2005 Polaris Sportsman 400/500 Service Manual, Page 31Get this manual
MAINTENANCE TRANSMISSION SPECIFICATIONS Specified Lubricant: AGL Gearcase Lubricant: (PN 2873603) (Gallon) (PN 2873602) (12 oz Capacity: At change: Approx32 oz(948 ml) Drain PlugFill Plug: 22 ftlbs(30 Nm)
To check the level: 1Remove fill plug2Fluid should be filled to bottom of fill plug hole threadsAdd the proper lubricant as required to bring level into operating range as shown2Remove the drain plug and wipe the magnetic end clean to remove accumulated metallic filings3After the oil has drained completely, install new sealing washer (if installed) and install the drain plugTorque to 22 ft.lbs(30 Nm)4Add the proper lubricant through the fill plug hole until the oil level is to the bottom of the fill plug hole threads (See Illustration above)Do not overfill5Check for leaks6Reinstall skid plate if removed in Step 1