Man thanks for this video I was about to sell my machine because of the leak it's been nothing but hell since I got it and this was the last thing

FYI WD-40 and Scotchbrite are amazing on clutch surface. Then use brake cleaner to remove all the nasty black from surface. Clutch surface will look and act like new.

That upper shaft, the one that goes to the clutch. Can that seal be changed from the outside or do you have to take the cover off and pull it from the inside?

@duneroller

4 жыл бұрын

Keith Rowe If I remember correctly both seals in the cover are installed from the outside. The secondary clutch comes off easily if you want to take a look. Remove the belt and the bolt holding the secondary clutch. Keep the shims for alignment and you should be able to see t with the rear belt cover in place.

Did this fix work? I have a leaky drive shaft seal as well. I assume that it is where the leak is coming from. It leaks pretty bad. I just bought my 2008 RZR 800 and am just going crazy with how many repairs I am doing. The previous owner did an excellent job hiding all the issues. I guess I am just asking what you did? It sounded like you pulled the transmission (not sure if it was trans or transfer) cover and resealed it then replaced the shaft seal and sealed it as well. You mentioned that the manual said you can not do this... Was that just the part about sliding the front dif forward? Thanks for the video, any input would be great..

@duneroller

6 жыл бұрын

Nathan Yeager sorry for the delayed response. I know it's too late to help you but it could help someone else. Mine was leaking at thetransfer case seam. Spicer did not put enough sealer on at the factory. Mine was leaking at a spot near the bottom that had no sealant at all. As far as the case seal this process would work to replace that as well if it's only a seal issue. If a bad bearing caused the seal issue it depends on which bearing is bad. The shop manual says the transmission, transfer case, and engine must be removed as a unit and repaired and reinstalled. Jeff

@lifeisforgotten

5 жыл бұрын

@@duneroller Got the same leak you got right now... motor blew so was cleaning the trans/transfer/diff and found the leak. Now to reseal. Joyous engineering feat of non serviceability from Poolaris

Would I be able to replace the output shaft bearing after pulling cover like this?

@duneroller

5 жыл бұрын

Tim Hill If that is all that’s wrong the bearing can be changed.

Hello Jeff how did u get that little red stubby bolt out behind the clutch cooling cast. I’m having a heck of a time getting that one?

@duneroller

3 жыл бұрын

That's the hardest part of the entire job. I took a wrench and basically removed the bolt one flat at a time. The adapter between the engine and transmission/transfer case has to move out as the bolt comes out to clear. It's not easy but it's better than removing the entire backend and pulling the motor and transmission as a unit.

@nathandoran6500

3 жыл бұрын

@@duneroller ok thanks. I’ll give it another shot tried 3 different wrench can’t get a good bite on it

@michaelfear4801

10 ай бұрын

I'm doing this job now and on ours we definitely don't have the room like the one in this video,

How do I get the case to move down

@duneroller

6 жыл бұрын

Joseph Cordell the motor mount on the driver's side must be completely removed and the mount from motor to transmission must be very loose.

@michaelfear4801

10 ай бұрын

oh boy ours isn't moving at all

My 800s is puking oil out the vent line for the transmission any ideas on this

@duneroller

5 жыл бұрын

steve billow did anyone service the transmission and transfer case recently? One has a check plug and the other is fill to plug. I’ve seen many people overfill the one with the check plug.

@stevebillow395

5 жыл бұрын

@@duneroller no service work

@stevebillow395

5 жыл бұрын

@@duneroller I filled to the check plug and I also filled to the run over plug

@duneroller

5 жыл бұрын

steve billow Sorry to hear that. No more ideas here.

@stevebillow395

5 жыл бұрын

@@duneroller some guys has said something about a broken clip in the trans would do that, but I have no idea.

can you find a replacement gasket online no clue what Honda bond is. 16 and attempting this at technical school and need any help I can get

@duneroller

3 жыл бұрын

Google Hondabond 4. It's Honda's version of form-a-gasket. I like it because it seals but does not get as hard as form-a-gasket and is much easier to clean if you have to work on it again.

@duneroller

3 жыл бұрын

There is no gasket between the transfer case halves. It is aluminum to aluminum sealed only by the machined surfaces and liquid gasket material (Hondabond, Yamabond, Form a Gasket sealer).

@cd5732

3 жыл бұрын

@@duneroller another question I have is which motor mounts do I have to take off and undo I have gotten to the stage where I have to remove em but I have no clue which ones

@duneroller

3 жыл бұрын

@@cd5732The only motor mount bolts that have to be removed are the ones connected to the steel piece that connects the engine to the transfer case. The others will support the engine but allow it to swing away from the transfer case.

@cd5732

3 жыл бұрын

@@duneroller and what did you mean by bouncing the transfer case with a 2 by 4 till it sits