This entry was posted in and tagged , , on by. S Do not overfill the tank. Remove the handlebar cover A to expose the handlebar and the four adjuster block bolts B. A smaller distance indicates low brake fluid level or air in the hydraulic system. Intake Silencer Do not operate the engine with the intake silencer or filter removed.
Housing Bolt Torque: 9 Ft lbs 12 Nm V. Slide armature into field coil housing. Install pilot jet, main jet, starter jet, and idle screw. Cylinder Head Warp Service Limit:. Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. Measure belt width and replace if worn severely. The rear suspension also must provide weight transfer and maintain track tension.
Oil Pump Mounting Screw Torque: 48 - 72 in. Support shock and strike body cap end 2-3 times with a soft faced hammer to remove all air trapped inside the valve piston. Crankshaft repair should be performed by trained Polaris service technicians in a properly equipped shop. This test cannot be performed if the engine or starting system is not working properly. After clutch offset has been verified, inspect alignment. Water Pump Cover Bolt Torque: 9 Ft lbs 12. Reinstall the chaincase cover and drain plug.
Rear Torque Arm Front Torque Arm. Track warranties are void if track damage or failure results from improper or excessive stud installation or the use of non-Polaris traction products. Check for specified slack A between the wear surface of the track clip and the plastic slider. Complete factory service repair manual for the 2003 Polaris Deep Snow Snowmobile. S Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. Use caution and good judgement when driving in hilly terrain. With carburetor in an inverted position, float arms A should be parallel with body B.
Remove bolts and separate case halves. Maintain alignment by tightening cover bolts evenly and carefully. Set aside damper rod assembly for reinstallation. Remove taillight assembly and wire harness. Install new taillight assembly and rivet into place.
Remove retaining nuts as shown. This entry was posted in and tagged , , on by. Make sure that the crankshaft rotates smoothly and does not bind. Determine the largest diameter within this area and refer to the chart below for clearance specifications. Insert suspension, rear first, into the track.
Do not allow brake fluid to come in contact with finished surfaces. Remove drive clutch retaining bolt, grease puller thread and tip lightly and install puller into clutch. It is great to have, will save you a lot and know moreabout your 2006 Polaris Snowmobile, in the long run. When replacing a faulty valve, be sure the identification number stamped on the valve body is correct. Using a flywheel puller, remove the flywheel from the engine. Rear Suspension Lubricate the rear suspension pivot shafts with Polaris Premium All Season Grease at 500 miles 800 km initially, every 1000 miles 1600 km after that, and before off-season storage each year.
Reinstall clutch offset washers on jackshaft and install driven clutch. Foxt t t t Part Numbers can be found on pg 7. Lubricate main bearing oil holes with Polaris Premium 2 Cycle or Premium Gold engine oil and rotate crankshaft to distribute oil evenly. Inspect water pump weep hole for signs of leakage or blockage. Clean thoroughly to remove all grease, oil, dirt, and old sealant. Install valve in cylinder and move it through the entire travel Clean with Solvent range to check for free movement without bind- ing.
Your Polaris snowmobile has been engineered for this range of adjustability. Buried objects or uneven ter- rain can cause loss of control. A decal on the hood of these models indicates that the vehicle is designed for one operator and one passenger only. Change fluid every 2 years or whenever the fluid is dark or con- tamination is suspected. Reinstall air box, adjusting box properly. Never rotate a damaged track under power.
To adjust float arm, bend tang contacting inlet needle. Once correct jackshaft alignment has been achieved, install lock nuts on chaincase mounting bolts and torque to specification. Spring and seal lip must face inward toward crankshaft. Connect one of the tester leads to the yellow alternator wire and the other lead to the brown alternator wire. Complete factory service repair manual for the 1972-1981 Polaris Snowmobile. Install a box end wrench on caliper bleeder screw fitting. Since snow provides the only lubrication for the power slide suspension and, on liquid cooled models, cooling for the engine, adequate snow cover is a requirement for operation of your machine.