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94
MAINTENANCE
Front Gearcase (Demand Drive) Fluid
See the table on page 88 for fluid recommendations, capacities and plug
torques. Always check and change the demand drive fluid at the inter-
vals outlined in the Periodic Maintenance Chart beginning on page 84.
See page 135 for the part numbers of POLARIS products.
Change the front gearcase fluid every 25 hours if the ADC unit is
exposed to extreme use. Extreme use includes any of the following:
• operation in ADC mode for prolonged periods
• constant ADC operation on hilly or mountainous terrain
• ADC is the primary mode of all-wheel-drive operation
Tip: If the front gearcase is makes excessive noise during ADC operation,
change the demand drive fluid. If the noise continues, please see your
POLARIS dealer for service.
Use the recommended fluid. Use of other fluids may result in improper
operation of components. Maintain the fluid level at the bottom of the
fill hole threads. The fill plug is located on the right side of the demand
drive unit. The drain plug is located on the bottom right side of the unit.
Fluid Check
1. Position the vehicle on a level sur-
face. Remove the fill plug. Check
the fluid level.
2. Add the recommended fluid as
needed to bring the level to the bot-
tom of the fill hole threads.
3. Reinstall the fill plug. Torque to
specification.
Fluid Change
1. Position the vehicle on a level sur-
face. Remove the fill plug.
2. Place a drain pan under the demand drive unit. Remove the drain
plug. Allow the fluid to drain completely.
3. Clean and reinstall the drain plug. Torque to specification.
4. Add the proper amount of the recommended fluid.
5. Reinstall the fill plug. Torque to specification.
6. Check for leaks. Dispose of used fluid properly.
Drain Plug
Fill
Plug
Fill
Level
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