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POLARIS OFF-ROAD VEHICLES
CENTRE D'AIDE
9/11/2023

2006-2013 Sportsman 500 Front Gearcase Fluid Replacement

Required Tools and Supplies

  • 8mm Allen Socket
  • Ratchet
  • Torque Wrench
  • Fluid Filler
  • Drain Pan
  • Demand Drive Fluid
  • Nitrile Gloves
  • Safety Glasses
  • Shop Rags

To learn more about tools, read the Tools and Fasteners Guide

Always wear safety glasses and nitrile gloves when servicing your vehicle. For optimal performance, always use Polaris recommended fluids as described in your Owner’s Manual. To change the front gearcase fluid on your Sportsman 500, follow these steps:

1. Park the vehicle on a flat, level surface, ensure it is in park and set the parking brake.

2. Place a drain pan underneath the front gearcase. Tip: Placing a rag in the bottom of the drain pan will help prevent the splashing of fluid.

3. Before removing, clean the area around the fill plug in the left front wheel well below the radiator. 

4. Remove the fill plug with an 8mm Allen socket and set aside.

5. Clean the area around the drain plug.

6. Remove the drain plug with an 8mm Allen socket, and allow the fluid to drain completely.

7. Clean any dirt or debris from the fill and drain plugs.

8. Inspect the O-rings on both plugs and replace if necessary.

9. Reinstall the drain plug, and torque to 8-10 ft-lbs (11-14 Nm).

10. Fill the gearcase through the fill plug hole until fluid reaches the bottom threads and begins to spill out. Demand Drive Fluid is part number 2877922. The gearcase's capacity is 8.97 fl oz (265 mL).

11. Reinstall the gearcase fill plug, and torque to 11 ft-lbs (15 Nm).

12. Clean any residual fluid off the vehicle and inspect for leaks.

13. Finally, dispose of the used fluid properly at your local recycling center.

For more information, see your authorized Polaris Dealer. Find a dealer near you with the Dealer Locator.
Maintenance tips, procedures and specifications can be found in your Owner's Manual.
To find diagrams and replacement part numbers, use the online parts catalog.

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