Tried to change the oil in my 2007 Sportsman 800 but I could not get the drain plug out. It would not budge. I twisted the allen wrench I was using like a cork screw! I know it was a Chinese cheapy, but it shouild have been enough to loosen the drain plug. I might try a better quality socket allen with an extension on the wrench handle, but I'm then afraid I'll mess up the plug. Also thought about beating up the plug with a propane tourch. I did notice the instructions in the Polaris oil change kit said on the Frontier to use a vacuum tube remover down the dipstick tube to remove the oil. Will this work with the 800? Has any My quad is a new leftover 07 with 12 hours on it. This would have been the first oil change. Has anybody else had a problem with the drain plug on a Polaris, and what did you do?

 

Should'nt be that tight ,try a 6mm socket type allen head, some one prosably put it in with an impact.

 

i agree w/ keybirds on trying a socket allen and make sure your going the right way to loosen it and if it doesnt seem to want to move then i would use a hammer impact lighty as it sometimes will vibrate it enough to loosen the seal. just dont round off the allen bolt of the plug. use a good fit and quailty allen socket. imo.

 

Putting heat on the plug will NOT help. When you heat you will be expanding the plug and compounding the problem. I would have to consider taking it back to the dealer and have them "demonstrate" how to properly take it out. OR, I would seriously consider taking it in and without divulging the problem tell them that you would like them to change the oil for you. It is crap like this that makes you want to scream isn't it? I would say that it was put in with an impact and the threads are probably trashed. Either way it looks like you are bound to get screwed over the deal. I certainly hope not though.