I have a 2005 Sportsman 500 with the brake fluid resevoir leaking. There are 2 screws that fasten the top plastic cap onto the metal resevoir. The brake fluid is leaking at that seal. I tightened both screws, but it still leaks a little. I thought about just replacing the seal, but I cannot see anything wrong with the seal (not cut, tear, hole, rip,...). Are the Sportsman's notorious for this leak? Any suggestions to fix it (other than simply replacing the seal, and/or replacing the seal and plastic cap?

Thank you

 

my trailblazer was doing the same thing. it is a design flaw. here is how i fixed mine. remove the cap clean the brake fluid from around the top and sides. clean the top itself. reinstall top and seal all the way around the seam with rtv sealant and let cure overnite. mine has not leaked since.

 

Had the same problem with my Magnum.

Dealer said Polaris wouldn't cover it under warranty. So they just cleaned the seal and tightened the screws. Still leaks a little. Just drained a little more of the fluid, and doesn't seem to do it as much.

 

Had the same problem on mine. Took off the cover, cleaned up the sludge/gunk (that just happened to have eated the paint away overtime!), topped off the fluid, then bolted it back down. Hope it fixes the problem. If not, I'll be looking for a fix right back here so lets hear from others on this issue.