2001 XCSP 800 Oil Tank Leak - HCS Snowmobile Forums

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Old 09-18-2006, 01:45 PM   #1 (permalink)
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I know this has been discussed on here before but I am unable to search to find the topics. On my 2001 800 Edge I know I have the problem with the sending unit o-ring leaking on the bottom of the tank. I was going to replace the o-ring but I have recently discovered oil in the air box area. I have heard that the airbox on this sled is known to crack by the oil tank. Can someone let me know where to look for the crack? Is there a way to repair the crack? Am I better off to get a new factory airbox/oil tank or is there an aftermarket "fix" to this? Has Polaris made changes or can I expect the next one to crack too? How big of a project is it to remove and replace the airbox/oil tank?

An advice on a very good clutching/jetting/ set up for this snowmobile would be appreciated.

Thanks in advance for all help.
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Old 09-18-2006, 02:33 PM   #2 (permalink)
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I have an 01 xcsp 600, had the same problem. Luckly my sled was still under warranty, but it cracked right at the top of the inside of the air box. Kind of in the back corner closest to the gas tank. I havent had the problem agian and have probally put about 3000 miles on it. From what the dealer told me it took a lot because you have to rip the steering post out, but i really dont know how big of a project it was. Hope this helps you some. Let me know if you have any questions
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Old 09-18-2006, 05:31 PM   #3 (permalink)
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my 2001 xc 800 has a small crack in it also , I know getting the airbox out is a good time! Its riveted in from the gas tank side and the motor side , not sure how much has to come off to drill the rivets out.
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Old 09-19-2006, 08:35 AM   #4 (permalink)
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How big of a chore is it to get the airbox out? Drilling rivets is not a big deal, but how does the steering post come out? Is buy a replacement airbox/oil tank the best choice for repair?

Thanks
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Old 09-19-2006, 09:13 AM   #5 (permalink)
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I am attempting to use my xcr 800 airbox in my 02 xc 800 chassis and if it all fits good.. I'll pass on my airbox/oil res from my 02 chassis.. as far as I know it's not a leaker.. and the deal is right..Freebe.. I just need to make sure my xcr airbox is useable in the xc chassis.. I am sure I'll make it fit
it'll be a few weeks before I actually know anything..
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Old 09-19-2006, 09:49 AM   #6 (permalink)
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Quote:
my 2001 xc 800 has a small crack in it also , I know getting the airbox out is a good time! Its riveted in from the gas tank side and the motor side , not sure how much has to come off to drill the rivets out.[/b]
It's riveted only on the bottom facing the engine, and 1 rivet behind the oil filler neck, no rivets under the tank. If the leak can be located, you can use 2 part plumbers epoxy, it will be stronger then the tank itself, we have fixed several that way for our customers.
A new tank costs $180 from Polaris and shows no recall or substitutions.

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Old 09-19-2006, 10:30 AM   #7 (permalink)
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XCR1250,

What do you use to clean the tank before you epoxy it? Want to make sure the epoxy holds. Sounds like a much better fix than replacing.



RogerBzXCR,

I may still be interested in your tank if it is available in a few weeks.



Thanks
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Old 09-19-2006, 05:58 PM   #8 (permalink)
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Mine -an 02, leaked bad. I discovered my filler neck was oblong so I warmed it up with a heat gun (carefully) and then squeezed it round and held it till it cooled. No more leaks, if you can't find a crack check filler neck.
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Old 01-08-2012, 09:11 AM   #9 (permalink)
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Quote:
Originally Posted by thinksno View Post
Mine -an 02, leaked bad. I discovered my filler neck was oblong so I warmed it up with a heat gun (carefully) and then squeezed it round and held it till it cooled. No more leaks, if you can't find a crack check filler neck.

see my post dougs1967 it will have many of you questions to upgrade answered.
2002 XCSP 700 Oil Tank & Airbox Upgrade Conversion

2002 XCSP 700 Oil Tank & Airbox Upgrade Conversion
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Old 01-08-2012, 10:10 PM   #10 (permalink)
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This is so weird, I don't even know how many edges I've had and have and I've never had this problem, except the 2 I bought a few weeks ago. Can you fix the oil leak issue on the bottom where the outlet to the oil pump is without taking out the airbox? I've seen how its mounted and it would be a major pain in the ass to take it out.
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