Periodic Maintenance Chart - Polaris SPORTSMAN 600 2003 Service Manual

PERIODIC MAINTENANCE CHART

Inspection, adjustment and lubrication intervals of important components is listed in the following chart.
Maintenance intervals are based upon average riding conditions and a vehicle speed of approximately 10 mph.
Inspect, clean, lubricate, adjust or replace parts as necessary.
NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. The following
symbols denote potential items to be aware of during maintenance:
H= CAUTION: Due to the nature of these adjustments, it is recommended this service be performed
by an authorized Polaris dealer.
= Vehicles subjected to severe use (operation in wet or dusty areas, low speed heavy load
"
operation, prolonged idle) should be inspected and serviced more frequently. For engine oil,
short trip cold weather riding also constitutes severe use. Pay special attention to oil level. A
rise in oil level in cold weather can indicate contaminants collecting in the oil sump or
crankcase. Change oil immediately if oil level begins to rise.
E= Emission Control System Service (California).
Item
E Engine Oil - Level/Change
"
E Oil Filter
E Air Filter - Screen Pre-Cleaner
"
Air Filter - Main Element
E
"
" Air Box Sediment Tube
" Engine Breather Filter
E Idle Speed
H
Throttle Cable / ETC Switch
Choke (Enricher) Cable
Carburetor Float Bowl
Carburetor Air Intake Ducts/Flange
E Fuel System
H
E Fuel Filter
H
Coolant/Level Inspection
Coolant Strength / Pressure Test
System
Radiator
Cooling System Hoses
Engine Mounts
Exhaust Muffler / Pipe
E Spark Plug
Wiring
Ignition Timing
Battery
Headlight Aim
Headlamp Inspection
Tail Lamp Inspection
2.2
PERIODIC MAINTENANCE - ENGINE
Maintenance Interval
(Whichever comes first)
Hours Calendar
100 hrs 6 months
100 hrs 6 months
Daily Daily
Weekly Weekly
- - Daily
20 hrs Monthly
As required As required
50 hrs 6 months
50 hrs 6 months
50 hrs 6 months
50 hrs 6 months
100 hrs 12 months
100 hrs 12 months
Daily Daily
100 hrs 6 months
100 hrs 12 months
100 hrs 12 months
100 hrs 12 months
100 hrs 12 months
ELECTRICAL
100 hrs 12 months
100 hrs 12 months
100 hrs 12 months
20 hrs Monthly
As required As required
Daily Daily
Daily Daily
MAINTENANCE MAINTENANCE
Miles
(Km)
1000 (1600) Check Level Daily; Break- -In service at 1 month
1000 (1600) Replace with oil change
- - Inspect-Clean & oil more often in dirty conditions
- - Inspect - Replace if necessary
- - Drain deposits whenever visible
200 (320) Inspect and replace if necessary
- - Adjust as required
500 (800) Inspect -Adjust, Lubricate, Replace if necessary
500 (800) Inspect -Adjust, Lubricate, Replace if necessary
500 (800) Drain bowl periodically and prior to storage
500 (800) Inspect all ducts for proper sealing/air leaks
1000 (1600) Check for leaks at tank cap, lines, fuel valve, filter,
pump & carburetor. Replace lines every 2 years.
1000 (1600) Replace filter annually
Replace engine coolant every 2 years
1000 (1600) Inspect strength seasonally;
Pressure test system annually
1000 (1600) Inspect / Clean external surface
1000 (1600)
1000 (1600)
1000 (1600)
1000 (1600) Inspect - Replace if necessary
1000 (1600) Inspect for abrasion, routing, security
1000 (1600)
200 (320) Check terminals; Clean; Check fluid level
- - Adjust if Necessary
- - Check operation daily; Apply Nyogelt
Grease to connector when lamp is replaced
- - Check Operation Daily; Apply Nyogelt
Grease to socket when lamp is replaced
Remarks
Inspect
Inspect
Inspect
Inspect