What you'll need to change all Polaris Ranger GENERAL Fluids at the 25 Hour First Service Interval

So you're new General 1000 has just reached the 25 hour break-in service interval.  Polaris doesn't give these Ranger General's away so it's important to follow their recommendations when it comes to service.  Three fluids need to be changed on this initial service: engine oil, transmission or main gearcase and front differential or front gearcase.

It can sometimes be a challenge to get all the fluids and tools together and just finding the time to complete the service.  We just completed the process and I've listed everything you'll need in order to complete the 25 hour break-in service.  I'd suggest using the Polaris recommended fluids at least until the warranty expires as it may save you from footing the bill for repairs.    
-All the below information and fluids can be seen by clicking this link.

Tools:

• 6mm allen wrench (oil drain plug)
• 8mm allen wrench (transmission & front differential drain & fill plugs)

Required for Engine:

• 2.5 qts. 5w-50 synthetic oil
• oil filter

Required for Transmission (Main Gearcase):

• 1.3 qts. Polaris AGL Fluid

Required for Front Differential (Front Gearcase)

• 7.5 ounces Polaris Demand Drive Fluid

 Each one of the fluid changes can be seen below by clicking on the text.
-Engine Oil Change, Polaris General 1000
-Transmission (Main Gearcase) Oil Change
-Front Differential (Front Gearcase) Oil Change

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 800 Popping and Sqeeking Noise in Front End Suspension: How to check Ball Joints

So you're Polaris Ranger is well broke in and while trail riding you begin hearing the popping, squeaking and just irritating noise coming from the front end. Recently we replaced all four ball joints on a Ranger 800 Crew, uppers and lower ball-joints.  To check your ball-joints raise the front end of the Ranger with a jack.  With the pressure no off all the joints you can simply grab the tire and check for movement.  This video demonstrates how to check the ball-joints on a Polaris Ranger.  We were able to successfully change all the joints with basic tools that included: hammer, socket, snap ring pliers, hand held MAP gas torch and a lot of banging around.

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.

Polaris Ranger 800 Transmission Rear Differential or Main Gearcase Oil Change: Capacity 1.1 Quart or 34 Oz.

The 2010 Polaris Ranger 800 transmission and rear diff oil run in what Polaris refers to as the main gearcase on the Rangers and oil capacity is relatively small at  34 oz. or 1.1 qt. AGL Fluid.  This oil change is relatively quick, but is messy and awkward getting to the drain plug and fill plug.  Removing the rear passenger side tire would allow better access to the plugs.  This article and the free video explains how to change the oil.

Before you get started make sure to have whats needed to complete the job.
- 8mm allen wrench    - 1.1 qt Polaris AGL Fluid    - oil catch pan   -flexible funnel or hose   - rags  

Before removing the drain plug on your Ranger drive it around for 15 minutes or longer to heat the transmission-rear diff or main gearcase oil.  Now remove the oil Drain Plug with a 8 mm allen Wrench and attempt to catch as much oil as possible.  This part made a mess on our Ranger 800 skid plate.  After draining remove the Fill Plug with the 8mm allen wrench.  The tricky part is getting the new oil back into the gearcase.  Some have claimed to fill through the vent hose, but we filled through the Fill Plug opening.  Our AGL Fluid came with a nozzle that was applied after removing the cap and breaking the seal.  After installing the nozzle we cut the tip and placed a foot piece of clear hose on it to feed into the case.  Our Polaris Ranger 800 used 1 quart, although specs claimed 1.1 quarts.