MAINTENANCE STEERING AND SUSPENSION 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. Steering Inspection Spark Plug Gap 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. 2 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. Gap - .035" (0.90 mm) 10. If necessary, replace spark plug with proper type. CAUTION: Severe engine damage may occur if the incorrect spark plug is used. NOTE: Whenever steering components are replaced, check front end alignment. 11. Apply anti-seize compound to the spark plug threads. 12. Install spark plug and torque to specification. WARNING Recommended Spark Plug:
Champion RC7YC3 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. Spark Plug Torque: 18 ft. lbs. (24 Nm) Engine To Frame Ground Steering Wheel Freeplay 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. Check the steering wheel for specified freeplay and operation. 1. Position the vehicle on level ground.
Ground Terminal Location 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 Engine Ground Strap U-Joints Tie Rod Tie Rod Gearbox 2.27