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MAINTENANCE
Gearcases
Gearcase Specification Chart
Use of other fluids may result in improper operation of components. See
page 126 for the part numbers of POLARIS products.
Spark Plugs
Spark Plug Gap/Torque
NOTICE: Using non-recommended spark plugs can result in serious engine
damage. Always use POLARIS-recommended spark plugs. Refer to
the specifications section beginning on page 122.
Spark plug condition is indicative of engine operation. The spark plug
firing end condition should be read after the engine is warmed up and
the vehicle is driven at higher speeds. Immediately check the spark plug
for correct color. See page 87.
CAUTION! A hot exhaust system and engine can cause burns. Wear
protective gloves when removing a spark plug for inspection.
Gearcase Lubricant Capacity Fill Plug
Torque
Drain Plug/
Level Check
Plug Torque
Transmission
(Main Gearcase)
Premium AGL
Synthetic
Gearcase Fluid
24 oz.
(710 ml)
40-50 ft. lbs.
(54-68 Nm)
30-45 in. lbs.
(3-5 Nm)
Transmission
(Transfer Case)
Premium AGL
Synthetic
Gearcase Fluid
14 oz.
(414 ml)
40-50 ft. lbs.
(54-68 Nm)
30-45 in. lbs.
(3-5 Nm)
Demand Drive Unit
(Front Gearcase)
Demand Drive
Plus Fluid
6.75 oz.
(200 ml)
8-10 ft. lbs.
(11-13.6 Nm)
11 ft. lbs.
(15 Nm)
Rear Gearcase Premium ATV
Angle Drive Fluid
26 oz.
(769 ml)
40-50 ft. lbs.
(54-68 Nm)
30-45 in. lbs.
(3-5 Nm)
Electrode Gap New Plug Torque Used Plug Torque
.035" (.9 mm) 18 ft. lbs.
(24 Nm)
18 ft. lbs.
(24 Nm)