I have a 2004 polaris 600 and I cant seem to keep the water out of the drive belt casing . I have replaced the gasket and the plug. The outer casing doesnt seem to have a crack. Help please.....

 

hello there i've heard this problem alot thats why i'm heitating on getting on some people though dont have a problem going up to the seat with them . what some people have done was put a bead of silicon around the case and that solved the problem u could probly try that it is just a shame the money these things cost it takes some silicoe to solve problem good luck.[img]i/expressions/face-icon-small-cool.gif[/img]

 

Here are some ideas.
The rear plastic is warped... Changed it on a 2000 sp 500 .... need to pull the clutch.
The rubber boot sealing behind the clutch is torn.... Changed this on my 2003 sp 700... Kids put there feet on the belt housing and push down enough to tear that seal.
Outer seal is not holding... Silicone....

I have never used silicone on mine...

Jon

 

Welcome......Huntsville here......I read someone filled the belt housing up with water (at home in your yard) and see where it leaks out!!!..This will tell you the weak spot!!!!!.......I know your going to ask me how do I get the water inside the housing...RIGHT........It has a breather hose going up follow that and fill there....Hope this helps.........Caper...........let us know..what you find!!!!!

 

most likely its a bad rear seal behind the clutch.

 

hello once again i'm not saying take cover off ,just put a bead of silicone on top of case and smooth it out i'm no expert just going by what friends did on there polaris and it worked it's a quick fix and lasted awhile. so go have fun.[img]i/expressions/face-icon-small-cool.gif[/img]

 

im cheap so when i put my cover back on i put clear silcone on the gasket just as an extra seal, instead of buying a new seal like on mamma's bike @$21.00. will see if it works.

 

Thanks everyone for all your suggestions and especially Huntsville . Filling up the case with water ,I found that the rubber gasket for the air intake behind the case was torn . replaced it and no water.......Thanks Again