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MAINTENANCE
2.20
1. Insert .006² feeler gauge between end of exhaust
valve stem and adjuster screw.
EXHAUST VALVE CLEARANCE:
0.006±0.0008
I (0.15±0.02 mm)
BTDC on compression
2. Loosen locknut and turn adjuster screw until there
is a slight drag on feeler gauge.
3. When clearance is correct, hold adjuster screw
and tighten locknut securely
4. Re-check the valve clearance.
5. Repeat adjustment procedure if necessary until
clearance is correct with locknut secured.
6. Inspect o-rings on the plastic valve plugs, replace
if damaged. Securely fasten valve plugs.
7. Reinstall fuel tank and any body panels that were
removed to gain access.
STEERING
The steering components should be checked
periodically for loose fasteners, worn tie rod ends, and
damage. Also check to make sure all cotter pins are
in place. If cotter pins are removed, they must not be
re-used. Always use new cotter pins.
Replace any worn or damaged steering components.
Steering should move freely through entire range of
travel without binding. Check routing of all cables,
hoses, and wiring to be sure the steering mechanism
is not restricted or limited. NOTE: Whenever steering
components are replaced, check front end alignment.
Use only genuine Polaris parts.
W ARNING
NOTE: Due to the critical nature of the pr ocedures
outlined in this chapter, Polaris recommends steering
component repair and adjustment be performed by an
authorized Polaris Dealer. Only a qualified technician
should replace worn or damaged steering parts. Use
only genuine Polaris replacement parts.
One of two methods can be used to measure toe
alignment: The string method and the chalk method.
If adjustment is required, refer to following pages for
procedure.
TIE ROD END / STEERING
INSPECTION
To check for play in the tie rod end, grasp the steering
tie rod, pull in all directions feeling for movement.
G Repeat inspection for inner tie rod
end (on steering post).
G Replace any worn steering
components. Steering should move
freely through entire range of travel
without binding.
G Elevate front end of machine so front
wheels are off the ground. Check for
any looseness in front hub / wheel
assembly by grasping the tire firmly
at top and bottom first, and then at
front and rear. Try to move the wheel
and hub by pushing inward and
pulling outward.
Check for Loose Wheel or Hub