OK I have a problem. Being a good American I thought I was buying an American product with a Polaris. I changed the oil 2 years ago after break in when I got the Hawkeye and forgot what size hex head to use, and now I was getting near 50 hours and was going to change again. Thought it was a 7/32" (again thought USA) and stripped the bolt. I have 3 questions.

1. I don't ride this thing much, in 2 years I have put 440 miles and 48 hours on it, is there a way I can pump the oil out of it from the oil fill hole, or just change the filter and drain by tipping forward or something? Any recommendations or alternatives would be great.

2. Does the skid plate on the bottom come off easily, and if so could i get something else around the plug to get removed since it isn't flush, and anybody ever done this?

3. If I HAVE to get this fixed (again, probably only 1 or 2 more changes on this thing over the life I'll have it) what does it run to get it drilled out (obviously I wouldn't want to do this myself and get shavings in the case)

Any help would be great. Thanks.

Mike

 

Get a set of easy-outs or extractors and pull it out. Sears and Irwin tools have them.

 

I know what you are talking about, but this is an allen key type hex head that you insert into, not a hex type bolt. Do they make extractors for those, I don't see how it would work?

 

If there is enough of the head showing you could cut a groove in the head with a Dremal, then use a large flat head screw driver to turn the bolt out, slide a closed head wrench up the screw driver shaft for torque as you press on the handle of the screw driver and turn the wrench.

 

Regardless if you get that plug out or not...Invest in a oil extractor/pump. There's many makes on the market from some that run off a drill to hand pump type. No more messy oil changes. I've been using a PELA hand pump on my 4 stroke outboards for a couple years now...If my ATV were 4 stroke, I'd use it on that as well...but it's not.

My only concern when I first bought the pump was it not getting all the oil out. I pumped the oil out, pulled the plug, she was empty. They work great.

 

You should be able to take the skid plate off and get on it with a small pair of vice grips.

 

I can't remember what my Hawkeye looked like on the bottom, but I believe the skid plate was welded on as a permanant part of the frame.

I read somewhere that you could take an allen wrench and JB Weld it into the stripped hole. After it has cured then you'll be able to turn it right out just like normal. Granted you'll have to replace the drain plug after that, but you were going to do that anyway right?