Snowmobile Polaris DEEP SNOW (2005 year). Manual - part 10

GENERAL INFORMATION

2.19

OIL PUMP BLEEDING

(A)

FUSION OIL PUMP

NOTE:

Any time the engine is disassembled or repaired, it is important that the oil supply from the pump
to the engine be checked.

IMPORTANT: The oil pump must always be bled following any service to the injector system or engine.

Fill oil reservoir with the appropriate Polaris injector oil. This will add pressure to the oil lines to aid in bleeding the air out.

Loosen bleed screw (A). After :30 seconds or so, oil should flow from beneath the screw head to indicate the pump is free of air.

Tighten bleed bleed screw securely.

GENERAL INFORMATION

2.20

OIL PUMP ADJUSTMENT PROCEDURE

.010-.030, (.25-.8 mm)

Throttle Freeplay

Figure 2

Figure 3

Figure 4

REQUIRED SERVICE: Carburetor synchronization.

VM TYPE: Verify that carburetor slides leave their respective resting positions upon opening within .01, to .03, of throttle cable

movement, not throttle lever movement. See figure 2.

TM TYPE: Verify that carburetor slides are within .0625” of each other when passing the top of the carburetor throat. You may

have to move slides with the starter lever.

Adjust throttle cable freeplay to .010, - .030, (.25 - .8mm).

Set idle to specified idle speed listed in the specifications chapter.

Verify that the oil pump alignment lines are aligned at the point where the carburetor slides begin to raise from their resting posi-

tions. Note: Marks may not line up without throttle engagement. See figure 3.

Make adjustments so that the lines are at the position shown in figure 4.

Torque cable locknuts to 10 - 20 in.lbs.

NOTE:

Use a mirror when aligning the oil pump marks whenever the oil pump is difficult to view.

THROTTLE BODY TYPE (900)

All you need to do for the 900 oil pump is to verify that the oil pump marks line up (figure 4) when the throttle is in the idle position.

You may need a mirror to see the marks straight on. If the line does not line up (figure 3) you will need to adjust the oil cable

at the throttle bell housing.

To adjust this loosen the lock nut and thread the barrel nut in or out depending on the direction you need the line to move.

Moving the barrel nut in will adjust the line more to the top.

DO NOT adjust the idle. This is all set at the factory and should not be tapered with.

GENERAL INFORMATION

2.21

COOLING SYSTEM OVERVIEW

DANGER

Never remove the pressure cap when the engine is warm or hot. If the pressure cap is to be removed,
the engine must be cool. Severe personal injury could result from steam or hot liquid.
Use of a non-standard pressure cap will not allow the recovery system to function properly.
If the cap should need replacement, install the correct Polaris cap with the same pressure rating.
Refer to the appropriate parts manual.

COOLANT LEVEL

Coolant level in the coolant bottle must be maintained between the MINIMUM and MAXIMUM levels to prevent overheating

and serious engine damage.

RECOMMENDED COOLANT

Use a 60/40 mixture of antifreeze and distilled water depending on the freeze protection required for your area.

Do not use tap water in the system or reduced cooling or filter contamination may result.

Replace coolant every 2 years or if contaminated.

BLEEDING THE COOLING SYSTEM

Allow the system to cool completely.

Loosen the bleed screw and full the reservoir to the indicated Full Cold mark.

Once Full, tighten the bleed screw.

Apply parking brake and run the engine at specified idle RPM until the thermostat opens (approximately 5 to 8 minutes).

NOTE:

It is important that the thermostat stays open! When the thermostat opens it will draw in cold coolant

from the heat exchangers and the cold coolant may close the thermostat again. Make sure the thermo-

stat opens and stays open! Once the thermostat is open tip the snowmobile slightly on its right side.

Cycle the RPM from idle to enough RPM (4000) to get coolant to flow but not enough RPM to engage

the clutch. This allows air to bleed from the rear crossover tube. Then tilt the machine slightly on its

left side so that the coolant bottle is the highest point in the cooling system. Cycle the RPM from idle to

enough RPM (4000) to get coolant to flow but not enough RPM to engage the clutch. It is important to

get enough coolant flow to purge the air from the front close-off cooler and observe this air reaching the

bottle.

Place the snowmobile in its normal riding position and loosen the bleed screw at the top of the water outlet manifold until trapped air

has been purged.

Tighten the bleed screw. Turn off the machine and release parking brake. Allow the system to cool completely. Re-check the cool-

ant level after the cap has been removed and add coolant to fill line if necessary. After the machine has cooled down, 3 ounces

or more of coolant may have to be added.

This procedure should take approximately 15 minutes.

NOTE:

It is important to get enough coolant flow to purge the air from the crossover hose or rear
cooler and observe this air reaching the bottle.

DANGER

When performing the following checks and adjustments, stay clear of all moving parts to avoid
serious personal injury.
Never remove the pressure cap when the engine is warm or hot. If the pressure cap is to be
removed, the engine must be cool. Severe personal injury could result from stream or hot liquid.

GENERAL INFORMATION

2.22

900 FUSION* COOLING SYSTEM

2004 Polaris Sales Inc.

11.

13.

17.

18.

19.

21.

26.

12.

14.

16.

15.

22.

10.

20.

23.

24.

25.

27.

1. Mount, Radiator, Rubber

2. Exchanger, Gripper/Cooler, LH

Exchanger, Gripper/Cooler, RH

3. Asm., Radiator

4. Hose, Gripper/Rear Cooler, LH

Hose, Gripper/Rear Cooler, RH

5. Mount, Radiator, Foam

6. Asm., Rear Cooler, Long

7. Hose, Tee/Radiator Inlet

8. Clamp, Springband, Brown

9. Clamp, Springband, Black

10. Rivet

11. Hose, Radiator/Bottle

12. Hose, Tube/Gripper, LH

13. Fitting, Tee

14. Cooler, Center

15. Clamp, Springband, Black

16. Hose, Tee/Center Cooler

17. Hose, Coolant Bottle/Engine
18. Hose, Engine Out/Tee
19. Cap, Pressure
20. Line, Fuel
21. Bottle, Coolant
22. Clamp, Hose

Clamp, Narrow

23. Nut
24. Clamp, Rubber Coated, .75
25. Tube, Coolant, Front, RH
26. Hose, Bottle/Tube
27. Hose, Gripper, Front, RH

*For other cooling diagrams please refer to the models parts book.

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