1500 Mile (2400 Km) Maintenance Inspection - Polaris INDY TRAIL RMK Service Manual

1500 Mile (2400 km) Maintenance Inspection

__1. Check cylinder head and base area for signs of exhaust or
coolant leaks.
__2. Re-torque cylinder heads & cylinder base nuts (cold).
__3. Check compression and record readings.
__4. Check ignition timing.
______ observed BTDC
______ corrected BTDC
__5. Inspect recoil starter rope..
__6. Check drive to driven clutch offset (belt removed).
__7. Remove clutches, disassemble & inspect all wear
surfaces. Clean sheaves, repair clutch as necessary,
reassemble clutches and torque to specifications.
__8. Check belt condition.
__9. Check and adjust belt deflection.
__10. Inspect rubber engine mounts.
__11. Torque engine mounting plate to chassis fasteners.
__12. Adjust engine torque stop (if equipped) (0.10"-0.30").
__13 Carburetor Inspections.
A. Adjust choke plungers.
B. Adjust pilot air screw.
C. Synchronize carburetor slide valves at idle.
and off idle.
D. Adjust engine idle RPM.
E. Adjust throttle lever free play.
F. Synchronize oil pump lever.
G. Inspect Choke/Throttle Cables.
H. Inspect vent lines for wear or kinking.
__14. Remove chaincase cover, flush chaincase, inspect.
and adjust chain, refill with new chaincase oil.
__15. Change primary fuel filter and oil filter.
__16. Check fuel and oil line condition and routing.
__17 Inspect fuel and oil tank vent lines/routing.
__18. Inspect airbox fit/air filter. Clean or replace.
__19. Change shock oil (Fox) annually before storage.
__20. V.E.S (Variable Exhaust System) - if applicable.
A. Disassemble and clean components.
__21. ACCS
A. Inspect vent lines.
Polaris Service Technician: __________________________
Authorized Dealer: _________________________________
Base Inspection Price: ______________________________
Date: __________ Parts: __________ Labor: ___________
MAINTENANCE / TUNE UP
__21a. Brakes-Hydraulic
A. Check brake fluid level.
B. Check for proper hose routing; tighness of banjo bolts and line
fasteners.
C. Check for system fluid leaks.
D. Visually inspect pads for wear damage or looseness.
E. Check security and surface condition of brake disc.
F. Flush brake fluid and change every two years.
__21b. Brake-Mechanical
A. Check cable conditions / routing.
B. Check brake pad and brake disc condition and mounting.
C. Adjust brake to proper specifications.
__22. Check auxiliary shut-off switch & perform throttle safety
switch tests.
__23. Inspect brake light, tail light, oil light and all electrical accessories.
__24. Inspect Hi/Lo beam operation and aim headlight; check fasteners.
__25. Liquid cooled models:
A. Check coolant level and specific gravity.
B. Check water pump drive belt condition & deflection
(where applicable).
C. Check coolant hose, routing and clamps.
D. Inspect heat exchangers condition and fasteners.
E. Check cooling system for proper coolant circulation.
F. Replace recovery line filter: NOTE: Must use correct filter.
G. Check coolant recovery line one way check valve (must hold
pressure) where applicable.
H. Pressure test cooling system.
__26. Fan Cooled: Inspect cooling fins and shrouds.
__27. Remove chaincase cover, flush chaincase, inspect chain & sprock-
ets and adjust chain. Inspect chaincase seals.
__28. Check condition of drive shaft and jackshaft bearings. Lubricate
greaseable bearings with Premium All Season grease.
__29. Inspect and adjust reverse cable (if applicable).
__30. Remove ski pivot bushings and lubricate.
__31. Inspect ski wear bars.
__32. Check camber alignment and lubricate spindles.
__33. Remove radius rod end bushings, lubricate and reinstall, inspect all
radius rod ends.
__34. Reinstall skis and inspect/adjust toe alignment.
__35. Check handlebar centering and lubricate all steering pivots.
__36. Torque tie rod end bolts and jam nuts.
__37. Inspect steering arms and torque bolts. Inspect handlebar bolt
torque.
__38. Lubricate rear suspension pivot shafts.
__39. Torque suspension mounting bolts and check all rear suspension
fasteners and components.
__40. Inspect rear suspension wheels, bearings and hi-fax.
__41. Inspect track for damage. Adjust tension and alignment.
For optimum performance and reliability, repeat the above mainte-
nance and inspections annually (preferably before off-season stor-
age) or every 1000 miles, except where noted.
RECOMMENDATION: ________________________________________
___________________________________________________________
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