Polaris 2004-2005 Sportsman 6x6, Service Manual

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MAINTENANCE
2.25
G
-- Water will enter the recoil housing if the
starter handle is disengaged from the rope
guide when under water.
G
-- After travelling in wet areas the recoil
housing and starter should always be
drained completely by removing the
recoil.
G
-- Do not open the crankcase drain unless
the engine has ingested water. Some
engine oil will be lost if crankcase drain is
opened.
G
-- If recoil handle seal has been damaged,
the handle should be replaced.
ENGINE OIL SERVICE
A
The oil tank is located on the left side of the vehicle.
To check the oil level:
1. Set machine on a level surface.
2. Start and run engine for 20-30 seconds. This will
return oil to its true level in the oil tank.
3. Stop engine, remove dipstick (A) and wipe dry
with a clean cloth.
4. Reinstall dipstick, screw the dipstick into place.
NOTE: The dipstick must be screwed completely in
to ensure accurate measurement.
ADD 8 OZ. NORMAL FULL
Maintain Oil Level In Normal Range
Screw Dipstick in completely to check
0W/40
5. Remove dipstick and check to see that the oil
level is in the normal range. The oil should be
between the top line and the bottom line on the
dipstick. Add oil as indicated by the level on the
dipstick. Do not overfill.
NOTE: A rising oil level between checks in cool
weather driving can indicate contaminants collecting
in the oil reservoir. If the oil level is over the full mark,
change the oil.
OIL AND FILTER CHANGE
WARNING
Personal injury can occur when han-
dling used oil. Hot oil can cause burns
or skin damage.
NOTICE:
Care must be taken to ensure that fluids are
contained. Be prepared to collect the fluid
with suitable containers before opening any
compartment or disassembly any component
containing fluids.
1. Place vehicle on a level surface.
2. Run engine two to three minutes until warm. Stop
engine.
3. Clean area around drain plug (B) at bottom of oil
tank. Remove drain plug (B).
4. Place a drain pan beneath oil tank and remove
drain plug. CAUTION: Oil may be hot. Do not
allow hot oil to come into contact with skin as
serious burns may result.
B
A
C
D
5. Allow oil to drain completely.
6. Replace sealing washer (A) on drain plug (B).
NOTE: The sealing surfaces on drain plug and oil
tank should be clean and free of burrs, nicks or
scratches.
7. Reinstall drain plug (B) and torque to 14 ft. lbs. (19
Nm).
8. Loosen clamp (D).
9. Remove oil hose from screen fitting (C) on bottom
of oil tank.
10. Remove screen fitting (C) and clean the screen.