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.