Front Gearcase Lubrication - Polaris Sportsman XP 1000 S 2020 Service Manual

FRONT GEARCASE LUBRICATION

NOTICE
It is important to follow the front gearcase maintenance
intervals described in the maintenance interval charts.
Regular fluid level inspections should be performed as
well.
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 and check the fluid level.
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
Front Gearcase Drain / Fill Plug
19 ft-lbs (26 N·m)
FRONT GEARCASE FLUID CHANGE
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.
1. Remove the fill plug (see "Front Gearcase Fluid Level
Check").
9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
© Copyright Polaris Inc.
2. Place a drain pan under the front gearcase drain
plug.
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3. Remove the drain plug
completely.
4. Clean the drain plug magnetic surface.
5. Inspect the drain plug and O-ring for signs of damage
or a leak. If found, replace the plug.
6. Install the drain plug and torque to specification.
TORQUE
Front Gearcase Drain / Fill Plug
19 ft-lbs (26 N·m)
7. 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)
8. Inspect the fill plug and O-ring for signs of damage or
a leak. If found, replace the plug.
9. Install the fill plug and torque to specification.
TORQUE
Front Gearcase Drain / Fill Plug
19 ft-lbs (26 N·m)
10. Check for leaks. Dispose of used fluid properly.
MAINTENANCE
and allow fluid to drain
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