Front Gearcase Lubrication - Polaris 2005 SPORTSMAN 500 Servise Manual

MAINTENANCE
PRE-RIDE / DAILY
INSPECTION
Perform the following pre-ride inspection daily, and
when servicing the vehicle at each scheduled
maintenance.
Tires - check condition and pressures
S
Fuel and oil tanks - fill both tanks to their
S
proper level; Do not overfill oil tank
All brakes - check operation and adjustment
S
(includes auxiliary brake)
Throttle - check for free operation
S
Headlight/Taillight/Brakelight - check operation
S
of all indicator lights and switches
Engine stop switch - check for proper function
S
Wheels - check for loose wheel nuts and axle
S
nuts; check to be sure axle nuts are secured by
cotter pins
Air cleaner element - check for dirt or water;
S
clean or replace
Steering - check for free operation, noting any
S
unusual looseness in any area
Loose parts - visually inspect vehicle for any
S
damaged or loose nuts, bolts or fasteners
Engine coolant - check for proper level at the
S
recovery bottle
FRONT GEARCASE
LUBRICATION
The gearcase lubricant level should be checked and
changed in accordance with the maintenance
schedule.
S Be sure vehicle is level before proceeding and in
PARK.
S Check vent hose to be sure it is routed properly
and unobstructed.
S The correct front gearcase lubricant to use is
Polaris Premium Demand Drive Hub Fluid.
2.10
FRONT GEARCASE SPECIFICATIONS
Specified Lubricant:
Premium Demand Drive Hub Fluid
(PN 2871654)
Capacity: . . . . . . . . .5.0 Oz. (150 ml.)
Fill Plug Torque: 8- -10 ft.lbs. (11- -14 Nm)
Drain Plug Torque: 11 ft. lbs. (15 Nm)
FRONT GEARCASE
Make sure vent is unobstructed
11 ft.lbs.
Drain plug
(15 Nm)
ILL. 1
To check the lubricant level:
The front lubricant level cannot be checked with a
dipstick. The gearcase must be drained and re-filled
with the proper amount of lubricant or be filled to the
bottom of the fill plug hole threads.
procedures.
Fill plug
8--10 ft.lbs.
(11--14 Nm)
Refer to