Front Gearcase Lubrication; Rear Gearcase Lubrication - Polaris Sportsman 850 Service Manual

MAINTENANCE

FRONT GEARCASE LUBRICATION

It is important to follow the front gearcase maintenance
intervals described in the Periodic Maintenance Chart.
Regular fluid level inspections should be performed as
SERVICE NOTE: Under extreme use, change fluid every
25 hours. "Extreme Use" is defined as constant ADC
operation on hilly or mountainous terrain, or if ADC is the
primary mode of AWD operation.
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.
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2. Remove the fill plug
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.
TORQUE
Drain / Fill Plug:
10 ft-lbs (14 Nm)
Front Gearcase Fluid Change:
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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.
2.28
NOTE
well.
and check the fluid level.
5. Remove the fill plug (refer to "Front Gearcase Fluid
Level Check").
6. Place a drain pan under the front gearcase drain
plug.
7. Remove the drain plug and allow fluid to drain
completely.
8. Clean the drain plug magnetic surface.
9. Reinstall drain plug with a new O-ring and torque to
specification.
10. Add the recommended amount of fluid through the fill
hole. Maintain the fluid level even with the bottom
threads of the fill plug hole.
FLUID CAPACITY
Recommended Front Gearcase Fluid:
Polaris Demand Drive Fluid
Capacity:
9.3 oz (275 mL)
11. Reinstall fill plug and torque to specification.
TORQUE
Drain / Fill Plug:
10 ft-lbs (14 Nm)
12. Check for leaks. Dispose of used fluid properly.

REAR GEARCASE LUBRICATION

It is important to follow the rear gearcase maintenance
intervals described in the Periodic Maintenance Chart.
Regular fluid level inspections should be performed as
The rear 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.
Rear Gearcase Fluid Level Check:
The fill plug is located on the right side of the rear
gearcase. Maintain the fluid level even with the bottom
threads of the fill plug hole.
1. Position the vehicle on a level surface.
NOTE
well.