Polaris 2005 Sportsman MV7, Service Manual

Page: 31 / 312

MAINTENANCE
2.13
REAR GEARCASE
LUBRICATION
The gearcase lubricant level should be checked and
changed in accordance with the maintenance
schedule.
G
Be sure vehicle is level and in Park before
proceeding.
G
Check vent hose to be sure it is routed properly
and unobstructed.
G
The correct rear gearcase lubricant to use is
Polaris ATV Angle Drive Fluid.
Specified Lubricant:
ATV Angle Drive Fluid (PN 2871653 )
Capacity: 10 Oz. (300 ml.)
Drain Plug / Fill Plug Torque:
14--18 ft. lbs. (19--24 Nm)
REAR GEARCASE SPECIFICATIONS
To Check Lubricant Level:
NOTE: The rear gearcase has two fill plugs. The rear
fill plug is located on the rear of the gearcase and is
not easily accessible. The side fill plug is located on
the left side of the gearcase. Use the side fill plug
when checking or changing oil.
1. Position the vehicle on a level surface.
Fill Plug
ILL. 1
2. Remove the side fill plug and view the oil level
through the fill plug hole.
3. Add lubricant as needed. The lubricant level
should be at the bottom of the fill plug hole
threads.
4. Reinstall fill plug and torque to 14 ft.lbs. (19 Nm).
To Change Lubricant:
1. Remove gearcase drain plug located on the
bottom of the gearcase and drain oil. Let the oil
completely drain from the gearcase. (The drain
plug is accessible through the skid plate.) Catch
and discard used oil properly.
A
B
2. Clean and reinstall drain plug (A) using a new
sealing washer (B). Torque plug to 14--18 ft.lbs.
(19--24 Nm).
3. Remove fill plug show in illustration 1.
4. Fill with the recommended fluid amount of 10 oz.
(300 ml.) or to the bottom of the fill plug threads.
5. Install fill plug and check for leaks.
Fill to bottom of fill
plug threads
Fill Plug Threads