I have a 2005 Sportsman 500. I "was" having trouble with the brake fluid resevoir cap leaking. I fixed that by removing the cap, applying a small abount of black RTV sealant, and re-tightening.

Now, it appears the resevoir is leaking somewhere else as well. The steel braided brake line that is fastened to the resevoir looks dry. All of the fluid brake fluid leaking appears to be toward the bottom of the resevoir. Any suggestions as to where and why it is leaking? Are these resevoirs notorious for cracking? Could the piston that moves back and forth by the brake level be leaking and need rebuilt? Should I just order a completely new brake resevoir, and throw away the current one?

I appreciate your suggestions.

Thank you

 

when i wife rolled her t.blazer she broke the res. right off. once the screws are out there isnt much to hold a seal w/ its basicly nipple in a rubber i think. anyways i just retapped it and screwed it back on w/ no leakage. isnt that much pressure to them. do the brakes work good? maybe the piston isnt working right and forcing fluid backwards. it will come out some where.

 

From your description your leak may be lower than this but brake fluid is notorious for being one place and coming out another. I discovered that if brake fluid gets between the gasket/bladder and the top cover it will leak no matter what you do as the design is meant to keep the fluid below the gasket in the reservoir and it does not seal above that. The fix is to remove the cover and gasket, separate both and thoroughly clean both pieces-reassemble. Just a sugg.

 

I notice Polaris cops out here by saying to replace the seal every time you open the reservoir up, and I bet it is expensive