Snowmobile Polaris Two Stroke (2007 year). Manual - part 17

3.11

MAINTENANCE

Crankshaft Trueing

Lubricate the bearings and clamp the crankshaft securely in the holding fixture.If trueing the crankshaft requires striking with a
hammer, always be sure to re-check previously straightened areas to verify trueing. Refer to the illustrations below. Use Crankshaft
alignment kit PN 2870569.

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

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.

3.12

MAINTENANCE

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.

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 Liberty™
engines. 0 - .0025" (0 - .07mm) on Fuji engines.

Oil Pump Bleeding

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.

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.

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.

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 3.12.

MAG END

1/2”(12.7

PTO END

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 removing
them. If a fuel line has been damaged or kinked it must
be replaced.

3.13

MAINTENANCE

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).

CFI models fuel filter should be replaced every 1000 miles
(1600km).

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 7.20.

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.

See “Brake Fluid Replacement & Bleeding” on page 7.20.

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.

Exhaust System Removal/Installation

Remove the exhaust springs (1,2) with Exhaust Spring
Tool PN PU-45485.

Disconnect exhaust temperature sensor (3) if so equipped.

Remove the exhaust pipe (4).

Remove resonator fasteners if equipped.

Remove the resonator (5).

Replace in reverse order.

NOTE: The light gray springs (2) are made stainless
steel and should be used at the head pipe.

Manifold Installation

Install new exhaust manifold gaskets (8).

Place the exhaust manifold (7) on to the engine and torque
the mounting bolts (6) to 18 ft-lb (24 N-m).

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

1/2” (1.27cm)

= T

Manifold Fasteners: 18 ft-lb (24 N-m)

FULL

LOW

(Stainless steel springs)

(Gold colored springs)

3.14

MAINTENANCE

Belt Deflection Inspection

Belt deflection is critical for optimum belt performance and belt
life. It should be checked at 500 miles (800km) and then in 1000
mile (1600km) increments after that.

Too much belt deflection is when the belt is too long or the center
distance is too short. The initial starting ratio will be too high,
resulting in performance loss. This is due to the belt rising too
high in the drive clutch sheaves upon engagement (A).

Not enough belt deflection (B) is when the belt is too short or the
center distance is too long. The initial starting ratio will be too
low. In addition, the machine may creep when the engine idles,
causing damage to the internal face of the drive belt.

Measuring Belt Deflection

Measure the belt deflection with both clutches at rest and
in their full neutral position.

Place a straight edge across the tow clutches, on top the belt.

Apply downward pressure to the belt and measure the
distance at point (D).

The measurement should be 1 1/4" (3.2cm).

If the measurement is not correct adjust driven clutch. See
“Adjusting Belt Deflection” on page 6.11.

= In. / mm.

Belt Deflection: 1.25" (3.2cm)

Content .. 15 16 17 18 ..