I've got a 2005 Yamaha Kodiak 400 4x4. Really like it and when I bought it, I've been religious on keeping up on the maintenance. For years, I've been doing my own maintenance aside for maybe when I buy something initially. I'll have a shop take a look at it and change the fluids, etc. since it's there. But after that, I always do it. Just trying to paint the picture that I'm not a rookie.
I change the rear diff and front diff every other year and the engine oil/filter every year. When changing the rear diff fluid, it's a pretty tight fit to pour in the oil, so I will use a Pro Honda Hypoid final gear oil 8oz bottle since my machine uses 0.24qts (~8oz). Anyway, it's a pointy bottle with a little nipple on the end of it. As I was test driving how to exactly get the bottle wedged in the machine to pour it in.....the little plastic cap (about the size of the piece you cut off a tube of caulk) came off and went into the rear diff! I tried filling it up and draining again, compressed air.....nothing. Couldnt get the little piece out. Any ideas what I should do? How do i get it out......do I run it a little and then do another rear diff (final gear oil) fluid change? Can't believe this happened. Thanks in advance for any help.

 

No takers on this?

 

You know what I,d do. The pinion/Ring gears in that rear end is tuff and large. Run the ATV around and let the pinion/Ring gears grind that little piece of plastic to nothing and the little plastic that's left (Pulverized by now) should just drain out the bottom of the diff on your next fluid change.

That little piece of plastic has as much chance as a stick in a wood chipper.
Now if it was a small nut or screw I would not recommend it, but you basically dropped a marshmallow in there.

Here's what the insides look like in the diff (Almost Half way through video) no way a piece of plastic caulking tube cap will hurt anything.


Now if you want to take the diff off and split it like the top video you can have it off and in your hands this quick.
OR

 

Thanks TLC. Enjoyed the video as well. the more I think about it and the more I ask around.....I'm doing just what you said. For the cost of some oil.....this is a no brainer and should create minimal damage. Thanks again.'