2015 xp front gearcase fill plug - Polaris ATV Forum
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post #1 of 12 (permalink) Old 04-03-2019, 03:24 AM Thread Starter
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2015 xp front gearcase fill plug

Used an English hex by accident, rounded hex socket plug on front gearcase fill plug. Failed to remove with extracting bits. Tig welded nuts and bolts to plug but could only access top side of plug so weld continually broke. Any other methods in this tight space? I plan on drilling it out and sucking up the $30 for a new one.
Does anyone know if it's a standard SAE plug?

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post #2 of 12 (permalink) Old 04-03-2019, 04:11 AM
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Everything on that machine should be metric.
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post #3 of 12 (permalink) Old 04-03-2019, 06:45 PM
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The Allen is metric the plug threads are metric.

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post #4 of 12 (permalink) Old 04-03-2019, 09:04 PM Thread Starter
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Thanks everyone for your replies. I've found they are made to iso 6149. I will be making new plugs but incorporating a male metric hex for longevity. Using 316 or 2205 ss grade material for corrosion prevention. Will attach some photos shortly. Thinking I'll replace the rear gearcase, tranny, and engine plugs as well with this style.

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post #5 of 12 (permalink) Old 04-04-2019, 04:03 AM
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Quote:
Originally Posted by nd012 View Post
Thanks everyone for your replies. I've found they are made to iso 6149. I will be making new plugs but incorporating a male metric hex for longevity. Using 316 or 2205 ss grade material for corrosion prevention. Will attach some photos shortly. Thinking I'll replace the rear gearcase, tranny, and engine plugs as well with this style.
Please keep us updated, I'd love to see what you come up with. Will you be planning on selling these?
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post #6 of 12 (permalink) Old 04-04-2019, 04:34 AM Thread Starter
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I'm a mechanical project engineer for a manufacturing tech firm. On occasion there are a few of us gear head nuts that will make newer better parts for personal rides. I design and generate prints but the chip cutting credit goes to some talented individuals.

I have considered proposing ideas likes this. Major issue is the volume needed to compete with our other projects. We make a specific profit/hr per machine, so we'd want to exceed that no. for an alternative project to take priority.

However at the end of the day we can make significantly better parts for less than what is offered. I'll need to discuss selling direct as opposed through distribution, legal is not my interest, they're always in my way.

I personally like the idea of selling a kit which includes all drain and fill plugs built with a male hex, with a fkm style oring included. 8 or so plugs, in a superior material for an attractive price. Bushing kits too we'd kill. Will update after testing out on my unit.

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post #7 of 12 (permalink) Old 04-04-2019, 09:45 AM
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Sounds like a lot of work to go through for metric drain plugs with a male hex drive. If you really think you need stainless steel with a male hex drive you can buy those for about $4.50 each. You can get galvanized steel plugs with male hex also. Lot of options out there for oil cooler type drain plugs, Parker hydraulics , McMaster Carr. Search around you might find something that you like.
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Gulf550 likes this.

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post #8 of 12 (permalink) Old 04-04-2019, 12:06 PM Thread Starter
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Quote:
Originally Posted by MNDS View Post
Sounds like a lot of work to go through for metric drain plugs with a male hex drive. If you really think you need stainless steel with a male hex drive you can buy those for about $4.50 each. You can get galvanized steel plugs with male hex also. Lot of options out there for oil cooler type drain plugs, Parker hydraulics , McMaster Carr. Search around you might find something that you like.
Thank you for looking into this. We do sell and buy with Parker but their website is obnoxiously bad, I try to avoid it. I found exactly what I wanted via belmetric where I may get quite a few things. I ended up ordering a drain plug for a Subaru m16x1.5 with metal crush washer for $9 so I can be up and running quickly.

After evaluating our costs vs what you can buy hex plugs, even in ss which surprised me, we'd need to run about 500 min qty in every size for our costs to be low enough. The other issue is we don't sell direct so if we went through mcmaster or another customer to supply to public with bigger media presence the price would not be attractive, defeating the purpose.

Subaru 32195AA001 for those looking for a quick solution. Also 'hexhead drain plugs' in belmetric site, per MNDS's lead.

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post #9 of 12 (permalink) Old 04-10-2019, 07:55 AM Thread Starter
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I installed the M16X1.5 at 12 ft-lb with crush washer utilizing a male hex head originally for a Subaru oil or transmission plug. It was $4 plus tax. I have about 30 miles on it and not a drop anywhere around it. I will be swapping the remaining plugs at the end of this season, when I swap all fluids again. With these new sources for parts it is not remotely cost effectively to put any effort into machining and selling this type of product. This forum has helped me make some tough decisions and educated me substantially on these rides I will do my best to contribute going forward.
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post #10 of 12 (permalink) Old 04-10-2019, 10:29 AM
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That's good info right there guys. I've never felt the need to change them but a lot of guys have problems with the allen plugs. I'll be saving this info for future reference.

Thanks for posting.
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