most likely its your tank leaking not the cap. ive seen it happen to several people. some were able to just teflon tape the threads, but others had to replace the tanks. try gettin a friend or dealer to let you use their cap for a minute to see if it solves the problem and go from there.

 

Thanks. Didn't think of that. I'll give it a go.

 

I have an 04 Pred that leaked. It actually had a split on the threads. I had a Polaris dealership "weld" the plastic on the inside of the tank. So far, so good. Last summer there was a thread on it. It sounded like this was a problem for a few 04's.

 

MY 03 had the same thing. Just take it to the dealer and they should change it out for you... at least they did for me, but take it in anyway.

 

Mine did the same. First I tried changing the cap, along with the rubber gasket and it continued to leak. Finally I just took some teflon tape around the threads of the tank and fixed the problem. With the gas cap off it looked ghetto but once on you couldn't see the tape, worked good, no gas leaks.

 

My 04 had the same problem. The threads on the filler nexk were cracked. Luckily it was still under warranty at the time so I had my tank replaed for nothing. I have heard that electrical tape works pretty well though.

 

Thanks for all the input.
Found the problem. The threads were cracked down on the first turn. Cut it off with a hack saw & filed the top square again. All fixed.
Makes the cap sit a bit lower too which looks much better.
Lesson learned - don't over tighten the gas cap on a plastic tank.

 

Yes it a problem with the tank. My dealer has like a dozen broken tanks laying around his yard.