Periodic Maintenance Chart - Polaris Magnum 2x4 Service Manual

MAINTENANCE
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 miles
per hour.
Inspect, clean, lubricate, adjust or replace parts as necessary. NOTE: Inspection may reveal the need for re-
placement parts. Always use genuine Polaris parts.
-CAUTION: Due to the nature of these adjustments, it is recommended that service be periormed by an
authorized Polaris dealer. 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 moisture collecting in the oil tank .
.... Vehicles subjected to severe use, such as operation in wet or dusty areas, should be inspected and serviced
more frequently.
E Emission Control System Service (California). For 4-cycle models built after January 1, 1997.
ENGINE
Item Hours Frequency See Page Remarks
E ....
Engine Oil - Level/Change 100 hrs 6 months 2.23 Check Level Daily; Break In service at 1 month
E Oil Filter (4-strokes) 100 hrs 6 months 2.23 Replace with oil change
Oil Filter (2-strokes) 100 hrs 12 months 2.22 Replace
Oil Pump Cable (2-strokes) 50 hrs 6 months 2.19 Inspect, Adjust, Lubricate, Replace if Required
E ....
Air Filter - Foam Pre-Cleaner Daily Daily 2.22/2.25 Inspect Clean & oil more often in dirty condo
E ....
Air Filter - Main Element Weekly
Weekly 2.22/2.25
Inspect - Replace if necessary
....
Air Box Sediment Tube
Daily
2.26
Drain deposits whenever visible
....
Engine Breather Filter 20 hrs
Monthly
Inspect and replace if necessary
....
Oil Tank Vent Hose 100 hrs 12 months Inspect hose routing /hose condition
E.
Valve Clearance (4-strokes) 100 hrs 12 months 2.27 Inspect/Adjust
....
Counter Balancer Fluid (400s) 100 hrs 12 months 2.21 Check Monthly / Change Annually
E Idle Speed As required As required 2.11 Adjust
•
Throttle Cable / ETC Switch 50 hrs 6 months 2.11 Inspect -Adjust, Lubricate, Replace
if
necessary
Choke (Enricher) Cable 50 hrs 6 months 2.12 Inspect -Adjust, Lubricate, Replace if necessary
Carburetor Float Bowl 50 hrs 6 months 2.13 Drain bowl periodically and prior to storage
Carburetor Air Intake Ducts/Flange 50 hrs 6 months
-
Inspect all ducts for proper sealing/air leaks
E.
Fuel System 100 hrs
12 months
2.13
Check for leaks at tank cap, lines, fuel valve, filter,
pump & carburetor. Replace lines every 2 years.
E- Fuel Filter
100 hrs 12 months
2.13
Replace filter annually
Coolant/Level Inspection
Daily Daily
2.18
Replace engine coolant every 2 years
Coolant Strength / Pressure Test 100 hrs 6 months 2.18 Inspect strength seasonally: Pressure test sys-
System tem annually
Radiator 100 hrs 12 months 2.18 Inspect / Clean external surface
Cooling System Hoses
100 hrs 12 months 2.18
Inspect
Engine Mounts 100 hrs 12 months 2.17 Inspect
Drain Recoil Housing Weekly Weekly 2.21 More often if operating in wet environment
Exhaust Muffler
I
Pipe
100 hrs 12 months
ELECTRICAL
E Spark Plug 100 hrs 12 months 2.17 Inspect - Replace if necessary
Ignition Timing 100 hrs 12 months 10.10 Inspect
Battery
20 hrs Monthly 2.16 Check terminals; Clean; Check fluid level
Headlight Aim As required As required 10.4
Adjust if Necessary
Headlamp Inspection Daily Daily 10.4 Check operation daily; Apply Polaris Dielectric
Grease to connector when lamp is replaced
Tail Lamp Inspection
Daily Daily 10.9 Check Operation Daily; Apply Polaris Dielectric
Grease to socket when lamp is replaced
5/98
2.1 Polaris Industries Inc.