I have a slow oil leak on a Polaris Sportsman 500, 2003. The leak seems to be from the plug at the bottom of the oil resevoir. There did not seem to be any oil on the resevoir, above the level of the plug. I have put on a new gasket that I got from the dealer. It is hard white plastic, looks like nylon to me. I tightened it to 14 ft lbs as specified by the service manual. The leak is slow, but still there. I do not see any trash or rough spots on the plug or the surface where it seals.

Any ideas on how to stop this leak?

 

Get a tiny o-ring to put on the oil plug bolt, very plyable.

 

Can wrap drain bolt with SMALL amount teflon tape,just dont overtighten! Have had one mans son spin the tank insert and tank had to be replaced. Good luck