2000 xc700sp chaincase oil keeps disappearing. I've had the cover off a couple of times and it seems to be going back on properly and tight but the oil keeps running out somewhere.
The rubber gasket seems to have a gap at the top so it doesn't go all the way around. it leaves 1/32" to 1/16" space. This could be where it is running out but I don't see much oil around the top and it just seems to be loosing a lot of oil and too fast to be coming out this small hole at the top. If it were at the bottom I would think differently.
Has anyone had this problem? How did you fix it?
Thanks

Are you seeing oil under it when it's been sitting for a while?

2 most common places I see are the gasket, and the driveshaft seal. Usually there is a big mess near one or the other indicating the source of your leak.

It generally only leaks out when I'm moving. When I stop there is no oil and no puddle.
The drive shaft seal sounds like a big job.
I was speaking to a friend about this, he says he knows a guy with the exact same sled having the same problem. He has replaced the gasket because it had a gap like mine does but this did not fix the problem. This is why I am not running out right away to replace this gasket.
Where would the oil appear if it were leaking from the drive shaft seal?
Thanks Michahicks you alsways seem to answer my questions.

You can usually see the mess on the inside of the tunnel. Just take a look at that area from the opposite side of the sled. If you're running in a lot of snow it may be keeping that area clean, but there should still be traces of a mess that aren't too hard to see.

The gap in the gasket you are talking about is usually sealed with silicone gasket cement. But I doubt that's your problem. That gasket is a pain in the rear. I usaully cement it on to the one side with sealer in an attempt to assure myself it's not going anywhere during assembly. Reverse adds to the fun big time. That's why I've learned to be very carefull putting the two halves together. Don't like the instant replay factor when you find it leaks like a seive when filling it.

I had a similar problem last year. All the oil leaked out, I noticed it first in the back of my truck. Have a look at the dipstick, there are 2 little groves in behind the o-rings. This is how your chaincase is vented. If for some reason they get plugged or somehow prevent air from escaping the chain case as it heats up it will actually presurize the case. If the presure is high enough it can litterally force the oil out past the gasket. Here's what I would try first. Clean and inspect the dipstick, take off the cover and change the gasket. Use some red rtv to hold it in place. Bolt the sucker back on, service with new polaris synthetic chain case oil (for those cold days we don't seem to get around here anymore) Make sure the dipstick is clean and that the bore it goes through is also and put it in. Test drive for a bit and see if this fixes the problem, It fixed mine.

I'll have a look but I'm going to wait until the rain stops.

The silicone may help. If the air cant get in, the oil won't run out. In theory anyway.
This should at least slow down the leak.

Thanks

Originally posted by squidbrain@Feb 7 2005, 08:53 AM
I had a similar problem last year. All the oil leaked out, I noticed it first in the back of my truck. Have a look at the dipstick, there are 2 little groves in behind the o-rings. This is how your chaincase is vented. If for some reason they get plugged or somehow prevent air from escaping the chain case as it heats up it will actually presurize the case. If the presure is high enough it can litterally force the oil out past the gasket. Here's what I would try first. Clean and inspect the dipstick, take off the cover and change the gasket. Use some red rtv to hold it in place. Bolt the sucker back on, service with new polaris synthetic chain case oil (for those cold days we don't seem to get around here anymore) Make sure the dipstick is clean and that the bore it goes through is also and put it in. Test drive for a bit and see if this fixes the problem, It fixed mine.
399070


Just put a brand new dipstick in on Saturday.
Pulled the old one out and only got the top end.
That's why I tore into it in the first place.
Then I found I had the bottom gear on backwards, the bolt had come out and the oil was missing.
Got the thread fixed in the hole, turned the gear around, got the screw back in, cover back on, new dipstick in and the oil ran out, did it agian, took it for a ride, came back no oil again.
On top of that I think mice built a nest in my silencer because the weekend before it was glowing red on the trails. Took it off and put the can back on (wanted to go back to quiet for this year) The can doesn't glow red. The heat from the silencer actually cooked the oil that was left in the chaincase because it was down so low.
Not my year. This is why when I talk about getting a newer sled I want it to be fast from the factory and keep it stock. It's me tearing into it that seems to be causing all the problems.
Thanks for the help

I looked under the sled in the tunnel where the drive shaft comes through at the gear housing. There was no oil at all, totally dry.
I supose this is a good thing because it means the oil is coming out from around the gasket.
I took it all apart again, took the gasket off and cleaned it and the contact areas. I bought some silicone gasket stuff and ran it all olong the groove in the gasket, put some extra around the split at the top where the two ends meet and put the cover back on. I decided to tighten the bolts good and tight and actually don't know how many lbs they should be. did you guess where I was going here?
I broke the bottom rear bolt in half.
I'm getting further and further from riding this thing.
Ever have one of those weeks when you think you have the wrong hobby or are playing the wrong sport?
That is me this week 350 miloes on my sled this season, snow melting fast and no plans to ride any time soon.