Polaris 1999 Sportsman 400 Service Manual page 60

54
level mu st be between the upp er and lower lines on
the dipstick (Figure 2). If necessary. ad d the correc t
type of oil to bring the level up to the upper line. Re-
fer to T able 3.
2. Check the tran sm ission oil leve l as follows :
a. Remove the oi l fill dip stick (Figure 3) and
wipe it clean. Reinsert the dipstick and re-
move
it.
b. The o il level must be within the knurled sec-
tion of the dipstick (Fi gure 4 ).
c. If necessary, add the co rrect type o f oi l to
bring the level within the knur led section of
the dipstick. Refer to Ta ble 3 .
d. Install the oil fill cap/dipstick.
WA RNING
When perf orming any ser vice work
10
the engine or cooling system, nel' e r re-
l1/O\'e the radiator cap (Figure 5), cool-
ant drain
scn..>ws
or disconnect any
coo/alit hose when the engine and radi-
ator are hot. Scalding fl uid and steam
are under pressure and wil!
cause seri-
O/iS
injury
if
allowedto escape.
I I
t
C HAPTE R T H REE
".~
u
'I _
3. Chec k the coola nt level with the eng ine co ld.
Check the coo ling system for leaks and make sure
the co olant is up to the FULL mark on the coolant
rese rvoir (F igure 6). Always add co olant to the res-
ervoir tank, not the radiator.
4. Turn the handlebar from side to side and check
for steering play. Check that the co ntro l cables arc
properly routed and do not interfere with the han-
dlebar or the handlebar controls.
5. Check the throttle operation . Op en the throttle
all the way and release it. The thrott le should close
quickly with no bindin g or roughness . Repeat this
step with the handlebar facing straig ht ahea d and
both full lock positions.
6. Check that the front master cy linder brake lever
and rear maste r cy linder peda l opera te properly
with no bind ing. Replace any bro ke n lever or peda l.
Check the lever and pedal housings for damage.
WARNING
When checking the brake
Jerel ;
check
the ball
0 11
the end ofthe level:
If
it is
broken off, replace the lever immedi-
ately. The lever balls help
to
prevent
the lever from pnncnning a hand or
arm during afall or crash.
7. Inspect the front and rear suspension; mak e sure
they have a good solid feel with no looseness.
8. Chec k all four wheels and tires for dama ge.
9. Make sure the air filter element is clean and that
the air box and carbureto r or thrott le body boots arc
secured tightl y.
10. Check tire pressure as listed in Ta ble 2.
I I. Check the exhaust sys tem for loo seness or
da mage .
12. Check the lightness of all fasteners, especially
engine, steering and suspension mounting hardware,
13. Make sure the fue l tank is full of fresh gaso line.