Snowmobile Polaris (2006 year). Manual - part 20

3.16

MAINTENANCE

EXHAUST SYSTEM

At approximately 2000 miles, or in preparation for off season 
storage, it is a good idea to check the exhaust system for wear 
or damage. To inspect, allow the engine and exhaust system to 
cool completely. Open the hood and inspect the muffler and 
pipes for cracks or damage. Check for weak or missing 
retaining springs, and also check the damper/support 
grommets.

Springs are installed in such a way so that the opening of the 
hook that you are puling on is facing the item being held.

Stainless steel (gray color) springs (AA) are located at the 
header pipe. Other (gold color) springs (A) are everywhere 
else.

EXHAUST REMOVAL

1.

Let engine and exhaust system to cool completely before
preforming any service.

2.

Disconnect and remove all the exhaust springs (A and
AA).

NOTE:  The stainless steel springs (gray in color), 
hold the exhaust pipe to the manifold are designed 
to handle higher temperature ranges then the other 
springs.

3.

Disconnect the exhaust temperature sensor (if equipped).

4.

Remove the exhaust pipe (C), resonator seal (D) and
manifold seal (E).

5.

Remove the resonator (F). Some models use rubber
isolators (G) and will need the nut (L) removed in order to
remove the resonator. 

6.

Remove the manifold (H) and gaskets (I) by removing the
manifold mounting bolts (J).

7.

Check the condition of the vibration dampener (K) and
replace if damaged.

8.

Check the condition of the resonator outlet boot (M) and
replace if damaged.

EXHAUST INSTALLATION

1.

Install new exhaust manifold gaskets (I).

2.

Place the exhaust manifold (H) on to the engine and torque
the mounting bolts (J) to 18 ft-lb(24Nm).

3.

Install the resonator (F). Some models utilize resonator
locating tabs (M) that need to be lined up and pushed down
to assure the correct position.

4.

If rubber isolators (G) are used on the resonator, secure
them by installing the isolator nuts (L).

5.

Check the condition of the vibration dampener (K) and
replace if it is damaged.

6.

Insert the exhaust seals (D,E) onto the manifold (H) and

A

C

D

E

F

G

H

I

J

K

L

M

AA

B

3.17

MAINTENANCE

the exhaust pipe (C).

7.

Install the exhaust pipe on the manifold and resonator.

8.

Install all the exhaust springs.

BELT DEFLECTION

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

1.

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

2.

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

3.

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

4.

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

5.

If the measurement is not correct adjust driven clutch, See
“TEAM BELT DEFLECTION” on page 26.

LUBRICATION 

GREASE POINTS

NOTE:  A grease gun kit (PN 2871312) comes with 
grease and adapters to lubricate all the fittings 
needed to service Polaris snowmobiles.

Lubricate the following fittings with Polaris Premium All 
Season grease every 1000 miles (1600 km) and before summer 
storage. When applying grease to these points, free up all the 
weight form the component being greased to permit better 
penetration.

• Ski spindles

• Ski pivots

• Steering post pivots

• Rear suspension pivot shafts

• Jackshaft

• Driveshaft

JACKSHAFT BEARING

1.

Loosen the driven clutch retaining bolt and pull the clutch
away form the flange fitting to expose the bearing grease
point.

2.

Apply grease with the grease gun with just a few pumps.

3.

Install the driven clutch see “DRIVEN CLUTCH
INSTALLATION” on page 7.20.

1 1/4”

Straight Edge

B

A

Too high on initial engagement

Belt too tight

3.18

MAINTENANCE

DRIVESHAFT BEARING

1.

Locate the driveshaft bearing grease zerk that is located on
the flange of the bearing cover.

2.

Apply a few pumps of grease into the grease zerk and
clean up any residual grease on the fitting.

REAR SUSPENSION

To maintain rider comfort and to retard wear of the pivot 
shafts, the suspension pivot shafts should be lubricated with 
Polaris Premium All Season Grease at 500 miles (800 km) 
initially; 1000 miles (1600 km) and before summer storage 
each year. The riding characteristics of the snowmobile will be 
affected by lack of lubrication of these shafts.

CHAINCASE

The drive chain is continuously immersed in the chaincase oil. 
Depending on the style chaincase the proper oil level is 
determined by checking on the dipstick or sight glass. To get 
an accurate level reading the machine must be placed on a 
level surface.

DIP STICK

If your chaincase has a dip stick, the correct level will be 
indicated between the “SAFE” markings. To add fluid to this 
style chaincase you can add it through the dipstick hole.

The dip stick also has safety magnetic tip that catches any 
metal shavings that are in the system. This magnetic tip 
should be cleaned every time you check the fluid level.It is 
common to see shavings during break in of a new gear(s) or 
chain.

SIGHT GLASS

If your chaincase uses a sight glass, make sure that the level of 
fluid is even with the mark on the glass. To add fluid to this 
style chaincase, add fluid through the fill cover.

The drain plug is magnetic so that any shavings are collected 
here. You should remove any shavings from this drain plug 
when changing the fluid.

STEERING U JOINT

The steering U joint should be 
lubricated with Polaris fogging oil 
(PN 2870791). Follow the 
maintenance chart at the 
beginning of this chapter.

CAUTION

Do not mix or use improper types of lubricants in the 

chaincase. Excessive wear to chain, sprockets and 

bearings may result.

MAGNETIC END

DIP STICK

SAFE FLUID AREA

SIGHT GLASS

Apply

Fogging

Oil

3.19

MAINTENANCE

ADJUSTMENT

CHAINCASE DRIVE TENSION

1.

Elevate the rear of the machine so that the track is off the
floor.

2.

Rotate the driven clutch counterclockwise to move all the
chain slack to the tensioner side.

3.

Lock the parking brake.

4.

Loosen the adjuster bolt jam nut (B)

5.

Finger tighten the adjuster bolt (A).

6.

Back off the adjuster bolt 1/4 turn out (counterclockwise).

7.

Tighten the jam nut while holding the adjuster bolt.

8.

Release parking brake.

NOTE:  It may be necessary to remove the exhaust 
pipe and resonator to access this area.

A

B