2005 Polaris Sportsman 400/500 Service Manual, Page 47Get this manual
MAINTENANCE S EXHAUST VALVE CLEARANCE .006 (.15 mm) 3When clearance is correct, hold adjuster screw and tighten locknut securely 4Re-check the valve clearance5Repeat adjustment procedure if necessary until clearance is correct with locknut securedRepeat inspection for inner tie rod end on steering post
STEERING
The steering components should be checked periodically for loose fasteners, worn tie rod ends, and damageAlso check to make sure all cotter pins are in placeIf cotter pins are removed, they must not be re-usedAlways use new cotter pinsReplace any worn or damaged steering componentsSteering should move freely through entire range of travel without bindingCheck routing of all cables, hoses, and wiring to be sure the steering mechanism is not restricted or limitedNOTE: Whenever steering components are replaced, check front end alignmentUse only genuine Polaris partsWARNING Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component repair and adjustment be performed by an authorized Polaris MSD-certified technician when replacing worn or damaged steering partsUse only genuine Polaris replacement parts