Service Manual

2.27
MAINTENANCE
2
9. Measure gap with a wire gauge. Refer to specifications in
the following illustration for proper spark plug type and
gap. Adjust gap if necessary by carefully bending the side
electrode.
10. If necessary, replace spark plug with proper type.
CAUTION: Severe engine damage may occur if the
incorrect spark plug is used.
11. Apply anti-seize compound to the spark plug threads.
12. Install spark plug and torque to specification.
Engine To Frame Ground
Inspect engine ground cable connection. Be sure it is clean and
tight. The ground cable runs from the engine starter motor to the
ground terminal location under the driver’s seat near the battery.
STEERING AND SUSPENSION
Steering Inspection
The steering components should be checked periodically for
loose fasteners, worn tie rod ends, ball joints, 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 the 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.
Steering Wheel Freeplay
Check the steering wheel for specified freeplay and operation.
1. Position the vehicle on level ground.
2. Lightly turn the steering wheel left and right.
3. There should be 0.8”-1.0” (20-25 mm) of freeplay.
4. If there is excessive freeplay or the steering feels rough,
inspect the following components.
• Tie Rod Ends
• Steering Shaft U-Joints
• Steering Gearbox
Recommended Spark Plug:
Champion RC7YC3
Spark Plug Torque:
18 ft. lbs. (24 Nm)
Gap - .035" (0.90 mm)
Spark Plug Gap
Ground
Terminal Location
Engine
Ground Strap
WARNING
Due to the critical nature of the procedures outlined in
this chapter, Polaris recommends steering component
repair and adjustment be performed by an authorized
Polaris MSD certified technician when replacing
worn or damaged steering parts.
Use only genuine Polaris replacement parts.
Tie Rod
U-Joints
Gearbox
Tie Rod