Outback, sounds like he's faulting the chain for excessive slack rather than the plug for excessive length?

If that's the case, then my chain has excessive slack and should be replaced. Please let us know how this works out and if you can get us a copy (pic) of your repair slip with that diagnosis. This way we might have better luck in presenting our own cases to our respective dealers.

TIA!!

 

by the looks the 07' and 08' have the same drain plug so im wondering about it myself.

 

I noticed wear on my '06 plug when changing fluids last month. Gournd it down a bit and will check again for wear.

 

I had the same problem on my 07 800 and the dealer groudn it down (that is what polaris told them to do and they were aware of the problem and they simply got a batch of bolts that were too long. Hope this is accurate because I will get beligerant if I have a problem later on with the chain and find out this was a fluff answer to appease me until my warranty is up.