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9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual
© Copyright Polaris Industries Inc.
500 HOUR / 5000 MILE (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.
XU / D
Clutches (Drive and Driven) Inspect; clean; replace worn parts
D
Front Wheel Bearings Inspect; replace as needed
XU / D Shocks
Change shock oil and inspect seals
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 - 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, return to the 25 hours / 250 mile chart and start the interval
process over.
MAINTENANCE
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