105
MAINTENANCE
Front Gearcase (Demand Drive) Fluid
See the table on page 100 for fluid recommendations, capacities and
plug torques. Always check and change the demand drive fluid at the
intervals outlined in the Periodic Maintenance Chart beginning on page
96. See page 147 for the part numbers of POLARIS products.
4WDC Models:
Change the front gearcase fluid every 25 hours if the
4WDC unit is exposed to extreme use. Extreme use includes any of the
following:
• operation in 4WDC mode for prolonged periods
• constant 4WDC operation on hilly or mountainous terrain
• 4WDC is the primary mode of all-wheel-drive operation
Tip:
If the front gearcase is makes excessive noise during 4WDC operation,
change the demand drive fluid. If the noise continues, please see your
POLARIS dealer for service.
Use the recommended fluid. Use of other fluids may result in improper
operation of components. Maintain the fluid level at the bottom of the
fill hole threads. See below for capacity.
The fill plug is located on the right
side of the demand drive unit. The
drain plug is located on the bottom
right side of the unit.
Fluid Check
1. Position the vehicle on a level
surface. Remove the fill plug.
Check the fluid level.
2. Add the recommended fluid as
needed to bring the level to the
bottom of the fill hole threads.
3. Reinstall the fill plug. Torque to specification.
Fluid Change
1. Position the vehicle on a level surface. Remove the fill plug.
2. Place a drain pan under the demand drive unit. Remove the drain
plug. Allow the fluid to drain completely.
3. Clean and reinstall the drain plug. Torque to specification.
4. Add the proper amount of the recommended fluid.
5. Reinstall the fill plug. Torque to specification.
6. Check for leaks. Dispose of used fluid properly.
Drain Plug
Fill
Plug
Fill
Level
