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I did alot of research on this, the Polaris Owners Manual and Service Manual is wrong for the listed amounts on the front and rear gearcase fluids. I know the following information is correct for the 700 and 800 machines, I think the same will be true for the smaller machines, 500 and 600.

DO NOT fill to the bottom of the fill hole (to the threads). You only want 5 oz. of fluid in the front and rear gearcase.

Also, the fluids are confusing, the rear calls for 'ATV Angle Drive Fluid' in both the Owners Manual and service manual. Well, it is right to some degree, only the part number. The 8 oz. bottles says on it 'ATV Front Drive Fluid', the part number is 2871653....this is the fluid you want to use in the rear.

In the front, again only put in 5 oz., the fluid is called 'Premium Demand Drive Hub Fluid', part number for the 8 oz. bottle is 2871654.

I have talked to people that said that Polaris put out an addendum to the Owners manual that says 'DO NOT fill to the bottom of the hole/threads'. This addendum is PN 9919999.

The transmission lubrication is correct in the manual, to the bottom of the threads...15 oz., which you would be lucky to get in there.

So, here is what you use:

Rear Gearcase, 5 oz of 'ATV Front Drive Fluid', PN 2871653 (for 8 oz. bottle)
Front Gearcase, 5 oz of 'Premium Demand Drive Hub Fluid', PN 2871654 (for 8 oz bottle)
Transmission, 15 oz (bottom of fill hole), 'AGL Gearcase Lubricant', PN 2873602 (which is quart bottle, but listed as a 12 oz bottle in my Service Manual)

I did notice that for 2006, the wording that I was originally told about in the adendum did make it in the owners manuals, but it is only for checking the level of your rear gear case fluid...when filling, you changing, you add only 5 oz. to refill.

Hope this helps everyone.
Dave
 

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Thanks for the info, think I need to check fluid levels now and maybe change as well It never hurts to change ahead of schedule anyway.
 

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The manuals I have found have a lot of contradicting info...Many errors.
Thanks Dave.


Jim
 

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Easy way to fill your fluids

Here is a good way to fill your front & rear gear cases along with your transmission without spilling a lot of your fluids onto the floor or ground...

Find a couple old rearend grease bottles with a cone tipped style bottle cap, Rinse the bottles out really good with some gas to get any old lube out of them, And then wash them out with some hot soapy water then rinse them with plenty of plain hot water to make sure they are clean...

Once all bottles have been cleaned and dried out, Put or mark what kind of fluid you want to use it for on it, Thats why you want to get a few of these bottles, So that you can use different fluids in different bottles...

Next you want to get a couple sections of clear 3/8" rubber tubing to wedge onto the cone tip of the bottle cap, The length of the tubing is up to you, I cut mine at 20" long, So that I can hold the bottles on the outside of the bike when I turn them upside down to add my fluids into there rightful place...

I found that I can fill the bottle with the exact amount of fluid that I need, Put the end of the tubing in the fill hole, Turn the bottle upside down and gental squeeze the bottle untill all of the fluid runs out of the tube, This is why I use clear rubber tubing verses using a solid color rubber tubing like rubber gas line, But if that is all you can get it will work just as good...

So by using a bottle with a flexible rubber tubing on it, You can fill the componets of your bike from pretty much any position, Just by putting in the recommended amounts and types of fluid into the bottle, Then put the end of the tubing into the fill hole, Turn the bottle upside down and fill it up, When you are done pull the end of the tubing out of the fill hole and turn the opening upword so you do not drip, Reinstall you fill hole plug and you are good to go without have to clean up a big mess that spilled because of trying to use funnels...

I hope this tech tip helps a lot of you DIY-ers out there, That like to work on and maintain you own equipment as I do, If you like this tip let me know this is how a lot of shops do it, To save them on time and clean up...:)
 
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