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Old 10-10-2009, 11:33 AM
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Default 2006 Sportsman 700 EFI fluid change/front gearcase

Gents,
It's been awhile but y'all have always been very helpful. After 130 tough hours, snowplowing, short rides etc I have changed the tranny and rear gearcase fluid along with my second oil change. My issue is regarding the front gear case; I can't loosen the filler cap. It is a Allen wrench hole with a gash like spAce that you can stick a screwdriver in. It seems to not be functional but is there a special tool? I feel like I am going to strip it out? There is a plastic shield that protects the front drive shaft that I am going to remove next but was reaching out to you pros out there that seem to know every trick that is not in the book! As always everyones input is much appreciated and to anyone who is considering doing the fluid change themselves do not wait past 100 hours. My rear diff fluid was milky in texture and shud have been done sooner

live free or die!

TRS.
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Old 10-10-2009, 01:02 PM
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the drain plug should be on the bottom of front diff. and is toqued at 11 ft lbs you may need to use an impact type tool or even tap the end of the allen wrench type tool to loosen w/ viberation. sometimes being in for awhile they tend to be tight. make sure you have the correct size allen wrench so you won't strip it out.
oh yea and it takes about 5 ozs of fluid.
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Old 10-10-2009, 01:23 PM
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Stendori,
the drain plug is easy. It's the fill plug that is giving me the headache. I loosened the drain plug no problem and luckily I didn't drain before attempting to open the fill plug. I will try some vibration techniques. Ty
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Old 10-10-2009, 01:31 PM
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Get a large punch about 1/2-3/4 at the end give it a good smack with a small sledge hammer. Works for me on all boss oring plugs!
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Old 10-10-2009, 05:26 PM
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Quote:
Originally Posted by bluefin646 View Post
Stendori,
the drain plug is easy. It's the fill plug that is giving me the headache. I loosened the drain plug no problem and luckily I didn't drain before attempting to open the fill plug. I will try some vibration techniques. Ty

yea my bad for saying drain plug. but the same should be for the filler plug as well.
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2006, 700, 700efi, 800, atv, case, change, drain, efi, fluid, gear, oil, plug, polaris, sportsman



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