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Discussion Starter #1
I found an oil leak from my recently purchased Fourtrax. Its leaking at the drain plug. I thought it may have a worn washer on it so I went to the dealer and purchased a new washer. The washer was too small to fit on the drain plug. I verified that the washer was the correct size and part. It looks like the previous owner tapped out the hole to a larger size. I tried putting the bolt back in, but its stripped out.

What are my options as the larger drain plug is now leaking? Re-tap to an even larger size?

Thanks for the help.
 

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I found an oil leak from my recently purchased Fourtrax. Its leaking at the drain plug. I thought it may have a worn washer on it so I went to the dealer and purchased a new washer. The washer was too small to fit on the drain plug. I verified that the washer was the correct size and part. It looks like the previous owner tapped out the hole to a larger size. I tried putting the bolt back in, but its stripped out.

What are my options as the larger drain plug is now leaking? Re-tap to an even larger size?

Thanks for the help.
if there is any threads left at all..wrap some teflon tape around the bolt threads..if that don't work..yes..go to a larger bolt hole..drill it out..re-tap it, make sure you get a large copper washer to use on the bolt..also..watch your drilling..you will get metal shavings inside the diff..if your not careful..to be on the safe side..drain the diff..wash it out..blow it out with a air hose..re-fill after your new bolt is in..good luck.
 

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Discussion Starter #3
Shadetree - Sorry I wasn't clear earlier. The drain bolt that is leaking is the crankcase drain bolt not the differential drain bolt.

As its already been tapped out, how big of a bolt can I use on it?
 

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1/2" pipe plug works good I had to tap my drain out get you a couple of quarts of hyd oil it's thinner, stick your finger over the hole and dump in about a half of a quart then remove your finger and let it drain. do this for a quart or so. make sure when you tap it you do it with the quad sitting on the wheels, crawl under it and tap it out, that way all the shavings stay in the bottom of the crankcase. good luck.
 

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yeah..like trx said..keep the bike level..you dont want any shaving's inside the crank case..well..you will probally get some in it..but this way..it won't be much..what don't drain out..your filter screen will catch..sooo..later down the road..remember to pull the screen out < if it does in fact have one > and clean it...and when your tapping it..try to go 1/2 turn..then 1/2 turn back...this will let the shavings drop out more..instead of following the tap inside the motor.
 

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Be careful, it's a little harder to tap threads in aluminum. It's easy to mess up. Use tapping fluid or at least WD-40 and most of the shavings will stick to the tap instead of falling in the engine.
 

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Discussion Starter #7
I see that HeliCoil and Time Sert make tool kits made specifically for aluminum oil pans.

Anyone ever use either the Heli Coil or Time Sert products? If so, how did they work?
 
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