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MOTONEIGE POLARIS
CENTRE D'AIDE
8/25/2023

2023+ ProStar S4 INDY Adventure Spark Plug Inspection and Replacement

Required Tools and Supplies

  • T30 TORX® Socket
  • Spark Plug Wrench
  • 5/8-inch Spark Plug Socket 
  • Torque Wrench
  • Multi-Function Pliers
  • Flat Head Screwdriver
  • Side Cutters
  • Air Chuck
  • Panduit Strap
  • Safety Glasses
  • Nitrile Gloves
  • Shop Rags

To learn more about tools, read the Tools and Fasteners Guide

Always wear safety glasses and nitrile gloves when servicing your Polaris snowmobile. To inspect and replace the spark plugs on your ProStar S4 INDY Adventure snowmobile, follow these steps:

1. Ensure the snowmobile is on a flat, level surface.

2. Remove both side panels by turning the three quarter-turn latches. Pivot the panels away from the sled and pull out to remove.

3. Disconnect the two hood latches.

4. Lift the hood up slightly and disconnect the 7S display connector.

5. Pivot the hood back and remove from the sled.

6. Remove the two push-pin rivets on top of the air duct with the multifunction pliers.

7. Cut and remove the Panduit strap from the air duct with the side cutters.

8. Continue by separating the air duct from the duct system and setting the duct aside

9. Clean the area around the spark plug coils.

10. Remove the two fasteners on each spark plug coil with a T30 TORX® socket or T30 TORX® wrench (included in tool kit).

11. Disconnect the connectors on the rear of the coils. A flat head screwdriver may be used to aid in disconnecting the connectors.

12. Carefully pull upward on both spark plug coils to remove.

13. Blow any dirt or debris out of the spark plug wells with compressed air to prevent anything from falling into the cylinders. 

14. Remove the spark plug wrench from the spark plug holder.

15. Loosen the two spark plugs with a spark plug wrench and remove from the vehicle. If reusing, take note of the cylinders they were installed in for reinstallation.

16. Inspect the electrodes for wear and carbon buildup, and verify there are no cracks around the insulation. The spark plug should have a sharp outer edge with no rounding or erosion.

17. Inspect and adjust the spark plug gap if needed. The gap should measure 0.027 – 0.031 inches (0.7 – 0.8 mm).

18. If necessary, replace with the recommended spark plug. Refer to your Owner’s Manual for the recommended plugs.

19. Install the spark plugs into the engine, and torque to 8.8 ft-lbs (12 Nm).

20. Carefully push the spark plug coils onto the spark plugs and ensure they are secure.

21. Reinstall the coil fasteners, and torque to 71 in-lbs (8 Nm).

22. Reconnect the coil connectors.

23. Reinstall the hood panel, ensuring the tabs in front are properly engaged. 

24. Reconnect the connector underneath and verify it is secure.

25. Reconnect both ends of the air duct to the duct system.

26. Reinstall the two push-rivets into the top of the air duct.

27. Secure the air duct tab to the frame using a Panduit strap.

28. Reinstall the hood panel, ensuring the front tabs are properly engaged. 

29. Reconnect the connector underneath and verify it is secure.

30. Secure the two hood panel latches.

31. Reinstall both side panels by inserting the upper tab and pivoting in to engage the lower tab. 

32. Latch the three quarter-turn latches to secure each panel.

33. Finally, in a well-ventilated area, start the vehicle to ensure proper operation.

For more information, see your authorized Polaris Dealer. To find a dealer near you, use the Dealer Locator.
Maintenance tips, procedures and specifications can be found in your Owner's Manual.
To find diagrams and replacement part numbers, use the online parts catalog.

NGK® is a registered trademark of NGK Spark Plug Co., Ltd. 
TORX® is a registered trademark of Acument Intellectual Properties, LLC

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Unless noted, trademarks are the property of Polaris Industries Inc.
© 2023 Polaris Industries Inc.