Rear Gearcase Oil - Polaris Sportsman 800 EFI Owner's Manual

MAINTENANCE AND LUBRICATION

Rear Gearcase Oil

The rear gearcase fill plug (1) is located
on the rear of the gearcase. The drain
plug (2) is on the bottom of the
gearcase. Always check and change
the rear gearcase oil at the intervals
outlined in the Periodic
Maintenance Chart beginning on
page 64. The oil capacity is 5
ounces (150 ml). Do not overfill.
We recommend the use of Polaris ATV
Angle Drive Fluid (or GL5 80-90 weight gear lube).
See page 107 for the part numbers of Polaris products.
Oil Check
1. Position the ATV on a level surface. Remove the fill plug.
Use a light colored non-absorbent
NOTE:
object (such as a cable tie, L-shaped
wire or a small L-shaped tool) to
measure the oil level.
2. Insert the measuring object into the fill
plug hole with the short end pointing
downward. Guide the object (at a
slight angle downward and to the left)
approximately two inches (5 cm) into
the left side of the gearcase. Remove it
and verify that oil is present on the tip.
S If oil is present, do not add oil.
S If oil is not present, add 5-10 ml of the recommended oil.
3. After adding oil, recheck the oil level. Add oil as needed until oil
appears on the tip of the measuring object. DO NOT OVERFILL.
4. Reinstall the fill plug. Torque to 14 ft. lbs. (19 Nm).
Oil Change
1. Place a drain pan beneath the drain and remove the drain plug.
Catch and discard used oil properly.
2. Clean and reinstall the drain plug with a new sealing washer.
Torque to 14 ft. lbs. (19 Nm).
3. Remove the fill plug and add 5 ounces (150 ml) of the
recommended gearcase oil. DO NOT OVERFILL.
4. Reinstall the fill plug. Torque to 14 ft. lbs. (19 Nm). Check for
leaks.
1
2
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