I have a 2003 Sportsman 500 This problem started right after I changed my oil the last time. After I run the machine, the oil drips from around the drain plug. There will be a spot on the cardboard I put under it on the garage floor. It will quit after a short while until I run it again. At first I thought it was because I tried to reuse the gasket, so I changed out the gasket with a new one and torqued it to specs. It still dripped after running it so I gave the drain plug a little extra turn, and it still drips. I'm wondering if it is building up pressure when operating or some other problem. Any ideas?
Is your crankcase vent/filter clogged? That might possibly cause pressure buildup, I'd also try a bit of pipe or thread Teflon Tape like plumbers use, could be the threads on the crankcase are buggered up. Just a thought...
One way to "cure" the problem is drain oil completely then wipe crankcase with carb clean or brakekleen or something of this type around drain hole, then use some type of pliable "form a gasket" around base of drain plug over your drain plug gasket, let set for 5-10 mins and then fill with oil---Be sure to use pliable form a gasket so it can be removed and cleaned for the next time. Its not the prettiest of fixes but nobody but you will know and it will work, Ive done this with auto's and motorcycles for years with success.
Originally posted by MaineWheeler: One way to "cure" the problem is drain oil completely then wipe crankcase with carb clean or brakekleen or something of this type around drain hole, then use some type of pliable "form a gasket" around base of drain plug over your drain plug gasket, let set for 5-10 mins and then fill with oil---Be sure to use pliable form a gasket so it can be removed and cleaned for the next time. Its not the prettiest of fixes but nobody but you will know and it will work, Ive done this with auto's and motorcycles for years with success.
Do you leave the Polaris supplied gasket off when you do this? How heavy of a bead do you apply? I'm assuming you don't put any on the plug threads.
What I finally ended up doing to mine was going to local hardware store and picking up a few good quality Teflon washers. I took my stock plug and washer and just added the Teflon one--plug,stock washer then Teflon one against case and screw in and torque to specs. Its not as messy as the form-a-gasket, and Ive been able to reuse the Teflon ones. Its worked so good Ive done all my drain plugs like this--Differentials, crankcase, transfer case and have not had a drop leak ever since. I was kind of worried because I figured if oil could leak out, water could get in. No more worries now though.
