Content Source: 2021 RZR S4 1000 Owner’s Manual (9931549 R02) > 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, use genuine POLARIS parts available from your POLARIS dealer.
Record maintenance and service in the Maintenance Log at the end of the manual.
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
  • Racing or race-style high RPM use
  • Prolonged low speed, heavy load operation
  • Extended idle
  • Frequent short trip operation in cold weather (engine frequently does not operate long enough to reach full operating temperature)
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 authorized dealer.

Pre-Ride Inspection

Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition.
Item Remarks Ref

Brake system/pedal travel

Ensure proper operation

 Brake and Throttle Pedals
Brakes

Brake fluid

Ensure proper level

 Brake Fluid

Front suspension

Inspect, lubricate if necessary

 Lubrication Recommendations

Rear suspension

Inspect, lubricate if necessary

 Lubrication Recommendations

Steering

Ensure free operation

 Steering Wheel Inspection

Tires

Inspect condition and pressure

 Load / Passenger / Tire Pressure Warning
Tire Tread Depth

Wheels/fasteners

Inspect, ensure fastener tightness

 Wheel Removal

Frame nuts, bolts, fasteners

Inspect, ensure tightness

 –

Fuel and oil

Ensure proper levels

 Fuel Cap
Oil Check

Coolant level

Ensure proper level

 Cooling System

Coolant hoses

Inspect for leaks

 –

Throttle

Ensure proper operation

 –

Indicator lights/switches

Ensure proper operation

 Indicator Lamps

PVT intake pre-filter

Inspect, clean

 POLARIS Variable Transmission (PVT) System

Headlights

Check operation

 –

Brake light/taillight

Check operation

 –

Seat Latches

Push down on both seat backs to ensure the latches are secure

 Seats

Seat Belts

Check length of belt for damage, check latches for proper operation

 Seat Belt Inspection

Cab Doors

Check doors and latches for wear or damage.

 Cab Doors

Grass and Leaves

Remove grass, leaves, foreign matter, and other flammable material or debris, especially near the exhaust system.

 –

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 (8000 km), return to the 25 hours / 250 miles (400 km) chart and start the interval process over.

25 Hour / 250 miles (400 km) Service

Item Remarks
XU / D Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear
  Fuel System Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion
XU / D Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours
XU Engine Breather Inspect; clean
  Battery Check terminals; clean; test
XU Engine Oil & Filter Change (Break-In) Perform a break-in oil and filter change at 25 hours or one month; perform every 50 hours or 6 months thereafter
XU Front Gearcase Lubricant Initial fluid level inspection; add lubricant if needed
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 qualified person perform these services.

50 Hour / 500 miles (800 km) Service

Item Remarks
XU / D Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit
  Fuel System Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion
XU / D Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours
XU Engine Breather Inspect; clean
  Battery Check terminals; clean; test
XU Front Gearcase Lubricant Inspect / add lubricant if needed
XU Transmission Lubricant (AGL) Inspect / add lubricant if needed
XU General Lubrication Lubricate all fittings, pivots, cables, etc.
D Throttle Pedal Inspect; replace if it sticks
  Throttle Body Intake Ducts/Flange Inspect ducts for proper sealing / air leaks
  Shift Cable / Linkage Inspect; adjust as needed
D Steering Lubricate (if applicable)
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
D Clutches (Drive and Driven) Inspect; clean; replace worn parts
XU Engine Oil Lines/Fasteners Inspect for leaks and loose fittings
XU Shock Absorbers Inspect for leaks, loose joints, and wear
XU - Perform these procedures more often for vehicles subjected to severe use.
D - Have an authorized Polaris dealer or qualified person perform these services.

75 Hour / 750 miles (1200 km) Service

Item Remarks
XU / D Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit
  Fuel System Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion
XU / D Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours
XU Engine Breather Inspect; clean
  Battery Check terminals; clean; test
XU Engine Oil & Filter Change Change oil and filter, inspect used oil for contaminants
XU Air Filter Inspect; replace as needed
XU Front Gearcase Lubricant Inspect / add lubricant if needed
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 qualified person perform these services.

100 Hour / 1000 miles (1600 km) Service

Item Remarks
XU / D Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit
  Fuel System Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion
XU / D Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours
XU Engine Breather Inspect; clean
  Battery Check terminals; clean; test
XU General Lubrication Lubricate all fittings, pivots, cables, etc.
D Throttle Pedal Inspect; replace if it sticks
  Throttle Body Intake Ducts/Flange Inspect ducts for proper sealing / air leaks
  Shift Cable / Linkage Inspect; adjust as needed
D Steering Lubricate (if applicable)
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 Engine Oil Lines/Fasteners Inspect for leaks and loose fittings
XU / D Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension as needed
XU Front Gearcase Lubricant Change lubricant
XU Transmission Lubricant (AGL) Change lubricant
D Fuel System Check for leaks at fill cap, fuel line / rail, and fuel pump.
D Spark Plug Inspection Inspect; replace as needed; torque to specification
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
  Cam Chain Tensioner Inspect/clean; replace as needed
XU Shock Absorbers Inspect for leaks, loose joints, and wear
XU - Perform these procedures more often for vehicles subjected to severe use.
D - Have an authorized Polaris dealer or qualified person perform these services.

125 Hour / 1250 miles (2000 km) Service

Item Remarks
XU / D Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit
  Fuel System Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion
XU / D Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours
XU Engine Breather Inspect; clean
  Battery Check terminals; clean; test
XU Engine Oil & Filter Change Change oil and filter, inspect used oil for contaminants
XU Air Filter Inspect; replace as needed
XU Front Gearcase Lubricant Inspect / add lubricant if needed
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 qualified person perform these services.

150 Hour / 1500 miles (2400 km) Service

Item Remarks
XU / D Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit
  Fuel System Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion
XU / D Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours
XU Engine Breather Inspect; clean
  Battery Check terminals; clean; test
XU Front Gearcase Lubricant Inspect / add lubricant if needed
XU Transmission Lubricant (AGL) Inspect / add lubricant if needed
XU General Lubrication Lubricate all fittings, pivots, cables, etc.
D Throttle Pedal Inspect; replace if it sticks
  Throttle Body Intake Ducts/Flange Inspect ducts for proper sealing / air leaks
  Shift Cable / Linkage Inspect; adjust as needed
D Steering Lubricate (if applicable)
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
D Clutches (Drive and Driven) Inspect; clean; replace worn parts
XU Engine Oil Lines/Fasteners Inspect for leaks and loose fittings
XU Shock Absorbers Inspect for leaks, loose joints, and wear
XU - Perform these procedures more often for vehicles subjected to severe use.
D - Have an authorized Polaris dealer or qualified person perform these services.

175 Hour / 1750 miles (2800 km) Service

Item Remarks
XU / D Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit
  Fuel System Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion
XU / D Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours
XU Engine Breather Inspect; clean
  Battery Check terminals; clean; test
XU Engine Oil & Filter Change Change oil and filter, inspect used oil for contaminants
XU Air Filter Inspect; replace as needed
XU Front Gearcase Lubricant Inspect / add lubricant if needed
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 qualified person perform these services.

200 Hour / 2000 miles (3200 km) Service

Item Remarks
XU / D Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit
  Fuel System Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion
XU / D Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours
XU Engine Breather Inspect; clean
  Battery Check terminals; clean; test
XU General Lubrication Lubricate all fittings, pivots, cables, etc.
D Throttle Pedal Inspect; replace if it sticks
  Throttle Body Intake Ducts/Flange Inspect ducts for proper sealing / air leaks
  Shift Cable / Linkage Inspect; adjust as needed
D Steering Lubricate (if applicable)
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
D Clutches (Drive and Driven) Inspect; clean; replace worn parts
XU Engine Oil Lines/Fasteners Inspect for leaks and loose fittings
XU / D Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension as needed
XU Front Gearcase Lubricant Change lubricant
XU Transmission Lubricant (AGL) Change lubricant
D Fuel System Check for leaks at fill cap, fuel line / rail, and fuel pump.
D Spark Plug Inspection Inspect; replace as needed; torque to specification
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 routing and for wear; inspect connectors subjected to water/mud.
D Front Wheel Bearings Inspect; replace as needed
D Brake Fluid Change every two years (DOT 4)
  Spark Arrestor Clean daily if driven in mud / water; replace a damaged arrestor before operating
  Cam Chain Tensioner Inspect/clean; replace as needed
D Valve Clearance Inspect; adjust as needed
XU Shock Absorbers Inspect for leaks, loose joints, and wear
XU - Perform these procedures more often for vehicles subjected to severe use.
D - Have an authorized Polaris dealer or qualified person perform these services.

225 Hour / 2250 miles (3600 km) Service

Item Remarks
XU / D Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit
  Fuel System Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion
XU / D Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours
XU Engine Breather Inspect; clean
  Battery Check terminals; clean; test
XU Engine Oil & Filter Change Change oil and filter, inspect used oil for contaminants
XU Air Filter Inspect; replace as needed
XU Front Gearcase Lubricant Inspect / add lubricant if needed
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 qualified person perform these services.

250 Hour / 2500 miles (4000 km) Service

Item Remarks
XU / D Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit
  Fuel System Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion
XU / D Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours
XU Engine Breather Inspect; clean
  Battery Check terminals; clean; test
XU Front Gearcase Lubricant Inspect / add lubricant if needed
XU Transmission Lubricant (AGL) Inspect / add lubricant if needed
XU General Lubrication Lubricate all fittings, pivots, cables, etc.
D Throttle Pedal Inspect; replace if it sticks
  Throttle Body Intake Ducts/Flange Inspect ducts for proper sealing / air leaks
  Shift Cable / Linkage Inspect; adjust as needed
D Steering Lubricate (if applicable)
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
D Clutches (Drive and Driven) Inspect; clean; replace worn parts
XU Engine Oil Lines/Fasteners Inspect for leaks and loose fittings
XU / D Shock Absorbers Replace or rebuild (if applicable)
XU - Perform these procedures more often for vehicles subjected to severe use.
D - Have an authorized Polaris dealer or qualified person perform these services.

275 Hour / 2750 miles (4400 km) Service

Item Remarks
XU / D Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit
  Fuel System Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion
XU / D Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours
XU Engine Breather Inspect; clean
  Battery Check terminals; clean; test
XU Engine Oil & Filter Change Change oil and filter, inspect used oil for contaminants
XU Air Filter Inspect; replace as needed
XU Front Gearcase Lubricant Inspect / add lubricant if needed
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 qualified person perform these services.

300 Hour / 3000 miles (4800 km) Service

Item Remarks
XU / D Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit
  Fuel System Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion
XU / D Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours
XU Engine Breather Inspect; clean
  Battery Check terminals; clean; test
XU General Lubrication Lubricate all fittings, pivots, cables, etc.
D Throttle Pedal Inspect; replace if it sticks
  Throttle Body Intake Ducts/Flange Inspect ducts for proper sealing / air leaks
  Shift Cable / Linkage Inspect; adjust as needed
D Steering Lubricate (if applicable)
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
D Clutches (Drive and Driven) Inspect; clean; replace worn parts
XU Engine Oil Lines/Fasteners Inspect for leaks and loose fittings
XU / D Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension as needed
XU Front Gearcase Lubricant Change lubricant
XU Transmission Lubricant (AGL) Change lubricant
D Fuel System Check for leaks at fill cap, fuel line / rail, and fuel pump.
D Spark Plug Inspection Inspect; replace as needed; torque to specification
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 Front Wheel Bearings Inspect; replace as needed
  Cam Chain Tensioner Inspect/clean; replace as needed
XU Shock Absorbers Inspect for leaks, loose joints, and wear
XU - Perform these procedures more often for vehicles subjected to severe use.
D - Have an authorized Polaris dealer or qualified person perform these services.

325 Hour / 3250 miles (5200 km) Service

Item Remarks
XU / D Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit
  Fuel System Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion
XU / D Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours
XU Engine Breather Inspect; clean
  Battery Check terminals; clean; test
XU Engine Oil & Filter Change Change oil and filter, inspect used oil for contaminants
XU Air Filter Inspect; replace as needed
XU Front Gearcase Lubricant Inspect / add lubricant if needed
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 qualified person perform these services.

350 Hour / 3500 miles (5600 km) Service

Item Remarks
XU / D Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit
  Fuel System Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion
XU / D Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours
XU Engine Breather Inspect; clean
  Battery Check terminals; clean; test
XU Front Gearcase Lubricant Inspect / add lubricant if needed
XU Transmission Lubricant (AGL) Inspect / add lubricant if needed
XU General Lubrication Lubricate all fittings, pivots, cables, etc.
D Throttle Pedal Inspect; replace if it sticks
  Throttle Body Intake Ducts/Flange Inspect ducts for proper sealing / air leaks
  Shift Cable / Linkage Inspect; adjust as needed
D Steering Lubricate (if applicable)
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
D Clutches (Drive and Driven) Inspect; clean; replace worn parts
XU Engine Oil Lines/Fasteners Inspect for leaks and loose fittings
XU Shock Absorbers Inspect for leaks, loose joints, and wear
XU - Perform these procedures more often for vehicles subjected to severe use.
D - Have an authorized Polaris dealer or qualified person perform these services.

375 Hour / 3750 miles (6000 km) Service

Item Remarks
XU / D Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit
  Fuel System Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion
XU / D Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours
XU Engine Breather Inspect; clean
  Battery Check terminals; clean; test
XU Engine Oil & Filter Change Change oil and filter, inspect used oil for contaminants
XU Air Filter Inspect; replace as needed
XU Front Gearcase Lubricant Inspect / add lubricant if needed
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 qualified person perform these services.

400 Hour / 4000 miles (6400 km) Service

Item Remarks
XU / D Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit
  Fuel System Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion
XU / D Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours
XU Engine Breather Inspect; clean
  Battery Check terminals; clean; test
XU General Lubrication Lubricate all fittings, pivots, cables, etc.
D Throttle Pedal Inspect; replace if it sticks
  Throttle Body Intake Ducts/Flange Inspect ducts for proper sealing / air leaks
  Shift Cable / Linkage Inspect; adjust as needed
D Steering Lubricate (if applicable)
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
D Clutches (Drive and Driven) Inspect; clean; replace worn parts
XU Engine Oil Lines/Fasteners Inspect for leaks and loose fittings
XU / D Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension as needed
XU Front Gearcase Lubricant Change lubricant
XU Transmission Lubricant (AGL) Change lubricant
D Fuel System Check for leaks at fill cap, fuel line / rail, and fuel pump.
D Spark Plug Inspection Inspect; replace as needed; torque to specification
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 Front Wheel Bearings Inspect; replace as needed
D Brake Fluid Change every two years (DOT 4)
  Spark Arrestor Clean daily if driven in mud / water; replace a damaged arrestor before operating
  Cam Chain Tensioner Inspect/clean; replace as needed
D Valve Clearance Inspect; adjust as needed
XU Shock Absorbers Inspect for leaks, loose joints, and wear
XU - Perform these procedures more often for vehicles subjected to severe use.
D - Have an authorized Polaris dealer or qualified person perform these services.

425 Hour / 4250 miles (6800 km) Service

Item Remarks
XU / D Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit
  Fuel System Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion
XU / D Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours
XU Engine Breather Inspect; clean
  Battery Check terminals; clean; test
XU Engine Oil & Filter Change Change oil and filter, inspect used oil for contaminants
XU Air Filter Inspect; replace as needed
XU Front Gearcase Lubricant Inspect / add lubricant if needed
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 qualified person perform these services.

450 Hour / 4500 miles (7200 km) Service

Item Remarks
XU / D Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit
  Fuel System Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion
XU / D Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours
XU Engine Breather Inspect; clean
  Battery Check terminals; clean; test
XU Front Gearcase Lubricant Inspect / add lubricant if needed
XU Transmission Lubricant (AGL) Inspect / add lubricant if needed
XU General Lubrication Lubricate all fittings, pivots, cables, etc.
D Throttle Pedal Inspect; replace if it sticks
  Throttle Body Intake Ducts/Flange Inspect ducts for proper sealing / air leaks
  Shift Cable / Linkage Inspect; adjust as needed
D Steering Lubricate (if applicable)
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
D Clutches (Drive and Driven) Inspect; clean; replace worn parts
XU Engine Oil Lines/Fasteners Inspect for leaks and loose fittings
XU Shock Absorbers Inspect for leaks, loose joints, and wear
XU - Perform these procedures more often for vehicles subjected to severe use.
D - Have an authorized Polaris dealer or qualified person perform these services.

475 Hour / 4750 miles (7600 km) Service

Item Remarks
XU / D Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit
  Fuel System Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion
XU / D Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours
XU Engine Breather Inspect; clean
  Battery Check terminals; clean; test
XU Engine Oil & Filter Change Change oil and filter, inspect used oil for contaminants
XU Air Filter Inspect; replace as needed
XU Front Gearcase Lubricant Inspect / add lubricant if needed
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 qualified person perform these services.

500 Hour / 5000 miles (8000 km) Service

Item Remarks
XU / D Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit
  Fuel System Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion
XU / D Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours
XU Engine Breather Inspect; clean
  Battery Check terminals; clean; test
XU General Lubrication Lubricate all fittings, pivots, cables, etc.
D Throttle Pedal Inspect; replace if it sticks
  Throttle Body Intake Ducts/Flange Inspect ducts for proper sealing / air leaks
  Shift Cable / Linkage Inspect; adjust as needed
D Steering Lubricate (if applicable)
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 Engine Oil Lines/Fasteners Inspect for leaks and loose fittings
XU / D Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension as needed
XU Front Gearcase Lubricant Change lubricant
XU Transmission Lubricant (AGL) Change lubricant
D Fuel System Check for leaks at fill cap, fuel line / rail, and fuel pump.
D Spark Plug Inspection Inspect; replace as needed; torque to specification
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
D Brake Fluid Change every two years (DOT 4)
  Spark Arrestor Clean daily if driven in mud / water; replace a damaged arrestor before operating
  Cam Chain Tensioner Inspect; replace as needed
D Valve Clearance Inspect; adjust as needed
D Spark Plug Replacement Replace; torque to specification
XU Coolant Replace coolant
D Toe Adjustment Inspect periodically; adjust when parts are replaced
  Cam Chain Tensioner Inspect/clean; replace as needed
XU / D Shock Absorbers Replace or rebuild (if applicable)
XU - Perform these procedures more often for vehicles subjected to severe use.
D - Have an authorized Polaris dealer or qualified person perform these services.
When the vehicle goes beyond 500 hours / 5000 miles (8000 km), return to the 25 hours / 250 miles (400 km) chart and start the interval process over.

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