96
MAINTENANCE
Air Cleaner
Trail Blazer, Trail Boss, Xpress 300,
Xplorer 300, Xplorer 400
Secondary (Main) Filter
Inspect the secondary filter weekly or after every 50 hours of operation.
CAUTION: Never operate the ATV with the filter element removed. Dirt will enter
the engine causing serious rapid wear and damage to the engine.
Secondary filter removal and installation procedure:
1. Remove ATV seat.
2. Remove primary air filter box.
3. Remove four wing nuts holding
cover assembly to secondary air fil-
ter housing.
4. Remove filter element.
5. Inspect gaskets on both sides of fil-
ter. Replace if required.
6. Coattop and bottomgaskets offilter
with a generous amount of grease.
7. Check condition of air box and replace if necessary. Install filter into airbox.
Be sure filter element seats securely.
8. Check cover gasket and replace if required. Be sure cover is seated properly
and wing nuts are finger tightened securely.
9. Reinstall primary air filter box as per instructions found on page 95.
10. Reinstall ATV seat.
Cleaning the Main Filter
Important:
It is advisable to replace the filter when it is dirty. However, in an emergency it is
permissible to clean the main filter if you observe the following practices.
1. Never immerse the filter in water since dirt can be transferred to the clean air
side of the filter.
2. If compressed air is used never exceed a pressure of 40 PSI. Always use a
dispersion type nozzle to prevent filter damage and clean from the outside to
the inside.
NOTE: Replace the air filter every 50 hours, and possibly more often in very dirty
conditions.
