Gents,
2006 sprtsman 700 efi.

Cant believe i did this.

Snapped the drain plug, must have cross-threaded it. Needless to say, majority of threads are stuck. I have the head and about 2.5-3 threads, balance is up in the housing. UGH!!!

Tap and die ??? Any suggestions???

Thx
Tim

 

Looks like it's time to drill it and then use an easy out to remove it. If you can not get it out with an easy out, you will need to drill it out and little at a time, trying to not get into any of the gear case threads. After you get the rest of the plug removed, ideally you should be able to clean the threads up with a tap; if you manage to mess up the threads beyond repair, you would need to either find a thread repair kit (helicoil) or drill out to the next size up and tap it to a larger plug. Either way, be careful and take your time and you should be able to save it.

 

Try Sears bolt and screw remover set, similar to my Snap-on set but only about 25 bucks. Has different size removers in the set that grips the remainder of the broken plug and will pull it out. Wish I could post some pics,but each one is knurled on the end to grip any size broken plug or bolt.If not feasible,then probably will have to do as John mentioned. Good luck OPT

 

Maybe a Heli coil insert. How to Repair Threads With A Heli-Coil Insert - YouTube

 

Thx gents.

Seems i have a leak in one of the front bearings to boot (pun intended) lol.

Might be time to bite the bullet and take it into the shop.

Appreciate the advice, as always!