Throttle Cable Replacement; Starting Enrichment (Choke) Cable Removal/Installation - Polaris 1999 Sportsman 400 Service Manual

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188
mainjet
may
be required for
optimum pcrfonnance
at
higher altitudes
and at wanner
temperatures. A
larger
main jet
may be used
at colder
temp
eratures.
6.
Install the main j
et
and
reassemble the ca
rbure-
tor
by reversing
the
disassembly procedure.
THROTTLE CABLE
REPLACEMENT
I. Place the
vehicle
on
leve l
ground
and set
the
parking brake
.
2. Remove the seat
as
described in
Chapter Fifteen
.
3.
Remove
the
front fender
as descri bed
in Chapter
Fifteen.
4
. Disconnect
the throttle cable
from the ca
rburetor
as described under
Carburetor
Remo val/lnsta lla-
lion
in
this
chapter.
5. Disconnect the
throttle
cable
from the
handl e-
bar-m
ounted
thrott
le lever as follows:
a.
Use
a
screwdriver
to
remove
the
throttle
COIl-
trol cover (Figure
60).
b.
Detach the cab
le
from the
throttle
ann
(A,
Figure
6
1).
If the cable
end
ca
n
not
be discon -
nected, remove the
throttle ann
nut, washer
and
lever,
then disco nnect the
cable
.
c.
Withdraw
the ca
ble
from
the
throttle
housing
(8,
Figu re
61)
.
6.
Disconnect
the
throttl
e
ca ble from any clips or
tic
wraps
securing the cable
to
the
frame.
7.
Mark the original path of the cab
le
by
attaching
a
piece
of string to
the
cable
before withdrawin g it
8.
Make
a
note of
the cabl
e routing
path throu
gh the
frame, then remo
ve
it
9
.
Lubricate the
new ca
ble
as described
in Chapter
Three.
10.
Attach the
new
cable
to the
string
and
pull
in
into the positio n
of
the original
cable.
I
I. Reverse
Steps
1-6 to
insta
ll the
new cab
le as-
sembly.
\
2
.
Reattach the thro
ttle
cab
le to
the
carburetor
as
described under Carburetor
Removal/installation
in this
chapter.
13.
App
ly
grea
se
to the hand
lebar
end
ofthe cab le
and attach it to
the
throttle
lever
and hou
sing.
t4
.
Insta
ll
the
co
ver
onto the thrott
le
housin
g.
15.
Adjust the
cable free play as described
in Chap-
ter
Three.
16.
Operate the throttl
e lever
and ma
ke sure
the
carburetor throttle
linkage is operating correctly
with
no
binding.
If operation
is incorr ect
or
there
is
CHAPTER SIX
binding,
mak
e
sure
the
cable
is
attached
correctly
and there
arc no
tight
bends
in
the
cab
le,
17.
Slowly
test
ride the
vehicle
and make 5llre the
throttle
is
opera ting
correctly.
START1:-1G
E:-IRICH:\IENT
(CHOKE) CABLE
Removal/Installation
I.
Place the ve
hicle on
level
ground aod set the
parking
brake.

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