Snowmobile Polaris (2006 year). Manual - part 17

3.4

MAINTENANCE

Brake Disc

I

I

I

I

Parking Brakes

I

I

I

I

I

Brake System

I

Brake Fluid

R

FUEL MANAGEMENT

Pilot Air Screws

I

I

I

Carburetor 

(synchronize)

I

I

I

Idle RPM

I

I

I

Throttle Lever

I

I

I

I

I

Oil Pump Lever 

(synchronize)

I

I

I

Throttle Cable

L

L

L

Choke Cable

L

L

L

Choke

I

I

I

Vent Lines

I

I

I

I

Throttle Position 

Sensor

I

I

I

Fuel Lines

I

I

I

I

I

Fuel Filter

R

R

Oil Filter

R

R

Oil Lines

I

I

I

Air Box

I

I

I

I

I

Drain and Water Traps

I

I

I

ELECTRICAL

Auxiliary Shut-Off Switch

I

I

I

I

I

I

Throttle Safety Switch

I

I

I

I

I

I

Ignition Switch

I

I

I

I

I

I

Taillight

I

I

I

I

I

I

Brakelight

I

I

I

I

I

I

Headlight

I

I

I

I

I

I

Tether Switch and Strap

I

I

I

I

I

I

CHASSIS

Ski Toe Alignment

I

I

I

Suspension Mounting Bolts

I

I

I

I

I

I

Steering Fasteners

I

I

I

I

C

Rear Suspension Fasteners

I

I

I

I

I

Suspension Shock Oil

I

I

I

I

Cooling Fins and Shroud

I

I

I

I

Drive Shaft Bearing

L

L

L

I

Jackshaft Bearings

L

L

L

I

Skags (Wear Bars)

I

I

I

I

I

I

Ski Saddle/Spindle Bolts

I

I

I

I

I

I

Drive Chain Tension

I

I

I

I

I

Hood Straps

I

I

I

I

I

I

Table 3-1: Maintenance Intervals

Item

Pre-Ride

Frequency Miles (km)

Pre-

Season

150 (240)

500 (240)

1000 (1600)

2000 (3200)

I:Inspect (clean, adjust, tighten, lubricate, replace if necessary) C:Clean R:Replace L:Lubricate

3.5

MAINTENANCE

INSPECTONS

CYLINDER HEAD INSPECTION

Inspect each piston dome area of the cylinder head for warping 
by placing a straight edge across the dome area.

With a feeler gauge measure any gap under the straight edge.

Replace cylinder head if measurement exceeds the service 
limit of .003" (.08mm). 

NOTE: Cylinder head warp service limit is: 

.003”(.08mm).

Seat Latches

I

Rear Wheel Idler Bolts

I

I

I

I

I

I

Idler Bolt Jam Nut

I

I

I

I

I

Rear Suspension Pivot Shafts

L

L

L

Handle Bar U-Joint

L

L

L

Camber Alignment

I

I

I

Handlebar Centering

I

Track Alignment

I

I

I

I

I

I

Track Tension

I

I

I

I

I

Rail Slide Condition

I

I

Chaincase Oil

I

I

I

I

R

I

Injection Oil Level

I

Table 3-1: Maintenance Intervals

Item

Pre-Ride

Frequency Miles (km)

Pre-

Season

150 (240)

500 (240)

1000 (1600)

2000 (3200)

I:Inspect (clean, adjust, tighten, lubricate, replace if necessary) C:Clean R:Replace L:Lubricate

Limit .003” (.08mm)

3.6

MAINTENANCE

CYLINDER MEASUREMENT

Inspect each cylinder for wear, scratches, or damage. If no 
damage is evident, measure the cylinder for taper and out of 
round with a telescoping gauge or a dial bore gauge. Measure 
the bore 1/2” from the top of the cylinder; in line with the 

piston pin and 90_ to the pin to determine if the bore is out of 
round. Repeat the measurements at the middle of the cylinder 
and the bottom of the cylinder to determine taper or out of 
round at the bottom. Use the chart below and record all 
measurements.

CYLINDER HONING

The cylinder bore must be de-glazed whenever new piston 
rings are installed. A light honing with fine stones removes 
only a very small amount of material. A proper crosshatch 
pattern is important to provide a surface that will hold oil, and 
allow the rings to seat properly. If the crosshatch is too steep, 
oil retention will be reduced. A crosshatch angle which is too 
shallow will cause ring vibration, poor sealing, and 
overheating of the rings due to blow-by and reduced contact 
with the cylinder wall. Service life of the pistons and rings 
will be greatly reduced.

NOTE:  A Nikasil cylinder can be lightly honed with a 
soft stone hone but an not be oversized.

Table 3-2: Cylinder Measurement Worksheet

TOP

Tx

Ty

MIDDLE

Mx

My

BOTTOM

Bx

By

Out of round = Tx - Ty and By - Bx

Taper limit = Ty - By and Tx - Bx

Cylinder taper limit is .002”(.051mm) 

Max 

Cylinder out of round limit is 

.002”(.051mm)

Top

Middle

Bottom

Tx

Mx

Bx

Ty

My

By

EXAMPLE OF A CROSS HATCH PATTERN

3.7

MAINTENANCE

HONING PROCEDURE

1.

Wash the cylinder with solvent.

2.

Clamp the cylinder in a soft jawed vise by the exhaust port
studs.

3.

Place hone in cylinder and tighten stone adjusting knob
until stone contacts the cylinder walls (DO NOT
OVERTIGHTEN). Cylinders may be wet or dry honed
depending on the hone manufacturer's recommendations.
Wet honing removes more material faster and leaves a
more distinct pattern in the bore. Using a 1/2" (13 mm)
drill motor rotating at a speed of 300-500 RPM, run the
hone in and out of the cylinder rapidly until cutting tension
decreases. Remember to keep the hone drive shaft centered
to prevent edge loading and always bring the stone
approximately 1/2" (1.3 cm) beyond the bore at the end of
each stroke.

4.

Release the hone at regular intervals to inspect bore size
and finish.

HONING TO OVER SIZE (340/550/500 FUJI 
ENGINES ONLY)

If cylinder wear or damage is excessive, it will be necessary to 
oversize the cylinder using a new oversize piston and rings. 
This may be accomplished by either boring the cylinder and 
then finish honing to the final bore size, or by rough honing 
followed by finish honing.

For oversize honing always wet hone using honing oil and a 
coarse roughing stone. Measure the new piston at room 
temperature (see piston measurement) and rough hone to the 
size of the piston or slightly larger. Always leave .002" - .003" 
(.05 - .07 mm) for finish honing. Complete the sizing with fine 
grit stones to provide the proper cross-hatch finish and 
required piston clearance.

Inspect cylinder for taper and out-of-round. Taper or out-of-
round on the finished bore should not exceed .0004" 
(.002mm).

NOTE:  Portable rigid hones are not recommended 
for oversizing cylinders, cylinder boring, and finish 
honing. The use of an arbor type honing machine is 
recommended. Always check piston to cylinder 
clearance and piston ring installed gap after boring/
honing is complete.

CLEANING THE CYLINDER AFTER HONING

It is very important that the cylinder be thoroughly cleaned 
after honing to remove all grit material. Wash the cylinder in a 
solvent, then in hot soapy water. Pay close attention to areas 
where the cylinder sleeve meets the aluminum casting 

(transfer port area). Use electrical contact cleaner if necessary 
to clean these areas. Rinse thoroughly, dry with compressed 
air, and oil the bore immediately with Polaris Premium 2 
Cycle Lubricant.

NOTE:  Always check piston to cylinder clearance 
and piston ring installed gap after honing or boring 
is complete.

PISTON INSPECTION

Check piston for scoring or cracks in piston crown or pin area. 
Excessive carbon buildup below the ring lands is an indication 
of piston, ring or cylinder wear. For Libertyt engines, 
measure piston outside diameter at a point 3/8" (10mm) up 
from the bottom of the skirt at a 90_ angle to the direction of 
the piston pin. For Fuji engines, measure piston outside 
diameter at a point that is 1/2" (12.7mm) up form the bottom 
of the skirt at a 90_ angle to the direction of the piston pin.

NOTE:  The piston is measured at this point to 
provide an accurate piston to cylinder 
measurements.

Subtract this measurement from the minimum cylinder 
measurement (90_ to the pin) recorded previously when you 
recorded the cylinder measurements. If clearance exceeds the 
service limit, the cylinder should be re-bored and new pistons 
and rings installed. Refer to piston to cylinder clearance limits 
in the General Information section listed per model.

90

q to pin

DOMESTIC ENGINES - Measure 3/8

s (10.0mm)

up from bottom of skirt

FUJI ENGINES - Measure 1/2

s (12.7mm) up

from bottom of skirt