Content Source: 2019 PRO XD Diesel (9930762 Rev 01) > Maintenance Chapter

IMPORTANT

The Owner's Manual for this vehicle contains warnings, instructions and other information you must read and fully understand before safely riding or performing maintenance on this vehicle.Always follow the warnings and instructions in Owner's Manual.

Click the CONTENTS link above for the Table Of Contents, or download a full PDF of the Owner Manual in the Owner Support area of Polaris.com

Throttle System

WARNING
Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation.
Always check the pedal for free movement and return before starting the engine and occasionally during operation. Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal. Immediately contact your dealer for service if throttle problems arise.

Throttle Freeplay

If the throttle pedal has excessive play due to cable stretch or maladjustment, it will cause a delay in throttle response, especially at low engine speed. The throttle may also not open fully. If the throttle pedal has no freeplay, the throttle may be hard to control, and the idle speed may be erratic.
Check the throttle pedal freeplay at the intervals outlined in the Periodic Maintenance Chart. Adjust the freeplay if necessary.

Throttle Freeplay Inspection

  1. Apply the brakes. Engage the park brake. Shift the transmission to neutral.
  2. Start the engine. Allow it to warm up thoroughly.
  3. Measure the distance the throttle pedal moves before the engine begins to pick up speed. Freeplay should be 1/16 of an inch to 1/8 of an inch (1.6-3.2 mm).

Idle RPM

Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your POLARIS dealer for adjustment.

Throttle Cable Adjustment

Cable Adjustment

  1. Ensure that the throttle cable is properly routed and retained to the unit.
    Image
  2. On the pedal side, tighten jam nuts .
    TORQUE

    Throttle Cable Jam Nut (pedal side)

    43 in-lbs (5 Nm)
  3. On the engine side, tighten jam nuts .
    TORQUE

    Throttle Cable Jam Nut (engine side)

    10 ft–lbs (13 Nm)
  4. Slide back the protective cover to expose the jam nut and adjuster screw.
  5. Loosen the jam nut and turn the adjuster screw until the throttle lever on the engine moves.
  6. Loosen the adjuster back so there is no tension in the cable.
  7. Once properly adjusted, tighten the jam nut against the adjuster and re-install the protective sleeve.
  8. Start the engine and allow if to warm up thoroughly. Measure the distance the throttle pedal moves before the engine begins to pick up speed. Freeplay should be 1/16 of an inch to 1/8 of an inch (1.6-3.2 mm).

Throttle Pedal Adjustment

NOTICE
It is ideal to adjust the throttle pedal with the help of an assistant.
  1. Loosen the adjustment screw and jam nut .Image
  2. With the vehicle off and in park, have the assistant fully depress and hold down the throttle pedal.
  3. The person on the engine side should manually press the lever on the engine to ensure that full travel is being achieved.
  4. Release the pedal and engine lever and adjust the pedal adjustment screw out 1/2 turn at a time and continue this process until full travel of the engine lever is NOT obtained.
  5. Slowly adjust the pedal adjuster in a 1/4 turn at a tie until the full engine throttle IS obtained. Once proper adjustment is obtained, tighten jam nut in place to hold the adjustment position.
    TORQUE

    Throttle Pedal Adjuster Jam Nut

    14 ft–lbs (19 Nm)
  6. With the unit in park, start the unit. Ensure the engine idle is still within range of 1200 +/- 100 RPM. Fully depress the throttle pedal and ensure that the engine RPM gets to 3850 +/- 50 RPM.
    caution

    DO NOT HOLD hold the unit wide open for more than 10 seconds.

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