MAINTENANCE
2.9
FRONT GEARCASE LUBRICATION
The gearcase lubricant level should be checked and
changed in accordance with the maintenance
schedule.
G Be sure vehicle is level before proceeding.
G Check vent hose to be sure it is routed properly
and unobstructed.
G The correct front gearcase lubricant to use is
Polaris Premium Demand Hub Fluid.
NOTE:
The Late 2004 front gearcase has a
different fill plug height than the Early 2004
front gearcase. Be sure to follow the correct
procedure below when servicing the front
gearcase. Refer to Page 1.3 to help identify
which model of ATV you have.
Specified Lubricant:
Capacity:.........5.0 Oz. (150 ml.)
Drain Plug / Fill Plug Torque:
14 ft. lbs. (19.4 Nm)
FRONT GEARCASE SPECIFICATIONS
Premium Demand Drive Hub Fluid
(PN 2871654)
Fill plug
Make sure vent is unobstructed
Drain plug
FRONT GEARCASE
ILL. 1
14 ft.lbs.
(19 Nm)
To check th e lu b ricant level:
The front and rear 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 procedures below.
To chan g e g earcase lubricant:
Early 2004 Front Gearcase
1. Remove gearcase drain plug (11 mm) located on
the bottom of the gearcase and drain oil. (The
drain plug is accessible through the skid plate.)
Catch and discard used oil properly.
2. Clean and reinstall drain plug using a new sealing
washer.
3. Remove fill plug (8 mm hex).
4. Fill with the recommended fluid amount (5 oz.).
(See ILL. 1 & ILL. 2).
Plug Threads
Fill with 5 oz. lubricant.
Front Gearcase
ILL. 2
5. Install fill plug and check for leaks.
Late 2004 Front
Gearcase
1. Remove gearcase drain plug (11 mm) located on
the bottom of the gearcase and drain oil. (The
drain plug is accessible through the skid plate.)
Catch and discard used oil properly.
2. Clean and reinstall drain plug using a new sealing
washer.
3. Remove fill plug (8 mm hex). Check the O--ring.
4. Fill with the recommended fluid amount (5 oz.) or
to the bottom of the fill plug hole threads. (See ILL.
1 & ILL. 3).
Plug Threads
Fill with 5 oz. lubricant
or bottom of fill plug
threads.
Front Gearcase
ILL. 3
5. Install fill plug and check for leaks.
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