I have a 2007 800 and just changed the tranny fluid. The drain bolt has a grove worn in it from something inside the tranny rubbing on it! What causes this...is it normal and what is the fix. My bike is under warranty so I will take it to the dealer but wanted to know if anyone else has encountered this and what the fix is? Could it be the chain in the tranny hitting the tranny drain bolt? Please respond I am nervous.

 

My best guess would be the silent chain... Good luck with everything

 

stupid question, but is it pre groved already to fit the bolt or can you see it wore. let us know what you find out from the dealer for sure. not enough miles on mine yet to change. only 175 miles.[img]i/expressions/face-icon-small-sad.gif[/img]

 

There was a thread that mentioned gear case drain bolts being too long. I'll try to find it.

I believe guys were grinding the excess from the bolts before reinstalling, can't say for sure though. I haven't changed my fluid yet either.

 

Guys,

Check these two threads from the ATVquadsquad forums.

1.

2.

 

i'll have to check mine next year when i service my trany. i didnt notice anything on my 06' 800 when i did the complete sevice before i traded it so maybe its not alll models but you never know. the chain loose would be a good reason for all the extra sound we hear.

 

Have seen a few of these at the local dealership. They have been taking the trans out and apart under warranty to fix the issue. Never heard of too long of plug.

 

Took it to the shop. They had one there for the same thing. They are pulling the tranny out and replacing the chain and the gears if they are broke. They had one there for the same thing except it broke the chain already. Mechanic told me that mine would do the same if I didnt bring it in.

 

So its a loose chain?

 

Now I am being told that Polaris said the bolt is too long and they just shave the end of the bolt off. This sounds like B.S. to me but I know a lot of the 800 are havign this problem. Sounds like polaris is blowing me off with a temporary fix hoping the big problem (chain and gear breaking) happens out of warranty? What do you think