Annual Fluid Change - Polaris Riders


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Old 06-12-2006, 05:46 PM   #1 (permalink)
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Default Annual Fluid Change

I did the annual fluid change on my Sportsman today -- both differentials and the transmission. I didn't do the engine oil yet because I want to wait approx 6 more hours -- I like even numbers to go by on the display.

The differentials seem easy enough... the rear IS easy. The drain is on the bottom and both fill and drain plugs are 5/8" in size. Both are easy to reach.

On the front, the drain is 7/16", and the fill is 1/4" Hex (aka Allen). Filling it is something of a pain. Ideally you should probably pull the LF tire for easier access.

Then the transmission... man what a pain. It's obvious that Polaris didn't really have ease of servicing in mind when they came up with this. You get to remove the right-side footwell, which is comprised of four push-pegs and four T25 torx bolts and 3/8" nuts behind them.

Once the footwell is off, both the fill and drain are 1/4" Hex (aka Allen). The fill, despite how the manual describes it, is actually on the BACK of the transmission, not "behind the footwell."

The drain is again easy, but refilling takes some work. You really need some fancy funnels to get the fluid into the tranny and the front diff, fancier than even my fancy ones, because I managed to spill more fluid on the floor than got into the machine.

The best part of the three jobs is that getting the level right is easy -- just fill it to the bottom of the fill hole. The front takes 5 oz, the rear takes 10 oz and the tranny takes 15 oz, in case anybody cares. AND, all three jobs require a different fluid -- Polaris Premium Demand Drive Fluid for the front, Polaris AGL for the transmission, and 80-90W gear oil for the rear diff. Add in the 0W40 PS4 oil for the motor and you have FOUR different fluids to keep track of for this thing. My Grizzly only requires two -- Gear Oil for both diffs, and 10W40 for the motor.

Later tonight or tomorrow I'll work on changing the belt...

Rob
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Old 06-12-2006, 09:34 PM   #2 (permalink)
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Rob, a couple of things, DO NOT fill to the bottom of the fill holes on the front and rear differentials...ONLY and I mean ONLY put in 5 oz in each. Polaris had a supplement to the owners manual, I can dig up the PN if you want that says that the manual has a mistake and only fill to 5 oz...I also confirmed this with them on the phone.

Also, do not remove the right footwell to get to the fill hole on the tranny, it is easier if you remove the right rear tire to get to the hole, but no reason to remove the footwell...

tranny you do fill to the bottom of the fill hole...
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Old 06-12-2006, 10:24 PM   #3 (permalink)
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Dave do you know if the 5 oz rule pertains to the 05 500 as well? I just changed my trany and fromt diff, I over filled a little, and let the fluid run out. Then I put the plugs back in.

We ran 25 miles in the National Grasslands up here, and it went great....

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Old 06-12-2006, 11:34 PM   #4 (permalink)
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Workaholic, its the same on the '05 500, only 5 oz in the differentials...

you won't really see a problem though, underfilling will cause problems, not sure what overfilling will cause, probably just added resistance or something in the differential..
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Old 06-13-2006, 03:56 AM   #5 (permalink)
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Rob, how much did all the fluid cost and what kind of fancy apparatus can you recommend for getting it filled back up ??
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Old 06-13-2006, 04:01 AM   #6 (permalink)
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I agree with Dave.
I believe all the machines with the centralized Hilliard (all twins and '04 up 400/500 sportsman's) take 5 oz. PPDD fluid.


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Old 06-13-2006, 09:24 AM   #7 (permalink)
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Dave:

Any idea how far below the fill hole in the front diff 5 oz would be? I'd hate to have to drain the diff and refill it, but I will if I have to...

Rob
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Old 06-13-2006, 05:48 PM   #8 (permalink)
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Man what an enormous PITA this has been changing these fluids. I drained the rear end again and tried to put 5 oz of fluid in there and managed to spill most of it because of an inadequate funnel.

Dave... if the front only gets 5 oz, which is correct in the owners manual, and it also shows the correct line as being the bottom of the fill hole, is that not correct? Or do I get to drain the front diff again and try again there as well?

I know it seems minor, but this has been a big enough pain that I'm not so sure I'll buy another Polaris. Again, to cite my Grizzly, all ya do is fill both diffs to the fill hole, and you're done... with the same fluid. No funky measuring, AND you can actually get a funnel in place to do it.

Grrr.

Rob
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Old 06-13-2006, 08:16 PM   #9 (permalink)
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Rob,
Are you using Polaris fluids? The Polaris fluids are marked on the sides for the level. On the rear, if you use the Polaris fluid, there is no need to use a funnel, as the tip can be stuck right in the hole and then you squeeze some in and then check the level....I shine a flashlight on the opposite side of the reading so I can see where it is at.

On the front, I use some clear plastic hose that I bought at home depot, it fits right over the polaris nozzle on the fluid container, and I do the same thing for measuring it....doesn't take long at all.

The fluid is pretty far below the fill hole. In the supplement, which I have somewhere, it talks about using something to put in the fill hole and it can tell you how close you are, at least I think that was in the supplement, but its so simple with the Polaris 1 quart bottles that there is no need...

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Old 06-13-2006, 09:49 PM   #10 (permalink)
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I pre-measure out all the fluids then use a hose on the end of the bottle fittings to gain easier access to the fill holes.
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