Snowmobile Polaris 2006 - 2007 FS / FST. Manual - part 11

 

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Snowmobile Polaris 2006 - 2007 FS / FST. Manual - part 11

 

 

3.5

Maintenance

3

Rev. 1 07/2006

ENGINE OIL MAINTENANCE

Engine Oil Level Check

NOTE:  The following procedure must be performed
when the engine coolant temperature is between
145

° and 160° F (63° - 71°C). Failure to verify engine

oil level between these temperatures will yield false
oil level readings.

1.

To verify there is oil in the storage tank, position the
snowmobile on a flat, level surface. Start the engine and let
run for no more than 5 seconds. Turn off the engine.

2.

Verify there is engine oil on the dipstick. If low, add just
enough oil so that oil can be seen on the dipstick.

3.

If the engine is cold (engine temperature is not between
145

° and 160°F), start the engine and allow it to idle until

the engine coolant temperature reaches the specified range.
Proceed with step 4.

4.

If the engine has been running, stop the engine and verify
the engine coolant temperature is within the specified
range. Allow the engine to cool if required. Once the
coolant temperature is within the specified range, re-start
the engine and let it run for no more than 20 seconds to
circulate the oil from the engine back into the storage tank.

5.

Turn the engine off.

6.

Remove and clean the dipstick. Re-insert the dipstick
completely.

7.

Quickly remove dipstick again to verify the oil level.

NOTE:  The oil level inside the storage tank will only
be accurate for approximately 3 minutes after
stopping the engine. After 3 minutes, re-start the
engine and let idle for 20 seconds to re-fill the
storage tank.

8.

Maintain the oil level in the “SAFE” operating range
located between the upper and lower marks on the dipstick.
If the level is low, add oil in 2 oz. increments and re-check
the level.

9.

If the oil level is high. the excess oil MUST be removed
from the storage tank. Again, remove excess oil from the
tank in 2 oz. increments.

Engine Oil and Filter Change Procedure

NOTE:  A jumper harness, PN 4011491, is required to
bypass the main relay system so the engine can be
turned-over using the start key without starting the
engine. The jumper is included with the oil change
kit, PN 2875522. The kit includes the jumper, three

CAUTION

Severe engine damage may occur if the procedure for 

checking the oil level is not followed precisely.

 Always verify the oil level with the snowmobile on a flat, 

level surface. Always check the oil level when the 
engine coolant temperature is within the specified 

range.

WARNING

Never attempt to verify the oil level inside the storage 

tank immediately after operating the snowmobile at a 

high rate of speed for an extended period of time OR if 

the nose of the snowmobile is pointed downwards.

Always close the engine compartment doors and hood 

while the engine is running.

Always run the engine outside or in an open 

environment with plenty of fresh air.

CAUTION

Never overfill the oil storage tank. Severe engine 

damage, airbox / EMS sensor damage, or poor engine 
performance may occur if the storage tank is overfilled.

WARNING

The following procedure involves working with and 

around hot oil, engine parts, and exhaust components 

which can cause serious burns if your skin or clothing 

comes into contact with them.

Never turnover the engine or run the engine without first 

closing the side panels and hood on the snowmobile.

Always run the engine outside or in an open 

environment with plenty of fresh air.

3.6

Maintenance

Rev. 1 07/2006

quarts of Polaris 0W-50 synthetic oil, one oil filter
cartridge, and o ring.

1.

Position the snowmobile on a flat, level surface.

2.

Verify the engine coolant temperature is between 145

° and

160

°F (63° - 71°C).

NOTE:  The coolant temperature must be within the
specified range prior to beginning the oil change
procedure.

3.

Verify the engine is off.

4.

Open the hood, and remove the left-side panel.

5.

Disconnect the starter motor solenoid control harness.

6.

Insert the female WHT/RED plug into the male pin from
the solenoid.

7.

Insert the BROWN male pin from the jumper harness into
the solenoid’s female port.

8.

Open the handlebar cover. Locate the connector with the
BROWN and RED/WHITE wires connected to it.

9.

Connect the plug from the jumper to the handlebar harness
connector so that the BROWN wires match.

10. Open the fuse panel cover and remove the 20A EFI fuse

from the fuse panel.

11. Reinstall the left-side compartment door panel.

12. Remove the oil return hose from the front of the oil storage

tank.

13. Have an assistant, wearing eye protection and protective

gloves, position the end of the hose into an oil collection
container or oil pan.

14. Turn the start key to the “START” position and hold until

the ECU switches the solenoid off.

15. Wait 30 seconds to allow the starter motor to cool down.

16. Repeat steps 14 and 15 four more times for a total of five

cycles.

17. Reinstall the oil return hose and tighten the gear clamp.

Verify the hose cannot be pulled off of the storage tank’s
nozzle, but do not overtighten the clamp.

18. Remove the jumper harness from the handlebar harness and

starter solenoid plug.

19. Reconnect the starter solenoid plug to the solenoid.

Reinstall the 20A EFI fuse, then install the cover.

20. REMOVE THE KEY FROM THE IGNITION SWITCH.

21. Open the air box by removing the top cover plate.

22. Locate the foam breather in the back of the airbox.

23. Clean the foam breather using a mixture of hot, soapy water

and allow to air dry.

24. Locate the oil filter cover. Verify at least five minutes has

passed since the engine has been turned over before
removing filter cover.

25. Remove filter cover. Remove filter from inside of cover and

inspect for signs of foreign material such as metal pieces.

26. Insert new filter element into cover.

27. Inspect oil filter cap o-ring. Replace o-ring if damaged.

28. Reinstall o-ring and torque cover to 17 ft.lbs. (23Nm).

29. Re-install the foam breather element (if dry) into the air box

and secure air box cover.

30. Remove the oil storage tank dipstick and add two quarts of

Polaris 0W-50 synthetic oil to the tank. Reinstall the
dipstick.

31. Start the engine and run until the engine coolant

temperature is between 145

° and 160°F. Turn off the

engine.

32. Remove the dipstick and clean with a shop rag. Reinstall

the dipstick and screw in completely.

33. Remove the dipstick and observe the oil level. Add

additional oil to bring the oil level up to the oil change fill
mark. Reference the chart for the approximate amounts to
add to the tank during this step. DO NOT OVERFILL
THE OIL STORAGE TANK
.

34. Reinstall the dipstick and test drive the snowmobile.

JUMPER HARNESS (4011491)

MODEL

OIL ADDED AT STEP 33

FS

4 - 6 OUNCES (118 - 473ML)

FST

24 - 32 OUNCES (710 - 946 ML)

3.7

Maintenance

3

Rev. 1 07/2006

Airbox Oil Breather Foam Element

The breather foam will soak up oil discharged by the ventilation
cyclone.

Clean the element during each oil change and after the
snowmobile has been tipped over on to its left-side three or more
times.

1.

Open the hood, then open the air box cover.

2.

Remove the breather foam  and inspect for damage.
Replace the element if damaged.

3.

Clean the element in a mixture of hot water and dishwater

soap. Once clean, air dry the element.

4.

Reinstall the element when dry. Reinstall the airbox cover
and fasten each retaining clip.

Spark Plug Servicing

Due to the location of several components, follow these steps to
access the MAG-side ignition coil pack.

1.

Remove the screw securing the filler neck to the oil storage
tank.

2.

Re-route the bleed hose so it is not between the fuel hoses.

3.

Move the filler neck away from storage tank, then move
bleed hose out of the way of the coil.

4.

Lift the cooling hose to access the ignition coil pack.

5.

Torque spark plug to 18 - 20 Ft.Lbs. (24 - 27 Nm). Torque
the coil pack fasteners to 7 Ft.Lbs. (10 Nm).

6.

Return bleed hose to original position. Do not over-tighten
the filler neck-to-storage tank fastener.

CAUTION

Operating the snowmobile with a saturated breather 

element may cause severe engine damage and/or poor 

engine performance.

Tipping the snowmobile over on to its left side or rolling 

the snowmobile over increases the amount of oil 

discharged by the ventilation system.

3.8

Maintenance

Rev. 1 07/2006

Engine Lubrication System Overview

There are two lubrication systems; low and high pressure.

The low pressure lubrication system consists of the engine sump
scavenge pump, oil cooler, and storage tank. The high pressure
lubrication system consists of the storage tank, high pressure oil

pump, oil filter, main - counter balancer - piston jets, cylinder
head oil supply and turbocharger oil supply on FST models.

A crankcase ventilation system is used to return unburned fuel
vapors present in the oil storage tank to the air intake system as

well as oil mist back into the engine sump.

 

 

 

 

 

 

 

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