CHAPTER 2 MAINTENANCE Periodic Maintenance Chart . .. os 21-22 Pre-Ride Inspection .......60.ccccecceeeesees 22 Recommended Lubricants and Capacities ....... 2.3 Lubricant and Maintenance Product Numbers .... 2.4 Lubrication Chart : 25-29 Front Gearcase Lubrication cecceeees 240 Carburetor Adjustments ....... ween 2.11-2.12b Carburetor Draining .... 2AB214 Breather System Maintenance . ceveceees 2Ada-2.14b Compression Test .......... 22.15 Battery Maintenance seve BAG General Maintenance 247 Coolant System Maintenance 22.18 2 Stroke Engine Maintenance 4 Stroke Engine Maintenance Toe Alignment inspection .. 2.30 Chassis Maintenance ceeeeeee 2BT245 Drive Chain Inspection/Adjustment 2,36-2.39 Drive Chain Adjustment, Concentric Swingarm ... 2.974 2.19-2.22d 2.220-2.29MAINTENANCE Periodic Maintenance Chart Inspection, adjustment and lubrication intervals of important components is listed in the following chart. Maintenance intervals are based upon average riding conditions and a vehicle speed of approximately 10 miles per hour. Inspect, clean, lubricate, adjust or replace parts as necessary. NOTE: Inspection may reveal the need for re- placement parts. Always use genuine Polaris parts. "CAUTION: Due to the nature of these adjustments, it is recommended that service be performed by an authorized Polaris dealer. For engine oil, shor trip cold weather riding also constitutes severe use. Pay special attention to cil level. A rise in cil evel in cold weather can indicate moisture collecting in the oil tank. PVehicles subjected to severe use, such as operation in wet or dusty areas, should be inspected and serviced more frequently, E Emission Control System Service (California). For 4-cycle models built after January 1, 1997. ENGINE Tem Hours | Frequency | See Page Remarks Ep | Eraine OF Lever Change yoows | emonihe [325 ‘Check Level Daly: Break eovvce at man E_ | Ol Fiter-trokesy Toone [@monhe [225 Faplace with ol change Gi Fifer esweKe3) Toons | Temenhs [222 Repco Gi Pump Cable stones) [SONS Smonhs [218 Tnspet, Adjust, Lubroate, Replace W Requred Ep | Ai Fiter- Foam Pre-Cleaner | Daily Bally ZERTEES | Wapest- Clean & Ol more ofan in Gy Cond Ep | Ai Fiter- Wain Elemont Weary | Weenly DERTEDS [Tape Replace W nacoesary Ce Bally 2a Drain deposits whenever visible [Engine Breather Fitor ane Wonihy Tspect and replace W necessary DB _ | Oi Tank Vent Hose TOO FS T2 months, { Thspect hose routing hose condition Ex | Valve Clearance (eatoresy | 100he [F2monis | 227 TrepectAgjust D_| Counter Batancer Fa woos) [Toons _| Tenens [221 ‘Check Morty Change Anrwaly E |e Speed Asrequred [As requred 217 Aahast = | Trrotie Cable ETC Swich [50 ‘Simone [Bat Trepect Adu, Lubreato, Rapate Wneceseary Chore (Envicher) Cable Sone ‘Smonthe [BZ Trapac Aaja, Libabate, Rapana W necessary Carburetor Float Bow Sons Smonhs [273 Drain boul pariodaly and porto siorage Carburetor Ar itake DusFange [SOR mone Inspect all ducts for proper sealing/air leaks Ex | Fuel System Toons [Tenens ETS ‘Check for leake atari cap nas, fel valve, er, ump & carbureter. Replace Ines every 2 years. Ee | Foal Fiter Toons | Temonhs [21S place War annually ‘CosianiLavel nepacion Daly Daly Bo Raplave engine coolant every 2 years Coat Siengh esas Te [Toone [Eanes [Te Trspei Seng seasonal, Pressures y= tam tem annualy Faiator Toons [Bons [are Tnapect/ Crean oriomal surace Cooling System Hoses Too [monte [are inspect Engine Mounts Toms _[imonhs _[aa7 Trspect Drain Reco Hous Weakly | Weeky Bai Mare offen oporating in wet env Fonment Exhaust Mulier Pipe Toons [1 months ELECTRICAL E [Seak PG Toons ——[i2manihs [2.17 Inspect. Raplace Wnecessary Tonition Tring Toone | months | 10.10 Trepect Baty One Wenthiy [16 ‘Check torminasy Grenn, Check Wud ove) Foadight An Asrouured [As required [104 aust t Necessary Fieadlamp Inspection Dally Daily Tos ‘Check oparation daly: Apply Polaris Dieleotie Grease fo connector wnen lamp is replaced "Tal Lamp Inspection Daly Daly 738 ‘Ghack Operation Dally, Appy Polaris Dilecine Grease to socket when lamp fs replaced 5/98 24 Polaris Industries inc.MAINTENANCE Periodic Maintenance Chart, Cont. CHASSIS: = Tem Hours or | Frequency | See Page Remarks > Odometer > | Genaral lubrication sone mona [25-29 | Lubreate AlFiings, Pivots, Cables, Ele | Front HubalFiad Check Ons fémonta [282 Check monty | Front HubsiFiua Change Tons _[vemonns [202 ‘Check monthly = [Front wheel Bearings (xa) [Annually _[Annwaly _| 727 Tnepect and replace W necessary = | Front Hub Spindle Nat Torque [Annually [Annually [727 Thepect Torque and Locking Fastonerand (AWD Models) place if necessary Dave Be Bone femonns [6.12 Inspect Adjust, Replace f Necessary Ghiches (Dive And iver) [100m __| tmonhs [a7 Tnspect, ean D | Transmission Oi Level Bie Worthy _[2at Tnspect Monthy, Change Annvally Shit Unkage sone ‘Emortne [eat Tnepect Labrcate, Adjust hit Selector Box BiOhe—|PAmonths [aa ‘Change Lubricant Every Two Voare = | Searing Bone morte 2aT Tnspect Dally, Lubricate © | Toe agjustment ‘Asroqured [Asroqured |2at Parodie inspection, Adjust When Parts are Re- placed > | Rear ae Sone Gmonhe [720 Inspect Bearings, Grease Ftng > | Front Suspension sone months [240 inspect Lubricate | Rear Suspension Bohs oe Eo Inspect Lubicate Drive Chain Bone months [237 Tnspoct Dally, Adjust and Lubricate WNooded Tires Preride [Provide [aaa Inspect Daly Pre-Rige Inspection lem @ [Brake Fina Boone __etmonhs [24 ‘Change Every Two Years > [Brake Fiud Lover Prove _|Prevde [aaa Tnspect Dally, Pre-Ride Inspection lem D | rake Lever Travet Provide _[Previe (aaa Inspect Daly, Pre-Ride Inspection lem = [Brake Pad Wear TostiGo [hontiy [P34 Tnepect Petiodaly ‘Aunilary Brake Adustnent __Asrequred [Asrequred [295 Taspect Dalacion Dally, Adust ‘Curput Shaft Bearing Monhiy_ [Monthly __[2? (Grosse Monthly Brake System Proide _[Preige [234 Pre Ride Inepection lam Wrocle Provide [2a2 Pre-Ride Inepeston tam Frame Nuts, Bots, Fasteners Prevge [Pas Pre-Ride nepecton Nem Pre-Ride / Daily Inspection Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance. Tires - check condition and pressures Fuel and oil tanks - fill both tanks to their proper level; Do not overfill 4-stroke oil tank All brakes - check operation and adjustment (includes auxiliary brake) Throttle - check for free operation and closing HeadlighV/Tailigh¥/Brakelight - check operation ot all indicator lights and switches Engine stop switch - check for proper function Wheels - check for tightness of wheel nuts and axle nuts; check to be sure axle nuts are secured by cotter pins Drive chain - condition and slack; refer to drive chain adjustment Air cleaner element - check for dirt; clean or replace Steering - check for free operation noting any unusual looseness in any area Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners Engine coolant - check for proper level at the recovery bottle 9198 22 Polaris Industries inc.Recommended Lubricants - Quick Reference MAINTENANCE Recommended Lubricants and Capacities Lubricants and maintenance product part numbers are listed on page 2.4. item Type Capacity Notes See Page Engine Oi Polaris Premium 4 [2 Quarts |Add to proper level on dipstick. Seeoll [2.23 4-Strokes ‘Synthetic, OW/40 change. Engine Injector _ | Polaris Premium 2 Quans [Addo top of oil reservoir as required. 222 Oil (2-Strokes) _| TC-W3 2-Stroke oil ‘Counter Balancer |SAE 10W30 Motor Ol [3.2 oz. __ | Add to proper level on dipstick Bat il (400L Engines) | (SG/SH Rated) Transmission __ | Polaris Synthetic Gear ‘Add to proper evel on dipstick. See Wwans- [2.41 (Gearcase) Case Oil mission oil change. Type tll HLR 20 oz Type Il HR 16 oz. Type IV 3202. | Capacity after draining is approx. 20 ounces Front Gear Case [Premium Front Gear- [3.25 0z. | Addto bottom of fil plug threads. 2.10 (Shatt Drive) case Fluid or GL5 | (100 ce) 80-90 Gear Lube Shift Selector Box | Polans OW/40 Syn- | toz. Oilin selector box should be at the center [6.9 thetic Engine Lubr-__ | 30cc line of the shift selector plungers. Do not cant or 10W Motor Oil over or the selector may hydro-lock. Coolant Level | Polaris Premium ‘Approx. _ | Fill reservoir tank to fullline. Check after [2.18 60/40 pre-mixed Anti- [2 Quarts | short period of operation when system is treeze/Coolant or cold. Add if necessary. Refer to 2.18 for 50/50 mixture more information. antitreeze/coolant and distilled water Front Hubs Premium Demand [2502 | Fillhhub at 4:00 or 6:00 position untifuid [2.02 {AWD Models) _| Drive Hub Fluid (75cc)__| trickles out. Do not force fluid into hub. Brake Fluid Polaris DOT 8 Brake = | -Fillreservoirto 1/4” (6.4 mm) below cover [2.34 Fluid ‘gasket surface for aluminum reservoi -Fill between “Min’ & "Max’ indicators on plastic reservoir 5/98 23 Polaris Industries Inc.MAINTENANCE Recommended Lubricants Polaris Premium Lubricant and Maintenance Product Part Numbers Part No. Description 2871281 Premium 4 Synthetic 0-W40 (4-Cycle) Engine Oil (Quart) | 2871567 Premium 4 Synthetic 0-W40 (4-Cycle) Engine Oil (16 Gallon) — 2871098 Premium 2 Cycle Engine Oil (Quart) 2871097 Premium 2 Oycle Engine Oil (Gallon) 2871240 Premium 2 Cycle Engine Oil (2.5 Gallon) 2871566 Premium 2 Cycle Engine Oil (16 Gallon) 2871385, Premium 2 Gycle Engine Oil (30 Gallon) 2871240 Premium 2 Cycle Engine Oil (55 Gallon) - 2871721 Premium Gold 2 Cycle Synthetic Lubricant 2871477 Premium Synthetic Gearcase Lubricant (1 Gal.) _ 2871478 | Premium Synthetic Gearcase Lubricant (12 02. bottle) _ 2870465 Oil Pump for Gearcase Oil 2871654 Premium Demand Drive Hub Fluid (12 02.) —— 2871653 Premium Front Gearcase Fluid (1202) 2870510 Cable Lube 2870584 Loctite RO 680-10ce Retaining Compound 2870587 518 Gasket Eliminator _ 2870601 Loctite Chisel Gasket Remover 7 2870661 RIV Silicone Sealer _ 8560054 Marine Grade Silicone Sealer (14 02. c3 2870791 Fogging Oil a 2870990 DOTS Brake Flu 2871027 | Anti-Corrosive Dielectric Grease _ 2871322 (Boz. cartridg 2871423 Premium All Season Grease (14 oz. cartridge) [zart460 Starter Dive Grease - 2871515 Premium U-doint Lube (3 02.) 2871551 2871323 {60/40 Coolant Gallon - - [2871534 60/40 Coolant Quart [2871312 Grease Gun Kit 2871306 Premium Garbon Clean 12 oz [2670652 Fuel Stabilizer 16 02. 5/98 24 Polaris industries inc.MAINTENANCE Lubrication Chart jm. Item Lube Rec. Method Frequency* Engine Ol | Polaris OW/A0_ [Add oll o proper level. Ses page | Change after 1st month, 6 months or 100 (4 Strokes) | Synthetic 2.23, hours thereafter; Change more often (25-50 hours) in extremely dirty conditions, of short {tip cold weather operation. 2 | Transmission | Polaris Synthet- | Add lube to FULL level on dip- | Change annually (0 icGear Case |stick. See pages 2.41 Lubricant 3 [Brake Fluid [Polaris DOTS | Fill master cylinder reservoirto__| As required. Change fluid every 2 years, Brake Fluid | 1/4” (6.4mm) from top, or between indicated lines. See page 2.34. 4 | Throttie Cable [Polaris Cable | See page 2.11. ~— [Semi-annvally Lube S Polaris Cable | Disconnect cable on back of | Semiannually [1] a Lube speedometer and lubricate inner cable. Polaris Chain | Apply to chain link plates and As required” Lube or O-Ring | rollers. chain lube y Transmission Dipstick 6 a Operating Range Operating Range 1. Engine Ol and Filter (4 Cycle) 2. Transmission Dipstick. Master Cylinder, Reservoir Max at 5. Speedometer Cable 6. Drive Chain(s) 4. Throttle Cable 5/98 25 Polaris Industries inc.MAINTENANCE Lubrication Chart K fs (2x4 Models) 11, Front A-Arm Pivot Shatt 14 seeing Post sree one ade Stan 12. Rod end 13. Counter- balance dipstick (4x4 Models) 7. Demand 4 Hubs 4.0r 8 O'clock position- (end view) 11. Front A-Arm = Pivot Shaft 10. Bal Joint i. tem abe Res. Method 1 Frequency * 7 | Demand 4 Habs - | Polaris Demand | Remove filer hole screw in hubs. Rotate wheels to | Semrannualy AlWheel Dive | Drive Huo Fudor | 4.0r8 Ocock postion, If lubricants not visible acd | C0 avs ATF Type F tnt lows am lr hole sere Relnstal rem. 8 | Front Wheel Bear- | Sealed; Replace Inspect and replace bearings if necessary ‘Annually 2 ings - Non - driving | front wheels 3 [Front Drive Axlo"U" [Polaris Usoint | Locate grease iting and grease with grease gun. | Semrannually soins Grease" a 10 | Ball int Polaris AiSeason | Locate grease fing on back side of sits and | SemPannualy Grease" grease wth grease gun a 1 [Front AvArm Pivot [Polaris Al Season | Locate grease fiting on pival shall and grease with” | Semannually Shalt Grease" reese gun. o 72 | Tie Red Ends | Polar Al Season | Locate groaso fing and grease wih grease gun | Somrannually Greose’ (where appieable. Onotiers: itboet. Clean | away dirt and grease. Apply fresh grease by hand and reassemble, 3 | Counter Balance | TOW30 Motor OI — Check level on dpsick and add ol as necessary. Change Housing (4000) Ghange annualy. To change ol see page 221. | Annually Z 14 | Stooring Poet Bush- | AllSeason Locate ftings on upper and iowerstering post and’ Semi-annualy lings Grease" crease wih grease gun 5/98 26 Polaris Industries ino.MAINTENANCE, Lubrication Chart 15. Output shatt support bearing grease fiting ge 16; Sac ote Bearings (875) 18. Genter and Front Eccentries JL i. swing arm 25 Bushings 17. Center Swing Army Housing (6x6) 419. Roar Strut Stabilizer (6x6) 16. Rear Axle Bearing Wi, tem Lube Rec. Method Frequency" 4 15 | Transmission | Polaris AllSeason | Locate grease fing on transmission oulpul shaft | Semrannually Output Shatt Grease" and grease with grease gun. a 15 | Rear Siu Assy | Polaris All Season 16 | Rear and Middle Locate grease iting on escent and Grease win | Semanal fxie Bearings tease gun. a (8) 7 [Swing Arm Polaris Al Season — | Locate grease ing on sing arm and grease wih_| Semrannuall | Bushings and | Grease" ‘tease gun. Fy | Center Swing Arm Housing (6x6) 75 [Chain Adjusters —| Polar Al Season | Lovato groaso Wing on canter occonic and____| Somrannually |{Genterand Front | Groase™ (pease Locate grossa iting on ont eosenkic (se | | Eccentries) ‘opposite chain) and grease. 1 | Rear Sint 6x8) | Polaris Al Season | Locate tng on rear sia and grease with grease | Semrannvaly Grosse oun ft * More offen under severe use, such as wet or dusty conditions **Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or Mobilegrease Special [0 Semi-annually or 50 hours of operation [Annually or 100 hours of operation NOTE: Hours are based on 10 mph average. 5/98 27 Polaris Industries inc.MAINTENANCE. Lubrication Chart - Type IV Transmission (Shaft Drive) 3. Rear Haltshatt 1 io Gear Cave @ Fil plug (Woint) 4, Axle Cardan (Uzoin) 2. Slip Yoke Full | 6.Transmission u ok “b operating 4, Front Prop Shaft Axle Cardan (UsJoint) a4 5. Propshatt Yoke _/ pupa max) Range ~ Magnet (Pre-1998) i. tem 1 | Front Gearcase Oi GL5 80-90 Weight Gear Lube LubeRec. | ‘Method NOTE: On Shaft Drive models, lubricate these areas in addition to applicable general lubrication items. Frequency’ ‘Add to bottom af fil plug threads. See page 2.10 Change annually 2 | Slip Yoke (No grease fiting on late models) Rear Halfshalts |__| Shaft Prop Shatt Premium U-Joint Grease Premium U-Joint Grease Locate fitings and grease - 3 pumps maximum Locate Fittings and Grease ‘Semiannvallyi ~Sembannualivaa 5 | Propshaft Yoke @ | Transmission Approx 32 oz inital filter by. Premium UsJoint Locate Fitings and Grease | Semi-annvaliyi Grosse | Promium UsJoint | Locate fitings and grease 3 Annually) Grease pumps maximum Synthetic ‘Add to proper level on iptick. | Inspect Monti; ‘Transmission Approx. 20 02. at change; anon anvil Lubricant Chara wy * More often under severe use, such as wet or dusty conditions D_ Semi-annually or 50 hours of operation Z_ Annually or 100 hours of operation NOTE: Hours are based on 10 mph average. 5/98 28 Polaris Industries inc.MAINTENANCE Lubrication Chart - Type IV Transmission (Shaft Drive) 7. Upper Control Arm, Lower Control 3 & Lower Control ‘Arm 10. Rear Anti: 9. Rear Wheel Hub Bearing Roll Bar a Carrier Wi Tem Method Frequency’ | | * 7” | Upper Control Arms Locate fitings and grease | Semi-annualy e Locate fitings and grease | Seriannually 1 [Locate fitings and grease | Sem-annualy (0 Semiannuelly Tower Control Arms ‘Locate fitings and grease * More often under severe use, such as wet or dusty conditions *-Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or Mobilegrease Special ] Semi-annually or 50 hours of operation @_ Annually or 100 hours of operation NOTE: Hours are based on 10 mph average. 5/98 29 Polaris Industries inc.MAINTENANCE Front Gearcase Lubrication - Type IV Transmission (Shaft Drive) Front Gearcase Lubrication “The front gearcase fil plug is located on the right side of the machine. ‘The gearcase lubricant level should be checked every six months or 1000 miles (1600 km), whichever comes. first. Change front gearcase lubricant annually or at 400 hour intervals, whichever comes first. With the ATV on a level surface, remove fil plug and check the lubricant level. Lubricant should be kept at the bottom of the fil hole threads. The correct gearcase lubricant to use is GL5 80-90 Gear Lube, Front Gearcase Lubricant PN 2671653 ‘Or GLS 80-90 Gearlube Gearcase Lubricant Change 4. Remove fill plug 2. Remove gearcase drain plug located on the bottom, right hand side and drain the oil. Catch and discard used cil properly. 8. Clean and reinstall the drain plug using a new seal- ing washer. 4, Add GLS 80-90W Gear Lube to bottom of fill hole threads. 5. Install fil plug, 6. Check for leaks. 7. Make sure vent hose is clear and free of kinks. Make sure vent is unobstructed 5/98 2.10 Polaris Industries Inc.Carburetor Adjustments Idle Speed Adjustment 1. Start engine and warm it up thoroughly. 2. Adjust idle speed by turning the idle adjustment screw. See illustrations at right. NOTE: Adjusting the idle speed affects throttle cable ‘reeplay and electronic throttle contro! (ETC) adjustment. Always check throttle cable freeplay after adjusting idle speed and adjust if necessary. Idle Speed: (+- 100 RPM) 425/500 Engine 250/300/400 Engines 1200 700, Throttle Cable / Electronic Throttle Control (ETC Switch) Adjustment 1. Slide boot off throttle cable adjuster and jam nut at throttle block. 2, Place shift selector in neutral and set parking brake. 3, Start engine and set idle to. NOTE: Be sure the engine is at operating temperature, See Idle Speed Adjustment. 4. Loosen lock nut 5. Tum cable adjuster out until engine RPM starts to increase. 6. Turn cable adjuster back in until throttle lever has 4/16" (16 om) of travel before engine RPM increases. Be sure ETC switch plunger is held inward by throttle cable tension. 7. Tighten lock nut securely and slide boot completely in place to ensure a water-tight seal NOTE: On 2 stroke models, whenever throttle cable ad- justments are made, always check oil pump adjustment. Refer to pages 2.19 - 2.20 for adjustment procedure. 8. Tum handtebars from lett to right through the entire tuming range. If idle speed increases, the throttle cable freeplay must be increased, or check for proper cable routing Throttle Operation Check for smooth throttle opening and closing in all han- dlebar positions, Throttle lever operation should be ‘smooth and lever must return freely without binding. Re- place the throttle cable if worn, kinked, or damaged. 5/98 2.11 MAINTENANCE Carburetor Adjustments 425/500 Engines Idle Screw Cable f= Adjuster Lock Nut 4/16" Throttle Lever Freeplay" *— ‘Switch Plunger Must Be Held In By Cable Tension Polaris Industries Inc.MAINTENANCE Carburetor Adjustments Throttle Cable Adjustment NOTE: If the proper freeplay cannot be obtained with the throttle block adjuster, adjust the cable at the carburetor using the following procedure. See I. 1 and 3. 1. Remove fuel tank. 2. Slide boot off throttle cable adjuster and jam nut 3. Loosen lock nut and turn adjuster until proper throttle lever freeplay is obtained. 4, Tighten locknut and slide boot back over adjuster. 5. Reinstall fuel tank. 6. Check for proper throttle operation and correct {reeplay in all handlebar positions Choke Adjustments With the choke control toggle flipped to the full off position, the choke plunger must be seated on the fuel passage way in the carburetor. If the plunger is not seated on the pas- sage way, the engine will flood or run too rich, causing plug fouling and very poor engine performance. It cable slack is 100 great there will be excessive toggle free play resulting in hard cold starting. Also, the half on position Used for intermittent applications will not function. 1. Flip choke toggle to full off position, 2, Loosen adjustment locknut (A) on carburetor. 3. Tum cable sleeve adjusting nut (B) clockwise on carburetor until 1/4” (6 mm) o more choke toggle free play is evident. 4, Tum cable sleeve adjusting nut counterclockwise on carburetor until toggle has zero free play, then rotate it clockwise until 1/87-1/4” (3-6 mm) toggle free play is evident. 5. Tighten adjustment locknut (A), Choke Lever Freeplay ~ 118 - 1/4" (3 -.6 om), Throttle Control Lever Stop Adjustment The throttle control lever incorporates an adjustable stop. This can be adjusted to limit the amount of throttle opening by loosening the screw (A) and sliding the stop to a desired setting. Then tighten screw. See Ill 4. 5198 212 mt 4-Stroke CV Carburetor 1/8-1/4" (3-6 cm) Choke Toggle Position Freeplay ie Halon Xy a we Full On. Throttle Cable Adjuster B A M.S 2-Stroke VM Carburetor Bottom View m4 Polaris Industries Inc.Air Screw Adjustment 2-Stroke Models 1. Tum carburetor air screw in until lightly seated. Back screw out the specified number of turns. Air Screw Adjustment (2-Stroke engines) Refer to Specifications (Chapter 4) 2. Warm up the engine to operating temperature. 3. Set idle speed to 600-800 RPM. NOTE: Adjusting the air screw may affect idle speed, Always check throttle cable freeplay after adjusting ile speed and adjust if necessary. 4. Tum the screw in (to richen) or out (to lean) the mixture. Adjust air screw for best throttle response and smooth idle. 5. Re-adjust idle it necessary. Pilot Screw (Idle Mixture) Adjustment 4-Stroke Models NOTE: The pilot screw is pre-set at the factory. The fol- lowing adjustment procedure should be used after disas- sembly and cleaning or if the pilot screw is replaced, Be sure all engine maintenance items have been performed and are within specifications before adjusting pilot screw. 1. Turn pilot screw in (clockwise) until lightly seated Turn screw out the specified number of tums. Pilot Screw Adjustment (4-Stroke Engines) Refer to Specifications (Chapter 4) 2. Start engine and warm it up to operating temperature: (about 10 minutes). 3. Connect an accurate tachometer that will read in increments of + or - 50 RPM. 4, Set idle speed to 1200 RPM. Always check throttle cable freeplay after adjusting idle speed and adjust it necessary, 5. Slowly turn mixture screw clockwise until RPM begins to decrease by 50 RPM or greater. 5/98 2.12a MAINTENANCE Carburetor Ad jjustments 250/s00/400cc Engines 4, ima Air Screw Idle Speed Screw 425/500 Engines FRONT Engr) Pilot Screw Polaris Industries Inc.MAINTENANCE Carburetor Adjustments Pilot Screw (Idle Mixture) Adjustment, Cont. 4-Stroke Models NOTE: If tamper proof plug is installed refer to removal procedure below, 6. Slowly turn mixture screw counterclockwise unti idle speed increases to maximum RPM, Continue turning counterclockwise until idle RPM begins to drop. 7. Center the pilot screw between the points in step 5 and 6. 8. Re adjust idle speed if not within specification, FRONT {Engine Pilot Screw 5/98 2.12b Polaris Industries Inc.MAINTENANCE Fuel Lines/Vent Lines Fuel Lines 1, Check fuel lines for signs of wear, deterioration, damage or leakage. Replace if necessary. 2. Be sure fuel ines are routed properly and secured with cable ties. CAUTION: Make sure lines are not kinked. or pinched 8. Replace all fuel lines every two years. Vent Lines 1. Check fuel tank, oil tank, carburetor, battery and transmission vent lines for signs of wear, deterioration, damage or leakage. Replace every two years. 2. Be sure vent lines are routed properly and secured with cable ties. CAUTION: Make sure lines are not kinked or pinched. Fuel Filter ‘The fue fiter should be replaced periodically or whenever sediment is visible in the fer. 1, Shut off fuel supply at fuel valve, 2. Remove line clamps at both ends ofthe fier. 3. Remove fuel lines from fier. 4 Install new filter and clamps onto fuel ines with arrow pointed in direction of fuel flow. Install clamps on fuel line, 6. Start engine and inspect for leaks. 7. Reinstall fuel tank Carburetor Float Bowl Drai Gasoline is extremely flammable and explosive under certain conditions. Always stop the engine and refuel outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. Do not overfill the tank. Do not fill the tank neck If you get gasoline in your eyes or it you swallow gasoline, see your doctor immediately. If you spill gasoline on your skin or clothing, immediately wash it off with soap and water and change clothing, Never start the engine or let it run in an enclosed area. Gasoline powored engine exhaust fumes are poison- ‘ous and can cause loss of consciousness and death in a short time. > PPBPP PE Never drain the float bow! when the engine is hot. Severe bums may result 5/98 2.13 Polaris Industries inc.