Polaris SPORTSMAN 600 2003, Service Manual, Page: 31 / 262

MAINTENANCE
2.9
GEARCASE LUBRICATION
The gearcase lubricant level should be checked and changed in accordance with the maintenance schedule.
G Be sure vehicle is level before proceeding.
G
Check vent hose to be sure it is routed properly and unobstructed.
G
The correct front gearcase lubricant to use is Polaris Premium Demand Hub Fluid.
G The correct rear gearcase lubricant to use is Polaris Premium Gear Drive Fluid.
To check the lubricant level:
The front and rear gearcases 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 gearcase lubricant:
1. Remove gearcase drain plug located on the bottom
of the gearcase and drain oil. (The drain plug is
accessible through the skid plate.)
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:
Front Gearcase: Fill with the recommended fluid
amount or fill to 0.75 in. (19 mm) below the threads of
the fill plug. (See ILL. 1 & ILL. 2)
Rear Gearcase: Fill with the recommended fluid
amount or fill to the bottom of the fill plug hole threads.
(See ILL.3)
5. Install fill plug and check for leaks.
Fill Plug Threads
Fill to 3/4 in.below
threads or fill
with 5 oz. lubricant.
Front Gearcase
ILL. 1
Specified Lubricant:
Capacity: . . . . . . . . . 5.0 Oz. (150 ml.)
Drain Plug / Fill Plug Torque:
14 ft. lbs. (19.4 Nm)
FRONT GEARCASE SPECIFICATIONS
Premium Demand Drive Hub Fluid
(
PN 2871654 )
Specified Lubricant:
Polaris Gear Drive Fluid (PN 2871653 )
Capacity: 5 Oz. (150 ml.)
Drain Plug / Fill Plug Torque:
14 ft. lbs. (19.4 Nm)
REAR GEARCASE SPECIFICATIONS
Make sure vent is unobstructed
Drain plug
REAR GEARCASE
Fill Plug
ILL. 3
Fill plug
Make sure vent is unobstructed
Drain plug
FRONT GEARCASE
ILL. 2
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