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POLARIS OFF-ROAD VEHICLES

HELP CENTER

6/6/2021
RZR Trail Front Gearcase Fluid Replacement

Required Tools and Supplies:

  • 8mm Allen Socket
  • Ratchet
  • Torque Wrench
  • Demand Drive Fluid
  • Drain Pan
  • Fluid Filler
  • Safety Glasses
  • Nitrile Gloves
  • Shop Rags

Always wear safety glasses and nitrile gloves when servicing your Polaris RZR. For optimal performance, always use Polaris-recommended fluids as described in your Owner’s Manual.  

To change the front gearcase fluid on your RZR Trail, follow these steps:

1. Park the vehicle on a flat, level surface, and ensure it is in PARK.

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

3. Clean the area around the fill plug in the right front wheel well.

4. Remove the front gearcase fill plug with an 8mm Allen socket and set it aside.

5. Clean the area around the drain plug. 

6. With an 8mm Allen socket, remove the drain plug, and allow the fluid to drain completely.

7. Before reinstalling, clean any dirt or debris from the fill and drain plugs. 

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

9. Reinstall the drain plug. Torque to 19 ft-lbs (26 Nm).

10. Fill the gearcase through the fill plug hole until it reaches the bottom threads and begins to spill out. The gearcase has a capacity of 7.5 ounces (222 mL). Demand Drive Fluid is part number 2877922 for 1 quart (946 ml).

11. Reinstall the gearcase fill plug. Torque to 19 ft-lbs (26 Nm).

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

13. Dispose of the used fluid properly at your local recycling center.

For more information, see your authorized Polaris Dealer. Find a dealer near you with the Dealer Locator.
More 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.