2004 Polaris Sportsman 500 Owners Manual - Page 81

MAINTENANCE AND LUBRICATION Oil and Filter Change The recommended oil change interval is 100 hours, 1000 miles, or every six months, whichever comes first. Suggested break-in oil change is at 20 hours, 200 miles, or one month, whichever comes first. Severe use operation requires more frequent service. Severe use includes continuous duty in dusty or wet conditions and cold weather riding. NOTE: Severe use cold weather riding is all riding below 10° F., and riding between 10° F and 30° F when most trips are slow speed and less than five miles. Be sure to change the oil filter whenever changing the oil. Oil Change (400/500) 1. Position the vehicle on a level surface. Clean the area around the drain plug at the bottom of the oil tank and the bottom of the engine. 2. Run the engine for two to three minutes, then turn it off. 3. Place a drain pan beneath the oil tank and remove the drain plug (1). Allow the oil to drain completely. 4. Install a new sealing washer (2) on the oil drain plug. NOTE: The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs, nicks or scratches. 5. Reinstall the drain plug and torque to 14-17 ft. lbs. (19-23 Nm) 6. Disconnect the lower oil delivery hose and remove 2 the screen fitting (3) from 1 the oil tank. Clean and reinstall the fitting, 3 4 torquing to 25 ft. lbs. Reattach the oil line. NOTE: The fitting threads must be sealed with Loctitet PST 505 or PTFE seal tape. The fitting must also line up with the mark (4) on the rear side of the oil tank. 78