Chain Chase Leak'n

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bigred_tr

New member
I have a 1999 Polaris 500 XC and had lost a lower bearing last year. We had a "Local" fix it for me with in one night and was back on the trail. Wellll...found oil leaking from bottom area of chain case next day. Long story short I went back and took the chain case back off and found that he did not put any seals back in. I put in new seals,bearings again and put it back together. Rode it this weekend seems to be losing oil still. I replaced the rubber gasget that fits on the cover too. When we had it a part we didn't see anything out of the ordinary with the case or cover...cracks or chips. Every thing seems tight. Could these get warped or something? Should I try a new chain case? Should I try any kind of gasget sealer? Suggestions ??

Thanks,

BR
 
T

treetrunk

New member
I've had the same problem in the past. I would try some RTV high heat silicone on your plug thats in the bottom of the chain case, also maybe around the whole cover and see if that helps out. I would try that before going and getting a new chain case.
 
M

mjkaliszak

New member
Just changed from High temp rtv to Three Bond 1194. Either will work, TB is faster, when I used the HT RTV I waited 20 minutes to develope the " skin " and then assembled. According to the local bike shop guy's this is the stuff.
 
J

jccams

New member
Had the same problem with my 99 XC5. Always leaked from the bottom of the chaincase cover. I started tightening the lower cover bolts before the upper bolts and that took care of it.
 
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jim_golding

New member
I had the same problem. The easy fix is to grind off a little of the aluminum pads on the cover which limits how far the cover will compress the gasket. Don't take off too much or you will over crush/cut the gasket.
 
B

bigred_tr

New member
Thanks !

I will be checking the sled out Thursday night. Let you all know how it goes. Thanks for your responses !

BR
 
B

bigred_tr

New member
Completed

Well thanks again for alll the suggestions ! I ended up taking 1/100th off the bolt pads and then I used a good RTV ( Blue ) inside the " U " shaped rubber gasket, then a small bead around the inside of the cover.

We did 22 miles or so on what little snow we have in southern Michigan and ( Woo Woo !!! ) NO Freak'n leak'n !

TX

BR
 
A

arcticgeorge

New member
no need to grind the cover. any silicone will work

Same thing happened on my 02 zr 800, even with a new ring gasket it leaked. My buddy Mark told me to put a rib of silicone on the bottom half of the chain case and it worked great. Make sure you let it dry thoroughly then fill.
 
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bigred_tr

New member
arcticgeorge said:
Same thing happened on my 02 zr 800, even with a new ring gasket it leaked. My buddy Mark told me to put a rib of silicone on the bottom half of the chain case and it worked great. Make sure you let it dry thoroughly then fill.
Click to expand...


We Let both skin over a little before assembling together then let the sled sit overnight and filled the case with chain case fluid.

BR
 
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