Just picked up a new to me 2007 Sportsman 800 on Friday. Took it for a shake down run this weekend, and after 40 trouble free miles decided to drain all fluids/replace all filters because it didn't need anything specific repaired (for now). Got everything I needed to tear into it this afternoon...anddddd that's where the fun starts.
The guy I bought it from claimed to be a Polaris mechanic. Started off with the front diff, drain plug was torqued on well above spec and metal was soft. Penetrating oil didn't help, and needless to say, it stripped. Not a problem, easy out took care of it, but drilling through the plug popped the magnet off and it was stuck to the inside of the differential. Took forever, but using my pinky finger and my girlfriend's hair clip I was able to wedge the magnet out. Now, time to order a nice new $30 drain plug and flush the fluid 1-2x to ensure all of the metal pieces are 100% out of the differential.
PS The oil filter was WAY over torqued as well. Can't wait to tackle the trans and rear diff tomorrow :|