Polaris SPORTSMAN 400 2003 - Transmission Lubrication; Front Gearcase Lubrication

MAINTENANCE
2.9
TRANSMISSION
LUBRICA
TION
The transmission lubricant level should be checked
and changed in accordance with the maintenance
schedule.
SPORTSMAN 400/500 TRANSMISSION
Dipstick Location
S Be sure vehicle is level before
proceeding.
S Check vent hose to be sure it is
routed properly and unobstructed.
Specified Lubricant:
Polaris Premium Synthetic Gearcase Lubricant
PN 2871477 (Gallon) PN 2871478 (12 oz..)
Capacity: At change: Approx. 20 oz.....
Drain Plug:
14 ft. lbs. (19.4 Nm)
TRANSMISSION SPECIFICATIONS
Full
Operating
Range
To check the level:
1. Remove dipstick and wipe clean.
2. Reinstall dipstick completely, remove and check
the level. Add the proper lubricant as required to
bring level into operating range as shown.
To change lubricant:
1. Remove skid plate (if necessary).
2. Place a drain pan beneath the transmission oil
drain plug area.
3. Remove the drain plug and wipe themagnetic end
clean to remove accumulated metallic filings.
4. After the oil has drained completely, install a new
sealing washer and install the drain plug. Torque
to 14 ft. lbs. (19 Nm).
5. Add the proper lubricant through the dipstick hole
until the oil level is between the upper and lower
limits. Do not overfill.
6. Check for leaks.
7. Reinstall skid plate if removed in Step 1.
FRONT GEARCASE
LUBRICA
TION
The gearcase lubricant level should be checked and
changed in accordance with the maintenance
schedule.
S Besure vehicleis level before proceeding.
S Check vent hose to be sure it is routed
properly and unobstructed.
S The correct gearcase lubricant to use is
Polaris Premium GL5 80-90 Gear Lube
(PN 2871653)
Specified Lubricant:
Polaris Front Gearcase Lube (PN
2871653)
...Or API GL5 80-90 Gearlube
Capacity: 4.0 Oz............
(120ml.)
Drain Plug / Fill Plug Torque:
14 ft. lbs. (19.4 Nm)
FRONT GEARCASE SPECIFICATIONS
To check the level:
1. The front gearcase lubricant level cannot be
checked
with a dipstick or by visual reference.
The gearcase must be drained and re-filled with
the proper amount of lubricant. Refer to
procedure below.
To change lubricant:
1. Remove gearcase drain plug located on the
bottom and drain oil. Catch and discard used oil
properly.
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