Throttle Cable; Fuel System; Fuel Lines - Polaris 2005 SPORTSMAN 500 Servise Manual

MAINTENANCE

THROTTLE CABLE /

ELECTRONIC THROTTLE
CONTROL (ETC SWITCH)
ADJUSTMENT
1. Slide boot off throttle cable adjuster and jam nut.
2. Place shift selector in neutral and set parking
brake.
3. Start engine and set idle to specified RPM.
Adjuster
Boot
Sleeve
Ill. 1
NOTE: Be sure the engine is at operating
temperature. See Idle Speed Adjustment.
4. Loosen lock nut on in-line cable adjuster (Ill. 1).
5. Turn adjuster until 1/16" to 1/8" freeplay is
achieved at thumb lever. (Ill. 2). After making
adjustments, quickly actuate the thumb lever
several times and verify freeplay.
Direction
of travel
1/16" - 1/8"
Freeplay
Ill. 2
6. Tighten lock nut securely and slide boot
completely in place to ensure a water-tight seal.
7. Turn handlebars from left to right through the
entire turning range. If idle speed increases,
check for proper cable routing. If cable is routed
properly and in good condition, repeat adjustment
procedure.
2.16
Lock-
Boot
nut

FUEL SYSTEM

WARNING
Gasoline is extremely flammable and explosive
under certain conditions.
Always stop the engine and refuel
S
outdoors or in a well ventilated
area.
Do not smoke or allow open
S
flames or sparks in or near the
area where refueling is performed
or where gasoline is stored.
Do not overfill the tank. Do not fill
S
the tank neck.
If you get gasoline in your eyes or
S
if you swallow gasoline, seek
medical attention immediately.
If you spill gasoline on your skin
S
or clothing, immediately wash it
off with soap and water and
change clothing.
Never start the engine or let it run
S
in an enclosed area.
exhaust fumes are poisonous and
can result loss of consciousness
or death in a short time.
Never drain the float bowl when
S
the engine is hot. Severe burns
may result.

FUEL LINES

Fuel Pump
Inspect
1. Check fuel lines for signs of wear, deterioration,
damage or leakage. Replace if necessary.
2. Be sure fuel lines are routed properly and secured
with cable ties. CAUTION: Make sure lines are
not kinked or pinched.
3. Replace all fuel lines every two years.
NOTE: See Chapter 4 for fuel line routing diagram.
Engine
Inspect
Fuel Lines