[GustoGuy]

I was reading how to fix the noisy chaincase on Polaris XCSP and the main issue is that Polaris put too much of a dog leg bend in the chain which causes lots of noise with the tensioner. I read that 25-39 gearing will work with the stock used 74 p chain and a modified tensioner or you could totally eliminate the tensioner since the chain is almost tensioned perfectly without it. Other gearing options are 24-40 or 23-41. The 25-39 or 23-41 are more desirable since I would only need to buy 1 gear instead or two gears. I like the acceleration of the XCSP and I don't care so much about top speed since a snappy off the start performance with decent top end is so much desirable than all out top speed which will hurt the bottom end. Plus I was wondering what gearing could help with the rather abysmal fuel economy of stock 2002 Polaris XCSP 600? I went on 130 mile ride on Saturday and every time we filled up the XCSP 600 it would burn consistently about 2 more gallons of gasoline the my 1996 Polaris XLT touring sled.

 

[GustoGuy]

I also have the mechanical reverse on the XCSP too

 

[GustoGuy]

I read that a 23-40 combination of gears will work with the 74 p chain. A used chain like mine will fit with some material removed from the heel of the stock tensioner. I will post pictures and let everyone know about how it works.

 

[tgsmartcows]

You have bad components in that chaincase or you're running the wrong oil. Reverse cases run a better synthetic gear oil than standard. Also you need to flush and change oil every 1000 miles for best longevity.
Tension should be checked every 500 miles. Loosen lock nut 3-4 turns, turn screw in by hand till tight. Back off 1/4 turn. Hold tension screw while tightening lock nut.
A whine usually comes from a chain that's worn so much it's stretched beyond its pitch and won't mesh with the sprockets(they are not gears). Pull cover and, with tension correct, try to lift chain at the top of the top sprocket. If it lifts off the sprocket more than .030", replace the chain.
100% if you have issues with that gear case, maintenance was not adequate. It's a good gearcase, no real known issues.
BTW, if dealer serviced, know that they will often skip the gear case inspection and just tighten the chains, the slackers.
Bottom line, tear it down, inspect everything(sprockets, chain, tensioner,cross shaft and drive shaft bearings.)
I'm positive you will find the bad part. And if there is gear oil outside the case, find the leak and fix it. There's only about 4 ounces of oil in it.

 

[GustoGuy]

Snowmobile has 3400 miles on the odometer. I was reading that chaincase noise is fairly common with the Edge snowmobiles and I gave been using a full synthetic Arctic Blue with molybdenum chaincase lube in all 3 of my snowmobiles. I used to use Amsoil but where I live now it not readily available in stores. I was reading about how the noise is caused by the tensioner and the dogleg bend in the chain. I read that going with 23-40 sprocket combination with a modified tensioner will lead to little to no dogleg bend in the chain with nearly silent running chaincase with less drag and slightly better acceleration due to slightly lower gear ratio. The other 2 snowmobiles are and XLT Touring with reverse and plain non reverse chaincase on indy 488 Fan cooled Touring. Those chaincases run quietly.