Polaris Service Maintenance Schedule | Sappington Pro Outdoor, Jackson MO

Polaris Service Maintenance Schedule

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10 - 50 Hour Maintenance Interval

  Maintenance Interval
(Whichever Comes First)		  
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)		  
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      
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