Lubrication Guide - Polaris Sportsman 2004 Owner's Manual

MAINTENANCE AND LUBRICATION

Lubrication Guide

NOTE: Hours in the frequency column are based on 10 mph average.
If service is due at 20 hours, the equivalent odometer reading would be
200 miles. Perform all services at whichever reading is reached first.
Lubrication Guide Key
More often under severe use, such as wet or dusty conditions
"
Polaris Premium All Season Grease or grease conforming to NLGI
L
No. 2, such as Conoco Superlube M or Mobilegrease Special
Use Polaris Premium U-Joint Lube every 500 miles, before long
F
periods of storage, or after pressure washing or submerging.
Item
Engine Oil Polaris Premium 4
Synthetic 0W40
Brake Fluid DOT 3 Only
Transmission Polaris Premium
Oil Synthetic
Gearcase Lube
Front Gear- Premium Drive
case Oil Hub Fluid
Rear Gear- Premium Synthet-
case Oil ic Gearcase Lube
(or GL5 80-90
weight gear lube)
Front Prop
F
Shaft Yoke
(Fig. 1)
Front Drive
F
Axle (U Joint)
(Fig. 2)
Ball Joint
"
(Fig. 3)
74
Lube
Grease
Grease
Grease
L
Method
Add to proper level on dip-
stick.
Maintain level between fill
lines. See page 39.
See page 81 (400/500)
or page 83 (600/700).
See page 82.
See page 84 (600/700).
Grease fittings (3 pumps
maximum)
Locate grease fitting and
grease with grease gun.
Locate fitting on back side of
struts and grease with
grease gun.
Frequency
Check level daily.
As required; change
every two years or
200 hours
Check every 6
months/1000 miles.
Change annually or
at 100 hours
Change annually or
at 100 hours
Change annually or
at 100 hours
Every 3 months or
50 hours
Every 3 months or
50 hours
Every 3 months or
50 hours