72
MAINTENANCE
Gearcases
Front Gearcase
Always check and change the front gearcase oil at the intervals outlined in the Periodic
Maintenance Chart beginning on page 65. Maintain the oil level even with the bottom thread
of the fill plug hole.
Refer to the Gearcase Specifications Chart on page 71 for recommended lubricants,
capacities and torque specifications. See page 100 for the part numbers of POLARIS
products.
ADC Models: Change the front gearcase fluid every 25 hours if the ADC unit is exposed to
extreme use. Extreme use includes any of the following:
• operation in ADC mode for prolonged periods
• constant ADC operation on hilly or mountainous terrain
• ADC is the primary mode of all-wheel-drive operation
Tip: If the front gearcase makes excessive noise during ADC operation, change the demand drive fluid.
If the noise continues, please see your POLARIS dealer or other qualified service person for
service.
Oil Check
The front gearcase fill plug is located on the right
side of the front gearcase.
1. Position the vehicle on a level surface.
2. Place the transmission in PARK.
3. Remove the fill plug. Check the oil level.
4. Add the recommended oil as needed.
5. Reinstall the fill plug. Torque to specification.
Oil Change
1. Support the vehicle securely with a jackstand.
2. Remove the fill plug.
3. Place a drain pan under the drain plug.
4. Remove the drain plug. Allow the oil to drain
completely.
5. Clean and reinstall the drain plug. Torque to
specification.
6. Add the recommended oil.
7. Reinstall the fill plug. Torque to specification.
8. Check for leaks. Dispose of used oil properly.
Recessed
Drain Plug
Fill
Plug
Fill
Level
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