Transmission Lubrication; Transmission Oil Change - Polaris 2004 Sportsman 6x6 Owner's Manual For Maintenance And Safety

MAINTENANCE AND LUBRICATION
Lubrication Recommendations

Transmission Lubrication

The transmission lubricant level should
be checked every six months or
1000 miles (1600 km),
whichever comes first. Maintain
the oil level at the bottom of the
fill hole threads. Change
transmission oil annually. We
recommend the use of AGL
Synthetic Gearcase Lubricant.
See page 118 for the part numbers
of Polaris products.
1. Position the ATV on a level surface
and remove the propshaft shield
from the right side of the vehicle.
2. Remove the fill plug (1) and add
the recommended lubricant as
needed to maintain the oil level at
the bottom of the fill hole (2).
The proper level is 1 5/8" from
the top of the fill hole. NOTE: Do not
fill to the bottom of the fill hole threads.
3. Reinstall the fill plug and propshaft shield.

Transmission Oil Change

1. Position the ATV on a level surface and remove the propshaft
shield from the right side of the vehicle.
2. Remove the transmission drain plug located on the bottom
left-hand side and drain the oil into an appropriate container.
Discard used oil properly.
3. Clean and reinstall the drain plug with a new sealing washer.
Torque to 14 ft. lbs. (19 Nm).
4. Remove the fill plug and add the recommended lubricant. Refer to
the specifications section beginning on page 116 for capacities.
5. Reinstall the fill plug and check for leaks.
6. Reinstall the propshaft shield.
80
1 5/8"
2
Front
View
1