Attch d - Polaris PMI Schedule.pdf

MAINTENANCE

Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the peri-odic maintenance chart.

Inspect, clean, lubricate, adjust and replace parts as necessary.

When inspection reveals the need for replacement parts, use genuine POLARIS parts available from your POLARIS dealer.

Record maintenance and service in the Maintenance Log beginning on page 136.

Tip: Service and adjustments are important for proper vehicle opera-tion. If you're not familiar with safe service and adjustment proce-dures, have a qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 MPH (16 km/h). 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 or see your dealer.

Maintenance Chart Key ► = Perform these operations more often for vehicles sub-jected to severe use.

E = Emission-related service (Failure to conduct this mainte-nance will not void the emissions warranty but may affect emissions.)

D = Caution: Due to the nature of these adjustments, it is rec-ommended this service be performed by an authorized POLARIS dealer.

Tip: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.

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 perform these services.

Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first.

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

E Emission-Related Service D Have an authorized POLARIS dealer perform these services.

Item Maintenance Interval (whichever comes first)

Remarks

Hours Calen-dar

Miles (Km)

► Brake fluid level

- Daily - Check the levels and add as needed

► Coolant

► Diesel fuel level

►E Engine oil level

► Hydraulic oil level

► Brake system / pedal travel

Daily Ensure proper operationEngine speed control lever (if applicable)

Travel control pedal

Head lights/Tail lights

- Daily - Check for proper operationIndicator lights/Switches

►E Air filter - Daily - Inspect filter element, replace as needed or every 150 hours

►E Air intake sediment drains - Daily - Inspect drains on bottom of engine air intake duct and air filter housing for obstructions

► Cooling system - Daily - Inspect oil cooler, radiator A/C condenser (if equipped) and grills for debris, remove debris if needed.

Drive shaft boots Daily Inspect boots for damage, tears, ear or leaking grease

E Engine intake pre-filter screen (LH side)

- Daily - Inspect; clean often

Frame fasteners Daily Inspect and ensure tightness

Periodic Maintenance Chart

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

E Emission-Related Service D Have an authorized POLARIS dealer perform these services.

Item Maintenance Interval (whichever comes first)

Remarks

Hours Calendar Miles (Km)

E Fuel filter/water separator - Daily - Drain daily (severe conditions with poor fuel quality) or every 50 hours (normal conditions with quality fuel)

► Heater / A/C filter (if equipped) - Daily - Clean or replace filter as needed during heating and cooling seasons

PTO (if applicable) - Daily - Inspect; splines, guards, shields and mounting hardware. Tighten and replace as needed.

ROPS/OPS - Daily - Check the condition of the ROPS/OPS and mounting hardware

Safety signs / Decals - Daily - Check for damaged signs (decals); replace any that are damaged

Seat belts - Daily - Check the condition of the seat belts; clean or replace seat belt retrac-tors as needed

Steering / suspension - Daily - Inspect for broken parts, loose hardware and free operation

Tires - Daily - Check for wear, damage and correct tire pressure

Wheels/fasteners - Daily - Check for loose wheel nuts and tighten to the correct torque value;

re-torque wheel nuts after 8 hours of use or any time the nuts are removed for service

► Front gearcase lubricant (Demand Drive Plus) 25 H 1 M 250 (400) Initial fluid level inspection; add lubricant if needed

► Transmission lubricant (AGL Gearcase Lubri-cant)

25 H 1 M 250 (400) Initial fluid level inspection; add lubricant if needed

► Attachment interface mounting hardware (HD/

HDPTO

25 H - - Re torque the lower mounting bolts to 95 ft-lbs

►D Brake pad wear - 1 M 250 (400) Initial fluid level inspection; add lubricant if needed

Periodic Maintenance Chart

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

E Emission-Related Service D Have an authorized POLARIS dealer perform these services.

Item Maintenance Interval (whichever comes first)

Remarks

Hours Calendar Miles (Km)

D Alternator/Fan/Water pump drive belt 50 H - - Check and adjust the V-belt after the initial 50 hours of operation; per-form every 200 hours thereafter

D Air conditioning drive belt (if applicable) 50 H - - Check and adjust the V-belt after the initial 50 hours of operation; per-form every 200 hours thereafter

►E Engine oil & filter change 50 H - - Perform an oil and filter change after the initial 50 hours of operation;

perform every 100 hours or 6 months thereafter

Hydraulic / hydrostatic system 50 H - - Replace hydraulic filter only after the initial 50 hours of operation;

replace hydraulic fluid, filter and reservoir breather cap every 400 hours thereafter

Battery 50 H 1 M - Check terminals; clean; test

E Fuel filter / water separator 50 H 3 M - Drain every 50 hours (normal conditions with quality fuel) or daily (severe conditions with poor fuel quality)

► General grease lubrication 50 H 3 M 500 (800) Lubricate all grease fittings, pivots, etc.

E Air intake ducts / adapters 50 H 6 M - Inspect ducts for proper sealing/air leaks

Attachment interface mounting hardware

(HD/HDPTO)

100 H - - Re-torque the lower mounting bolts to 95 ft-lbs

PTO gearbox (if equipped) 100 H - - Inspect for leaks

►E Engine oil & filter change 100 H 6 M - Perform an oil and filter change after the initial 50 hours of operation;

perform every 100 hours or 6 months thereafter

► Front / rear suspension 100 H 6 M 1000 (1600) Inspect for wear

Shift cable / linkage 100 H 6 M 1000 (1600) Inspect, lubricate, adjust

D Steering 100 H 6 M 1000 (1600) Inspect steering freeplay

D,E Travel Control And Engine Speed Control System

100 H 6 M 1000 (1600) Inspect for proper operation and adjust if necessary

Periodic Maintenance Chart

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

E Emission-Related Service D Have an authorized POLARIS dealer perform these services.

Item Maintenance Interval (whichever comes first)

Remarks

Hours Calendar Miles (Km)

► Cooling Hoses 100 H 12 M - Inspect for leaks; replace if necessary

► Engine mounts 100 H 12 M - Inspect, torque to specifications

Exhaust silencer/pipe 100 H 12 M - Inspect

D,E Fuel system 100 H 12 M - Check for leaks at fill cap, fuel lines and fuel pump

D Front wheel bearings 100 H 12 M 1000 (1600) Inspect; replace as needed

► Front Gearcase lubricant (Demand Drive Plus) 100 H 12 M 1000 (1600) Change lubricant

► Transmission lubricant (AGL Gearcase Lubri-cant)

100 H 12 M 1000 (1600) Change lubricant

Hydraulic, hydrostatic and power steering hoses 100 H 12 M 1000 (1600) Inspect for damage and leaks; repair or replace as needed

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

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

Cooling system - 12 M - Test coolant strength and pressure test system

►E Air filter 150 H - - Replace air filter; replace more often if vehicle is subject to severe use

E Fuel filter/water separator 150 H 12 M - Replace fuel filter / water separator

Periodic Maintenance Chart

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

E Emission-Related Service D Have an authorized POLARIS dealer perform these services.

Item Maintenance Interval (whichever comes first)

Remarks

Hours Calendar Miles (Km)

D Air conditioning drive belt (if equipped) 200 H - - Check and adjust the V-belt after the initial 50 hours of operation; perform every 200 hours thereafter, replace as needed

D Alternator/Fan/Water pump drive belt 200 H - - Check and adjust the V-belt after the initial 50 hours of operation; perform every 200 hours thereafter; replace as needed

D PTO drive belt (if equipped) 200 H - - Inspect for damage; replace as needed.

D Toe adjustment 200 H 24 M 2000 (3200) Inspect; adjust if necessary or when parts are replaced

D Brake fluid 200 H 24 M 2000 (3200) Change every two years (DOT 4)

Spark arrester, exhaust clean out 300 H 36 M - Remove plug and clean out

Hydraulic / hydrostatic system 400 H - - Replace hydraulic fluid, filter and reservoir breather cap

PTO gearbox lubricant (if equipped) 400 H 12 M - Change lubricant

PTO shaft u-joints (if equipped) 400 H 12 M - Inspect for wear; replace as needed

PTO clutch brake (if equipped) 400 H 12 M - Adjust tension

D,E Engine valve clearance 1000 H Inspect and adjust as needed

► Coolant 1000 H 24 M - Replace coolant

D,E Fuel injectors 1500 H - - Inspect, clean and test fuel injectors, if necessary

D,E Engine crankcase breather system 1500 H - - Inspect crankcase breather system

► Fuel hoses 2000 H 24 M - Replace rubberized fuel hoses

► Cooling hoses 2000 H 24 M - Replace coolant hoses

Headlight aim - Adjust as needed

Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 78, or more often under severe use, such as wet or dusty conditions. Items not listed in the chart should be lubricated at the general lubrication interval.

Item Lube Method Engine Oil See page 87.

Brake Fluid DOT 4 Maintain level between fill lines. See page 101.

Main Gearcase Oil (Transmission) AGL PLUS Transmission Fluid See page 89.

Front Gearcase Oil Demand Drive PLUS Fluid See page 90.

Front Prop Shaft Yoke and PTO shaft POLARIS Premium U-Joint Lube Locate fittings and grease (3 pumps maximum). See page 120.

Front and rear suspension POLARIS Premium U-Joint Lube Locate fittings and grease (3 pumps maximum). See page 120.