Service Manual

2.5
MAINTENANCE
2
50 - 300 Hour Maintenance Interval
 Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California)
 Have an authorized Polaris dealer perform these services.
Item
Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar
Miles
(KM)

E
Throttle Cable / Throttle
Pedal
50 H 6 M 300 (500)
Inspect; adjust; lubricate; replace if
necessary
E
Throttle Body Air Intake
Ducts / Flange
50 H 6 M 300 (500) Inspect ducts for proper sealing / air leaks

General Lubrication 50 H 3 M 500 (800) Lubricate all fittings, pivots, cables, etc.
Shift Linkage 50 H 6 M 500 (800) Inspect, lubricate, adjust
 Steering 50 H 6 M 500 (800) Lubricate

Front Suspension 50 H 6 M 500 (800) Lubricate

Rear Suspension 50 H 6 M 500 (800) Lubricate
Cooling System 50 H 6 M 500 (800)
Inspect coolant strength seasonally;
pressure test system yearly

E
Fuel System 100 H 12 M 600 (1000)
Check for leaks at tank cap, fuel line, fuel
pump, and fuel rail.
Replace lines every two years.

E
Spark Plug 100 H 12 M 600 (1000) Inspect; replace as needed

E
Engine Oil & Filter Change 100 H 6 M 1000 (1600)
Perform a break-in oil change at 25 hours or
one month / always replace oil filter when
changing engine oil
Drive Belt 100 H 12 M 1000 (1600) Inspect; replace as needed

Radiator 100 H 12 M 1000 (1600) Inspect; clean external surfaces

Cooling Hoses 100 H 12 M 1000 (1600) Inspect for leaks

Engine Assembly Mounts 100 H 12 M 1000 (1600) Inspect, torque to specification
Exhaust Muffler / Pipe 100 H 12 M 1000 (1600) Inspect

Wiring 100 H 12 M 1000 (1600)
Inspect for wear, routing, security; apply
dielectric grease to connectors subjected to
water, mud, etc.
 Clutches (Drive and Driven) 100 H 12 M 1000 (1600) Inspect; clean; replace worn parts
 Front Wheel Bearings 100 H 12 M 1000 (1600) Inspect; replace as needed
 Brake Fluid 200 H 24 M 2000 (3200) Change every two years (DOT 4)
Spark Arrestor 300 H 36 M 3000 (4800) Clean out
 Toe Adjustment -
Inspect periodically; adjust when parts are
replaced
Headlight Aim - Adjust as needed