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Need suggestions for removing Fill plug.

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5.9K views 36 replies 18 participants last post by  groundhog  
#1 · (Edited)
Neighbor kid was helping with some maintenance and stripped the Torx head on the front differential fill plug. There is too much in the way from the front of the RZR to get some pliers around the plug. Does anyone have any ideas how I might remove it?

View attachment 69385
 
#23 ·
X2

I stripped mine the first time trying to check the level. Dealer installed it way to tight!!!
I used a hammer and chisel as well worked great. A little tight but you can get it from the front. I then welded a 7/16 nut to it. Won't worry about stripping it any more!
 
#21 ·
Remove your front plastics,takes less than 5 min put channel locks on it. I had to on mine..
 
#28 ·
It will break easy with channel locks if you remove the front plastic so you can get leverage.
 
#34 ·
I cannot believe how tight that plug was. Completly damaged a new screw extractor, damaged my Craftsman box wrench (with a leverage bar attached to it), on the extractor and it still didn't come out. Finally drilled into with a large drill bit and hammered another type of extractor into it and finally it released. I used anti-seize compound on the new plug.