Content Source: 2020 PRO XD Gas Owner’s Manual (9930920 R01) > 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 Overview

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 may be used for such service.
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.
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 critical. If you’re not familiar with safe service and adjustment procedures, 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 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
  • 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.

Break-In Period

The break-in period consists of the first 25 hours of operation. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components.
  • Drive vehicle slowly at first while varying the throttle position. Do not operate at sustained idle.
  • Perform regular checks on fluid levels and other areas outlined on the daily pre-ride inspection checklist.
  • Change both the engine oil and filter after 25 hours or one month.

Maintenance Intervals

The maintenance interval charts list required maintenance and inspection based on vehicle hours / miles. Each table states a service that corresponds to the hour / mile chart below. Some items or components may need to be serviced more often due to severe use, such as operation in water, extreme temperatures, 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.
Hour / Mileage Service
25 hour / 250 mile Break-In Service
50 hour / 500 mile
100 hour / 1000 mile
150 hour / 1500 mile
200 hour / 2000 mile
250 hour / 2500 mile
300 hour / 3000 mile
350 hour / 3500 mile
400 hour / 4000 mile
450 hour / 4500 mile
500 hour / 5000 mile

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

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

E - Emission Control System Service (California)
Break-In Service
Code Item Action
XU Air Filter / Air Box Check filter and clean air box if needed
  Battery Check terminals; clean; test
  Brake Fluid Check level and color
XU / D Brake Pads Inspect pad wear
XU / E Engine Breather Inspect; clean
  Engine Oil & Filter Change (Break-In) Break in oil change at 25 hours
E EVAP System Inspect Fuel and EVAP system if equipped
XU Front Gearcase Lubricant Initial fluid level inspection; add lubricant if needed
  Fuel System Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion
XU Transmission Lubricant (AGL) Initial fluid level inspection; add lubricant if needed

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

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

E - Emission Control System Service (California)
Service
Code Item Action
XU Air Filter / Air Box Check filter and clean air box if needed
  Battery Check terminals; clean; test
  Brake Fluid Check level and color
XU / D Brake Pads Inspect pad wear
XU / D Clutches (Drive and Driven) Inspect; clean; replace worn parts
D Cooling System Inspect coolant strength seasonally; pressure test system yearly
D Drive Belt Inspect; replace as needed
XU / E Engine Breather Inspect; clean
XU Engine Oil & Filter Change Change oil and filter, inspect used oil for contaminants
XU Engine Oil Lines/Fasteners Inspect for leaks and loose fittings
E EVAP System Inspect Fuel and EVAP system if equipped
XU Front / Rear Suspension Lubricate (if applicable)
XU Front Gearcase Lubricant Inspect, add lubricant if needed
  Fuel System Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion. Replace as needed
XU Propshaft Inspect and lubricate
  Shift Cable / Linkage Inspect; adjust as needed
D Steering Inspect for loose components and torn boots; replace parts as needed
E Throttle Body Intake Ducts/Flange Inspect ducts for proper sealing / air leaks
D / E Throttle Pedal Inspect; replace if it sticks
XU Transmission Lubricant (AGL) Inspect, add lubricant if needed

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

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

E - Emission Control System Service (California)
Service
Code Item Action
XU Air Filter / Air Box Check filter and clean air box if needed
  Battery Check terminals; clean; test
  Brake Fluid Check level and color
XU / D Brake Pads Inspect pad wear
  Cam Chain Tensioner Inspect/clean; replace as needed
XU / D Clutches (Drive and Driven) Inspect; clean; replace worn parts
  Cooling Hoses Inspect for leaks; pressure test system
D Cooling System Inspect coolant strength seasonally; pressure test system yearly
D Drive Belt Inspect; replace as needed
XU / E Engine Breather Inspect; clean
  Engine Mounts Inspect, torque to specification
XU Engine Oil & Filter Change Change oil and filter, inspect used oil for contaminants
XU Engine Oil Lines/Fasteners Inspect for leaks and loose fittings
E EVAP System Inspect Fuel and EVAP system if equipped.
  Exhaust Silencer / Pipe Inspect
XU Front / Rear Suspension Lubricate (if applicable)
XU Front Gearcase Lubricant Change lubricant
XU Front Wheel Bearings Inspect; replace as needed
  Fuel System Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion. Replace as needed
XU Propshaft Inspect and lubricate
XU Radiator Inspect; clean external surfaces
  Shift Cable / Linkage Inspect; adjust as needed
XU Shocks Inspect for leaks
  Spark Plug Inspection Inspect; replace as needed; torque to specification
D Steering Inspect for loose components and torn boots; replace parts as needed
E Throttle Body Intake Ducts/Flange Inspect ducts for proper sealing / air leaks
D / E Throttle Pedal Inspect; replace if it sticks
XU Tires Inspect tread wear and rotate
XU Transmission Lubricant (AGL) Change lubricant
XU Wiring Inspect routing and for wear; inspect connectors subjected to water/mud.

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

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

E - Emission Control System Service (California)
Service
Code Item Action
D Change Brake Fluid Change every 2 years (DOT 4)
D / E Valve Clearance  Inspect; adjust as needed

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

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

E - Emission Control System Service (California)
Service
Code Item Action
XU Coolant Replace coolant
D / E Spark Plug Replacement Replace; torque to specification
D Toe Adjustment Inspect periodically; adjust when parts are replaced
D / E Valve Clearance Inspect; adjust as needed

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