Polaris Sportsman 450 H.O. service schedule

1. Park on level ground, engine off, key out, parking brake on.
2. Wipe each grease fitting on the front prop shaft clean.
3. Give each fitting no more than 3 pumps of U-joint grease.
4. Wipe off excess grease. Do the same after pressure washing or deep water.

Tools: Grease gun, Rag

1. Engine off, key out. Lift the back of the seat and pull it back off its tabs.
2. Undo the six clips and lift off the air box cover. Check the cover gasket sticks firmly all the way round.
3. Slacken the hose clamp and take out the filter. Wipe out any dirt in the box without letting it fall into the intake.
4. Put a little general-purpose grease on the sealing edges of the new filter.
5. Fit the filter on its mount so it sits on the supports, and tighten the clamp to 2 N·m.
6. Refit the cover and clips. When refitting the seat, make sure its slots engage the tabs on the fuel tank.

Tools: Screwdriver for the hose clamp, Torque screwdriver (2 N·m), General-purpose grease, Rag

1. Park on level ground, select PARK, lock the parking brake, stop the engine and take the key out. Let the engine and clutch cover cool.
2. Take out the outer PVT cover screws and remove the cover.
3. Look at the belt for loose cords, missing cogs, cracks, glazing, thin spots or hour-glass wear. Compare its width with a new belt.
4. If it needs replacing, follow the handbook's belt removal and fitting steps, marking the direction of rotation first.
5. Clean all dust and debris out of the cover before refitting it.
6. Use low range for slow work, steep ground and heavy loads to stop the belt slipping and burning.

Tools: Socket set, Torque screwdriver, Chalk or paint pen, Rags

1. Let the discs cool first; they get very hot.
2. Check the hand brake and foot brake reservoirs are between the fill lines. Do not overfill: Polaris warns an over-full master cylinder can make the brakes drag or lock.
3. If the level is low and the diaphragm under the cap has not extended, there is probably a leak; have it checked.
4. Check the hoses and joints for leaks and the brakes for long travel or a spongy feel.
5. Check the pads and replace them when worn to 0.76 mm (0.030 in).
6. Clean any grease off the discs with brake cleaner or alcohol only. See a dealer about cracked, corroded or warped discs.

Tools: Torch, Rule or vernier, Brake cleaner, Rag

1. Park on firm level ground, put the gear selector in PARK and lock the parking brake. Stop the engine and take the key out.
2. Hot oil burns. Let the engine cool a little, and wear gloves.
3. Clean round the drain plug, put the tray under the crankcase and take out the plug and washer. Let it drain fully.
4. Fit a new sealing washer and refit the drain plug at 16 N·m.
5. Put rags under the oil filter and unscrew it anticlockwise with the filter wrench. Wipe the sealing face on the crankcase clean.
6. Smear fresh oil on the new filter's O-ring, screw it on by hand until the seal touches, then turn it a further three-quarters of a turn.
7. Take off the right-hand engine access panel, pull the dipstick and add PS-4 5W-50 until the level is in the SAFE range (about 1.9 L). Do not overfill.
8. Start the engine and idle for 1–2 minutes. Stop it, check for leaks, then recheck the level and top up to the upper mark.
9. Take the old oil and filter to a proper disposal point.

Tools: Drain tray (3 L), Oil filter wrench (Polaris PU-50105 or similar), Socket set, Torque wrench (16 N·m), Funnel, Gloves, Rags

1. Let the engine cool completely; the exhaust and engine burn. Take the key out.
2. Turn the plug cap a quarter turn and pull it off by the cap, not the lead.
3. Unscrew the plug anticlockwise and look at it. A dry, light tan tip is normal; a wet, black tip means it is fouled.
4. Check the gap is 0.7–0.8 mm. Replace the plug if it is worn or damaged.
5. Screw the plug in by hand first, then tighten it to 20 N·m. Refit the cap.

Tools: Plug socket, Feeler gauge, Torque wrench (20 N·m), Gloves

1. Park on level ground, select PARK and lock the parking brake. Engine off, key out.
2. The fill plug is on the left behind the footwell; the drain plug is on the right. Clean round both.
3. Put the tray under the gearcase, take out the drain plug and let it drain fully. Clean the plug and refit it at 16 N·m.
4. Take out the fill plug and slowly add AGL until it reaches the bottom of the fill hole threads (about 0.95 L).
5. Refit the fill plug at 16 N·m, check for leaks and dispose of the old oil properly.

Tools: Drain tray, Socket set, Torque wrench (16 N·m), Oil pump or squeeze bottle, Rags

1. Park on level ground, select PARK and lock the parking brake. Engine off, key out.
2. The fill plug is on the right side of the Demand Drive unit and the drain plug is underneath on the right.
3. Take out the fill plug, then the drain plug, and let it drain fully. Clean and refit the drain plug at 26 N·m.
4. Fill with Polaris Demand Drive Fluid to the bottom of the fill hole threads (about 265 ml). Use only this fluid; others can stop AWD working properly.
5. Refit the fill plug at 26 N·m and check for leaks.
6. If the front gearcase is noisy in ADC mode, change the fluid; if the noise stays, see a dealer.

Tools: Small drain tray, Socket set, Torque wrench (26 N·m), Oil pump or squeeze bottle

1. Have this done by a Polaris dealer or a qualified mechanic with the service manual. The owner's handbook does not give the clearance figures.
2. The engine must be cold for the check.

Tools: Service manual, Feeler gauges

1. The handbook does not give the bleeding steps; have a dealer do it, or follow the service manual.
2. Both the hand-lever system and the foot-brake system need fresh fluid.
3. Brake fluid damages paint and plastics: wipe up spills at once.

Tools: Bleed tube and jar, Ring spanner for bleed nipples, Rags

1. Never take off the pressure cap while the engine is warm or hot: escaping steam and coolant scald.
2. The pressure cap is under the front box. The handbook does not give the full drain and bleed steps; have a dealer do it, or follow the service manual.
3. Use only 50/50 premix, undiluted. For top-ups, fill the recovery bottle (reached from the front left wheel well) between its marks with the engine cool; if it has run dry, also check the radiator.
4. Always refit the correct Polaris pressure cap; a non-standard cap stops the recovery system working.
5. Coolant is poisonous to animals: catch it all and dispose of it properly.

Tools: Drain tray, Funnel, Antifreeze tester