Hey guys,
All of you have been helpfull when I had a problem. I have a 2002 polaris 400 sportsman. I went to change the oil simple job. I reinstalled the drain plug and plastic washer in the plastic oil tank and it was leaking very slow. Replaced the plastic washer with a stainless from the dealer and still have a very little comming out. Any ideas? Thanks

 

Try some Teflon plumbers tape on the threads of the drain plug........

 

If you over tighten the drain bolt and washer and a new washer doesnt help,then the insert in the tank can be damaged and can move causing dripping also. Had a couple of these happen from owners that did their own service! Drain bolt just needs to be snug,don't crank down tight. OPT

 

Had the same thing happen on my 400... The insert has failed and will leak. A temporary fix would be an oversized rubber washer that covers the outer edge of the insert.. Garden hose washer??? I think I made my own out of something I had lying around... Worked until I could buy a new one.. Hope this helps...

 

to my way out,
do you have to buy a new tank or can you buy the insert?

 

You will have to buy a new tank... The insert is molded into the tank and once it has been unseated it leaks. I still have my old one... I was going to look into having it machined out and options to put a new one in... but wanted to ride instead...

 

That is a problem area ,on those plastic tanks. You may want to consider a used one off of an older unit that used aluminum tanks,lasts forever.
try e-bay

 

Yep, what he said!

 

Thank guys,
The oil was leaking from the oil plug so I put some high temp gasket maker around the plug before puting it back on. No more leak.

 

Another Polaris improvement, "let go from aluminum alloy oil tanks over to plastic like we did with the roller cages."

I swear Polaris has stock options in a plastic manufacturing plant somewhere.