I was looking on the Hilliard site, and when I found what I think is my front diff, the fluid capacity is not the same. 5 ounces vs 9 that Polars calls for.

Is the diff in our Sportsmans a little bigger for Polaris?


Centralized Front Differential - Hilliard Corporation

 

Could be a smaller gear case or the fluid capacity is misprinted. Just go by what your owners manual says. Looked at one manual for the 2008 500 shows 8.97 ounces for centralized,9.3 ounces for adc equipped. Seems like every year capacities changed.. Old non centralized gear cases took 5 ounces,but you were lucky to get 4 ounces of 80/90 GL5 in most of them after draining. Most techs I talked to did the same as I did. Fill to bottom of the fill plug threads on both the top mounted and side mounted fill plugs.

 

I just replaced the bearing inside the front diff/gearbox for a friend on his '06 Sportsman 800, fill 'er up til the fluid starts running out on the threads. I believe Polaris changed the fluid over to the Hub fluid now, that's what it called for on the repair I performed