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Sonders

KVF300 Prairie service manual

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Got the skidplate pulled this evening so I could see what I was actually working with.  Here is the plug that was in it and what the drain opening looked like.  I ground the remaining broken section down flush.  The new oem plug doesn’t fit; it is too small apparently.  I’ll have to find a new bolt and crush washer that will fit the opening.

 

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Wow that sucks.  What that plug you took out was nothing more then a half inch galvanized plumbing plug. Not good for that.   My guess is the previous owner stripped the old one and tapped/threaded  it a little bigger. It looks like the casing is a little cracked as well.  Maybe it just the pic. Anyhow if you can grind it flat and get a kit that will fit you might get lucky.   

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No cracks, just messed up opening.  I don’t see how the heck they busted it with the skidplate there.  I’m going to Napa in the morning to see what I can come up with for a new plug.  Hopefully it’ll work out.  If not, no idea what I’ll do then.

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It broke because it was over tightened and stripped. Happens all the time.   Sucks but some people just don’t know when to stop turning or they see oil drip and keep making it tighter only to find it later it was a washer that they needed.  

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Here is what I would do... that is a NPT fitting... get thread tape (pipe dope)... find you a NTP plug with a piggy back plug. Thread tape the new plug with piggy back and never remove it again... use the piggy back to drain from... the NPT fittings are tapered cut threads so they get tighter as you screw them in deeper so be careful you can bust the case easy with that thread type... but they seal easier when you cant use a gasket... 

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That sounds like a good alternative plan as well Spartacus.  If I can’t make a bolt and washer work I’ll try that route.  I’m not near a hardware store this weekend, but Napa is right in town so figured I’d give that a try first.  Wish me luck.

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Dorman makes a universal drain plug for auto applications you can get at napa, carquest, or advance auto parts. Amazon has them as well. Might work for you on this.

dorman universal drain plug atv

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Ha Ajmboy funny you should mention those. I actually bought one of the bottom ones you have listed.  I installed it yesterday and put a qt of oil in and am letting it sit for awhile to see how it works before I posted my results. I’ll report back later when I’ve had time to check on it.

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After 24 hrs the drain plug is holding tight with no oil leaking.  I think I’m good there.  However it appears I also have a leak at the back of the gear housing boot to rear drive axle.  I can see oil dripping out of the rubber boot.  What are my next steps to fix leak there?  The boot is torn in a few spots so it for sure needs replaced for starters.  It looks like the whole rear end/swingarm will have to come off to get to that; is that correct?  I’m not having much better luck with this bike than I did with the turd of a bike that I just got rid of ugh.

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Nice work with the oil plug.  That boot does not look like it’s sitting correct, it seems cocked and could also be the cause of that seal leaking under the boot.  Maybe it’s just the pic but it looks like it’s not aligned right.  That rear swing arm does have to be I bolted so it can swing away from the engine.  The four bolts have to come off.  What I would do if I were you is since the boot had holes in it already is cut it off and find the leak. See if it’s coming from the rear seal of that bevel gear.  You will also have a good look at the alignment with that boot off.  Lastly I would check the bushings on the swing arm right at the frame. 

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I would agree @Spartacus Stroppel IF THE BOOT was not torn in a few spots. But if he’s going to replace it anyway like he said then yes I would open it up/cut it off before it’s taken apart so you can see where and if it’s an alignment problem.  A boot with holes is useless.  It needs to be replaced along with the seal that’s leaking. 

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thanks Frank and Spartacus.  I'll try to get in there one evening this week and see what's going on with it.  Deer season (firearm) comes in this weekend so probably going to have limited time to mess with the bike the next few weeks haha.  Lesson learned on this thing...... be very cautious when looking at a bike that is freshly washed off and sitting in grass area so as not able to see oil spots under it.  I especially like how previous owner mentioned the "fresh oil change".  I'm now 0-2  with bad luck purchasing used bikes.

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It’s like buying a car on a rainy day there’s no squeaks or noise.  Everything else is manageable but the oil plug is a bitch! 
CANT WAIT FOR RIFLE SEASON!!  
got some big racks this year.  They are all nocturnal now. I went from over 1000 pics of these guys all hours of the day to maybe 20 and they are all in the middle of the night and with a doe.   

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where are you located Frank?  I'm in Southern Indiana and still seeing several during the day.  I've got a nice one picked out that keeps strolling across my back yard in the mornings between 2 fields.  The bastard destroyed 2 of my cypress trees that mark our rear property line.  My two labs have chased after him a couple of times, I'm going to be pissed if they run him off.  They're about to get locked in their kennels until the season is over hahaha.

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I’m in NY southern zone. I’ve seen some big deer and a bunch of little guys. They are all spread out now.   This new guy here showed up this weekend. Haven’t seen him until now. Nice big bodied deer. Racks are good but not like the monsters near you and Ohio and other states but I’ll take it.  

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looks like he'd go in the freezer as good as any other.  I tried to snap a pic of the buck I've been watching as he strolled across my driveway in front of me the other morning on my way to work but I was too slow getting phone up and with him moving it turned out blurry.  Here is his little brother that’s also been hanging around my backyard.  That’s about 50 yards behind my house.

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Edited by Sonders

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Punched my tag early so now I can get back to work on the bike.

 

 

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Ok lastnight I tried to pull the driveshaft boot back to take a look but couldn’t really see anything.  I went ahead and dropped the swingarm.  It looks to me like the oil seal had just popped out of place.  I seated it back around the opening all the way and cleaned everything up.  I’m ordering a new boot.  The good news is it looks like the swingarm has been off somewhat recently as it was pretty easy to get off, I’m assuming to replace the bearings as they are both in really good shape.  Below is backside shot of the gear housing as soon as I removed the swingarm.  The plastic ring around the shaft is the oil seal correct?  You can kind of see the oil pooled at bottom of the opening.  Hopefully that’s all it was.  Also, I didn’t pay attention to the swingarm while it was sitting on the jack and it tipped forward.  As it sat there it started pucking fluid out.  What type of oil is needed for the rear?  Guess I’ll go ahead and drain the remaining fluid from rear diff and refill with fresh fluid, although what leaked out looked pretty fresh.

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Nice work. That black seal is the O ring. It’s probably crushed a bit and that’s why it leaked. Obviously your changing the boot since it has holes in it correct? 
Get some carb cleaner spray and spray it on that dirt and wipe it clean.   
pop in the new O ring seal then add a drop of grease on the splines before you put it back together and your good to go. Just make sure you tighten the four nuts in a crisscross configuration so it seats evenly, I like to put a drop of lock tight on the threads.  

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There is no O ring there.  What is pictured is a hard plastic plug like ring.  Do I need to take that cover off that has the 4 bolts and look for an O ring?

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I’m sorry I thought you took it apart and screwed the nuts  on for safe keeping. 
So that drive shaft pops on and what holds it in place? It looks different from the previous pic you posted. A lot dirtier lol.  So you unbolted the swing arm and backed it off ? I have only taken the bayous apart and they are very similar so forgive me for being a little confused. Post a few more pics if you can. 

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Yeah the earlier picture with boot still on was from the side view.  The one just posted above is from rear view looking forward.  I had just pulled the swingarm off.  The driveshaft simply slid off the splined shaft pictured.  I’ll try to get more pictures tomorrow evening.  The plastic ring is listed as oil seal in parts diagram.  Like I mentioned above, it wasn’t fully seated around the splined shaft; it was crocked around the shaft.  I shoved it back into the opening as far as it would go.  I’m just not sure what would keep it from working it’s way back again though.

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