Snowmobile Polaris Two Stroke (2007 year). Instruction - part 15

3.3

MAINTENANCE

3

MAINTENANCE PROGRAM

Polaris Recommended Program

To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and service checks
outlined in this manual. The recommended maintenance schedule on your snowmobile calls for service and maintenance inspections
at 150 miles (240 km), 1000 miles (1600 km), and 2000 miles (3200 km). These inspections should be performed by a qualified
service technician. For continued optimum performance and component life, continue maintenance checks at 1000 mile (1600 km)
intervals. All necessary replacement parts and labor incurred, with the exception of authorized warranty repairs, become the
responsibility of the registered owner. If, during the course of the warranty period, part failures occur as a result of owner neglect
in performing recommended regular maintenance, the cost of repairs are the responsibility of the owner. 

Personal safety is critical when attempting to service or adjust your snowmobile. If you're not familiar with safe service or adjustment
procedures and the use of tools, or if you don't feel comfortable performing these tasks yourself, contact an authorized Polaris dealer
for service.

The following chart is a guide based on average riding conditions. You may need to increase frequency based on riding conditions.
When inspection reveals the need for replacement parts, always use genuine Polaris parts, available from your Polaris dealer.

I

TEM

P

RE

-

R

IDE

F

REQUENCY

 M

ILES

 (

KM

)

P

RE

-

S

EASON

150 

(240)

500 

(240)

1000 

(1600)

2000 

(3200)

CLUTCH

Clutch 

Alignment 

Offset (without 

belt)

I

I

I

Drive Belt 

Condition

I

I

I

I

I

Clutches 

(disassemble)

C

C

C

Belt Tension

I

I

I

I

Clutch Sheaves

I

I

I

I

ENGINE/COOLING

Engine Mounts

I

I

I

I

Heat Exchangers

I

I

I

I

I

Recoil Rope

I

I

I

I

I

Engine Torque 

Stop

I

I

I

I

Cylinder Head 

Bolts

I

I

I

Cylinder Base 

Nuts

I

I

I

I

Ignition Timing 

BTDC

I

I

I

VES System

C

C

C

I

Coolant Level

I

I

I

R

I

Coolant Hose

I

I

I

I

Coolant 

Circulation

I

I

I

Coolant Leaks

I

I

I

I

Spark Plug 

Condition

I

I

I

R

I

Exhaust Pipe

I

I

I:I

NSPECT

 (

CLEAN

, 

ADJUST

, 

TIGHTEN

, 

LUBRICATE

, 

REPLACE

 

IF

 

NECESSARY

) C:C

LEAN

 R:R

EPLACE

 L:L

UBRICATE

3.4

MAINTENANCE

Exhaust 

Retaining 

Springs

I

I

I

I

BRAKES

Hose Routing

I

I

I

I

Hose Condition

I

I

I

I

Fluid Leaks

I

I

I

I

Brake Pads

I

I

I

I

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 (Carb)

R

Fuel Filter (CFI)

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

I

TEM

P

RE

-

R

IDE

F

REQUENCY

 M

ILES

 (

KM

)

P

RE

-

S

EASON

150 

(240)

500 

(240)

1000 

(1600)

2000 

(3200)

I:I

NSPECT

 (

CLEAN

, 

ADJUST

, 

TIGHTEN

, 

LUBRICATE

, 

REPLACE

 

IF

 

NECESSARY

) C:C

LEAN

 R:R

EPLACE

 L:L

UBRICATE

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

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

I

TEM

P

RE

-

R

IDE

F

REQUENCY

 M

ILES

 (

KM

)

P

RE

-

S

EASON

150 

(240)

500 

(240)

1000 

(1600)

2000 

(3200)

I:I

NSPECT

 (

CLEAN

, 

ADJUST

, 

TIGHTEN

, 

LUBRICATE

, 

REPLACE

 

IF

 

NECESSARY

) C:C

LEAN

 R:R

EPLACE

 L:L

UBRICATE

3.5

MAINTENANCE

3

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).

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 .50" 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.

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)

Cylinder Measurement Worksheet

EXAMPLE OF A CROSS HATCH PATTERN

3.6

MAINTENANCE

Honing Procedure

1.

Wash the cylinder with cleaning solvent.

2.

Clamp the cylinder in a soft jawed vise by the cylinder
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 .50" (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 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 (340/500 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 over sizing 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 Liberty™ engines, measure
piston outside diameter at a point .375" (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 .50" (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.