Chain Case "Issues" - Blew my chain now can't get it off... started by Pance
	December 23rd 2008 at 10:15 PM  [ Modified December 23rd 2008 at 10:19 PM ] Post #1
	Pance Cummins Fanatic 3007 Posts Group: Members Member Since: February 19th 2006 Location: Eagle Bend, MN, USA Current Sled: 1998 XC 700 2008-2009 Miles: 150
	So the other day I came off an approach and had to open her up some to get out of a culvert... Then I heard a clunk and my revs spiked... Belt was fine so I pulled the dipstick and sure enough metal shavings galore... So I got it home and started ripping it apart (it being my 98 XC 700 with reverse << ) So I got 3 of the 4 bolts out of the chaincase cover and then ran into my first problem... The last bolt underneath the chaincase was nearly impossibly to get out... I ended up bending a wrench to get it out... then once I had everything out and loose but with the reverse on it and the CRC suspension (inboard trailing arms) I couldn't get the cover off because it was wedged in between the reverser gear the the bellypan... Also my tensioner assmebly had been wore off where it pivots on the stud... So I ordered a new tensioner, but that stud had broke off (I think because the guy from the polaris dealer pulled it backwards) So I'm going to see if the welding shop can weld that back on, but I need to get everything else out before I can do that... So any tips or tricks? I'll try and snap some pictures... 1999 Saab 9-3 5dr 2.0T 5spd with a long list of mods planned... 1998 Polaris XC 700 reverse, 96 studs... still stock... 2008 Polaris Sportsman 500 EFI winshield, Tool Box, Winch and Aluminum wheels... 1995 dodge ram 2500 cummins turbo diesel, 335000 miles. For Sale! -1954 ford f 100 w/ a 383 stroker, turbo 400 tranny, camaro front clip For more info on either of these PM me... SUPPORT OUR TROOPS I am pro-life, abortion is murder. God made Adam and Eve not Adam and Steve! I can only pray that Obama finds the lord. Rating: 0 Quick Edit Edit Topic

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	December 23rd 2008 at 10:49 PM Post #2
	whitexc Average Member 948 Posts Group: Members Member Since: February 19th 2006 Location: Pendleton, NY, USA Current Sled: XC
	The bolt that bolts the bottom gear on sheared off on me three years ago...not a pretty site or sound but it got home the 40 miles we had to go. It blew the bottom of the case out and made a mess of things..but I also don't have reverse. Good luck with that. Polaris...it IS the way out! Rating: 0 Quick Edit Full Edit

	December 23rd 2008 at 10:57 PM Post #3
	stringcheese Serpentine Slayer 647 Posts Group: Members Member Since: December 10th 2007 Location: Waterford, Michigan, USA Current Sled: 93 TCAT,F7,85 MX 2008-2009 Miles: 431
	Drill a hole in your side-panel to access that bolt on the bottom Brappp cough cough brap--PPAAAAAAAAAHHH pull pull pull pull cough pfffft cough BRAAPPP-POP pull pull pull pull pull SH!T! Rating: 0 Quick Edit Full Edit

	December 23rd 2008 at 11:00 PM Post #4
	Pance Cummins Fanatic 3007 Posts Group: Members Member Since: February 19th 2006 Location: Eagle Bend, MN, USA Current Sled: 1998 XC 700 2008-2009 Miles: 150
	I got the bolt on the bottom out, and the hole in the side wouldn't have helped really... But my custom bent wrench will work fine for it now, but the problem is getting the cover out of the sled... I'll get some pictures tomorrow to better explain my problems... 1999 Saab 9-3 5dr 2.0T 5spd with a long list of mods planned... 1998 Polaris XC 700 reverse, 96 studs... still stock... 2008 Polaris Sportsman 500 EFI winshield, Tool Box, Winch and Aluminum wheels... 1995 dodge ram 2500 cummins turbo diesel, 335000 miles. For Sale! -1954 ford f 100 w/ a 383 stroker, turbo 400 tranny, camaro front clip For more info on either of these PM me... SUPPORT OUR TROOPS I am pro-life, abortion is murder. God made Adam and Eve not Adam and Steve! I can only pray that Obama finds the lord. Rating: 0 Quick Edit Full Edit

	December 24th 2008 at 6:41 AM Post #5
	steve13 Starting Member 43 Posts Group: Members Member Since: December 28th 2006 Location: Quebec, Quebec, Canada Current Sled: XC 800 2002, XCR 800 2003
	I have to pull out the trailing arm and take out some rivet to take my cover out in my xc 600 1999. a hell of a job. buy some new rivet .50$/each, and good luck. Steve XCR 800 2003 XC 800 2002 Ultra 1998 LRM pipes Ultra SP 1996 project to come: XCR 800 motor in Ultra 96 body Rating: 0 Quick Edit Full Edit

	January 3rd 2009 at 3:14 PM Post #6
	Pance Cummins Fanatic 3007 Posts Group: Members Member Since: February 19th 2006 Location: Eagle Bend, MN, USA Current Sled: 1998 XC 700 2008-2009 Miles: 150
	So I have been waiting on my parts so I never really got my sled fully apart... Now my parts finally got here... I snapped a few quick pictures to show what my problems getting it apart are... I think when we had pulled it out of the ditch and down to the dealer (like 2 blocks) it had wore that off... but I'm not sure... was a 56 dollar mistake haha Yep it broke The stud that should be in the chaincase... Doesn't look like 180 dollars worth of stuff huh? See how it's up against the trailing arm "hump" in the bellypan It hangs up on that bottom reverser gear assembly.. Okay here's the chaincase with the hole where the stud that the tensioner turns on should've been 1999 Saab 9-3 5dr 2.0T 5spd with a long list of mods planned... 1998 Polaris XC 700 reverse, 96 studs... still stock... 2008 Polaris Sportsman 500 EFI winshield, Tool Box, Winch and Aluminum wheels... 1995 dodge ram 2500 cummins turbo diesel, 335000 miles. For Sale! -1954 ford f 100 w/ a 383 stroker, turbo 400 tranny, camaro front clip For more info on either of these PM me... SUPPORT OUR TROOPS I am pro-life, abortion is murder. God made Adam and Eve not Adam and Steve! I can only pray that Obama finds the lord. Rating: 0 Quick Edit Full Edit

	January 4th 2009 at 1:23 PM Post #7
	Pance Cummins Fanatic 3007 Posts Group: Members Member Since: February 19th 2006 Location: Eagle Bend, MN, USA Current Sled: 1998 XC 700 2008-2009 Miles: 150
	So I got everything apart... Now I'm debating whether to have that chaincase mended up or should I look for a used one? Are the inner halves of the chaincases the same as a non reverse sled? 1999 Saab 9-3 5dr 2.0T 5spd with a long list of mods planned... 1998 Polaris XC 700 reverse, 96 studs... still stock... 2008 Polaris Sportsman 500 EFI winshield, Tool Box, Winch and Aluminum wheels... 1995 dodge ram 2500 cummins turbo diesel, 335000 miles. For Sale! -1954 ford f 100 w/ a 383 stroker, turbo 400 tranny, camaro front clip For more info on either of these PM me... SUPPORT OUR TROOPS I am pro-life, abortion is murder. God made Adam and Eve not Adam and Steve! I can only pray that Obama finds the lord. Rating: 0 Quick Edit Full Edit