Any one have a solution to the leaky oil caps on the 04-06 summits?
Doo's leaky oil caps
- Thread starter powderseeker
- Start date
There is a guy on DooTalk who has an insert which returns the opening to round. I've just installed it on my 03 ZX Summit but haven't tried it yet.
Mike
Mike
2x on the poo cap. works perfect.
M
MTdream
Well-known member
yup, go down to Polaris and buy one for a edge chassis...it has a ball valve in it, it will solve the problem...I also put some electricians tape around the threads on mine for added measure, has not leaked since...
Don't know about the Revs, but I put a Cat cap on my ZX. Fits perfect and it has a check ball in it also.
We rerouted the breather line over and got rid of the check valve.
It only lets air into the tank. So, as the engine compartment heats, so does the oil tank, and as such builds pressure (non vented cap, check valve) oil cap is easy place to leak, so it does. Loose the check valve, and no more pressure. Worked for us anyway.
It only lets air into the tank. So, as the engine compartment heats, so does the oil tank, and as such builds pressure (non vented cap, check valve) oil cap is easy place to leak, so it does. Loose the check valve, and no more pressure. Worked for us anyway.
T
Tackbtch
ACCOUNT CLOSED
The ball valve in the Pol or Cat cap wont block air flow when the sled is upright, the ball falls against the cap opening when the sled is on its side or in my case on its top
Cheers DinoThanks for the solution guys, Its off to the poo dealer I must go.
Is it just me or doesn't it look like there should be an O-ring or a flat rubber gasket up inside the cap? I put one there tonight, the machine was tied down on the trailer so I didn't leak test it yet but most likely I'll have it on it's side tomorrow and find out how it works.
On my o5 summit , I solved the problem with about two wraps of black electrical tape on the threads of of the cannister
T
Tackbtch
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On my 02 the cap leaked out of the vent opening, and like I said earlier our 06 don't leak, I can see that its easy to cross tread the cap thus ruining it. The wife rides the 06 so it doesn't get tested often. The 02 spends alot of time on its side and the Pol cap has worked great. Dino
My 00 spends a good share of the day sideways or upside down also, and loses barely a drop now that it has a Cat cap on it.
The 02s have a crack in the side of the threads of the oil tank. We have 2 and they both have it. We got this plastic bonding stuff and it did the trick.
T
Tackbtch
ACCOUNT CLOSED
I will have to look closer at my 02 ... Thanks for the info! Dino
P
POPPS
New member
Gasket
All you have to doo is make a FULL gasket to fit inside the cap. If you look at the gasket in there you will see small holes which allow oil to get behind it and work it's way down the threads. I have done this for two years and no more oil leaks. Leave the old gasket in place and lay the new one in over it, only tighten the cap slightly, just enough to compress the gaskets.
All you have to doo is make a FULL gasket to fit inside the cap. If you look at the gasket in there you will see small holes which allow oil to get behind it and work it's way down the threads. I have done this for two years and no more oil leaks. Leave the old gasket in place and lay the new one in over it, only tighten the cap slightly, just enough to compress the gaskets.
A buddy of mine has an 03 which also had a hairline crack in the threads of the tank. Could barely see it. He had tried the Polaris cap prior to seeing the crack but it didn't help. He bought some plastic repair/bonding stuff at the auto-body supply place and it has worked very well so far. The material he used is what they recommended for repairing the hood but it seems to be holding up real well. You can check Doo's web site for the hood material type.
my sled is the one coldfinger is talking about................and yes on the skidoo caps u have to be careful not to overtighten it will ruin the rubber gasket in the cap.......also the threads on the resevoir crack u can use the same plastic you would use to repair the hood as also the resovoir......and that is urathane rrim ............doos hoods are made out of rrim urathane, just wipe it on the inside of the resovoir thrreads and biingo drys in 3 min and good to go.
I just picked up a 04 Rev 800HO. The oil cap was leaking when I checked it over before I bought it so now I'm looking for the fix. The way the cap threads on almost makes me think it might not be OEM. The thread pitch is the same, but the threads in the cap are come to a point at the crest. The threads on the filler neck are squared off. I doubt that the cap threads could have stripped off the filler threads because the cap is more pliable and there are no cross-threading marks. Can someone confirm if the filler neck threads are supposed to be sharp or flat? Thanks
Yes, they are all like that. No, the cap threads didn't strip the filler threads, it was an oversight by ski doo engineers is all. As said above, get a Pol cap or get some gasket material and make a new one. Or you can stick a Colander meatball in the top and wrap some spagetti around the filler neck and hope it holds.......
