Polaris TRAIL BOSS 325 2001, Manual

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MAINTENANCE
2.1
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. More frequent maintenance is required if vehicle
is used for utility work at speeds averaging less than 10 mph.
NOTE: Inspection may reveal the need for replace-
ment parts. Always use genuine Polaris parts.
H
CAUTION: 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. Change oil immediately if oil level begins to rise.
E Emission Control System Service (California).
PERIODIC MAINTENANCE - ENGINE
Frequency
(Whichever comes first)
Item Hours Calendar Miles
(Km)
Remarks
E
" Engine Oil - Level/Change 100 hrs 6 months 1000 (1600) Check Level Daily; Break In service at 1 month
E Oil Filter 100 hrs 6 months 1000 (1600) Replace with oil change
E
"
Air Filter - Foam Pre-Cleaner Daily Daily Inspect-Clean & oil more often in dirty conditions.
E
"
Air Filter - Main Element Weekly Weekly Inspect - Replace if necessary
"
Air Box Sediment Tube - Daily Drain deposits whenever visible
E H Valve Clearance 100 hrs 12 months 1000 (1600) Inspect/Adjust
E Idle Speed As required As required Adjust
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Throttle Cable / ETC Switch 50 hrs 6 months 500 (800) Inspect -Adjust, Lubricate, Replace if necessary
Choke (Enricher) Cable 50 hrs 6 months 500 (800) Inspect -Adjust, Lubricate, Replace if necessary
Carburetor Float Bowl 50 hrs 6 months 500 (800) Drain bowl periodically and prior to storage
Carburetor Air Intake Ducts/Flange 50 hrs 6 months 500 (800) Inspect all ducts for proper sealing/air leaks
E
H
Fuel System 100 hrs 12 months 1000 (1600) Check for leaks at tank cap, lines, fuel valve, filter,
pump & carburetor. Replace lines every 2 years.
E H Fuel Filter 100 hrs 12 months 1000 (1600) Replace filter annually
Radiator/Oil Cooler 100 hrs 12 months 1000 (1600) Inspect / Clean external surface
Engine Mounts 100 hrs 12 months 1000 (1600) Inspect
Drain Recoil Housing Weekly Weekly More often if operating in wet environment
Exhaust Muffler / Pipe 100 hrs 12 months 1000 (1600)
ELECTRICAL
E Spark Plug 100 hrs 12 months 1000 (1600) Inspect - Replace if necessary
Wiring 100 hrs 12 months 1000 (1600) Inspect for abrasion, routing, security
Ignition Timing 100 hrs 12 months 1000 (1600) Inspect
Battery 20 hrs Monthly 200 (320) Check terminals; Clean; Check fluid level
Headlight Aim As required As required Adjust if Necessary
Headlamp Inspection Daily Daily Check operation daily; Apply Polaris Dielectric
Grease to connector when lamp is replaced
Tail Lamp Inspection Daily Daily Check Operation Daily; Apply Polaris Dielectric
Grease to socket when lamp is replaced