Grease Service - Polaris 1999 Sportsman 400 Service Manual

LUBRI CATION, MAINTENAN CE AN D TUNE-U P 67
I. Ride the ATV for 10-15 minutes and shill
through both transmission range s. Shut off the en-
gine .
2. Plaee the ATV on level grou nd and set the park-
ing brake.
NOTE
Access
10
the f ront ge m-case can be
achie ved with
thefront
f ender
ill
place
by
removin g the
rightfront wheel
but
the working room is
vel )'
limited. Re-
move
whatever component
is mos t
convenient.
3A . Remove the front fender as descri bed in Chap-
ter Fifteen.
3B. Remove the right front whee l as described in
Chapter Twelve.
4. Place a drain pan under the fron t gearcase drain
plug.
5. Loose n the drain plug. Then remove the dra in
plug and gasket.
6. Unscrew the oil fill plug (Figu re 29) as this will
speed up the flow of oil
7. Allow the oi l to com pletely dra in.
g.
lnspcct the co ndition of the drained oil for co n-
tamination after it has cooled down. If any part icles
arc found. some type of internal front gcarcase dam-
age has occurred. Refer to Chapter Ten .
9. Install a new gask et on the drain plug.
10. Install the drain plug and its gasket. Tighten the
drain plug to the torque specification listed in Table
5.
II . Insert a funnel into the oil fill hole and fill the
gearea se with the correct weight (Ta ble 3) and
quantity of oil (Table 4).
12. Remo ve the funnel and install the oil fill plug
(Figure 29). Tighten the plug securely.
13. Check for leak s. Tighten if necessary.
Grease Service
Various suspens ion and drive train components
req uire periodic lubrication.
Wipe the grease fitting cle an prior to installing
the grease gun. Usc the recommended grease listed
in Ta ble 3 and inject the grease into the fitting with
a grease gun . Wipe off any exce ss grease from the
fitting.
App ly grea se
'0
the follow ing fittings :
I. The front
suspension anns (Figure 30 ).
2. The front struts (Figure 31).
3. The lower end o f the steeri ng shall (Figure 32 ).
4 . The front drive ax le inner U-jo ints (Figure
33).
5. The fron t propelle r shaft, front U-joi nt (F igure
34 ) and the rear V-joint (Figu re 35) .
6. Upper (Figure 36) and lower (Figure 37) rear
suspension arms.
7. Rear stabilizer bar assembly (Figure 38) .