Exhaust Pipe - Polaris SPORTSMAN 400 2003 Service Manual

To check front hub fluid: (See next page)
1. Place vehicle on a level surface.
2. Turn wheel until front hub fill/check plug is in either
the 4 o'clock or 8 o'clock position.
3. Remove fill/check plug.
4. Add Polaris Demand Drive Hub Fluid if necessary
until fluid trickles out. NOTE: Do not force the
fluid into the hub under pressure or seal damage
may occur.
5. Reinstall plug.
6. Repeat procedure for other hub.
FRONT HUB FLUID CHANGE
1. Place a drain pan beneath the hub.
2. Remove check/fill plug.
3. Turn the hub to the 6 o'clock position and drain the
fluid
into the drain pan.
4. Turn wheel until front hub fill/check plug is in either
the 4 or 8 o'clock position.
5. Add Polaris Demand Drive Hub Fluid (PN
2871654) until fluid trickles out. NOTE: Do not
force the fluid into the hub under pressure or seal
damage may occur.
Polaris Demand Drive Hub Fluid:
(PN 2871654) - 8 oz.
(PN 2872277) - 2.5 gallon

EXHAUST PIPE

WARNING
S Do not perform clean out immediately
after the engine has been run, as the ex-
haust system becomes very hot. Serious
burns could result from contact with ex-
haust components.
S To reduce fire hazard, make sure that
there are no combustible materials in the
area when purging the spark arrestor.
S Wear eye protection.
S Do not stand behind or in front of the ve-
hicle while purging the carbon from the
spark arrestor.
S Never run the engine in an enclosed
area. Exhaust contains poisonous car-
bon monoxide gas.
S Do not go under the machine while it is
inclined. Set the hand brake and block
the wheels to prevent roll back.
Failure to heed these warnings could result in
serious personal injury or death.
The exhaust pipe must be periodically purged of
accumulated carbon as follows:
1. Remove the clean out plugs located on the
bottom of the muffler as shown in illustration 1.
Ill.1
2. Place the transmission in neutral and start the
engine. Purge accumulated carbon from the
system by momentarily revving the engine
several times.
3. If some carbon is expelled, cover the exhaust
outlet and rap on the pipe around the clean out
plugs while revving the engine several more
times.
4. If particles are still suspected to be in the muffler,
back the machine onto an incline so the rear of the
machine is one foot higher than the front. Set the
hand brake and block the wheels. Make sure the
MAINTENANCE
Clean Out Plug
2.27