Snowmobile Polaris (2006 year). Manual - part 19

3.12

MAINTENANCE

NOTE:  The Rod Pin position in relation to the dial 
indicator tells you what action is required to 
straighten the shaft.

CRANKSHAFT RUNOUT INSPECTION

Crankshaft runout can be checked with the engine in the 
machine. Using a dial indicator with the crankshaft holding 
fixture (PN 2870569) will yield the most accurate results.

Table 3-3: Truing Examples

To correct a situation like this. Strike the shaft at point 
A with a brass hammer.

To correct a situation like the one shown in this. 
Squeeze the crankshaft at point A. You will use the 
tool from the alignment kit PN 2870569.

If the crank rod pin location is 180_ from the dial 
indicator (opposite of above), it will be necessary to 
spread the crankshaft at the A position as shown in 
illustration 3. When rebuilding and straightening a 
crankshaft, straightness is of utmost importance. 
Runout must be as close to zero as possible.

A

B

HIGH .004 (.1mm)

HIGH .004 (.1mm)

SUPPORT CRANKSHAFT
AT THESE TWO BEARINGS

A

A

HIGH .002 (.05mm)

HIGH .005 (.13mm)

A

HIGH .002 (.05mm)

HIGH .005(.13mm)

A

3.13

MAINTENANCE

When checking the crankshaft runout on the MAG side. Place 
the dial indicator end at 1/2” (12.7mm) from the bearing flat 
(A).

When checking the crankshaft runout from the PTO side. 
Place the dial indicator end where the taper starts after the 
bearing flat (B).

NOTE:  Acceptable crankshaft runout (in a crank 
fixture) is 0 - .0015” (0 - .04mm) on Libertyt engines. 
0 - .0025” (0 - .07mm) on Fuji engines.

OIL PUMP BLEEDING

1.

To aid in bleeding the air out of the oil lines, fill oil

reservoir with the appropriate Polaris injector oil. This will
add pressure to the oil lines.

2.

Loosen the bleed screw (A). After approximately 30
seconds oil should flow from beneath the screw head. This
will indicate the pump is free of the air.

3.

Tighten bleed screw (A) securely.

NOTE:  Any time that the engine is disassembled or 
repaired, it is important that the oil supply from the 
oil pump be checked and full of oil.

IMPORTANT: The oil pump must always be bled 
following any service to the oil injection system or 
engine.

FITTING TYPES

VERIFYING CHECK VALVE OPERATION

1.

To check the operation of the fittings, fill the oil reservoir,
bleed the pump.

2.

Remove the check valve (A,B) from the component.

3.

Place the oil line (with check valve) in a safe area where no
moving engine part will make contact with it.

4.

Start the engine and let it idle for approximately 1-2
minuets.

5.

Drops of oil should be visible from the check valve after
the engine has idled 1 to 2 minuets, with a drop occurring
every few seconds.

6.

If oil does not flow from one of the check valves, remove
the oil line from the check valve and repeat step 4, if oil is
present during this test replace the faulty check valve.

NOTE:  Valves should open with 2-7 lbs of pressure.

NOTE:  Install new sealing washers (C) upon 
installation on either side of the banjo check valve.

If oil does not flow with the check valves removed from their 
feed lines, check the following

• In line filter blocked

• Air may not be bled from the oil pump

• Feed lines leaking

MAG END

1/2”(12.7

A

PTO END

B

PTO END

A

BANJO TYPE

B

C

3.14

MAINTENANCE

• Oil tank vent restricted or kinked

• Defective pump

OIL / FUEL FILTER

NOTE:  The direction of the arrow indicates the 
direction of the flow through the filter. After 
changing the oil filter, the oil injection system must 
be bled of all trapped air. see “OIL PUMP 
BLEEDING” on page 3.13.

Most models use an oil and fuel filters which are of a special 
design and must not be substituted. These filters should be 
changed and the oil and fuel lines should be inspected 
annually or every 1000 miles (1600 km).

These filters may have an arrow on the filter or line. This 
arrow is the direction of flow. Install accordingly.

EDGE models utilize a special oil filter that is built into the 
oil sending unit located in the bottom of the oil tank. It should 
be replaced every two years or 2400 miles (3862 km).

700/900 FUSION/RMK models use the in-line filter and 
should be replaced every two years or 2400 miles (3862 km).

BRAKE LEVER TRAVEL

The brake lever travel should have a clearance no less than 1/
2” (1.27cm) from the handlebar grip. Inspection should be 
made with the lever firmly depressed. If the lever has less than 
this amount you may need to bleed the brake system, see 
“BRAKE FLUID REPLACEMENT & BLEEDING” on 
page 8.3.

BRAKE FLUID

Inspect the reservoir to be sure it contains the correct amount 
of fluid. Use only Polaris DOT 4 high temperature brake fluid. 
Change fluid every 2 years or whenever the fluid is dark or 
contamination is suspected.

CAUTION

The in tank fuel filter and fuel lines should be inspected 

regularly. Special attention should be given to the fuel 

line condition after periods of Summer storage. Normal 

deterioration from weather and fuel can occur during 

this storage period. Do not damage fuel lines when re-

moving them. If a fuel line has been damaged or kinked 

it must be replaced.

WARNING

Do not over fill the master cylinder. Fluid expansion 

could cause brakes to lock, resulting in serious injury or 

death. Once a bottle of brake fluid is opened, use what 

is necessary and discard the rest. Do not store or use 

a partial bottle of brake fluid. Brake fluid is hygroscopic, 

meaning it rapidly absorbs moisture from the air. This 

causes the boiling temperature of the brake fluid to 

drop, leading to early brake fade and the possibility of 

serious injury

3.15

MAINTENANCE

NOTE:  A low brake fluid level can be indicated 
through the sight glass on the cover. If the fluid is 
low this sight glass will glow a brighter. color.

BRAKE FLUID BLEEDING

see “BRAKE FLUID REPLACEMENT & BLEEDING” on 
page 8.3.

FULL

LOW