Polaris 1999 Sportsman 400 Service Manual page 69

LUBRICATION, MAINTENANCE AND TUNE-UP
63
8. Remove the scree n from the back side of the oil
tank as follows:
a. Loosen and remove the banjo bolt (Fig ure
22) and scaling washe rs securing thc oil hose
and disconnect the hose from the fittin g.
b. Unscrew the fitting and screen from the oil
tank.
c. Thoroughly clean the screen with solvent and
check for damage.
d. Apply Loct ite PSTSOS, or equiva lent thread
sealant, to the thread fittings.
e. Install the screen and fitting onto the oil tank
and tighten to the torque specific ation listed
in Ta ble
s.
f.
Install the
hose, with a sealing
washer on
each
side, and banjo bolt onto the fitting and
tighten securely.
9. There is approximately I cup of engine oil that
will
remain in the crankcase after the oil tank is
drained. Drain this oiIas follows:
a. Move the drain pan under the righ t side of the
crankcase below the recoil start er assembly.
b. On the right side, remove the dra in plug and
gaske t (Figure 23) from the crankcase and a l-
low the oil to completely drain.
c. Check that the sealing surface on the crank-
case and the drain plug are free of burrs and
damage. Clean
off
if necessary to maintain a
leak-free seal.
d. Install
a
new gasket
on
the drain plug and in-
sta ll the drain plug . Tighten to the torqu e
specification listed in Table
s.
10. To rep lace the oil filter, perform the follow ing:
a. Mov e the dra in pan under the oil filter, as re-
sidual oil w ill drai n out when the filter is loos-
ened and removed. Place
a
shop cloth under
the oil filter to catch residual oil as the oil fil-
ter is loosened.
b. Install a socket-type oil filter wrench onto the
oil tilter (Figure 24) and tum the filter
CO l/Il-
terclockwise until oil begins to run out onto
the shop cloth. Wait until the oil stops then
loosen the filter until it is easy to turn.
c. Due to lim ited space, remove the oi l filter
wrench from the end of the filter then com-
pletely unscrew and remove the filterholding
it
with
the open facing up.
d. Hold the filter over the drai n pan and pour out
any rema ining oil. Place the old filte r in a
heavy-duty plastic bag and close the bag. Dis-
card the old filter properly.
e. Thoro ughly clean the sea ling surface of the
crankcase where the filter's rubberseal seats.
This surface must be clean to achieve a good
oil seal when the filter is installed and tight-
ened.
f
Apply a light coat of clean eng ine oil to the
rubber seal on the new tilter.
g.
Installa new
oil lilteronto the threaded fitting
on the crankcase.
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