Content Source: 2021 Scout / Scout Sixty Owner’s Manual (9931427 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

Mechanical Clutch

Mechanical Clutch Lever Freeplay

caution
The clutch cable is located near the exhaust, which may still be hot after operation. Wait for the vehicle to cool down before attempting to adjust the clutch cable.
  1. The clutch cable adjuster nut is located along the lower right frame. While holding the clutch cable, slide the rubber protective cover away from the lock nut. Loosen the lock nut.Image
  2. While holding the cable, turn the cable adjuster inward or outward until clutch lever freeplay is 0.02–0.059 in (0.5–1.5 mm) .
  3. While holding the cable, tighten the adjuster lock nut securely.
  4. Verify that the safety switch activates properly. The engine should not start in gear with the clutch lever released.Image
NOTICE
The starter interlock switch is dependent on the clutch lever freeplay being set correctly to ensure activation of the clutch safety switch.

Mechanical Clutch Lever Lubrication

  1. Remove the clutch lever pivot nut and screw . Disconnect the clutch cable from the clutch lever.

    Image

  2. Remove any old grease and dirt from the lever and housing. Lubricate the clutch lever and pivot screw with moly assembly grease or all-purpose grease.
  3. Reconnect the clutch cable. Hold the screw down and tighten the nut.
    TORQUE
    96 in-lbs (10.8 N·m)
  4. Adjust clutch lever freeplay. See Mechanical Clutch Lever Freeplay.
  5. Tighten the adjuster nut and slide the protective cover over the adjuster.

Mechanical Clutch Cable Lubrication

Lubricate control cable barrel ends at the intervals recommended in the Periodic Maintenance Table.
NOTICE
The clutch cable is factory-lubricated. Additional lubrication could be detrimental to cable performance. Replace the clutch cable assembly if binding or sticking occurs. DO NOT lubricate between the cable and sheath.
Verify proper routing and smooth movement. Inspect for damage to the external casing, and inspect exposed cable wire for fraying, kinks or corrosion. Replace any damaged, sticky or sluggish cable.
  1. Disconnect the cable at the clutch lever and at the primary cover.
  2. Lubricate the barrel ends with all-purpose grease. Image
  3. Reconnect the cable and adjust freeplay as needed.

© Copyright Polaris Inc. All rights reserved.