Okay, maybe you guys can help me out here. A friend of mine let her daughter attempt to change the oil on her 06 Fourtrax, after that it had a very slow oil leak. I had a feeling that either she or someone previously had damaged the drain plug, because I’d ran into a similar problem on my older TRX300. I get out there, and low and behold it would seem that is in fact the problem. You can see the issue in the uploaded picture, there is a chunk out of the case. Its not as serious as the TRX I had, you could actually see the bolt threads through the oil and the drain plug design was a little bit different. But it would appear to me there isn’t enough surface area left to get a firm seal with the crush washer.
That being said, what would be the best way to go about fixing this? I have some ideas, and some experience with my own TRX, but that involved more black voodoo magic then I’d like to invest.. And this thing is isn’t in the best environment work on it. Shes thinking about just sending it to a shop, but I would prefer to fix it for her if I can. But I’d like some input before I make another attempt on it.
Thanks.
