Service Manual

2.10
MAINTENANCE
Fuel Filters
There are two fuel filters located within the fuel pump assembly.
The fuel pump is non-serviceable. If the internal fuel pump
filters require service, the fuel pump and fuel tank must be
replaced as an assembly.
NOTE: See the “Electronic Parts Catalog” for more
information. For all other information related to the EFI
System, refer to Chapter 3.
Vent Line
1. Check the vent line from the fuel tank for signs of wear,
deterioration, damage or leakage. Replace the line every
two years.
2. Verify vent line is routed properly and secured with an
appropriate number of cable ties.
Throttle Operation
Check for smooth throttle opening and closing in all handlebar
positions. Throttle lever operation should be smooth and lever
must return freely without binding.
1. Place the gear selector in neutral.
2. Set parking brake.
3. Start the engine and let it idle.
4. Turn handlebars from full right to full left. If idle speed
increases at any point in the turning range, inspect throttle
cable routing and condition. If cable is routed properly and
in good condition, no adjustment is required.
5. Replace the throttle cable if worn, kinked, or damaged.
Electronic Throttle Control Switch (ETC) /
Throttle Cable Adjustment
NOTE: Sportsman XP requires a new adjustment procedure.
1. Slide the boot back far enough to expose the inline cable
adjuster sleeve and loosen the adjuster locknut.
2. Remove the (4) screws and cover from the RH control.
3. With handlebars centered and wheels pointing forward,
slowly turn the adjuster sleeve counter-clockwise (out) just
until the gap is removed between the throttle arm and the
throttle arm stop (see illustration below).
NOTE: While moving the adjuster sleeve, “flip” the
throttle lever slightly to remove slack in the cable.
4. Turn the cable adjuster sleeve clockwise (in) 1.5 - 2 turns;
tighten locknut and reinstall boot. After this adjustment
there should be .079-.118” (2-3 mm) gap between throttle
arm and throttle arm stop.
5. Reinstall the RH control cover and ensure the O-ring is
properly in place. Securely tighten the (4) screws.
6. Place the vehicle in PARK and start the engine. Turn the
handlebars from full left to full right while listening for any
change in engine speed. If engine speed changes, loosen
the locknut and turn the adjuster sleeve clockwise (in) an
additional 1/2 turn and repeat this step.
CAUTION
Make sure lines are not kinked or pinched