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Old 05-13-2011, 06:18 AM
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Transmission leak/ Removal

So after riding my used 08 800 efi H.O for about 100 miles ,i decided to change all fluids and to my surprise when i remove the transmission drain not a drop of fluid comes out. As soon as i add some polaris transmission fluid it starts leaking pretty bad through the seals at the bottom of the gearcase.

I'm guessing the only way to fix this is to remove the transmission an re-seal it.Has anyone had this happened? Any tips or tutorials on how to remove the transmission?

I was really tempted to JB weld it ,but thinking that wouldn't do a great job for this type of leak.Suggestions?
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Old 05-13-2011, 06:50 AM
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Boy that doesn't sound good!
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Old 05-13-2011, 07:01 AM
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I know, it sucks. The bike only has 600 miles, I'm thinking the previous owner hit the bottom of the case somehow or used some type of oil that damaged the seals I have a feeling that removing the transmission is not fun at all especially getting the rolls pin out. I'm still tempted to patch it from the bottom without removing the transmission and keep on riding.
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Old 05-13-2011, 07:45 AM
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Quote:
Originally Posted by Indypo View Post
I know, it sucks. The bike only has 600 miles, I'm thinking the previous owner hit the bottom of the case somehow or used some type of oil that damaged the seals I have a feeling that removing the transmission is not fun at all especially getting the rolls pin out. I'm still tempted to patch it from the bottom without removing the transmission and keep on riding.
I would take the time to fix it properly. JB weld is a temporary patch.

My 2 cents.



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Old 05-13-2011, 08:57 AM
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I would remove the trans and replace the seals or have someone do it for you.
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Old 05-13-2011, 10:40 AM
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yea get it done right man, save you from more problems later on.
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Old 05-14-2011, 10:18 AM
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I'd clean it (degrease) very good to see exactly where it's leaking from. Your post said "seals" leaking but how would you JB a seal? If it's actually a seal, you can get everything off and out of the way and peel the old one out with a screwdriver or seal puller tool and put a new one in without removing the trans. I had a roll pin back out of the yoke on my 06 800 and rubbed a hole in the case. I thought it was a seal until I got it clean and got in there to replace the seal. The new roll pin I put in lasted about 25 miles and started backing out too. It had broken just like the old one. I replaced it with a grade 8 bolt and nylock nut and have had no problems now for more than 2000 miles.

Oh yeah, I fixed the case by degreasing well and course sanding and then a little ether to prep. Filled the rubbed notch with JB and covered with a small square of metal tape to hold the JB in place till it set up. Like I said above, that was more than 2000 miles ago and you can't even see the repair unless you know where to look.
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Old 05-19-2011, 01:28 PM
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Quote:
Originally Posted by polman500 View Post
I'd clean it (degrease) very good to see exactly where it's leaking from. Your post said "seals" leaking but how would you JB a seal? If it's actually a seal, you can get everything off and out of the way and peel the old one out with a screwdriver or seal puller tool and put a new one in without removing the trans. I had a roll pin back out of the yoke on my 06 800 and rubbed a hole in the case. I thought it was a seal until I got it clean and got in there to replace the seal. The new roll pin I put in lasted about 25 miles and started backing out too. It had broken just like the old one. I replaced it with a grade 8 bolt and nylock nut and have had no problems now for more than 2000 miles.

Oh yeah, I fixed the case by degreasing well and course sanding and then a little ether to prep. Filled the rubbed notch with JB and covered with a small square of metal tape to hold the JB in place till it set up. Like I said above, that was more than 2000 miles ago and you can't even see the repair unless you know where to look.
Thanks for the advice.I did clean the transmission with some brake cleaner and seems like(looking at the service manual) the leak is coming between the front housing cover and the transmission case where there is suppose to be crankcase sealant. It seems like the only way to re-seal this is to get the transmission out,remove that front housing cover(hopefully there will be no surprises inside from running dry) and apply some crankcase sealant.

I already started to take the bike apart and only have the prop shafts left to remove. I'm having difficulties completely removing the front one from the transmission since the u joint keeps getting stuck under the motor when i try to pull it out and as for the rear one seems like i have to loosen the rear differential and pull it back.I will give it a try again this weekend.Thanks for all the replies.
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Old 05-20-2011, 04:06 AM
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Yeah, on the rear you just loosen the diff. and move it back a couple inches for clearance. I think that on the front there may be enough extra spline length that you can move it forward on the front diff shaft once the roll pin is out but I'm not sure. If not you may have to loosen the front diff too.
Good luck
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Old 05-20-2011, 04:51 AM
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believe you have to take shaft off of front diff first to remove it
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