Does anyone know how to fix a brake fluid leak where the metal piston moves in-out of the brake fluid resevoir (this is the small metal rod covered by a rubber boot that moves in-out when the brake lever is depressed)? Can this even be repaired, or do I have to replace the entire brake fluid resevoir? If so, how do you dissassemble it? I assume there is some rubber seal in there?

FYI, I have confirmed the brake fluid is NOT leaking out of the brake fluid resevoir cap. Also, I have confirmed the brake fluid is NOT leaking where the brake line attaches to the resevoir. So, that must mean it is definetly leaking at the metal piston, right?. There are no other places for it to leak (unless the resevoir is cracked which I cannot see).

I appreciate your suggestions on how to fix this frustration leak. I

Thanks again

P.S. - I own a 2005 Sportsman 500

 

I would look at getting the unit replaced by Polaris through your dealer on warranty. The 05-06 units have been replaced on numerous units by the dealer here and I would request that the new 07 brake assembly be used as I saw one and they have redesigned it completely due to various problems they had with your design.

 

A friend of mine had an older Polaris with the same problem. Had to replace the entire unit.