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POLARIS GOVERNMENT & DEFENSE
HELP CENTER
2/24/2022

600 Voyageur Chaincase Fluid Replacement

Required Tools and Supplies
Prying Tool (Front Cover Method) Pliers (Front Cover Method) T40 TORX® Socket (Front Cover Method)
10mm and 6mm Sockets (Front Cover Method) Fluid Suction Device (Suction Method) Drain Pan (Front Cover Method)
Ratchet Torque Wrench Fluid Filler
Shop Rags Safety Glasses Nitrile Gloves

To learn more about tools, read the Tools and Fasteners Guide

This video will outline the pump and front cover methods that can be used to change the chaincase fluid on a Polaris 600 Voyageur 144. Always wear safety glasses and nitrile gloves when servicing your snowmobile. 

1. Ensure the vehicle is on a flat, level surface.
2. Set the parking brake.
3. Clean the area around the fill plug. Placing a rag under the fill plug will help catch any escaping fluid.
4. Remove the fill plug with a 6mm Allen socket. Set aside.
5. To extract the fluid using the pump method:

  • Safely elevate the front of the snowmobile using a floor jack or appropriate lift.
  • Insert the tube of the suction device into the fill hole. Direct the hose toward the bottom front area of the cover, away from the chain and sprocket.
  • Extract the oil using a suction device.
  • Then safely lower the snowmobile to fill the chaincase.

6. To drain the fluid using the front cover method: 

  • Remove the right side panel by releasing the rubber strap and turning the two quarter-turn latches. Pull the panel out and lift up to remove.
  • Remove the three push rivets securing the side panel trim. Pull the trim apart as needed.
  • Then remove the battery and bracket.
  • Using a T40 TORX® Socket, remove the two fasteners securing the lower fender to the chaincase.
  • Place a drain pan underneath the chaincase. Placing a rag in the bottom of the drain pan will help prevent the splashing of fluid.
  • Loosen but do not remove the three lower chaincase cover fasteners with a 10mm socket.
  • Carefully pry the cover open on the cover tab. DO NOT insert a screwdriver or pry bar between the cover and chaincase. Seal damage may occur.
  • Allow the fluid to drain completely.
  • Reinstall the three cover fasteners. Torque to 11 ft-lbs (15 Nm).

7. Fill the chaincase through the fill plug hole until fluid reaches the bottom threads and begins to spill out. The recommended fluid is Synthetic Snowmobile Chaincase Lubricant,  part number 2873105
8. Clean any dirt or debris from the fill plug.
9. Inspect the O-ring on the plug and replace if necessary. 
10. Reinstall the fill plug. Torque to 4 ft-lbs (6 Nm).
11. Clean any residual fluid off the vehicle and properly dispose of the used fluid.
12. If using the front cover method, continue with the following steps:

  • Reinstall the fasteners securing the lower fender to the chaincase. Torque to 36 in-lbs (4 Nm).
  • Install the battery bracket. Then install the battery. Connect the positive cable first. 
  • Reconnect the side panel trims and reinstall the three push rivets. 
  • Then reinstall the side panel by inserting the tabs on the bottom and top. Secure the rubber strap and quarter-turn latches.

For more information, see your authorized Polaris Dealer. To find a dealer near you, use 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.

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