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Discussion Starter · #1 ·
The rubber washers/gaskets inside the oil cap and gas cap that form a seal with the top of the tank threads are both just about toast. The oil cap one was literally falling apart in pieces; I'm sure I lost a small piece or two in the tank. Was able to replace that one ok with an o-ring I found with my dealer, since polaris doesn't give the gaskets separate part numbers. I haven't found anything yet for the gas cap gasket, was looking for ideas. Its pretty flat and wide so I'm not sure that an o-ring is gonna work too well. My dealer is supposed to be checking for me to see if we can get just the gasket, but probably will only be able to buy the whole cap. Any experience with this or ideas would be cool. Thanks.
 

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I had the same problem with mine. What I did was went to Home Depot and got some black tape that was next to the teflon tape. I don't remember the name of it but like I said it's black, about 1 inch wide and only about three to five feet long in the roll. It was around $4.50 for the roll. Kinda expensive but it has been working good so far. Just when you wrap you tank threads with it, wrap it tight so the cap will still thread on easily. Good luck
 

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Discussion Starter · #3 ·
Thanks, I will check into it. I pulled the gas cap washer out this morning, its not as wide as I originally thought. I'm going to wander around Home Depot, the auto parts store, and where ever else I can think of to find something that is close, maybe I can cut something down to fit, or maybe I will find a fat o-ring the right size. If not, and the tape seems to work, then I will just do that.
 

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My O-ring doesn't snug against the cap properly causing the leak. Just do the tape and forget about it. It's black and you can't even see it. you barely notice it when the cap is off.
 

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Discussion Starter · #5 ·
Went to Home Depot this weekend to look for the tape, wouldn't you know they were out of it! At least I was pretty sure it was what you were talking about, some stuff for leaky pipes, about 4.59. At any rate, I wandered over to the bathroom plumbing stuff and found a tub drain washer that was pretty much identical in material, thickness, and inner diameter. I trimmed down the outside to fit in the cap, and voila! I didn't get a chance to test it, but I'm thinking its gonna work. The inner diameter was a little, tiny bit big, but it squishes down in the cap alright. We'll see how it works this coming weekend.
 
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