a seal and/or the sleeve and oring on the drivesahft.

https://ea77029b4c67f377227e-af9c15...m/pol/5015/5015b008/assembly_files/10/1_0.png

Make sure 20 and 21 are in place and 21 is in good shape.

Have seen many 500 and 600 Polaris twins with rotted exhaust, get it cleaned up whatever way you can, sandblast is probably the best way. Paint, powdercoat or ceramic coat with the best high temp stuff you can find.

 

[1flatlander2]

i use high temp bbq paint on all my pipes. dosn't stop rusting but slows it down

 

[mezz]

1. Other than buying a new cover exhaust. Not available to order. Have to hunt. Is there a way to stop the orange/rust dust from slowly covering the inside of my sled hood?Big Red

This problem sounds like you may have some worn out exhaust springs which are allowing the muffler to separate from the silencer blowing the rust out into the engine compartment. Just a thought....-Mezz