All,

Well today was the day I was expecting to be a triumphant maintenance
day. I feel like Gilligan, "From here its smooth sailing"..- Cuuussshh

First of all not sure why our Polaris Engineers would make the 2008 SP800 drain plug to be an 6mm allen-wrench Vs. Hex-head like my SP450. Yes you could of guessed it, I stripped that dawg-gone thing. That sucker is on soo tight. I thought it was turning, tried different leverages, still no go. After about the third try, 1/4 turns, thinking its loosening. WRONG I was boring the head.

Okay what do I do now?

I called a local dealer and he had one drain plug left, shot up there and bought it. All good for my 2nd attempt this weekend. BUT, how do I remove this stripped drain plug? So after talking with them and auto store and sears people I was sold on getting those "SCREW OUT" bits for my drill to attempt to bore it enough, gripping it to remove it.

Well it didn't work and now its a mess. I think anymore of that and it will be drilled through and them nothing to be able to take out whats left of the plug and then I see Dealer Repair with $$$$$ to help.

Any ideas guys, I am burned out on this and its just turned out to be a nightmare!
Good news is I got my long awaited new Mudlites on (another thread to come, LOL).

Many thanks,

R'

 

Is there enough head left to drimal some slots for a large flat head screw driver?

 

Reno82, that is what my cousin wants to do, I am just so nervous now with a big trip coming up that I want to leave it alone for about 2weeks and then come back and do the overhaul. What I don't want is to drill it out or down only to find the remain pieces screwed into the threads and no way to remove and then engine RE-THREAD work would need to be done.

I think I am screwed anyways.

Just not a good day for me!

R'

 

I hear ya! sometimes better to walk away for a day or so till you calm down and can take your time. I have used the drimal trick with good results. I cut the slot, use a heavy flat head screw driver with a vise grip on the grip for more leverage. With one hand I push up on the screwdriver to keep it in the slot, with the other I turn the screw driver with the vise grips.....slowly.
Take a break for a few days and go back at it, I don't think you're screwed yet.

 

Did you try a nipple extractor?Another option is to cut a slot in it and use a hammer and a punch.Don't forget to shock the threads first with a hammer.

 

I have gotton them out by driving a TORX IN THE HOLE....select the right size and use a hammer socket over it till it is in tight.....then try taking it out....I use a impact tool just set it on light so it viberates as it backs it out....worse comes to worse I have wired welded a allen wrench to plugs before to get them out....but thats a tight spot were you are at. Torx has always worked for me.

Art

 

i would use an ease-out type remover. drill a small hole in the center of the plug and use the ease-out to back it out.

 

sent you a reply big R'

 

If nothing else works then use the drill and the EZ-out method.
Good luck R!

 

<div class="FTQUOTE"><begin quote>Originally posted by: RticKwad

First of all not sure why our Polaris Engineers would make the 2008 SP800 drain plug to be an 6mm allen-wrench Vs. Hex-head like my SP450.</end quote></div>

The reason is, a bolt head is easly stripped out because lots of people would use a cresent wrench, or a channel locks, or a pliers. The idea of the hex bolt is so you HAVE to use the proper tool.

I'm wondering if you used the wrong size allen wrench, the reason I say this is because it is next to impossible to strip those heads out except for one situation.

I'm not saying your bolt didn't have an imperfection but I do remember having to clean out mud in the bolt head with a pick so the hex tool would go in all the way. If I wouldn't have cleaned out the head I too would have stripped it out because like you said it is in there really really tight.

Good luck, and next time make sure its in all the way, or you could just put in a regular bolt in, I'm sure NAPA or something would have a suitable replacement.