3.16
Maintenance
BRAKE SYSTEM MAINTENANCE
Brake Lever Travel
The gap between the brake lever and handlebar grip should be
equal to or more than 1/2
″ (1.27cm) when depressing the brake
lever.
If the gap is less than 1/2
″ (1.27cm), the brake system should be
inspected and bled of any air within the fluid.
Brake Fluid
Inspect the reservoir to be sure it contains the correct amount of
fluid. Use only Polaris DOT 4 high temperature brake fluid.
Change fluid every 2 years or whenever the fluid is dark or
contamination is suspected.
NOTE: A low brake fluid level can be indicated
through the sight glass on the cover. If the fluid is
low this sight glass will glow a brighter. color.
THROTTLE AND CHOKE CABLE
ADJUSTMENTS
Throttle Lever Free Play - Non CFI
Throttle lever free play must always be at a specified clearance
(A) 0.010
″-0.030″ (0.25-0.80 mm) between the throttle lever
(B) and the throttle block (C). This clearance is controlled by the
throttle cable (D).
If adjustment is needed follow these steps:
1. Check the idle RPM and verify it is within the specified
range.
2. Shut off engine.
3. Locate the throttle cable that is attached to the carburetors
and adjust the throttle free play by adjusting the barrel nut
(E) and lock nuts (F).
WARNING
Do not over fill the master cylinder. Fluid expansion
could cause brakes to lock, resulting in serious injury or
death. Once a bottle of brake fluid is opened, use what
is necessary and discard the rest. Do not store or use
a partial bottle of brake fluid. Brake fluid is hygroscopic,
meaning it rapidly absorbs moisture from the air. This
causes the boiling temperature of the brake fluid to
drop, leading to early brake fade and the possibility of
serious injury
1/2” (1.27cm)
FULL
LOW
= In. / mm.
Throttle Lever Free Play: 0.010"-0.030" (.25-.8mm)
CAUTION
When adjusting throttle lever free-play, always verify the
engine RPM does not rise with bars in the full low and full up-
right Rider Select positions (if applicable) and while turning
the handlebars to the full left and full right positions.
CAUTION
After any idle speed adjustments are made, the throttle
lever clearance and the oil pump adjustment must be
checked and adjusted.
A
B
C
D
E
F
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