Polaris RZR 800 - Maintenance: Gearcase Specifications and Spark Plugs; Gearcase Specification Chart; Spark Plug Gap and Torque Specifications

92
MAINTENANCE
Gearcases
Demand Drive Unit (Front Gearcase)
Always check and change the fluid at the intervals outlined in the Peri-
odic Maintenance Chart beginning on page 77. Refer to the Gearcase
Specifications Chart on page 94 for recommended lubricants, capacities
and torque specifications.
Fluid Check
The fill plug is located on the
bottom right side of the demand
drive unit. Maintain the fluid
level even with the bottom
thread of the fill plug hole.
1. Position the vehicle on a
level surface.
2. Remove the fill plug. Check
the fluid level.
3. Add the recommended fluid
to the bottom thread of the
fill plug hole.
4. Reinstall the fill plug.
Torque to specification.
Fluid Change
The drain plug is located on the bottom of the gearcase.
1. Remove the fill plug.
2. Place a drain pan under the drain plug.
3. Remove the drain plug. Allow the fluid to drain completely.
4. Clean the drain plug. If the o-ring is damaged, install a new o-ring.
5. Reinstall the drain plug. Torque to specification.
6. Add the recommended fluid to the bottom thread of the fill plug
hole.
7. Reinstall the fill plug. Torque to specification.
8. Check for leaks. Discard used fluid properly.
Drain Plug
Fill Plug
View of
Bottom