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POLARIS OFF-ROAD VEHICLES

HELP CENTER

11/13/2020
RZR 800 or RANGER RZR Transmission Fluid Changes

Required Tools and Supplies: 

  • Allen Socket Set
  • Drain Pan
  • Shop Rags
  • Torque Wrench
  • Ratchet
  • Fluid Filler

Always wear safety glasses and nitrile gloves when servicing your Polaris RZR. The transmission fluid level on your RZR 800, RZR 4 800, RZR S 800, RANGER RZR or RANGER RZR S should be maintained at the bottom of the fill plug hole on the main gearcase. In the transfer case, it should be filled until it begins to spill out of the check plug hole. Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart in your Owner's Manual. To minimize confusion, perform the transmission fluid change on the main gearcase and transfer case separately.

Drain plug locations

Main Gearcase
The fill plug is located on the left side of the main gearcase, as shown below.

Fill plug

The drain plug is located on the bottom of the main gearcase. It can be accessed through the drain hole in the skid plate. To change the transmission fluid in the main gearcase, follow these steps:

1. Park the vehicle on a flat, level surface.

2. Make sure the vehicle is in PARK.

3. Place a drain pan underneath the drain plug. Placing a rag in the bottom of the drain pan will help prevent the splashing of fluid.

4. Clean the area around the fill plug.

5. Remove the fill plug.

6. Clean the area around the drain plug.

7. Remove the drain plug and allow the fluid to drain completely.

8. Clean any dirt or debris from the fill and drain plugs.

9. Inspect the O-rings on both plugs and replace if necessary.

10. Reinstall the drain plug. Torque to 30 to 45 in-lbs (3 to 5 Nm).

11. Fill the gearcase through the fill plug hole until fluid reaches the bottom of the fill plug hole. The capacity is 24 ounces (710 ml). AGL Gearcase Lubricant and Transmission Fluid is part number 2878068 for 1 quart (946 ml) and part number 2878069 for 1 gallon (3.78 L).

12. Reinstall the fill plug. Torque to 40 to 50 ft-lbs (54 to 68 Nm).

13. Clean any residual fluid off the vehicle and inspect for leaks.

14. Dispose of the used fluid properly.

Transfer Case
The fill plug and level check plug are located on the left side of the transfer case. The drain plug is located on the bottom of the transfer case and can be accessed through the drain hole in the skid plate.
 

Transfer case

To change the transmission fluid in the transfer case, follow these steps:

1. Park the vehicle on a flat, level surface.

2. Make sure the vehicle is in PARK.

3. Place a drain pan underneath the drain plug. Placing a rag in the bottom of the drain pan will help prevent the splashing of fluid.

4. Clean the area around the fill plug.

5. Remove the fill plug.

6. Clean the area around the drain plug.

7. Remove the drain plug and allow the fluid to drain completely.

8. Clean the area around the level check plug.

9. Remove the level check plug.

10. Clean any dirt or debris from the fill, drain and level plugs.

11. Inspect the O-ring on the drain plug and replace if necessary.

12. Reinstall the drain plug. Torque to 30 to 45 in-lbs (3to 5 Nm).

13. Add the recommended fluid to the fill plug hole until it begins to spill out of the check plug hole. The capacity is 14 ounces (414 ml). AGL Gearcase Lubricant and Transmission Fluid is part number 2878068 for 1 quart (946 ml) and part number 2878069 for 1 gallon (3.78 L).

14. Reinstall the level check plug. Torque to 30 to 45 in-lbs (3 to 5 Nm).

15. Reinstall the fill plug. Torque to 40 to 50 ft-lbs (54 to 68 Nm).

16. Clean any residual fluid off the vehicle and inspect for leaks.

17. Dispose of the used fluid properly.

For more information, see your authorized Polaris Dealer. Find a dealer near you with the Dealer Locator.
Maintenance tips, procedures and specifications can be found in your Owner's Manual.
To find diagrams and replacement part numbers, use the online parts catalog.