Can someone please give me some help. I have an 2003 artic cat 250 4x4. I got
the bike used but in good shape. The first time I took it out for a ride about 60 miles I noticed later I had a leak on the right side front axle seal. I replaced the seal and the diff fluid and about 100 miles later the seal started leaking again. I replaced it again and now about the same distance it is starting to leak again. I checked the bearings, the vent tube, the surface the seal rides on is smooth and clean. I get into very little mud and clean the bike after every ride with a garden hose nozzle, no pressure washer,.... The ball joints seem to have some slack in them but the outer bearing seem in very good shape. Could the ball joints casue this ?/ They seem evenly wore on both side but only the right seal has given me any problems. Please help!!!!! Thanks
TrailblznSonny

 

my right seal is wet around the differential, but no dripping or wet spots on the ground when it sits in 1 spot for a month, i left mine alone, its wet, or looks wet but no loss in fluid

 

Thanks booboo

It starts like that but if I keep riding it the fluid begins to get slung all over the place and then drips and puddles under the atv when I park it.
I do measure the fluid in when I change it. I do not fill it to the top of the fill plug..
Thanks again
trailblaznSonny

 

i had that happen to my 04 650, but my seal was totally chewed up, the flanged part that seals around the housing from the axle was torn and leaked fluid from there, but i swapped it out and no problems, u sure the seal seated correctly within the diff housing?

 

I thought that may have been the case on the first seal I changed but I was careful putting the seal in and making sure it was all the way seated on the second one and now it has failed....Thanks for the help....I am really pulling my hair out on this one....

 

Are you sure it is the seal that is the problem - did you look for a 'pin-hole' or a 'hair-line' crack. Only other thing I can think of.
Maybe look around and find a used differential housing and replace yours.

 

The last seal I replaced had a tiny piece of the seal missing right where it makes contact with the axle...But there is not a blemish on the axle. I examined it and even polished it with some super fine steel wool. It did not catch on anything...
thanks though. Anyone else have any ideas?????????? Is there anyway the balljoints letting the outer hub move slightly could cause this??????
Thanks
TrailblznSonny

 

I am going to take the axle to a machine shop and have them check and mic it..Maybe it is just out of round or bent...I do not lknow what else to do..Thanks for the help.

 

good luck trailblazn hope its not a major

 

did u make sure u pushed the axle all the way into the diff to the point at which the snap ring engaged? i didnt the first time and i had play in and out right there that would seal the bell housing to the seal, just fixed that up.