12
Front Differential/Rear
Drive Lubricant
NOTE: The rear drive incorporates a shock-limiting
clutch pack in the gear case input assembly that is
designed to cushion driveline shock.
When changing the lubricant, use approved SAE 80W-90
hypoid gear lube.
To check lubricant, remove the fill plug; the lubricant
level should be 1 in. below the threads of the plug. If low,
add SAE approved 80W-90 hypoid gear lubricant as nec-
essary.
To change the lubricant, use the following procedure.
1. Place the ATV on level ground.
2. Remove each fill plug.
AL677C
3. Drain the lubricant into a drain pan by removing in
turn the drain plug from each.
ATV0082A
737-651B
4. After all the lubricant has been drained, install the
drain plugs and tighten to 45 in.-lb.
5. Pour the appropriate amount of approved SAE
80W-90 hypoid gear lubricant into the filler hole.
NOTE: If the differential/rear drive lubricant is con-
taminated with water, inspect the drain plug, fill plug,
and/or bladder.
6. Install the fill plugs; then tighten to 16 ft-lb.
Nuts/Bolts/Cap Screws
Tighten all nuts, bolts, and cap screws. Make sure rivets
holding components together are tight. Replace all loose
rivets. Care must be taken that all calibrated nuts, bolts,
and cap screws are tightened to specifications (see Gen-
eral Information).
Headlights/Tail-
light-Brakelight
NOTE: The bulb portion of a headlight is fragile.
HANDLE WITH CARE. When replacing a headlight
bulb, do not touch the glass portion of the bulb. If the
glass is touched, it must be cleaned with a dry cloth
before installing. Skin oil residue on the bulb will
shorten the life of the bulb.
To replace a headlight bulb, use the following procedure.
1. Rotate the bulb assembly counterclockwise and
remove from the headlight housing; then disconnect
from the wiring harness.
CAUTION
Any lubricant used in place of the recommended gear
lube could result in premature failure of the shock lim-
iter. Do not use any lubricant containing graphite or
molybdenum additives or other friction-modified lubri-
cants as these may cause severe damage to shock lim-
iter components.
CAUTION
Water entering the outer end of the axle will not be able
to enter the rear drive unless the seals are damaged.
! WARNING
Do not attempt to remove a bulb when it is hot. Severe
burns may result.
