2004 Polaris Touring Cruiser Owners Manual - Page 110

2004 Polaris Touring Cruiser Manual

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MAINTENANCE Clutch Adjust Clutch Freeplay 1. With handlebars pointing straight ahead, measure the clutch lever free play (A) and compare to specification below. If adjustment is required, proceed to step 2. 2. Remove the seat (page 124). 3. Remove front and rear fuel tank screws. 4. Raise rear of fuel tank high enough to expose clutch cable adjuster. Disconnect fuel line by pushing tab on quickdisconnect, and support rear of tank with a block of wood. 5. Hold cable (1) and loosen the adjuster jam nut (2). Turn cable adjuster (3) while holding cable. 6. Turn the cable adjuster in or out until the clutch lever freeplay is .010-.030 inch (.25-.75 mm). 7. Tighten the adjuster jam nut securely while holding cable and reinstall the rubber cover. 8. Reinstall fuel tank screws and connect the fuel line (page 102-103. 9. Reinstall the seat (page 124). 10. Verify that the safety switch activates so the motorcycle can not be started in gear. 108 3 1 2 A 1. Adjuster Jam Nut 2. Clutch Cable 3. Cable Adjuster Clutch Lever Free Play: .010-.030 (.25-.75mm)

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108
MAINTENANCE
Clutch
AdjustClutchFreeplay
1.
With handlebars pointing straight ahead, measure the clutch
lever free play (A) and compare to specification below. If
adjustment is required, proceed to step 2.
2.
Remove the seat (page 124).
3.
Remove front and rear fuel tank screws.
4.
Raise rear of fuel tank high enough to expose clutch cable
adjuster. Disconnect fuel line by pushing tab on quick-
disconnect, and support rear of tank with a block of wood.
5.
Hold cable (1) and loosen the adjuster jam nut (2).
Turn cable
adjuster (3) while holding cable.
6.
Turn the cable adjuster in or out until the clutch lever freeplay is
.010-.030 inch (.25-.75 mm).
7.
Tighten the adjuster jam nut securely while holding cable and
reinstall the rubber cover.
8.
Reinstall fuel tank screws and connect the fuel line (page
102-103.
9.
Reinstall the seat (page 124).
10. Verify that the safety switch activates so the motorcycle can not
be started in gear.
Clutch Lever Free Play:
.010-.030 (.25-.75mm)
1. AdjusterJamNut
2. ClutchCable
3. CableAdjuster
3
A
1
2