I noticed when I got back from riding earlier today that I had oil dripping from the rear of my 2005 Sportsman 800. Upon closer inspection, I saw that the front pin that holds the rear drive shaft to the shaft exiting the rear of the gear case was about 75% out of one end. It has worn a small hole in the gear case from the pin cutting a grove into it as it spun. The hole is very small but obviously leaking oil.

I looked up the part online and found it for whopping $350! Any suggestions, because I'm sure I'm going to have to take it to a shop to be repaired/replaced? I'm almost wondering if it can be fixed with some type of weld or epoxy. However, I want it fixed right but I hate to spend that kind of money. I'm sure it will be $500 by the time I leave a shop.

I also noticed that while on my ride, I heard a squealing sound as I accelerated but it eventually went away. I haven't changed my belt yet so I assumed it was the belt but now I'm thinking it had something to do with the transmission.

Is this a common problem that you guys are aware of? I have just over 900 miles on the machine.

Thanks

 

I had this happen to my 2002 Sportsman 700..Reparied it with JB WELD..still ok ater about 5000 miles...

 

Yea jb weld works great on quads

 

I'm doing the JB deal now, it seems like it should work awesome. Thanks for the advise.

Craig

 

Make sure you use a new pin when you get it all back together.

Also, if you have any suspicion that dirt, metal shavings, etc., got into your transmission, you might want to flush it before putting it back into action.

And JB weld does work wonders. [img]i/expressions/face-icon-small-smile.gif[/img]

 

there is now jb quick, same stuff dries in 15min.....roughen up spot,,,,,,,

 

JB Weld is amazing stuff just be sure to really CLEAN & SCUFF the area your applying it to if you want it to be a "do it and forget about it" type of repair which JB will allow you to do if you get all oil residue off area, carburetor cleaner works good and hit it with some course sandpaper afterwards so it will adhere good. Nothing is worse then always having it in the back of your mind--is it holding?--while your out having fun so do it right if your going to do it.

 

I kow this is old but if you're still out there...
I have a 2002 sportsman 700 with a slow oil leak from tranny, I have removed the rear drive shaft and it doesn't really look like it is leaking here but how could I tell the shaft is boring a hole. Does the hole around the shaft just get bigger? Am I looking for a crack? Somewhat new to this repair scene but have the time to investigate. I can send a pic of what I am seeing once I clean it up. Not loosing a lot of tranny fluid, maybe a few ounces every few months, just enough to have to put a pan underneath.