I have posted this in the FAQ section and also took the liberty of changing the recall tiltle to "Recalls/TSB's". A TSB is a "Technical Service Bulletin" which is usually not distributed for the public but it would be nice to have a place for these when one is performed to your quad but I do need your input to find out about them so please submit any TSB which is performed to your machine.

This one is rather important as a fire or engine oil starvation could occur if you are affected by this.

March 05 2003

Modified

Jan 15 2004



Polaris along with many other brands have a crankcase ventilation hose, freeze up problem.



The tube, which originates from the valve cover and enters the air box, can get blocked with ice that is formed by condensation. When this happens, there is no way of relieving crankcase pressure and the weakest part of your engine will fail (valve cover, dipstick, oil pan, etc.)



The correct procedure (recommended by Polaris) is to cut a small slit in this tube, as close as possible to the valve cover (lots of heat and will never freeze in this area) This serves as an escape route, for any pressure should the hose freeze up. Otherwise if you blow the valve cover and do not notice it guess what happens? (I know of several cases in my area that led to motor failure due to oil starvation). This only happens in extreme cold -20c and below and will happen to quads stored outdoors that do not get to thaw out, they simply build more and more ice until it's finally blocked.



Another thing to check is that the hose is routed so it does not have any low spots. ( a U shape somewhere along it's path) If it does, the condensation/water will not be allowed to flow freely into the air box where it is supposed to go and when it dips below freezing, you get an ice cube in the system.



Jan 15 2004



Edit: Polaris has now released a TSB (Technical service bulletin) regarding this matter. The onus was put in the dealers hands to contact the customer in areas only where cold temps are seen on a regular basis. In general. Canada and the Northern States. I would not rely on your dealer contacting you as we all know how lazy some can be! If you own a 02, 03 or early 04, the TSB applies to you. If you have a 04 and are not sure, just look at the PCV hose which goes from the front of the airbox (left side) to the engine valve cover. If the hose is a plain black rubber hose and has a small in-line filter, you need to have it done. If the hose is a black rubber one but has a foil type insulation sleeve around it and no filter, then the mod is already done from the factory. You can see this hose by simply removing the seat.

The TSB is #S-03-05and the part # is 2202744



Input by

Snow, according to my dealer the part is on backorder from polaris

Thanks for the update and keep us posted as to when it does become available. It does not surprise me they under estimated the quantities they actually need.

By the way. The "new" hose has the "slit" made from the factory. If you are concerned about the part being backorder, just take off the existing tube and cut a small 3/8"-1/2" long slit (lenght wise) in the tube, about 1" from the end which is attached to the valve cover and then put it back on. This will ensure no pressure can be built up IF it freezes. To be honest with you, I doubt the thin loose fitting insulation actually will prevent freeze up in ALL conditions and obviously Polaris thinks the same, otherwise they would not have put the slit on the new part. To replace this hose your self or slit the exisiting tube is no more than a 10 min job and this is if you work slow and includes the time to put your tools away and clean your hands. Basically a very easy job.

Rainking, I think that is dependant on the dealer. I had mine done this week with no problem.

It is very possible that many dealers ordered a dozen or so and the late comers ended up with the backorder problem. Give your dealer a call to see if they have stock.

Does this apply to the 2004 EFI?

Thanks!

No it dose not. The EFI was released late enough to have the improvement done by Polaris at the factory.

Snowride,

I live in North Michigan and have a new 2004 1/2 SP 500HO, any news on the 500HO's??? We do a number of winter rides plus I plow snow with both my 03 400 and the 04 500HO.

Thanks,
Tom

Although I have seen it happen to HO's, it is rather rare. Polaris does not have a TSB out for them either. I was out today with a group of 20 quads -20C most of the day with a brief warm up to about -15C. Guess what I saw on the trails. A 04 700 which had blown the dipstick, 2 ticked off riders covered in oil. PCV hose freeze up!!!!

Thanks for the post, It's nice to know these problems are out there, Northern Michigan not much warmer then you. The club was out last weekend and we had a very nice ride, cold , but nice.
Tom

Finally got my breather tube today and also got the parts for the carb update...now I just have to find time to take care of it.

Thanks snowride, unfortunately I read this just a little too late. We run a LTZ400 in the ice races and had that very thing happen which blew all the oil out and seized the motor. OUCH!!

Ya should of bought a zuki.

I used to have one but it blew the engine. If you read the whole article I posted you will see you are not immune to this problem. Take a look at the post 2 places up. LTZ400 is a Zuki.