Snowmobile Polaris (2006 year). Manual - part 22

3.24

MAINTENANCE

THROTTLE LEVER FREE PLAY

Throttle lever free play must always be at a specified
clearance (A) .010”-.030” (.25-.80 mm) between the throttle
lever (B) and the throttle block (C). This clearance is
controlled by the throttle cable (D).

If adjustment is needed follow these steps:

Check the idle RPM and verify it is within the specified
range.

Shut off engine.

Locate the throttle cable that is attached to the carburetors
and adjust the throttle free play by adjusting the barrel nut
(E) and lock nuts (F).

Once you achieve the proper free play of .010”-.030” (.25-
.80mm), tighten the lock nuts.

Verify the oil pump index marks are with in range.

Check the idle RPM and verify it is within the specified
range.

NOTE: If the idle speed screw is adjusted inward
and the cable sleeve is not adjusted to take up the
throttle lever clearance, the engine may misfire or
kill upon initial throttle opening.

TORQUE STOP

After aligning clutches, adjust torque stop (A) by loosening
the lock nut and rotating the stop so that the clearance is .010”
- .030” (.25 - .75mm) from the whole surface of the torque
stop.

If replacing a new torque stop, adjust the torque stop so that
the tip (B) is touching the engine case.

Hold torque stop and tighten jam nut to 15-17 ft-lb. (21-24
Nm).

CLEANING

AIR FILTER

The intake foam filter (A) limits snow ingestion into the
intake system. When operating in loose powder, check the top
of the foam filter periodically to remove any accumulation of
snow.

NOTE: Do not operate a machine with the intake
filters removed. This may cause carburetor icing
resulting poor fuel economy or engine damage.

CAUTION

After any idle speed adjustments are made, the throttle

lever clearance and the oil pump adjustment must be

checked and adjusted.

gap=.010-.030”

THROTTLE FREE PLAY

.25-.80mm

TORQUE STOP

AIR FILTER CLEANING

3.25

MAINTENANCE

WATER SEDIMENT TRAP

Most Polaris
snowmobiles
incorporate a
patented
carburetor bowl
water / sediment
traps which are
located at the
bottom of each
carburetor. The
trap consists of a
hose with a plug
which should be
inspected for
contamination
every 1000 miles
(1600 km).

Turn the fuel tank supply valve to the “OFF” position.

Position a container or shop towels under the work area to
help catch some of the contaminated gasoline.

Slide the clamp (A) away from the drain plug (B) and
remove it from the sediment tube and drain the
contaminated material from the bowl. Repeat for each
carburetor.

Wipe off the residue from the plug and reinstall the
clamps.

NOSEPAN CARE

If your nosepan becomes dirty with soot, you can use Polaris
Carbon Clean (PN 2872890) to remove the soot.

STORAGE

CHASSIS AND HOOD

Proper storage starts by cleaning, washing and waxing the
hood, chassis, upholstery and plastic parts. Clean and touch up
with paint any rusted or bare metal surfaces. Ensure that all
corrosive salt and acids are removed from surfaces before
beginning preservation with waxes and rust inhibitors (grease,
oil, or paint).

If the machine is equipped with a battery, disconnect the
battery cables and clean the cables and battery posts. Fill
battery to proper level with distilled water and charge to full
capacity. Remove and store the battery in a cool dry place.

The machine should be stored in a dry garage or shed out of
the sunlight and covered with a fabric snowmobile cover. Do
not use plastic to cover the machine; moisture will be trapped
inside causing rust and corrosion problems.

CLUTCH AND DRIVE SYSTEM

Remove drive belt and store in a cool dry location. Lubricate
sheave faces and ramps of drive and driven clutches with light
oil or rust inhibitor. All lubrication applied as a rust
preventative measure must be cleaned off before installing belt
for service and operating machine.

CONTROLS AND LINKAGE

All bushings, spindle shafts and tie rod ends should be coated
with a light coat of oil or grease. Throttle controls and cables
should be lubricated. Force a small amount of lubricant down
cables.

ELECTRICAL CONNECTIONS

Separate electrical connector blocks and clean corrosive build-
up from connectors. Lubricate or pack connector blocks with
Nyogelt grease and reconnect. Replace worn or frayed
electrical wire and connectors.

CARBURETOR/THROTTLE BODY

Fog engine with Polaris Fogging Oil (aerosol type) according
to directions on can.

FUEL SYSTEM

Treat the fuel system with Polaris Carbon Clean. If Polaris
Carbon Clean is not used, fuel tank, fuel lines, and carburetor
should be completely drained of gasoline.

CORROSION

To prevent corrosion, always grease jackshaft and drive shaft
(clutch side) bearings with Polaris Premium all season grease.
Loosen driven clutch retaining bolt and pull clutch outward to
expose bearing. Use a point type grease gun fitting to inject
grease through hole in flangette into bearing until grease
purges out inside or outside bearing seal. Push clutch back on
shaft and replace clutch retaining bolt. Inject grease into fitting
on speedometer drive adaptor until grease purges out inside or
outside the bearing seal. Lubricate both front ski pivots at
bushings and spindles.

WARNING

When draining the traps, fuel spillage will occur. be

sure to work in a well ventilated area away from any-

thing which may cause the fuel to ignite such as an

open flame, heaters, trouble lights or cigarettes.

3.26

MAINTENANCE

SHOCKS

Use T-9 Metal Protectant (or equivalent) on shock absorber
shafts to help prevent corrosion.

BATTERY

Disconnect and remove the battery. Clean the terminals and
cables. Apply dielectric grease to the terminals. Store in a cool
dry place for storage.

REPLACEMENT

HEADLIGHT BULB REPLACEMENT

NOTE: Do not touch the bulb with your fingers. The
grease from body oil will cause a hot spot on the
bulb and cause bulb failure. If you do touch the bulb
clean the bulb with isopropyl alcohol.

EDGE HEADLIGHT BULB REPLACEMENT

Push in on the “PUSH” section of the plenum.

Slide the access panel down to gain access to the bulb.

Squeeze and move the bulb clip up.

Replace the bulb, clip and access panel.

IQ HEADLIGHT BULB REPLACEMENT

Unplug the headlight harness (1) form the bulb.

Remove the rubber boot (2) from the housing.

Pinch the ends of the spring (3) together and lift it until it
releases from the spring retainer.

Lift spring carefully around the wire harness and flip it to
the outside of the housing.

Grasp the bulb (4) by the metal base and carefully separate
the bulb from the harness.

Instal new bulb by the base and reverse the process for
installation.