Polaris gas cap assembly/repair

[Steve Foss]

Hey guys:

I just traded photo services for a 1992 Polaris Indy Trail DLX. It's a 2-up with reverse, heated grips, electric start, 488 air cooled. Only 1,492 miles and in near mint shape.

I had it out on the trails today and the only issue I found was that the threaded portion of the gas tank where the cap screws on is cracked, and it leaked gas with a full gas tank. What do you think is the best product to repair that crack/break? Plastic weld cement?

Also, I'm looking at replacing the gas cap/dipstick gauge assembly because the plastic top to the cap is so mildewed that you can't read how much gas is in there. Any idea where the best place is online for older Polaris parts?

[Dave S]

Sportwheels in Jordan might have something and may ship it to Ely iffin' your looking to replace the entire tank.

[Steve Foss]

Thanks, man.

I'm really hoping not to have to replace the tank. I've gotta think some type of plastic cement/epoxy/weld that's gas resistant would work but figured someone in here would know.

Come to think of it, I bet a strip of duct tape carefully applied so it hugs all the contours of the threads would offer some temporary relief and still allow the cap to screw on. It's not like it's under pressure or anything. Hmmmm.

[Wanderer]

I'm stopping at a Polaris dealer on my way home tonight. I'll ask for a recommendation - and gas cap price - and get back to ya.

[Steve Foss]

Thanks, buddy!

[jeffreyd]

make sure the neck is not cracked on the tank. my sportsman cracked the tank at the molded seam where the neck was molded together, i cut it off below the crack but it still seeps some when totally filled up.

[Steve Foss]

This crack is below where the cap threads end when tightened, but still on the neck threads themselves, not at all on the smooth portion of the tank below the threads. If the cap itself was deeper/taller, it'd screw down over the whole crack and probably seal just fine, but it's too shallow to do that.

[delcecchi]

You might look at 3m products, like 4693H Scotchweld. I couldn't tell if it is gasoline resistant.

Note from admin, please read forum policy befoe posting again,thank you.

[leech~~]

Foss, I worked in Plastics and Fiberglass for years. There really is not many if any thing that will stick to that kind of formed heavy plastic very well. Long run, better off looking for used tank.

[Dellfin]

I picked up a used 98 ACat 2-Up two years ago and didn't realize that the neck for the tank had a crack until I filled it and the vibration during the first ride caused fuel to splash all over my lap. Pretty frustrating.

I researched every possible option I could to repair it without success. Everyone I spoke with said that the gas would eventually eat away at any adhesive. The only thing that seemed plausible was to plastic weld the crack with heat, but that meant disassembly and removal of the tank. Since I would have to remove the tank anyway, I opted for replacing with a used tank that I found at a small ACat dealer near up north.

Good luck!

[MN Mike]

Thats what I am thinking too, replacing the gas tank might save ya lots of headaches.

Mike

[Steve Foss]

Thanks, guys. I'll probably repair it with one of the solvent-resistant epoxies/plastic welds (or heck, just the careful duct tape for this season), and keep my eyes open for a replacement gas tank.

As many Indy Trails as there are on the trails and in boneyards all over the northern U.S., no doubt I can put my hands on one eventually, and probably for pretty cheap. Considering I don't have $1 into its purchase, what's a few bucks?

[Dave S]

Checking around at a couple of places, I found one for an '89 for $22. Not sure if they're the same part number or not.

Couldn't imagine that a tank for a '92 would cost much more.

[Wanderer]

Yup, like everyone has said, a replacement is required for the real fix.

Dealer price on a new cap with gauge is about $35. I didn't ask for the price of a new tank since you'll prolly find one used.

I'm going to look in a catalog tomorrow to see if there is a type of shrink tubing that can span that neck since I know you're gonna nurse it through this season anyhew.

But you'd still have to drain it unless you feel REAL lucky.

[walleyehunterc15]

i jb welded my tank under the threads on my arctic cat 440 snopro and it still doesnet leak i let it cure the full 24 hours in a heated garage before fillin and roughted it up with some 40 grit sandpaper maybe try that

[jeffreyd]

babbits out of michigan might help too

[mudslinger64]

check out northland small engine in virginia over by the monson yard,i bought a new gauge from him last year cheap,he would probably have a used tank/seat for you to,there is also mohawks in hibbing if you ever get over that way.

[Black_Bay]

The torque placed on the cap from gas sloshing is what caused it and will continue to expand the crack. As leech said nothing will fix the tank long term. Call Mohawk Salvage in Hibbing.

[Wanderer]

I'm going to look in a catalog tomorrow to see if there is a type of shrink tubing that can span that neck

2 inch shrink tubing costs more than a used tank would.

J-B weld's J-B Qwick Kit claims to repair plastic and is petroleum resistant when fully cured, if you pland to go that route.

Just don't fill it all the way. That sled will run for a long time on 3/4 tank of fuel. I bungeed an extra 2 gallon tank to the back of mine last year and never came close to using it.

Good luck with it!

[ripstick]

Hey steve goggle emerrson stahl in proctor. He has a lot of sleds around. If he has 1 I can get it to you.

[Surface Tension]

JB weld and shrink tube is worth a try. Might just get you by till you find a tank for cheap.

[Steve Foss]

I picked up the JB weld today, and the sled is now warming up in a heated garage. Gas tank will be here in a week, but I'm planning on hitting Shags a few times the next coupla days.