I have a 99 400 Sport and it seems to have a slow gas leak does anybody else have this problem if so how can I fix it?

Kevin

 

I had the same thing, it was under warranty, so I took it back rather then messing with it myself. Turns out that the line going into the tank wasn't sealed. They fixed with an epoxy, thats made for gas tanks, apparently this is not an uncommen problem. Good luck

Bruce L. Hall
99 Sport 400

 

Wheres it comimg from? if its the carb, than its probaly the floats

 

99% of 99 Polaris Sport leaks gas. Mine and everyone else I know that has one does. I was told there was a recall on them at one dealer. At the next dealer I was told no recall, but Polaris instructed the to fix them all at no cost. They put a new tank on mine and fixed it. No way would I let anyone just rub epoxy on it and say "there you go"

 

Most of them leak around the knuckle at the bottom of the tank where the feul line connects. The knuckle (I don't know what the proper name is)is threded and epoxied to the fuel tank from the factory. So, if you get a new tank put on, the factroy "slapped some epoxy on it" wether the factory does it, the dealer does it, or you do it, it make no differance. It's the quality of the work thats done that's important. Would you rather have the guy in the shop, that you know, who's working on your machine for you, to do it. Or get another from the factory were they crank out a 1000 a day. The factory job is why its leaking in the first place.

Bruce L. Hall
99 Sport 400

 

Good point. My apologies. Although one of my local Polaris dealers has been fixing them by adding an extra rubber o-ring, the kind that you get at automotive store at 50 cents for 25. Mechanic told me they were billing Polaris under warranty work and Polaris told them to stop doing that method and replace the whole tank at Polaris' cost.

 

I fixed mine in no time at all. Drain the gas, unsrew the knuckel, wrap teflon tape on the threads add a little pipe dope for good measure screw it back in & leak is gone for good. The mechanic in the shop said thats how he does it & mine hasn't leaked since I did mine & it's been 8 months or so since I did it. It was a piece a cake.
Jim Maloney 98 400 Scrambler