Content Source: 2019 PRO XD Diesel (9930762 Rev 01) > Maintenance Chapter

IMPORTANT

The Owner's Manual for this vehicle contains warnings, instructions and other information you must read and fully understand before safely riding or performing maintenance on this vehicle.Always follow the warnings and instructions in Owner's Manual.

Click the CONTENTS link above for the Table Of Contents, or download a full PDF of the Owner Manual in the Owner Support area of Polaris.com

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 periodic maintenance chart.
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.
Record maintenance and service in the Maintenance Log at the end of the manual.
TIP
Service and adjustments are important for proper vehicle operation. If you're not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.
Vehicles subjected to heavy or severe use patterns must be inspected and serviced more frequently.

Severe Use Definition

  • Frequent immersion in mud, water or sand
  • Prolonged low speed, heavy load operation

Maintenance Intervals

The maintenance interval charts outline required maintenance and inspection based on vehicle hours / miles. Each table states the number of hours / miles that service is required on the vehicle. Some items or components may need to be serviced more often due to severe use, such as operation in water or under severe loads. When the vehicle goes beyond 500 hours / 5000 miles, return to the 50 hours / 500 mile chart and start the interval process over.

Chart Key

XU - Perform these procedures more often for vehicles subjected to severe use.
D - Have an authorized Polaris dealer or qualified person perform these services.
E - Emission Control System Service (California)

50 Hour / 500 mile (800 km) Service

Item Remarks
XU / D Brake Pads / Parking Brake Pads Inspect pad wear; replace if worn beyond service limit
D / E Fuel System Turn key on to pressurize fuel pump; check lines and fittings for leaks and abrasion
XU / D Parking Brake Cable Adjustment Inspect; adjust tension as needed
  Battery Check terminals; clean; test
XU / E Engine Oil & Filter Change Perform a break-in oil and filter change at 50 hours or one month; perform every 200 hours or 6 months thereafter
XU Front Gearcase Lubricant Inspect / add lubricant if needed
XU Transmission Lubricant (AGL) Inspect / add lubricant if needed
D / E Throttle Pedal Inspect; replace if it sticks
XU Air Filter / Air Box Inspect/clean; replace filter as needed, or yearly
E Air Intake Ducts/Adapters Inspect ducts for proper sealing / air leaks
  Shift Cable / Linkage Inspect; adjust as needed
D Steering Inspect for loose components and torn boots; replace parts as needed
XU Front / Rear Suspension Lubricate (if applicable)
E Fuel Filter / Water Separator Drain every 50 hrs (normal conditions with quality fuel) or daily (severe conditions with poor fuel quality)
D Cooling System Inspect coolant strength seasonally; pressure test system yearly
D Drive Belt Inspect; replace as needed
D Clutches (Drive and Driven) Inspect; clean; replace worn parts

100 Hour / 1000 mile (1600 km) Service

Item Remarks
XU / D Brake Pads / Parking Brake Pads Inspect pad wear; replace if worn beyond service limit
D / E Fuel System Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion
XU / D Parking Brake Cable Adjustment Inspect; adjust tension as needed
  Battery Check terminals; clean; test
D / E Throttle Pedal Inspect; replace if it sticks
XU Air Filter / Air Box Inspect/clean; replace filter as needed, or yearly
E Air Intake Ducts/Adapters Inspect ducts for proper sealing / air leaks
  Shift Cable / Linkage Inspect; adjust as needed
D Steering Inspect for loose components and torn boots; replace parts as needed
D Fan/Alternator Belt Check fan belt tension and damage
XU Front / Rear Suspension Lubricate (if applicable)
D Cooling System Inspect coolant strength seasonally; pressure test system yearly
D Drive Belt Inspect; replace as needed
XU Front Gearcase Lubricant Change lubricant
XU Transmission Lubricant (AGL) Change lubricant
D / E Fuel System Check for leaks at fill cap and fuel pump.
E Fuel Filter / Water Separator Drain every 50 hrs (normal conditions with quality fuel) or daily (severe conditions with poor fuel quality)
XU Radiator Inspect; clean external surfaces
XU Cooling Hoses Inspect for leaks; pressure test system
XU Engine Mounts Inspect, torque to specification
  Exhaust Silencer / Pipe Inspect
XU Wiring Inspect for wear, routing, security; inspect connectors subjected to water, mud, etc.
D Clutches (Drive and Driven) Inspect; clean; replace worn parts
D Front Wheel Bearings Inspect; replace as needed
  Tires / Wheels Inspect tire tread at 100 hrs; rotate as needed
XU Shocks Visually inspect shock seals; change oil and seals if leaking

150 Hour / 1500 mile (2400 km) Service

Item Remarks
XU / D Brake Pads / Parking Brake Pads Inspect pad wear; replace if worn beyond service limit
D / E Fuel System Turn key on to pressurize fuel pump; check lines and fittings for leaks and abrasion
XU / D Parking Brake Cable Adjustment Inspect; adjust tension as needed
  Battery Check terminals; clean; test
XU Front Gearcase Lubricant Inspect / add lubricant if needed
XU Transmission Lubricant (AGL) Inspect / add lubricant if needed
D / E Throttle Pedal Inspect; replace if it sticks
XU Air Filter / Air Box Inspect/clean; replace filter as needed, or yearly
E Air Intake Ducts/Adapters Inspect ducts for proper sealing / air leaks
  Shift Cable / Linkage Inspect; adjust as needed
D Steering Inspect for loose components and torn boots; replace parts as needed
XU Front / Rear Suspension Lubricate (if applicable)
E Fuel Filter / Water Separator Replace filter
D Cooling System Inspect coolant strength seasonally; pressure test system yearly
D Drive Belt Inspect; replace as needed
D Clutches (Drive and Driven) Inspect; clean; replace worn parts

200 Hour / 2000 mile (3200 km) Service

Item Remarks
XU / D Brake Pads / Parking Brake Pads Inspect pad wear; replace if worn beyond service limit
D / E Fuel System Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion
XU / D Parking Brake Cable Adjustment Inspect; adjust tension as needed
  Battery Check terminals; clean; test
D / E Throttle Pedal Inspect; replace if it sticks
XU Air Filter / Air Box Inspect/clean; replace filter as needed, or yearly
E Air Intake Ducts/Adapters Inspect ducts for proper sealing / air leaks
  Shift Cable / Linkage Inspect; adjust as needed
D Steering Inspect for loose components and torn boots; replace parts as needed
D Fan/Alternator Belt Check fan belt tension and damage
XU Front / Rear Suspension Lubricate (if applicable)
D Cooling System Inspect coolant strength seasonally; pressure test system yearly
D Drive Belt Inspect; replace as needed
XU Front Gearcase Lubricant Change lubricant
XU Transmission Lubricant (AGL) Change lubricant
D / E Fuel System Check for leaks at fill cap and fuel pump.
E Fuel Filter / Water Separator Drain every 50 hrs (normal conditions with quality fuel) or daily (severe conditions with poor fuel quality)
XU Radiator Inspect; clean external surfaces
XU Cooling Hoses Inspect for leaks; pressure test system
XU Engine Mounts Inspect, torque to specification
  Exhaust Silencer / Pipe Inspect
XU Wiring Inspect for wear, routing, security; inspect connectors subjected to water, mud, etc.
D Clutches (Drive and Driven) Inspect; clean; replace worn parts
D Front Wheel Bearings Inspect; replace as needed
  Tires / Wheels Inspect tire tread at 100 hrs; rotate as needed
XU Shocks Visually inspect shock seals; change oil and seals if leaking
D Brake Fluid Change every two years (DOT 4)

250 Hour / 2500 mile (4000 km) Service

Item Remarks
XU / D Brake Pads / Parking Brake Pads Inspect pad wear; replace if worn beyond service limit
D / E Fuel System Turn key on to pressurize fuel pump; check lines and fittings for leaks and abrasion
XU / D Parking Brake Cable Adjustment Inspect; adjust tension as needed
  Battery Check terminals; clean; test
XU / E Engine Oil & Filter Change Perform a break-in oil and filter change at 50 hours or one month; perform every 200 hours or 6 months thereafter
XU Front Gearcase Lubricant Inspect / add lubricant if needed
XU Transmission Lubricant (AGL) Inspect / add lubricant if needed
D / E Throttle Pedal Inspect; replace if it sticks
XU Air Filter / Air Box Inspect/clean; replace filter as needed, or yearly
E Air Intake Ducts/Adapters Inspect ducts for proper sealing / air leaks
  Shift Cable / Linkage Inspect; adjust as needed
D Steering Inspect for loose components and torn boots; replace parts as needed
  Suspension Bushings Inspect at 250 hours; replace if necessary
XU Front / Rear Suspension Lubricate (if applicable)
E Fuel Filter / Water Separator Drain every 50 hrs (normal conditions with quality fuel) or daily (severe conditions with poor fuel quality)
D Cooling System Inspect coolant strength seasonally; pressure test system yearly
D Drive Belt Inspect; replace as needed
D Clutches (Drive and Driven) Inspect; clean; replace worn parts

300 Hour / 3000 mile (4800 km) Service

Item Remarks
XU / D Brake Pads / Parking Brake Pads Inspect pad wear; replace if worn beyond service limit
D / E Fuel System Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion
XU / D Parking Brake Cable Adjustment Inspect; adjust tension as needed
  Battery Check terminals; clean; test
D / E Throttle Pedal Inspect; replace if it sticks
XU Air Filter / Air Box Inspect/clean; replace filter as needed, or yearly
E Air Intake Ducts/Adapters Inspect ducts for proper sealing / air leaks
  Shift Cable / Linkage Inspect; adjust as needed
D Steering Inspect for loose components and torn boots; replace parts as needed
D Fan/Alternator Belt Check fan belt tension and damage
XU Front / Rear Suspension Lubricate (if applicable)
D Cooling System Inspect coolant strength seasonally; pressure test system yearly
D Drive Belt Inspect; replace as needed
XU Front Gearcase Lubricant Change lubricant
XU Transmission Lubricant (AGL) Change lubricant
D / E Fuel System Check for leaks at fill cap and fuel pump.
E Fuel Filter / Water Separator Replace filter
XU Radiator Inspect; clean external surfaces
XU Cooling Hoses Inspect for leaks; pressure test system
XU Engine Mounts Inspect, torque to specification
  Exhaust Silencer / Pipe Inspect
XU Wiring Inspect for wear, routing, security; inspect connectors subjected to water, mud, etc.
D Clutches (Drive and Driven) Inspect; clean; replace worn parts
D Front Wheel Bearings Inspect; replace as needed
  Tires / Wheels Inspect tire tread at 100 hrs; rotate as needed
XU Shocks Visually inspect shock seals; change oil and seals if leaking

350 Hour / 3500 mile (5600 km) Service

Item Remarks
XU / D Brake Pads / Parking Brake Pads Inspect pad wear; replace if worn beyond service limit
D / E Fuel System Turn key on to pressurize fuel pump; check lines and fittings for leaks and abrasion
XU / D Parking Brake Cable Adjustment Inspect; adjust tension as needed
  Battery Check terminals; clean; test
XU Front Gearcase Lubricant Inspect / add lubricant if needed
XU Transmission Lubricant (AGL) Inspect / add lubricant if needed
D / E Throttle Pedal Inspect; replace if it sticks
XU Air Filter / Air Box Inspect/clean; replace filter as needed, or yearly
E Air Intake Ducts/Adapters Inspect ducts for proper sealing / air leaks
  Shift Cable / Linkage Inspect; adjust as needed
D Steering Inspect for loose components and torn boots; replace parts as needed
XU Front / Rear Suspension Lubricate (if applicable)
E Fuel Filter / Water Separator Drain every 50 hrs (normal conditions with quality fuel) or daily (severe conditions with poor fuel quality)
D Cooling System Inspect coolant strength seasonally; pressure test system yearly
D Drive Belt Inspect; replace as needed
D Clutches (Drive and Driven) Inspect; clean; replace worn parts

400 Hour / 4000 mile (6400 km) Service

Item Remarks
XU / D Brake Pads / Parking Brake Pads Inspect pad wear; replace if worn beyond service limit
D / E Fuel System Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion
XU / D Parking Brake Cable Adjustment Inspect; adjust tension as needed
  Battery Check terminals; clean; test
D / E Throttle Pedal Inspect; replace if it sticks
XU Air Filter / Air Box Inspect/clean; replace filter as needed, or yearly
E Air Intake Ducts/Adapters Inspect ducts for proper sealing / air leaks
  Shift Cable / Linkage Inspect; adjust as needed
D Steering Inspect for loose components and torn boots; replace parts as needed
D Fan/Alternator Belt Check fan belt tension and damage
XU Front / Rear Suspension Lubricate (if applicable)
D Cooling System Inspect coolant strength seasonally; pressure test system yearly
D Drive Belt Inspect; replace as needed
XU Front Gearcase Lubricant Change lubricant
XU Transmission Lubricant (AGL) Change lubricant
D / E Fuel System Check for leaks at fill cap and fuel pump.
E Fuel Filter / Water Separator Replace filter
XU Radiator Inspect; clean external surfaces
XU Cooling Hoses Inspect for leaks; pressure test system
XU Engine Mounts Inspect, torque to specification
  Exhaust Silencer / Pipe Inspect
XU Wiring Inspect for wear, routing, security; inspect connectors subjected to water, mud, etc.
D Clutches (Drive and Driven) Inspect; clean; replace worn parts
D Front Wheel Bearings Inspect; replace as needed
  Tires / Wheels Inspect tire tread at 100 hrs; rotate as needed
XU Shocks Visually inspect shock seals; change oil and seals if leaking
D Brake Fluid Change every two years (DOT 4)

450 Hour / 4500 mile (7200 km) Service

Item Remarks
XU / D Brake Pads / Parking Brake Pads Inspect pad wear; replace if worn beyond service limit
D / E Fuel System Turn key on to pressurize fuel pump; check lines and fittings for leaks and abrasion
XU / D Parking Brake Cable Adjustment Inspect; adjust tension as needed
  Battery Check terminals; clean; test
XU / E Engine Oil & Filter Change Perform a break-in oil and filter change at 50 hours or one month; perform every 200 hours or 6 months thereafter
XU Front Gearcase Lubricant Inspect / add lubricant if needed
XU Transmission Lubricant (AGL) Inspect / add lubricant if needed
D / E Throttle Pedal Inspect; replace if it sticks
XU Air Filter / Air Box Inspect/clean; replace filter as needed, or yearly
E Air Intake Ducts/Adapters Inspect ducts for proper sealing / air leaks
  Shift Cable / Linkage Inspect; adjust as needed
D Steering Inspect for loose components and torn boots; replace parts as needed
XU Front / Rear Suspension Lubricate (if applicable)
E Fuel Filter / Water Separator Replace filter
D Cooling System Inspect coolant strength seasonally; pressure test system yearly
D Drive Belt Inspect; replace as needed
D Clutches (Drive and Driven) Inspect; clean; replace worn parts

500 Hour / 5000 mile (8000 km) Service

Item Remarks
XU / D Brake Pads / Parking Brake Pads Inspect pad wear; replace if worn beyond service limit
D / E Fuel System Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion
XU / D Parking Brake Cable Adjustment Inspect; adjust tension as needed
  Battery Check terminals; clean; test
D / E Throttle Pedal Inspect; replace if it sticks
XU Air Filter / Air Box Inspect/clean; replace filter as needed, or yearly
E Air Intake Ducts/Adapters Inspect ducts for proper sealing / air leaks
  Shift Cable / Linkage Inspect; adjust as needed
D Steering Inspect for loose components and torn boots; replace parts as needed
  Suspension Bushings Inspect at 250 hours; replace if necessary
D Fan/Alternator Belt Replace belt
XU Front / Rear Suspension Lubricate (if applicable)
D Cooling System Inspect coolant strength seasonally; pressure test system yearly
D Drive Belt Inspect; replace as needed
XU Front Gearcase Lubricant Change lubricant
XU Transmission Lubricant (AGL) Change lubricant
D / E Fuel System Check for leaks at fill cap and fuel pump.
E Fuel Filter / Water Separator Drain every 50 hrs (normal conditions with quality fuel) or daily (severe conditions with poor fuel quality)
XU Radiator Inspect; clean external surfaces
XU Cooling Hoses Inspect for leaks; pressure test system
XU Engine Mounts Inspect, torque to specification
  Exhaust Silencer / Pipe Inspect
XU Wiring Inspect for wear, routing, security; inspect connectors subjected to water, mud, etc.
D Clutches (Drive and Driven) Inspect; clean; replace worn parts
D Front Wheel Bearings Inspect; replace as needed
  Tires / Wheels Inspect tire tread at 100 hrs; rotate as needed
XU Shocks Visually inspect shock seals; change oil and seals if leaking
D Brake Fluid Change every two years (DOT 4)
XU Coolant Replace coolant
D Toe Adjustment Inspect periodically; adjust when parts are replaced
When the vehicle goes beyond 500 hours / 5000 miles, return to the 50 hours / 500 mile chart and start the interval process over.

Extended Items

  Remarks
Engine Check valve clearance every 800 hours
Engine Check injection nozzle condition every 1000 hours
Engine Check injection timing every 3000 hours

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