Polaris General Front Differential Fluid Change: 7.5 Oz. Capacity

Changing the front differential fluid, also known as the Front Gearcase is a easy task.  The oil change is basically identical to all other Polaris ATV's and UTV's.  The fluid change requires only requires one tool and a couple minutes to complete.

Before getting started have everything you need on hand.
-Polaris Demand Drive Fluid (7.5 oz)
-8mm allen wrench
-catch pan

To make the fluid easier to drain warm it up by driving the General around for a couple minutes.  After warming it up park the General on level ground and place the catch pan under the front differential.  Next remove the 8mm allen style plug from the bottom of the differential, it's located via a hole in the skid plate.  As the old fluid drains remove the fill plug, it's located on the passenger side of the differential unit and is also a 8mm allen style plug.  Once the fluid has drained wipe any debris from the magnet drain plug and reinstall.  Some small debris is normal, but large shavings may indicate a problem within the gearcase.  The creative part is filling the differential with 7.5 oz of Demand Drive Fluid.  We general use a hose attached to the filler neck as seen in the video, but others have used turkey basters or funnels.  Once the front gearcase is full the fluid will be at the point of coming out the fill plug.

We would suggest performing this maintenance every 25 hours of use.  This may seem like a lot, but the front gearcase or differential is a costly repair.  A good  maintenance routine can save big bucks in the long term. 

Sportsman 800 Front Gearcase Differential Fluid Change

Changing the front differential gearcase fluid on a 2012 Polaris Sportsman is not a hard job.  There is much debate about fluid compatibility, using the recommended Polaris Demand Drive Fluid or Angle Drive Fluid.  The Angle Drive Fluid is a thicker oil and is used in approximately 2004 and earlier Polaris models that engage the AWD at the front hubs.  These models have a larger bolt on center cap on the front wheels.  In the newer models the AWD system is referred to as being centralized and engages in the front differential gearcase and uses the thinner Demand Drive Fluid.  See the Difference between Demand Drive Fluid and Angle Drive Fluid here. We recommend sticking with the factory recommended Demand Drive Fluid.  
To watch the entire fluid change click here.

Before getting started have the following ready:
1. Polaris Demand Drive Fluid (9oz.)
2. 8mm allen wrench
3. oil catch pan
4. rags

Begin by driving the Sportsman 800 for a couple miles at road speeds to warm the fluid. Next park on level ground and removing the 8mm allen head drain plug located under the front skid plate.  The drain plug is magnetic, check for debris and remember some build up is normal.  While the fluid is draining remove the 8mm allen head fill plug located on front of the differential gearcase.  Re-install the drain plug and fill the gearcase with Demand Drive Fluid, approximately 9 oz. or until it reaches the bottom of the fill plug.

What is the Difference in Demand Drive Fluid and Angle Drive Fluid: Polaris Front Gearcase Noise After Oil Change

Recently we were changing the front differential fluid on a 2012 Polaris Sportsman 800.  Some folks suggested using Angle Drive Fluid and that it replaced Demand Drive Fluid.  The Owner's Manual makes no mention of this fluid, so after much research and looking at the fluids, it's apparent that these two oils are different in every way.  Watch the Comparison.

Polaris Angle Drive Fluid is made for the earlier model Polaris 4x4 ATV's that have the electrically actuated hub assembly.  This means the AWD system engages at the hub assembly or similar to a old pick-up truck that you have to get out of and lock the 4wd system in at the center of the front wheels.  The front diff on these style quads use the Angle Drive Fluid, which appears to be the same consistency and very similar to a gear oil.

Polaris Demand Drive Fluid is formulated for (approximately) 2004 and newer Sportsman's that the AWD (4x4) system engages in the front differential.  This fluid is much thinner and resembles hydraulic fluid.  The Demand Drive Fluid is clear and very thin as you can see in the video.  Some folks have ran Angle Drive Fluid in the newer center actuating front differentials with no issues, while others report the fluid made their front gearcase make a loud popping noise and ultimately break down.

Polaris Ranger front Differential Fluid Change: 9.3 oz Fluid Capacity

Changing the front diff fluid on the Ranger 800 is a quick and easy job.  The most difficult part is of the entire job is removing the fill plug on the front of the diff.  The oil change is relatively mess free due to the low 9.3 oz. fluid capacity.  Before getting started make sure to have a 8mm allen wrench and Polaris Demand Drive Hub Fluid or Polaris Angle Drive Fluid on hand.  Lots of discussion out there on using different brands such as Amsoil and fluid variations such as automatic transmission fluid and hydraulic fluid in the front differential gearcase on these Rangers.  You can do you're own research on that, but many swear by these alternatives.
Begin the process by driving the Ranger at road speeds for 15 minutes or more to warm the fluid up making the drain process quicker and more complete.  Next remove the 8mm drain plug with the allen wrench, there is a hole in the front skid plate for access.  As the fluid drains remove the fill plug located on front of the differential, you can do this without removing plastics.  Once fluid is drained reinstall the drain plug.  To fill you can attach a hose to the top of the Polaris Demand Drive Hub Fluid or Angle Drive Fluid nozzle and plumb it into the fill hole or use a funnel with hose, just be creative.  Others have filled the front diff by pouring fluid down the vent hose under the hood.  I've attached the video of our fluid change, but to be honest it was early on and not the best.