400cc and 500cc ATV
Engine Oil Level
The oil tank is located on the left side of the vehicle. To
check the oil level:
1. Set machine on a level surface.
2. Clean the area around the dip stick.
3. Start and run engine for 20-30 seconds. This will
return oil to its true level in the oil tank.
4. Stop engine, remove dipstick (A) and wipe dry with a
clean cloth.
5. Reinstall dipstick, screw the dipstick into place.
NOTE: The dipstick must be screwed completely in to
ensure accurate measurement.
Maintain Oil Level In Normal range
Screw Dipstick in completely to check
6. Remove dipstick and check to see that the oil level is
in the normal range. The oil should be between the top
line and the bottom line on the dipstick. Add oil as
indicated by the level on the dipstick. Do not overfill.
NOTE: Rising oil level between checks in cool weather
driving, can indicate moisture collecting in the oil
reservoir. If the oil level is over the full mark, change the
Oil and Filter Change
Oil Filter Torque:
Turn by hand until filter gasket
contacts sealing surface, then
turn an additional 1/2 turn
Oil Filter Wrench:
Oil Tank Screen Fitting Torque:
25 ft-lb (34Nm)
Recommended Engine Oil:
Polaris PS 4 PLUS
Synthetic, 2W-50
NOTICE: Care must be taken to ensure that the fluids are
contained. Be prepared to collect the fluid with suitable
disassembly of any component containing fluids.
1. Place vehicle on a level surface.
2. Clean area around drain plug (A) at bottom of oil tank.
3. Run engine two to three minutes until the engine is
4. After two or three minutes stop the engine.
5. Place a drain pan beneath oil tank and remove the
drain plug (A). CAUTION: Oil may be hot. Do not allow
hot oil to come into contact with skin as serious burns
may result.
6. Allow oil to drain completely.
7. Replace sealing washer (B) on drain plug (A).
NOTE: The sealing surfaces on the drain plug and
the oil tank should be clean and free of burrs, nicks
or scratches.
Reinstall the drain plug (A) and torque it to
Oil Tank Drain Plug Torque:
14ft. Ibs. (19 Nm)
Crankcase Drain Plug Torque:
14ft. Ibs. (19 Nm)
9. Loosen clamp (D).
10. Remove oil hose (E)from screen fitting (C) on bottom
of oil tank.
11. Remove screen fitting (C) and clean the screen.
12. Apply Loctite™ thread sealant 505 or an equivalent
pipe thread sealant or PTFE sealant tape to clean, oil
free threads of fitting (C).
13. Install screen fitting (C) and rotate a minimum of 2 1/
2 turns (clockwise) into the tank threads. Then rotate
the screen fitting clockwise until the nipple of the
screen fitting aligns with the reference marking on the
Maximum torque for the screen fitting
is 25 ft-lb (34Nm), do not over tighten.
NOTE: Maximum torque for the screen fitting is 25
ft-lb (34Nm), do not over tighten.
14. Install oil hose (E) on fitting (C) and re-install clamp
15. Place shop towels beneath oil filter. Use Oil Filter
Wrench (PV-43527), turn filter counterclockwise to
16. Using a clean dry cloth, clean filter sealing surface on
the crankcase.
17. Lubricate the o-ring on new filter with a thin film of
engine oil. Check to make sure the O-ring is in good
18. Install the new filter and turn it by hand until the filter
gasket contacts the sealing surface, then turn an
additional 1/2 of a turn.
19. Approximately 1 cup of engine oil will remain in the
crankcase. To drain, remove drain plug found on lower
right side of crankcase.
Engine Sump Drain Plug- Bottom View
The sealing surfaces on the drain plug and
crankcase should be clean and free of burrs, nicks or
20. Reinstall drain plug and torque to specification.
21. Remove dipstick and fill tank with 2 quarts (1.9 L) of
Polaris Premium 4 Synthetic Oil.
22. Place gear selector in Park and set parking brake.
NOTE: Clamp or pinch off the vent line 2" from the oil
tank as shown in the Oil Pump Priming Procedure.
23. Re-check the oil level on the dipstick and add oil as
necessary to bring the level to the upper mark on the
24. Dispose of used filter and oil properly.
Oil Pump Priming Procedure
NOTE: This priming procedure must be performed
whenever the oil hose connection between the oil
tank and pump inlet has been disconnected.
1. Clamp or pinch off vent line (A) approximately 2" from
oil tank to avoid the end of oil tank vent fitting, and the
vent line's pressure relief slit
Run engine at IDLE for 10-15 seconds.
3. Remove the vent line clamp. The oil pump will now be
properly primed and ready for field operation. Note: If
the system is primed properly you should hear some
air release. If you do not, the system has not primed.
Repeat the process if necessary.
Precision Power Services