Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 33 / 289

MAINTENANCE
2.13
FRONT GEARCASE
LUBRICATION
The gearcase lubricant level should be checked and
changed in accordance with the maintenance
schedule.
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-- Be sure vehicle is level before proceeding.
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-- Check vent hose to be sure it is routed
properly and unobstructed.
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-- The correct gearcase lubricant to use is
ATV Angle Drive Fluid ( PN 2871653 ).
Specified Lubricant:
ATV Angle Drive Fluid (PN 2871653)
Capacity: 4.0 Oz. . . . . . . . . . . .
(120ml.)
Drain Plug / Fill Plug Torque:
14 ft. lbs. (19.4 Nm)
FRONT GEARCASE SPECIFICATIONS
To check the level:
1. The front gearcase lubricant level cannot be
checked with a dipstick or by visual reference.
The gearcase must be drained and re-filled with
the proper amount of lubricant. Refer to
procedure below.
To change lubricant:
1. Remove gearcase drain plug located on the
bottom and drain oil. Catch and discard used oil
properly.
2. Clean and reinstall drain plug using a new sealing
washer.
3. Remove fill plug.
4. Add proper amount of lubricant.
5. Install fill plug. Check for leaks.
Fill plug
Make sure vent
is unobstructed
Drain Plug
ADF
TRANSMISSION GEARSHIFT
LINKAGE ADJUSTMENT,
PRELIMINARY INSPECTION
Correctly Tightened
Jam Nut
Incorrectly Tightened
Jam Nut
Parallel
Linkage rod will rotate
1/8 -1/4 turn if rod ends
are tightened properly.
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If shifting problems are encountered, the
transmission linkage can be adjusted.
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Tighten shift linkage rod end jam nuts
properly after adjustment. You
should be able to rotate the linkage
rod between 1/8 and 1/4 turn after
both jam nuts are tight.
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The transmission shift linkage should
be periodically inspected for wear
and parts replaced as required to
remove excess play from shift
linkage.
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Refer to Transmission chapter for more
information.