Periodic Maintenance Chart - Polaris Sportsman 400 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 re-
placement parts. Always use genuine Polaris parts.
HCAUTION: Due to the nature of these adjustments, it is recommended that 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 consti-
tutes severe use. Pay special attention to oil level. A rise in oil level in cold weather can indicate moisture collect-
ing in the oil tank. Change oil immediately if oil level begins to rise.
E Emission Control System Service (California).
Item
E Engine Oil - Level/Change
"
E Oil Filter
Air Filter - Foam Pre-Cleaner
E
"
Air Filter - Main Element
E
"
" Air Box Sediment Tube
" Engine Breather Filter
" Oil Tank Vent Hose
E Valve Clearance
H
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
Drain Recoil Housing
Exhaust Muffler / Pipe
E Spark Plug
Wiring
Ignition Timing
Battery
Headlight Aim
Headlamp Inspection
Tail Lamp Inspection
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PERIODIC MAINTENANCE - ENGINE
Frequency
(Whichever comes first)
Hours Calendar
100 hrs 6 months 1000 (1600)
100 hrs 6 months 1000 (1600)
Daily Daily
Weekly Weekly
- Daily
20 hrs Monthly 200 (320)
100 hrs 12 months 1000 (1600)
100 hrs 12 months 1000 (1600)
As required As required
50 hrs 6 months 500 (800)
50 hrs 6 months 500 (800)
50 hrs 6 months 500 (800)
50 hrs 6 months 500 (800)
100 hrs 12 months 1000 (1600)
100 hrs 12 months 1000 (1600)
Daily Daily
100 hrs 6 months 1000 (1600)
100 hrs 12 months 1000 (1600)
100 hrs 12 months 1000 (1600)
100 hrs 12 months 1000 (1600)
Weekly Weekly
100 hrs 12 months 1000 (1600)
ELECTRICAL
100 hrs 12 months 1000 (1600)
100 hrs 12 months 1000 (1600)
100 hrs 12 months 1000 (1600)
20 hrs Monthly 200 (320)
As required As required
Daily Daily
Daily Daily
MAINTENANCE
Miles Remarks
(Km)
Check Level Daily; Break In service at 1 month
Replace with oil change
Inspect-Clean & oil more often in dirty conditions.
Inspect - Replace if necessary
Drain deposits whenever visible
Inspect and replace if necessary
Inspect hose routing /hose condition
Inspect/Adjust
Adjust
Inspect -Adjust, Lubricate, Replace if necessary
Inspect -Adjust, Lubricate, Replace if necessary
Drain bowl periodically and prior to storage
Inspect all ducts for proper sealing/air leaks
Check for leaks at tank cap, lines, fuel valve, filter,
pump & carburetor. Replace lines every 2 years.
Replace filter annually
Replace engine coolant every 2 years
Inspect strength seasonally; Pressure test sys-
tem annually
Inspect / Clean external surface
Inspect
Inspect
More often if operating in wet environment
Inspect - Replace if necessary
Inspect for abrasion, routing, security
Inspect
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
2.1