I am sure everyone has or had this problem on a newer Sportsman. So what kind of fixes have people come up with the keep the damn cover to access the radiator cap on so water does not flood the front box? After totally ruining every item in my wallet and rust on every tool/shackle/snatchblock or anything else I have put in there I have to come up with something.

 

I use duck tape and silicone. The late 06 and 07 models seal much better than the 05 and early 06 models so you could buy the new model lower box, if your 06 doesn't slready have it.

 

The question is, is the RAD cap the only thing
letting water in? I think the shock caps are big
holes there too and does the lid cover seal water
tight? cause when you bend down and look
at it doesn't seem too, leak proof there either.

Yes my cousin (06') 800 bought a replacement
lower box and the caps were sealed non-removable,
part of the shape of the box. So it appears water
tight but the lid is in question. Don't know the answer
cause never had mine submerged to that end.

R'

 

I have put 2 black philips head screws thru it to the box housing. works great

Or get the new style of cover that comes on the 07s it is rubber and does not come off as easily

 

As for the top lid not sealing well. I found that adding a front rack extension gave the lid a little more structure which hellped it seal properly.

 

there is all kinds of places it leaks so we just buy big zip lock bags to put the things we dont want wet into. no more problems.

 

That idea is just to easy for me to follow. I like to try to over-engineer things.

 

nothing wrong w/ that bud. i just take the easy way out(or i should say wife did) besides hit a few good hard trails and sometimes the shock caps or rad.cover will pop off anyways.

 

That bag idea got me thinking. Wouldn't it be great if polaris made a slip in liner for their front storage box. It would be waterproof, cushioned, and insulated like a cooler. Like one of those soft sided, zip-up coolers. That would be an accessorie that I would buy.

 

Yeah, I had tried the zip-lock bags too. I was just wanting to see if anyone came up with some better ideas than I have had to try to keep as much water amd muck out as possible. The box is very convenient but as I have found out not the best engineered thing I have ever found. I wonder if they think we all just ride around the yard on these things?