Polaris General Transmission Fluid Change

Changing the transmission fluid or as Polaris refers to it as the Main Gearcase on the General 1000 is pain free.  The General's design allows for the average UTV owner to maintain the entire running gear with just a hand full of tools.  Before getting started make sure you have the following ready.

• 1.3 quarts of Polaris AGL Fluid
• 8mm allen wrench
• catch pan

Begin by locating the drain plug which can be found where the main and rear skid plate meet.  Remove the drain plug with a 8mm allen wrench.  The drain plug is magnetic so take notice to any debris on it and wipe clean.   As the old AGL Fluid drains locate the fill plug above the reese hitch and below the rear sway bar.  The clearance is tight accessing the transmission fill plug on the General, but is doable.  Once the fill plug is broke loose you can remove it entirely with your fingers.  To fill we used a clear tube attached to the nozzle as seen in the below video.  Once 1.3 ounces of AGL Fluid is installed, or it crests the fill plug hole, reinstall the fill plug.

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.