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Old 03-22-2010, 07:00 PM
ericmichael54's Avatar
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transmission and front gearcase oil levels

I have a 2008 polaris sportsman 500 efi. I changed my oil in the transmission(#3602/32oz fill capacity) and front gearcase(#6251/9.3oz fill capacity. In both cases the oil filled to the bottom of the fill plug threads but neither one took the exact amount of oil recommended by the owners manual. But like I said the oil levels r right where they r supposed to be although they r a couple ounces under their capacity. Please help?? Is this normal?
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Old 03-22-2010, 10:41 PM
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as long as you followed the proper settings it should be correct, however sometimes the owners manual is not correct for example " a 2004.5 500 HO in the owners manual falls under 600 specs not 500 specs" that is just an example a came accross a time or two. Now some ppl may call me wrong but I have seen it with my own eyes on my own manual. However Your machine does take the appropriate level of fluids to mention But if u are unsure of yourself dont be afraid to take it for a test drive then check your fluids again and see if the level changes if so add a little bit it is better to have a wee bit more fluid then not enough in my opinion.Good Luck
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Old 03-23-2010, 02:00 AM
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you can never get all of the old oil out.
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2001 500 H.O. Sportsman "Hoggwaller"
2in. lift,with HD ranger springs up front w/stock axles,2in. in the back
heel clicker
Warn 2500 puller outter
SS108's
29.5's Laws skinny/fat
rubber down custom intake
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working on quads for 12 yrs let me know if i can help
"Hold my beer and let me show you how to really f#%* shit up"
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Old 10-16-2010, 10:29 AM
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The same problem

I have a 2008 polaris sportsman 500 HO and I have the same problem with capacity of rear gear, is it normal???
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Old 10-17-2010, 07:26 AM
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Fill it up till it runs out the hole and go riding. Why worry yourself over whether it held 31oz. or 32? So long as its full of oil what difference does it make?
Don't worry just be happy your riding a Polaris!
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Old 10-17-2010, 09:44 AM
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thanks for advice, I did as You said.

I love this machine and this is the reason of my worring.

Have a nice day.
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Old 10-17-2010, 10:52 AM
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Yea, with the Transmission it's not to critical if you have it a little over full. The front diff is more critical. It doesn't like to much fluid, or to little. Just ride it and see how it feels. If it starts acting strange in any way, you might need to remove or add some fluid.

Ideally, you want to get the ATV warmed up extremely well to change to fluid... get the fluid warm so that it flows and drains well.
Get it on a level surface and let it drain for a long time. Push up and down and side to side on the front of the ATV to try and get as much out as possible.
Put the new stuff in SLOWLY. The gears are very close to the drain hole, and if you put it in to fast, it will come back out on you and you think you have it full.

Good luck.
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