Polaris Service Maintenance Schedule
10 – 50 Hour Maintenance Interval
| Maintenance Interval (Whichever Comes First) |
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| ITEM | HRS | CALENDAR | MILES (KM) | REMARKS |
| Brake Pad Wear | 10 H | Monthly | 100 (160) | Inspect periodically |
| Battery | 25 H | Monthly | 200 (320) | Check terminals; clean; test |
| Fuel System | 25 H | Monthly | 200 (320) | Inspect; cycle key to pressurize fuel pump; check lines and fittings for leaks and abrasion |
| Demand Drive Fluid (Extreme Use) | 25 H | 1 M | – | Change fluid every 25 hours if ADC is subjected to extreme use |
| Front Gearcase Lubricant (Demand Drive Fluid) | 25 H | 1 M | – | Initial fluid level inspection; add lubricant if needed |
| Transmission Lubricant (AGL Gearcase Lubricant) | 25 H | 1 M | – | Initial fluid level inspection; add lubricant if needed |
| Engine Oil & Filter Change (Break-In Period) | 25 H | – | 250 (400) | Perform a break-in oil and filter change at 25 hours or one month; perform every 100 hours or 6 months thereafter |
| General Lubrication | 50 H | 3 M | 500 (800) | Lubricate all grease fittings, pivots, etc |
| Shift Cable / Linkage | 50 H | 6 M | 500 (800) | Inspect, lubricate, adjust |
| Steering | 50 H | 6 M | 500 (800) | Lubricate |
| Front / Rear Suspension | 50 H | 6 M | 500 (800) | Lubricate |
50 – 500 Hour Maintenance Interval
| Maintenance Interval (Whichever Comes First) |
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| ITEM | HRS | CALENDAR | MILES (KM) | REMARKS |
| Throttle Pedal | 50 H | 6 M | 500 (800) | Inspect for free movement; replace pedal assembly if needed |
| Air Intake Ducts / Adapters | 50 H | 6 M | 500 (800) | Inspect ducts for proper sealing/air leaks |
| Drive Belt | 50 H | 6 M | 500 (800) | Inspect; replace as needed |
| Cooling System | 50 H | 6 M | 500 (800) | Inspect coolant strength seasonally; pressure test system yearly |
| Radiator | 50 H | 6 M | 500 (800) | Inspect; clean external surfaces |
| Oil Lines, fasteners | 50 H | 6 M | 500 (800) | Inspect for leaks and loose fittings |
| Engine Oil and Filter Change | 100 H | 6 M | 1000 (1600) | Replace oil and filter during engine oil change |
| Front Gearcase Lubricant (Demand Drive Fluid) | 100 H | 12 M | 1000 (1600) | Change lubricant |
| Transmission Lubricant (AGL Gearcase Lubricant) | 100 H | 12 M | 1000 (1600) | Change lubricant |
| Fuel System | 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 |
| Cooling Hoses | 100 H | 12 M | 1000 (1600) | Inspect for leaks |
| Engine Mounts | 100 H | 12 M | 1000 (1600) | Inspect, torque to specification |
| Exhaust Silencer / Pipe | 100 H | 12 M | 1000 (1600) | Inspect |
| Drive Shafts | 100 H | 12 M | 1000 (1600) | Remove and grease |
| 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. |
| Clutches (Drive and Driven) | 100 H | 12 M | 1000 (1600) | Inspect; clean; replace worn parts |
| Wheel Bearings | 100 H | 12 M | 1000 (1600) | Inspect; replace as needed |
| Ratcheting Cam Chain Tensioner | 200 H | – | 2000 (3200) | Check; replace as needed |
| Brake Fluid | 200 H | 24 M | 2000 (3200) | Change every two years (DOT 4) |
| Suspension Bushings | 250 H | 24 M | 2000 (3200) | Inspect; replace if necessary |
| Spark Arrestor | 300 H | 36 M | 3000 (4800 | Clean out |
| Spark Plug Replacement | 500 H | 36 M | 5000 (8000) | Replace; torque to specification |
| Valve Clearance | 500 H | – | 5000 (8000) | Inspect; adjust as needed |
| Coolant | – | 60 M | – | Replace coolant |
| Toe Adjustment | – | Inspect periodically; adjust when parts are replaced | ||
| Headlight Aim | – | Adjust as needed | ||
| ITEM | LUBE REC. | METHOD | FREQUENCY* |
| Brake Fluid | Polaris DOT 4 Brake Fluid | Maintain fluid level between “MAX and “MIN” lines on the master cylinder reservoir | Check level during pre-ride inspection; change fluid every two years |
| Front Gearcase | Polaris Demand Drive | Add lubricant until it is visible at the fill hole threads≈ 7.5 oz. (222 ml) | Initial level check at 25 hours or 1 month; Change lubricant at 100 hours or every 12 months, whichever comes first |
| Transmission | Polaris AGL | Add lubricant until it is visible at the fill hole threads |
*More often under severe use, such as operation in water or under severe loads.
Grease Lubrication Points
There are grease fittings at each A-arm pivot point, each rear stabilizer bar bushing, and on the propshaft yoke. Apply grease until all traces of water have been purged out at each of these areas.
| ITEM | METHOD | RECOMMENDED LUBE | FREQUENCY |
| A-arm Pivot Bushings | Grease all fittings on each side of the vehicle. Grease the fitting (3 pumps maximum) | Polaris All Season Grease | Grease fittings every 500 miles (800 km); Grease before long periods of storage, and after thoroughly washing or submerging the vehicle |
| Stabilizer Bar Bushings | |||
| Propshaft Yoke |