Content Source: Polaris Power® P5500 and P6500 Owner’s Manual (9931064 R02) > 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

Spark Plug

Spark Plug Inspection

Using a non-recommended spark plug can result in serious engine damage. Always use recommended spark plugs. Refer to the Specification section for the recommended spark plug type. Always torque spark plugs to the specification.
In order to service the spark plug, the provided spark plug wrench is required.
caution
A hot exhaust system and engine can cause burns. Wear protective gloves when removing a spark plug for inspection.
IMPORTANT
The spark plug must be free of deposits and properly gapped for proper engine operation. If the engine has been running, allow it to cool before servicing.
  1. Remove the spark plug cap .
  2. Clean any dirt from around the base of the spark plug.
  3. Using the provided park plug wrench, remove the spark plug.
  4. Inspect the electrode for wear and carbon buildup. Look for a sharp outer edge with no rounding or erosion of the electrode.
Image
  1. Inspect spark plug. Replace if electrodes are worn or if insulator is cracked, chipped, or fouled.
  2. Clean the spark plug with a wire brush if it is to be reused.

Normal Plug

The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded.
This indicates the proper type and heat range for the engine and the service.

Wet Fouled Plug

The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. Fouling may be caused by excessive oil or by frequent short trips, especially in cold weather.

Spark Plug Replacement

IMPORTANT
Prior to replacing the spark plug, complete the inspection steps outlined on Spark Plug Replacement.
  1. Remove the spark plug cap.
  2. Clean any dirt from around the base of the spark plug.
  3. Using the provided park plug wrench, remove the spark plug.
  4. Using a wire-type feeler gauge, measure the spark plug electrode gap. If necessary, correct the gap by carefully bending the side electrode.
    MEASUREMENT

    Spark Plug Gap

    0.028-0.031 in (0.7-0.8 mm)
  5. Ensure the spark plug sealing washer is in good condition and thread the spark plug in by hand to prevent cross-threading.
  6. After a new spark plug has been seated by hand, it should be tightened 1/2 turn with a wrench to compress the sealing washer. If a used plug is being reinstalled, it should only require 1/8 to 1/4 turn after being seated.
  7. Re-install the spark plug cap.
    NOTICE

    A loose spark plug can overheat and damage the engine. Over tightening the spark plug can damage the plug threads.

    Never use a spark plug with an improper heat range.

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