Going to drain front diff and need to know what size allen wrench size fits fill plug. Also what is the best fluid to use, Polaris has some new fluid called angle drive is it better then the normal front diff fluid recomended?
Looks like its going to be hard to get a allen wrench the correct size to remove the plug, any easy way to remove it?
Thanks
Jimmy

 

STOP! Don't use the Angle Drive Fluid! That's not for your front gear case. Do this:

2006 Sportsman 500EFI

Drain Plug= 11mm Torq to 11lbs/15Nm*

Fill Plug= 8mm Hex Torq to 8-10lbs/11-14Nm*

Drain for about 15 min.

Clean the plugs, you will see fine metal shavings.*

Use only "Premium Demand Drive Hub Fluid Part #2871654" Use 5 oz "Fill to the bottom of the fill plug hole, that's 5oz." *

Don't over fill.

Don't over torq the plugs. *

I get the 8 oz bottle because it's easer to use.

Takes about 25 min. to do it right.

*Right out of the 2006 Polaris Sportsman 500EFI Service Manual

 

Thanks for the information, I purchased the correct hub fluid today from the polaris dealer but he could not tell me what size allen wrench too use I am going to pick up a long Tee handle 8-mm allen rench because it looks like a using a short one would be more difficult.
thanks again
Jimmy

 

No problem. Make sure you check the bottle for the right part #. Dealers are known for selling the wrong fluid. 2871654 for the 8oz and 2872277 for the 2.5 gal. "Premium Demand Drive Hub Fluid." The T-handle sounds good but I don't think you can use a torq wrench with it. 8-10 and 11 lbs is NOTt alot of torq, be careful not to over torq and strip the threads. This info is only for the 2006 500EFI not the X2. The reason I'm so paranoid about the front hub fluid is because on my 2004.5 500 the DEALER put the wrong fluid in and ruined my front hillard. He never was able to fix it so he ended up buying my 2004.5. Real pain in the...

 

redmtn,
Would you suppose that same oil would be correct for my 06 450 SP also? Seems as if it would right?

 

I would think so, but I would check your owners manual. I would still recomend getting a service manual. I believe all the sportsmans have the central hillard now and use the Premium Demand hub fluid. Just make sure you put the right stuff in. Also, I'm not sure if the 450 takes the same amount of fluid and has the same torq specs.