I ended up getting a 8mil T-handle w/ ball end, works for now but I'm afraid as time goes on it's going to get ugly.

 

Thanks

 

Similar challenge w/ my Pro XP. The factory plugs are garbage. Got the Sandcraft drain plug kit from @RockPeakUTV. Worth every penny.

 

The ball end alan head will probably work. That is what I had to use on my Turbo R. If you want a forum member price quote on the Sandcraft drain plug kit, just shoot me a PM.

 

This works perfectly. You only torque it to 11 or 12lbs so it should not strip out the plug over time.

Amazon.com

 

Tap the Allen wrench in with a hammer. If it's like all the other drain/fill plags it should go in an additional quarter of an inch or so. Something about the way they machine those plugs leaves little flares in the hole that makes it feels like the wrench has bottomed out before it actually does.

Also, always remove the fill plug before removing the drain plug. If something does strip out, at least it's with oil still in it.

 

They are in there WAY to tight. I stripped mine out and had to use a long cold chisel & hammer on the edge to get it out. The plugs are stupid soft and way to tight. Good luck.

John

 

A little trick is to take a hammer and hit the face of the plug with 2 or 3 good pops. It helps break that o-ring bond. Most of the time they will go from tight to coming right out. And yes always tap the allen bit into the hole to make sure it’s in all the way.

 

On all of my various RZRs I have always used a 1" diameter X 7" long aluminum drift punch and tapped it on the face of the plug with a 2 lb hammer a couple of times. This usually breaks the bond and it allows the plug to be removed much more easily. I also use an 8mm Allen with a 3/8" drive, tapped into the hex socket of the plug to insure full insertion, and a 3/8" ratchet to get the torque required for removal. It doesn't hurt to squirt brake clean into the plug hex and blow it out with air to insure cleanliness and make full insertion possible.

 

So, I'm not familiar with the Pro R or how much clearance there is between the plug and frame. I'm just curious... Was the Allen socket hitting the frame or the extension? Were you using 1/4" or 3/8" drive? Surely, Polaris would provide enough clearance to properly torque the plug (sarcasm). LOL

I love the Allen ball ends but they don't have as much grip if you need a lot of torque.

If it's the extension not clearing the frame, I'd try using a wobble extension.

If the 8mm Allen socket clears the frame but won't fully seat in the plug, I'd try a 5/16" Allen socket. It's about .003" smaller.

If the 5/16" Allen socket clears the frame but won't fully seat, I'd try "tapping" it with a hammer.

If an Allen socket won't clear the frame, I'd cut an Allen wrench to length and put a wrench on it.

And if all that didn't work, I'd smack the f*** out of it with a brass drift and use the Allen ball end or a cold chisel and hammer. Then, I'd order that $140 drain plug kit. LOL

 

some of you obviously have never worked on a pro r, or turbo r.

 

i agree, this solves the problem and not over torquing things.

 

mine was not very tight either...glad I changed mine early!

 

Take a dremel and make some room. Those rounded hex keys will strip much easier.

 

Did finally get it out. I used the suggested, tap on the ball end allen with a hammer and was able to get just enough grip to get it out. My advise "Be Careful". I have come close to stripping these plugs out on my previous xp also.

 

10 ft pounds is not much and the ball end should handle that.

 

First make sure it's clean and no dirt is in the Allen key hole then tap it in tight, good chance it'll still round out but then use a chisel and hammer to remove it, get new plugs with hex heads on them either way, factory ones strip way too easy.

 

Is it actually touching the frame or the skid plate? At my turbo R and my wife's turbo xp the Allen key is touching the skid plate.
Just make the hole a little longer so all fits in nicely and just don't over tight the plug when you put it back in. Polaris puts it in way to tight, I normally torque it on 20 Nm.