I purchased a 2011 Polaris rzr 800 over a month ago and have been going through it since. New tie rods, brake pads, Viper winch, fan override, wheel bearings, bushings, fluids throughout etc. While it was apart I decided to clean up the frame and coat it with Por-15. While I was under there I noticed that the transfer case was leaking and on further inspection it was the seam.
I read that some people coat the outside of the case but I wanted a better solution. So I set out today to rectify the leak by pulling the case cover while still in the side by side.
![643619]( "643619")
this is where I will start this. There plenty of information out there to get you to this point.
![643621]( "643621")
Start here, removing the mounting bracket. 3 bolts - remember where they go. There are 2 that hold the bracket to the frame.
![643622]( "643622")
this is the one bolt that you can’t readily access. It’s behind the air intake port of the clutch.
It’s possible but first we need to separate the engine and transfer case. There are four bolts on top. The back one is a pain but doable.
![643623]( "643623")
Then the two on the bottom.
![643624]( "643624")
Then all you have to do is lift the engine with a jack. I’d advise to use a 2x4 to protect the engine from the Jack. When you start to lift the engine you will see it separate from the transfer case and that bolt will now be accessible. Be careful to notice the location of gears and bearings when you pull the cover.
![643625]( "643625")
![643626]( "643626")
You can see my cover is pretty caked with oil and dirt. After a good cleaning and changing of the output shaft seal I used the Ultra gray gasket maker.
![643627]( "643627")
I used a large socket to set the seal.
If You look closely in the next picture you’ll see the lighter gray is where I had the leak.
![643628]( "643628")
I put it all back together finger tight and left it for an hour to set up. Then torqued all the bolts using the following diagram.
![643630]( "643630")
It took a couple of hours but now I am happy that I sealed it properly. Feel free to message me if there are any questions.
Joel
I read that some people coat the outside of the case but I wanted a better solution. So I set out today to rectify the leak by pulling the case cover while still in the side by side.
this is where I will start this. There plenty of information out there to get you to this point.
Start here, removing the mounting bracket. 3 bolts - remember where they go. There are 2 that hold the bracket to the frame.
this is the one bolt that you can’t readily access. It’s behind the air intake port of the clutch.
It’s possible but first we need to separate the engine and transfer case. There are four bolts on top. The back one is a pain but doable.
Then the two on the bottom.
Then all you have to do is lift the engine with a jack. I’d advise to use a 2x4 to protect the engine from the Jack. When you start to lift the engine you will see it separate from the transfer case and that bolt will now be accessible. Be careful to notice the location of gears and bearings when you pull the cover.
You can see my cover is pretty caked with oil and dirt. After a good cleaning and changing of the output shaft seal I used the Ultra gray gasket maker.
I used a large socket to set the seal.
If You look closely in the next picture you’ll see the lighter gray is where I had the leak.
I put it all back together finger tight and left it for an hour to set up. Then torqued all the bolts using the following diagram.
It took a couple of hours but now I am happy that I sealed it properly. Feel free to message me if there are any questions.
Joel
