Cable Inspection/Adjustment; Brake Cable Inspection; Brake Cable Adjustment; Throttle Lever Free Play - Polaris 2000 120 XCR Service Manual

CABLE INSPECTION/ADJUSTMENT

BRAKE CABLE INSPECTION

If excessive brake lever to brake block clearance is evident, the
brake cable or caliper should be adjusted using the following
methods.
Measure the clearance between the lever (1) and brake block(2).
Inspection should be made with the lever firmly depressed. The
distance (3) should be no more than 3/4" (1.9 cm).
2
The distance (3) should be no more than 3/4" (1.9 cm).
WARNING
Improper brake adjustment could result in brake failure
which could result in severe injury or death.

BRAKE CABLE ADJUSTMENT

1. Slide the two rubber covers that are in the center of the
brake cable and expose the barrel nut.
2. Using a 8mm open end wrench, hold the barrel nut.
3. Loosen the jam nut with a 10mm open end wrench.
4. Rotate the barrel nut until you have reached the proper
brake lever adjustment.
5. Check the actuator linkage to ensure there is adequate
freedom of movement for positive brake operation. Also
make sure that all floating parts move freely and that all
parts are mounted securely. Tighten hardware as required.
6. Tighten the adjuster jam nut and slide the rubber protectors
back onto the adjuster.
7. The brake band is adjusted correctly when there is
1/4"-3/8" (6-10mm) brake lever free play, and clearance
between the brake lever (2) and brake block (1) with the
lever fully depressed is no more than 3/4" (1.9 cm.) at (3).
3
1
= In. / mm.

THROTTLE LEVER FREE PLAY

Throttle lever free play must always provide a specified
clearance between throttle lever and throttle block. This
clearance is controlled by the throttle cable at the carburetor.
Proper lever free play is .010-.030" (.25-.80mm)
MAINTENANCE
.010-.030"
(.25-.80mm)
= In. / mm.
3.7
3