Polaris PREDATOR 2003, Service Manual

Page: 24 / 193

MAINTENANCE
2.9
CLUTCH ADJUSTMENT
Clutch Lever Freeplay
1. Measure clutch lever freeplay between the perch
and the lever (A). This distance should be 1/8
s
-
3/16
s
(3.1 mm - 4.7 mm).
C
B
A
2. If adjustment is required, slide the clutch perch
pivot boot down the clutch cable to access the
clutch adjustment screw (B) and lock ring (C).
3. Loosen the lock ring and turn the screw in
(clockwise) to increase lever travel. Turn the
screw out (counterclockwise) to decrease lever
travel. Tighten the lock ring.
4. Squeeze the lever fully and release. Slightly
squeeze the lever again until a slight resistance is
felt. Measure the freeplay again. If necessary,
repeat the adjustment procedure until proper
freeplay is attained.
5. Replace the clutch perch pivot boot over the
screw and lock ring.
THROTTLE INSPECTION
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.
Adjust cable tension as needed until lock--to--lock
turning can be accomplished with no rise in
engine rpm.
5. Replace the throttle cable if worn, kinked, or
damaged.
6. Inspect ETC cover seal and switch cavity by
removing the cover. Verify that no dirt, water or
mud is present.
To remove the ETC cover:
1. Use a medium flat blade screwdriver and insert
blade into the pocket of the cover starting on the
#1 position.
2. Twist screwdriver slightly while lifting on the cover
to release snap.
3. Repeat procedure at the other five locations as
shown.
NOTE: Do not attempt to remove cover until all
latch points are released.
1
2
3
4
5
6
5
6
ETC Cover
Removal Sequence
Ill. 1
CHOKE (ENRICHER)
ADJUSTMENT
If the choke knob does not stay out when pulled,
adjust the choke tension by tightening (clockwise) the
jam nut under the rubber boot between the choke
knob and nut. Firmly grasp the rubber boot and
tighten until the choke slides freely but stays out when
pulled.
Verify free play of 1/16--3/16” (1.6--4.76 mm) and
smooth operation of choke cable.
If smooth choke operation is not obtainable, inspect
choke cable for kinks or sharp bends in routing.
Choke
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