Polaris 2009 Sportsman XP 850 - Front Gearcase Lubrication

2.18
MAINTENANCE
Front Gearcase Lubrication
NOTE: It is important to follow the front gearcase
maintenance intervals described in the Periodic
Maintenance Chart. Regular fluid level inspections
should be performed as well.
The front gearcase fluid level should be checked and changed in
accordance with the maintenance schedule.
• Be sure vehicle is positioned on a level surface when
checking or changing the fluid.
• Check vent hose to be sure it is routed properly and
unobstructed.
Front Gearcase Fluid Level Check
The fill plug is located on the right side of the front gearcase.
Access the fill plug through the front right-hand wheel well or
through the front lower bumper. Maintain the fluid level even
with the bottom threads of the fill plug hole.
1. Position vehicle on a level surface.
2. Remove the fill plug and check the fluid level.
3. If fluid level is not even with the bottom threads, add the
recommended fluid as needed. Do not overfill.
4. Reinstall the fill plug and torque to specification.
Front Gearcase Fluid Change:
The drain plug is located on the bottom side of the front
gearcase. Access the drain plug through the access hole in the
front skid plate.
1. Remove the fill plug (refer to “Front Gearcase Fluid Level
Check”).
2. Place a drain pan under the front gearcase drain plug.
3. Remove the drain plug and allow fluid to drain completely.
4. Clean the drain plug magnetic surface.
5. Reinstall drain plug with a new O-ring and torque to
specification.
6. Add the recommended amount of fluid through the fill hole.
Maintain the fluid level even with the bottom threads of the
fill plug hole.
7. Reinstall fill plug with a new O-ring and torque to
specification.
8. Check for leaks. Dispose of used fluid properly.
= T
Drain / Fill Plug Torque:
8-10 ft. lbs. (11-14 Nm)
Fill Plug
8-10 ft. lbs.
Gearcase fluid
flush with the bottom
of thread area.
(11-14 Nm)
=
Recommended Front Gearcase Fluid:
Premium LT Demand Drive Fluid
(PN 2876251) (Quart)
Capacity: 9.3 oz. (275 ml)
= T
Drain / Fill Plug Torque:
8-10 ft. lbs. (11-14 Nm)
Fill Plug
8-10 ft. lbs.
(11-14 Nm)
Drain Plug
8-10 ft. lbs.
(11-14 Nm)
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