Polaris 2004-2005 Sportsman 6x6, Service Manual

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MAINTENANCE
2.5
MAINTENANCE AND LUBRICATION
Periodic Maintenance Chart
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
J
E
Fuel system 100 H 12 M 620
(1000)
Check for leaks at tank cap, lines, fuel valve, fil-
ter, pump, carburetor; replace lines every two
years
J
E
Fuel filter 100 H 12 M 620
(1000)
Replace yearly
"
Radiator
(if applicable)
100 H 12 M 620
(1000)
Inspect; clean external
surfaces
"
Cooling hoses
(if applicable)
100 H 12 M 620
(1000)
Inspect for leaks
"
Engine mounts 100 H 12 M 620
(1000)
Inspect
Exhaust muffler/
pipe
100 H 12 M 620
(1000)
Inspect
J
E
Spark plug 100 H 12 M 620
(1000)
Inspect; replace as needed
J
E
Ignition Timing 100 H 12 M 620
(1000)
Inspect
"
Wiring 100 H 12 M 620
(1000)
Inspect for wear, routing,
security; apply dielectric grease to connectors
subjected to water, mud, etc.
J
Clutches (drive
and driven)
100 H 12 M 620
(1000)
Inspect; clean; replace worn parts
J
Front wheel
bearings
100 H 12 M 1000
(1600)
Inspect; replace as needed
J
Brake fluid 200 H 24 M 1240
(2000)
Change every two years
Spark arrestor 300 H 36 M 1860
(3000)
Clean out
E Idle speed -- Adjust as needed
J
Toe adjustment -- Inspect periodically; adjust when parts are re-
placed
"
J
Auxiliary brake
--
Inspect daily; adjust as needed
Headlight aim
--
Adjust as needed
"
Perform these procedures more often for vehicles
subjected to severe use.
E Emission Control System Service (California)
J
Have an authorized Polaris dealer perform these
services.