Roof Leaks

[EricB4]

It seems roof leaks are a common issue on these Xpeditions. We live in Arizona were rain is hardly an issue. We just went through a major rain down poor. Both seams on the roof panels leak like there is is no seal on these seams. The headliner, front seats belts were soaking wet. As well as water standing in the back seats floor area.

We are way out of warranty, so the fix is on me. What type of weather seal is everyone using to stop these leaks.

 

[Keyster]

Totally get it. My roof on my XP5 was replaced twice for the constant bowing issue, and allowing enough separation on the roof for water to get in. I tried silicone caulk, but in sunlight and the cold, it just kept separating due to the temp changes and such. I gave up and went with a piece of black RV roofing tape. It contracts and expands better I think.

 

[Pirate7]

Hmmm...my 2026 ADV 2-seat came with a very strong adhesive between the front and rear roof sections. Getting the rear section off to do some part repalacement was difficult. The original adhesive seal was still in good shape, so I re-used it.
Under the bolts that hold the roof sections to the frame have a rubber washer to keep water from leaking in. Do you have all of them?
Haven't had water in the cab since it was new.
Pirate

 

[EricB4]

Hmmm...my 2026 ADV 2-seat came with a very strong adhesive between the front and rear roof sections. Getting the rear section off to do some part repalacement was difficult. The original adhesive seal was still in good shape, so I re-used it.
Under the bolts that hold the roof sections to the frame have a rubber washer to keep water from leaking in. Do you have all of them?
Haven't had water in the cab since it was new.
Pirate

All the rubber washers are there. All intact, not deformed and centered under that main large washer. The roof panela are warped wirh as much as 1/2 inch gap difference between panels. I can't see the gasket/sealer.

I'm sure to fix this requires removing all 3 roof panels and finding a better seal option.

 

[Pirate7]

Eric, I understand. My 2-seat has a two section roof. The 4-seat must have a three section roof.
So are some or all of the roof secction bowed up in the center? If so, you might add another bolt located at the side to side joint at the overlap of the roof sections. Also consider using a lower temp heat cut to warm the sections so they lay flat. Just not so much heat to melt the roof sections.
I have two Ace Hdwe heat guns. One is high heat, one is lower heat and works great for this type work.
Here is the info on the Polaris seals

Hope this is helpful
Pirate

 

[EricB4]

Eric, I understand. My 2-seat has a two section roof. The 4-seat must have a three section roof.
So are some or all of the roof secction bowed up in the center? If so, you might add another bolt located at the side to side joint at the overlap of the roof sections. Also consider using a lower temp heat cut to warm the sections so they lay flat. Just not so much heat to melt the roof sections.
I have two Ace Hdwe heat guns. One is high heat, one is lower heat and works great for this type work.
Here is the info on the Polaris seals
View attachment 7747
Hope this is helpful
Pirate

Thanks for the suggestion. I think heat is the issue here in Arizona. We often get temps over 110⁰ and higher. We don't often ride in thise temps, but these black roof really get hot in the sun.

 

[Pirate7]

Eric, a couple of thoughts.
Here is a diagram of the three piece roof taken from the polarisparts123.com website

Look at Item 8. These are the screws that hold the three sections together and will prevent warping.

These are the Item 8 screws:

Here is a clear definition of what this part is:
Technical Breakdown of the Part Name

• • SCR: Screw
  • TXPH: Torx Pan Head (a star-shaped drive with a rounded, low-profile top)
  • #14 X .75: Size 14 thread diameter with a length of 0.75 inches
  • HI-LO: Dual-height thread design (features high and low alternating threads for better grip in plastics, composites, or thin metals)
  • RIE: Rich-infusion or rust-inhibitive protective exterior finish coating [1, 2]
  Hope this is helpful.
  
  
• Pirate