Transmission leak/ Removal - Polaris ATV Forum
Polaris Sportsman Discussions for the Polaris Sportsman 90, 300, 355, 400, 450, 500, 550, 600, 700, 800, 850

Reply
 
LinkBack Thread Tools Display Modes
post #1 of 14 (permalink) Old 05-13-2011, 06:18 AM Thread Starter
Junior Member
 
Indypo's Avatar
 
Join Date: Oct 2010
Location: Florida
Posts: 15
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?
Indypo is offline  
Sponsored Links
Advertisement
 
post #2 of 14 (permalink) Old 05-13-2011, 06:50 AM
Polaris ATV Legend
 
Bruce!'s Avatar
 
Join Date: Feb 2009
Location: Port Angeles WA
Posts: 20,004
Boy that doesn't sound good!

I tried setting my password to "penis" but it said my password wasn't long enough...
Bruce! is offline  
post #3 of 14 (permalink) Old 05-13-2011, 07:01 AM Thread Starter
Junior Member
 
Indypo's Avatar
 
Join Date: Oct 2010
Location: Florida
Posts: 15
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.
Indypo is offline  
Sponsored Links
Advertisement
 
post #4 of 14 (permalink) Old 05-13-2011, 07:45 AM
Polaris ATV Legend
 
WilliamBos's Avatar
 
Join Date: Jun 2010
Location: on land.
Posts: 6,403
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.



Sent from my iPod Touch using Tapatalk, as if anybody actually gave a sh!t if it was a desktop, laptop, crackberry, I-phone or freakin' morse code or for that matter smoke signals...

Thanks,
Will

2012 Sportsman 400HO - 5,800KM and counting.
25" Traxion Grippers
Warn RT 25, Warn Hawse Fairlead, Synthetic Rope, Glacier III plow, Kolpin Rear Trailbox L&R Mounts.
6" Front LED Lightbar
Polaris HD Front coils
Polaris Hand & Thumb Warmers.
WilliamBos is offline  
post #5 of 14 (permalink) Old 05-13-2011, 08:57 AM
Polaris ATV Legend
 
Diesel man 03's Avatar
 
Join Date: Sep 2010
Location: Wisconsin
Posts: 1,801
I would remove the trans and replace the seals or have someone do it for you.
Diesel man 03 is offline  
post #6 of 14 (permalink) Old 05-13-2011, 10:40 AM
Polaris ATV Legend
 
jordaman17's Avatar
 
Join Date: Mar 2011
Location: Renfrew, Ontario, Canada
Posts: 2,479
yea get it done right man, save you from more problems later on.

2016 Sportsman 450, Polaris front bumper, running on 26" Kenda Bearclaw htr's.
2010 Polaris Ranger 400, Super ATV Roof, running on 26" Maxxis Zilla's.



(sold August 17th, 2015 ) 5490km 2008 Polaris Sportsman 500 Ho, Polaris Hand & Thumb warmers, RotoPax 4 Gallon Fuel Pack, Custom Made Rear Bumper, PowerMadd Hand Guards, Polaris Rear Work Lights, Ricochet Ultimate Armor, Polaris 3500lb Winch, Rear Rack Extender, Polaris Brush Guard, 3 Headlight Mod, Uni Air Filter, EPI 'patv1' primary clutch spring. All up on Interco Swamplites!

Subscribe to my youtube channel! ---> http://www.youtube.com/user/mudsling...ew=0&flow=grid
jordaman17 is offline  
post #7 of 14 (permalink) Old 05-14-2011, 10:18 AM
Polaris ATV Legend
 
polman500's Avatar
 
Join Date: Nov 2009
Location: SE Kentucky
Posts: 4,277
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.
polman500 is offline  
post #8 of 14 (permalink) Old 05-19-2011, 01:28 PM Thread Starter
Junior Member
 
Indypo's Avatar
 
Join Date: Oct 2010
Location: Florida
Posts: 15
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.
Indypo is offline  
post #9 of 14 (permalink) Old 05-20-2011, 04:06 AM
Polaris ATV Legend
 
polman500's Avatar
 
Join Date: Nov 2009
Location: SE Kentucky
Posts: 4,277
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
polman500 is offline  
post #10 of 14 (permalink) Old 05-20-2011, 04:51 AM
Polaris ATV Legend
 
Russ C's Avatar
 
Join Date: Feb 2011
Location: Douglas Wyo
Posts: 4,243
believe you have to take shaft off of front diff first to remove it
Russ C is offline  
Reply

  Lower Navigation
Go Back   Polaris ATV Forum > Polaris Model Specific Discussions > Polaris Sportsman

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Polaris ATV Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in









Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.



Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
Polaris transmission leak Nate101 ATV Repair and Maintenance 1 01-09-2011 06:30 PM
gas leak shawnboy87 ATV Repair and Maintenance 8 09-16-2010 02:15 PM
Bad Oil Leak Ozquad Polaris Sportsman 0 01-15-2010 08:23 PM
2002 magnum 325 4x4 Transmission leak dude ATV New Members 1 12-16-2009 05:36 PM
850 XP Oil Leak Irondog Polaris XP 3 12-14-2009 08:16 PM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome