I own a 2004.5 sportsman 500ho and was changing the fluids on my quad today. As I was finishing up I went to put the fill plug on for the front diff. and cross threaded it stripping the threads on the case. Anyone ever have this issue and how did you go about fixing it or any suggestions from anyone?

 

Helicoils or time serts are what a lot of shops use.Time serts if you can find one large enough are a stronger repair.Plus you might take the fill plug to a local auto supply to see what they may have as far as something to repair the threads in the case.

 

Also does anybody happen to know exactly what size the fill plug is?

 

3/4" x 16 pitch threads. Item #22.Dirt Cheap Yamaha, Polaris, Suzuki & Kawasaki OEM Parts & Accessories – Cycle Parts Warehouse