I have an 05 Sportsman 500 LE and I noticed two weekends ago when we got home from a ride that the lid to my brake resevoir was leaking. The brake fluid covered about half of the front of the resevoir. I removed the cover cleaned everything and re-installed it. I made sure that it was tightened down good. This weekend when we got home it was leaking again.

Anyone else have this problem? I ride with a group of 8 other Sportsman 500s and nobody else was leaking.

 

Had it happen with my Magnum. Check the seal for anything out of the ordinary. Mine somehow got dirt on the seal (maybe not tightened from factory, happened in the first month). Cleaned and tightened it and all has been fine.

 

my 2003 trailblazer did the exact same thing. took off the cover and retightened the screws evenly a little at a time. leaked as bad or worse. the cover is plastic and if you tighten the screws [john tight] it will distort. here is what i did to stop mine from leaking. get rtv sealant and make a small bead/gasket on the cover and let it cure till its firm. reinstall the cover till the screws are SNUG. the put rtv around the outside edge of the cover. make sure you clean all the surfaces the rtv will be applied on. mine has not leaked since. does not look pretty but mine dont leak. do not wait until you are going down a steep hill to find out your master cylinder is low.

 

My 2004 did the same thing also. The rubber gasket under the cover had been pinched and had a tiny cut in it and that was all it took to leak. Put a new gasket in and was good to go.

 

Thanks for the replys! I will check the gasket again and see if there is anything out of the ordinary.

 

I have found on mine that you can indeed overtourque....I place the lid on the resivoir and hold it firmly with my thumb in the center while tightening the screws. This seems to eliminate getting it too tight on the outside and keeps the center from buldging up and leaking