I know I will have to tear it back apart tonight, but this is driving me crazy already today at work. I did the final assembly of my wifes 02 XC800 last night and was all excited to hear it run. I didn't think too much of it, but it took nearly a gallon of antifreeze (all I had), and never filled-up the coolant bottle. I figured it had enough coolant in it to do a quick fire-up, so I tried to start it. No deals, it seems that some (alot) coolant made its way into the case. I dont think I ever got the level high enough to cover the head gaskets, so other than a leak in the base gaskets what should I look at? Now that I think about it, the coolant must have leaked pretty fast into the case. No coolant leaked outside of the engine.

Thanks,

Doug

pull the crankcase plugs to be sure the case is getting filled.. I thought the 800 twins where about 7 qt's of cool juice.. 1 3/4 gals..

you used new base gaskets and head o-rings??

I can't get at the case drain plugs, but I know the case is getting filled due to all the coolant blowing out of the spark plug holes. Yep, new base gaskets and head O-rings. I'm puzzled because I really try to pay attention when I put stuff back together. This is my first motor out of five complete teardowns that hasn't gone well. The case and bottom of jugs had all the old gasket removed. Dumb question, but is there a way to screw-up with the orientation of the base gaskets?

there is a right way and a wrong way.. you'll know by looking at em if they are on wrong..

were the cases damaged at all?? how far did you tear it down??

cases split?

how did you torq the cases / cylinders / heads in what order.. the twins
have a specific order to torqin the motor together..

http://www.imagessite.com/OEM_Images/Polar.../P02NP8CS11.gif

but I know the case is getting filled due to all the coolant blowing out of the spark plug holes.

Good indication that the head orings did not go on correct or the head is warped.. either way the seal between the coolant and combustion chamber
in not correct..

I might have the gaskets on wrong, I'll have to tear it apart and see. I've been burning the candle at both ends these days, so I could have had a brain fart. I understand your reply as I could have put them on wrong, but they still would have gone on, but leaked. Is this correct?

The whole motor came apart. I had to have the bottom half of the case welded where the connecting rod hit a broken piston piece into it. The case split-line was still flat afer welding (this guy welds molds for a living). Everyhting checked-out good with an indicator and straight edges: crank, cases, head. There is no coolant in the bottom case half, so either the top half has a crack, or I'm hoping the gaskets are just on wrong.

I torqued the jug and case bolts per the service manual page.

Edit after reading your last post: I dont think I had enough coolant in it to reach the head gaskets, and it never ran to pressurize the coolant and cause them to leak.

I guess I'm just asking to see if there is a possbility I have the base gaskets oriented wrong which would cause a fast leak into the case. If that is not possible, then I think I may have a crack in the top half of the case?

At least I'll be quicker with the teardown and re-assy since it's all still fresh in my mind, and all the right sockets/wrenches are still out.

I doubt it's the bottom end.. all the cool juice is pusing up thru the plug holes the cool juice sounds like it's pushing up thru the head and into the cumbustion chamber..

http://www.imagessite.com/OEM_Images/Polar.../P02NP8CS12.gif

Roger, I think I got it figured out. That last picture you sent me showing the base gaskets. I bet I have them backwards! The tab that sticks out is on the carb side if I remember right.

Man am I a dumbass! I should have known better!

Thanks for your help, I'll let you know how it turns out. This thing has been sort of a pain for me. It blew up the last ride of last season, and we have new sleds sno-checked, so all of this wrenching is just so it can be sold running. It has been competing for my time with all of my new home related projects, so I work outside until dark, them move into the garage and work on this sled until bedtime.

If you have any isoflex grease, I would apply some to the crank bearings if you have time, antifreeze does loads of stuff to grease and bearings.

Sounds like the same problem I have expect mine is coming out of the carb and out where the cylinder/crankcase line up on 1 side....

I had a lot of problems with the paper gaskets from polaris blowing out. or leaking. get cometic aluminum rubber coated gaskets. never had a problem. same price as paper ones but are reusable.

You don't want isoflex grease on these crank bearings, unless you seal the bearings off and religiously use it, it won't do any good.

Polaris offers a steel 800 twin base gasket, part number 5812363, around $8 apiece. :div20:
Jerry