Stripped Oil Drain Plug

Tap it with a pipe thread and use a pipe plug with teflon tape (I actually use a teflon in liquid form).
Use grease on your tap to collect small peices of metal.

Thanks for the info. brother. I'll try and get this done...

There are other threads on this on the forum with pictures

Indijoe said:

Started to do the 25K oil change yesterday, first time for me on this bike. I discovered that the tech that had done the last one tightened the outside drain plug so tight he stripped it. What is necessary to fix this and how big of a job is it?

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This has been a problem with several Chiefs, including mine at the first oil change. I used an over-size self-tapping drain plug from the auto parts store. I had a lathe available so I turned the end of the plug down flat after I'd tapped the threads. Be careful not to over-tighten the new plug! Snug and no more.
--- Randall

Mine striped out on the 5000 mile oil change. I bought a Time-Sert kit for the repair. TIme-Serts are similar to a helicoil but instead of being a spring insert, they are a solid steel insert. Makes for an extremely solid repair. The kit cost me around $125.00 which is a pretty expensive repair but I didn't feel like hassling w/ the dealer and I wanted the confidence knowing that the repair was done right.

I'm lucky with my drain plug so far.

Aeromach makes mew oil plugs, they sell them by the pair.

I got lucky I guess, dealership put a Sert kit in for me without charge, said they would try and get it covered by Indian, but not to worry if they wouldn't do it. Great dealership, Hattiesburg Cycles is a Polaris Suzuki Yamaha Triumph Sea Doo Kawasaki Indian KTM and Can-am powersports dealer New and used bikes ATVs and more financing parts and services provider in Hattiesburg Mississippi largest in the Southeast... Check 'em out.

The manual calls out for way too much torque on those plugs. About 50 inch lbs is plenty to let the crush washer seat. This is not a load bearing part. I wish Polaris would go back and change this pronto. Dean E

First off no saying anything about anybody and their maintenance practices. I have been turning wrenches for years. Steel on aluminum --- Use a good torque wrench, period! Even techs at the dealership buy junk torque wrenches and dont even have them calibrated. Mine get calibrated every year regardless of how much use they get. And guess what everyone of then are adjusted, so they do go out of calibration. Do not ever use one to break torque, they were never designed for that.
Cant stress it enough, purchase a good torque wrench and have them calibrated. Not sure about the new electronic ones, I'm old school.
Personally I have used Snap on torque wrenches since my aviation days and my diesel engine days and they have never let me down as long as you take care of them.

Once I had a mechanic not pay attention and use lbs instead of inch lbs. major mistake.

dfournier said:

Mine striped out on the 5000 mile oil change. I bought a Time-Sert kit for the repair. TIme-Serts are similar to a helicoil but instead of being a spring insert, they are a solid steel insert. Makes for an extremely solid repair. The kit cost me around $125.00 which is a pretty expensive repair but I didn't feel like hassling w/ the dealer and I wanted the confidence knowing that the repair was done right.

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Where did you buy the Time-Serts Kit from? Please let me know and thank you so much for the info.

My2skid said:

Where did you buy the Time-Serts Kit from? Please let me know and thank you so much for the info.

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I had to do the same repair, here's the kit you'll want: https://www.amazon.com/gp/product/B003SER3PA/ref=oh_aui_detailpage_o01_s00?ie=UTF8&psc=1

Be careful when you do it, I had my dealer do mine and they put it in a little off kilter....had a leak from the plug until I figured out how to make a gasket to fill in the gap.

Eddiec said:

I had to do the same repair, here's the kit you'll want: https://www.amazon.com/gp/product/B003SER3PA/ref=oh_aui_detailpage_o01_s00?ie=UTF8&psc=1

Be careful when you do it, I had my dealer do mine and they put it in a little off kilter....had a leak from the plug until I figured out how to make a gasket to fill in the gap.

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I found I have to use two copper crush washers to keep it from leaking. I put on two washers, torque to spec and I am good to go.

dfournier said:

I found I have to use two copper crush washers to keep it from leaking. I put on two washers, torque to spec and I am good to go.

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Never thought of that and I spent a lot of time pondering how to stop the leak....thanks for posting that, I'll give that a shot next time.

dfournier said:

Mine striped out on the 5000 mile oil change. I bought a Time-Sert kit for the repair. TIme-Serts are similar to a helicoil but instead of being a spring insert, they are a solid steel insert. Makes for an extremely solid repair. The kit cost me around $125.00 which is a pretty expensive repair but I didn't feel like hassling w/ the dealer and I wanted the confidence knowing that the repair was done right.

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Did it work is this holding no leaks?