Attachment 3- 2016 Polaris ATV Sportsman 450 HO Owners Manual.pdf

MAINTENANCE

Periodic Maintenance Chart Any qualified repair shop or person may maintain, replace or repair the emission control devices or systems on your vehicle. An authorized POLARIS dealer can perform any service that may be necessary for your vehicle. POLARIS also recommends POLARIS parts for emissions-related service, however equivalent parts can be used.

It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle’s emission controls. Tampering with emission controls is prohibited by federal law.

Owners are responsible for performing the scheduled maintenance identified in this owner’s manual.

Careful periodic maintenance will help keep your vehicle in safe, reliable condition. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, genuine POLARIS parts are available from your POLARIS dealer.

Equivalent parts may be used for emissions-related service.

Service and adjustments are important for proper vehicle operation. If you're not familiar with safe service and adjustment procedures, a qualified dealer can perform these operations.

Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise.

Monitor the oil level, and if it continues to rise, discontinue use and determine the cause. Your POLARIS dealer can assist.

Periodic Maintenance Chart Maintenance Chart Key

WARNING! Improperly performing the procedures marked with a “D” could result in component failure and lead to serious injury or death. Have an authorized POLARIS dealer or other qualified person perform these services.

Perform all services at whichever maintenance interval is reached first.

Record maintenance and service in the Maintenance Log beginning on page 171.

Perform these procedures more often for vehicles subjected to severe use.

D Have an authorized POLARIS dealer or other qualified person perform these services.

Symbol Description Perform these operations more often for vehicles subjected to severe use.

D Have an authorized POLARIS dealer or other qualified person perform these services.

Item Maintenance Interval (whichever comes first)

Remarks

Hours Calendar Miles (Km)

Steering -

Pre-Ride

Make adjustments as need

ed. See Pre-Ride Checklist on page 62.

Front suspension - - Rear suspension - - Tires - - Brake fluid level - - Brake lever travel - - Brake system - - Wheels/fasteners - - Frame fasteners - - Engine oil level - - Winch (if equipped) - - See pages 81-92 Air filter, pre-filter - Daily - Inspect; clean often; replace as needed Air box sediment tube

- Daily - Drain deposits when visible

Coolant - Daily - Check level Power steering unit (if equipped)

- Daily - Inspect daily; clean often

Headlight/taillight/ worklight

- Daily - Check operation; apply dielectric grease if replacing lamps

Periodic Maintenance Chart

Item Maintenance Interval (whichever comes first)

Remarks

Hours Calendar Miles (Km)

Air filter, main element

- Weekly - Inspect; replace as needed

Recoil housing - Weekly - Drain water as needed, check often if operating in wet conditions

D Brake pad wear 10 H Monthly 100 (160) Inspect periodically

Battery 20 H Monthly 200 (320) Check terminals; clean; test Fuel System 20 H Monthly - Inspect; cycle key to pressurize fuel pump; check lines and fittings for leaks and abrasion

Engine breather 25 H Monthly 250 (400) Inspect hose (and valve, if equipped); replace if needed

Engine oil change 25 H 1 M - Break-in oil and filter change Demand drive fluid (extreme use)

25 H 1 M 250 (400) Change fluid every 25 hours if ADC is subjected to extreme use. See page 107.

Demand drive fluid 25 H 1 M 250 (400) Break-in oil level check Rear gearcase oil 25 H 1 M 250 (400) Break-in oil level check Transmission oil 25 H 1 M 250 (400) Break-in oil level check General lubrication 50 H 3 M 500 (800) Lubricate all fittings, pivots, cables, etc.

D Throttle Cable/

Release Switch 50 H 6 M 500 (800) Inspect; adjust; lubricate;

replace if necessary Throttle Body Intake Duct

50 H 6 M 500 (800) Inspect duct for proper sealing/air leaks

Drive belt 50 H 6 M 500 (800) Inspect; adjust; replace as needed

Cooling system 50 H 6 M 1000 (1600) Inspect coolant strength seasonally; pressure test system yearly

Engine oil change 100 H 6 M 1000 (1600) Change the oil and filter Oil lines and fasteners

100 H 6 M 1000 (1600) Inspect for leaks and loose fittings

Periodic Maintenance Chart

Perform these procedures more often for vehicles subjected to severe use.

D Have an authorized POLARIS dealer or other qualified person perform these services.

Item Maintenance Interval (whichever comes first)

Remarks

Hours Calendar Miles (Km)

Demand drive fluid (normal use)

100 H 12 M 1000 (1600) Change fluid; change fluid every 25 hours if ADC is subjected to extreme use.

See page 107.

Rear gearcase oil 100 H 12 M 1000 (1600) Change fluid Transmission oil 100 H 12 M 1000 (1600) Change fluid

D Fuel system/filter 100 H 12 M 1000 (1600) Cycle key to pressurize fuel pump; check for leaks at fill cap, fuel lines/rail and fuel pump; replace lines every two years

Radiator (if applicable)

100 H 12 M 1000 (1600) Inspect; clean external surfaces

Cooling hoses (if applicable)

100 H 12 M 1000 (1600) Inspect for leaks

Engine mounts 100 H 12 M 1000 (1600) Inspect Exhaust muffler/ pipe

100 H 12 M 1000 (1600) Inspect

D Spark plug 100 H 12 M 1000 (1600) Inspect; replace as needed

Wiring 100 H 12 M 1000 (1600) Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc.

D Clutches (drive and driven)

100 H 12 M 1000 (1600) Inspect; clean; replace worn parts

D Front wheel bearings

100 H 12 M 1000 (1600) Inspect; replace as needed

D Brake fluid 200 H 24 M 2000 (3200) Change every two years Suspension bushings

250 H 24 M 2000 (3200) Inspect; replace if necessary

Spark arrester 300 H 36 M 3000 (4800) Clean out D Valve clearance 500 H - 5000 (8000) Inspect; adjust

Coolant - 60 M - Replace coolant Idle speed - Adjust as needed

D Toe adjustment - Inspect periodically; adjust when parts are replaced

Headlight aim - Adjust as needed

Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 94. Items not listed in the chart should be lubricated at the General Lubrication interval.

The a-arms and lower control arms are lubricated at the factory, and no additional lubrication will be needed. However, if these components are subjected to severe use, grease zerks have been provided for additional lubrication at the user's discretion.

Item Lube Capacity at Fluid Change

Inspection Procedure

Engine Oil (450/570)

PS-4 5W-50

4-Cycle Oil

2 qt. (1.9 l) Maintain level in safe range on dipstick. See page 102.

Engine Oil (325) PS-4 5W-50 4-Cycle Oil

1.75 qts. (1.65 l) Maintain level in safe range on dipstick. See page 99.

Brake Fluid DOT 4 Brake Fluid --- Maintain level between fill lines. See page 36.

Transmission Oil AGL Gearcase Lubricant & Transmission Fluid

32 oz. (948 ml) Maintain level at bottom of fill hole threads. See page 105.

Demand Drive (Front Gearcase)

Demand Drive Fluid

9 oz. (265 ml) Maintain level at bottom of fill hole threads. See page 107.

Front Prop Shaft Yoke

U-Joint Grease --- Grease fittings (3 pumps maximum) every 500 miles, before long periods of storage, or after pressure washing or submerging.

Front Prop Shaft Yoke