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Gimpy
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Number of posts : 7223
Registration date : 2009-10-01
Location : Louisville, KY

PostSubject: Looking for answer   Sun Jun 21, 2015 9:09 pm

Went to remove the plug in the XP today, and sure enough with my luck it striped out. Any suggestions? I will check and see what Troy at the local dealer and Waynes say. Anyone else dealt with this? I always felt my 800 was going to strip but hasn't.
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Goose
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Age : 68
Location : Barnesville, Ga.

PostSubject: Re: Looking for answer   Sun Jun 21, 2015 10:36 pm

Les had same trouble on the rear end. Found 3 cures. First new rear casing =$1200 second take plug to hardware store get next size larger self tapping put on an O ring tighten third is a plumbers plug this is what I've been running for about 9 months. If you tighten it enough it will not leak. I'm eventually going with the larger plug
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Gimpy
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PostSubject: Re: Looking for answer   Mon Jun 22, 2015 7:15 pm

Waynes Polaris said they tap a groove on the edge of the plug with a chisel, then hit it hard. That usually does it he said. I am not trying anything until after this next ride.
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pushrod 1
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Age : 66
Location : donnellson IA.

PostSubject: Re: Looking for answer   Mon Jun 22, 2015 9:38 pm

gimpy, I fix these all the time on 4 wheelers. find out what size plug is and get a hieli coil set to fix it. kit will come with all you need. you have to drill the old threads out retap it, screw in the new coil. these are stainless steal better than new. just make sure that the end of the coil is in the block or the plug will hit the coil first and not the block. THIS SHOULD BE A FIX FOR LIFE.
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oldmustangjunkie
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Location : Cumberland Plateau, TN

PostSubject: Re: Looking for answer   Tue Jun 23, 2015 11:28 am

If the threads are stripped, I'd helicoil it. If the allen hole is stripped in the plug head, get a torx bit and use an impact driver/hammer to remove it and buy a new one.
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Gimpy
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PostSubject: Re: Looking for answer   Tue Jun 23, 2015 10:22 pm

oldmustangjunkie wrote:
If the threads are stripped, I'd helicoil it.  If the allen hole is stripped in the plug head, get a torx bit and use an impact driver/hammer to remove it and buy a new one.

Yea, I will try that after I get done with riding this weekend. I have a good battery impact and an air impact. Should have used it first.
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oldmustangjunkie
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PostSubject: Re: Looking for answer   Wed Jun 24, 2015 9:00 am

I should have been more clear. I'm talking about an impact driver. You beat it with a hammer and it pushes the bit so I can't strip out the hole.
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Gimpy
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PostSubject: Re: Looking for answer   Wed Jun 24, 2015 9:58 pm

Yep, got one of those too.  I will try it after this weekends ride.  Don't want nothing messed up on the XP and have to ride the S.
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