Snowmobile Polaris (2006 year). Instruction - part 62

 

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Snowmobile Polaris (2006 year). Instruction - part 62

 

 

12.2

CHASSIS / HOOD

HOOD

REMOVAL / INSTALLATION

1.

On Edge models disconnect the speedo cable from the
speedo.

2.

Unplug the hood wiring harness connections.

3.

Remove the hood retention cable(s) from hood.

4.

Remove the hinge bolts.

5.

Remove the hood.

6.

Install in reverse order of removal.

HOOD REPAIR

Currently there is no procedures or materials recommended by 
Polaris for repairing hoods. Hoods are made of Thermoplastic 
Olefin (TPO) and cannot be repaired. If a hood is broken it 
must be replaced. For small cracks you may drill a small hole 
on both ends of the crack to limit spreading. This procedure is 
called “stop drilling".

INSTRUMENT / MFD

EDGE INSTRUMENT REMOVAL / 
INSTALLATION

1.

Remove the plenum from the underside of the hood and
keep track of the plenum filters.

2.

Remove the instrument holder from the back of the gauge.

3.

Pull the gauge out from the front.

4.

Installation is the reverse of removal.

IQ MFD REMOVAL / INSTALLATION

1.

Remove the intake from the under side of the hood (C).

2.

Disconnect the MFD harness from the gauge.

3.

Remove the MFD screws (D).

4.

Remove the MFD (E).

5.

Installation is the reverse of removal.

BUMPER

IQ FRONT BUMPER REMOVAL / 
INSTALLATION

1.

Open front Nosepan flap and remove the four (4) bumper
screws.

2.

Remove the center bumper nylock nut and bolt.

3.

Remove bumper.

4.

Installation is reverse of removal.

HEADLIGHT

IQ HEADLIGHT REMOVAL / INSTALLATION

1.

Disconnect all the headlight connections.

2.

Remove the headlight adjuster guide.

3.

Remove the headlight screws that hold the headlight
assembly on.

4.

Remove the headlight.

5.

Installation is the reverse of removal.

EDGE HEADLIGHT REMOVAL / 
INSTALLATION

1.

Remove the plenum from the bottom of the hood.

2.

Disconnect the head light connections.

3.

Remove the 4 screws holding the headlight in place.

4.

Installation is the reverse of removal.

WARNING

Exhaust system temperatures can exceed 900_ F 

(500_C). Serious burns may occur if this inspections 

performed without allowing adequate time for the ex-

haust system to cool. Never perform this procedure 

with the engine running.

12.3

CHASSIS / HOOD

COOLANT/OIL TANK

COOLANT TANK REMOVAL

1.

Drain coolant.

2.

Remove the 2 torx screws that hold the coolant tank to the
oil tank.

3.

Remove the coolant lines from bottle.

4.

Remove coolant bottle.

COOLANT TANK INSTALLATION

1.

Connect coolant lines to the bottle.

2.

Tighten the fasteners that hold the coolant bottle to the oil
tank.

3.

Fill to the correct fluid level.

4.

Bleed the cooling system.

OIL TANK

OIL TANK REMOVAL

1.

Remove the two fasteners that hold the tank to the chassis.

2.

Remove the two fasteners that hold the cooling bottle on
the oil tank.

3.

Remove the cross shaft oil supply line.

4.

Lift the rear of the tank and remove the supply line.

5.

Disconnect the oil sender connections.

6.

Remove tank.

OIL TANK INSTALLATION

1.

Attach the supply line to the supply fitting at the bottom of
the oil tank.

2.

Attach the cross shaft supply line to the fitting on the right
hand side.

3.

Line up the centering shafts with the chassis centering
bracket.

4.

Install the coolant bottle on the oil tank.

5.

Install the fasteners that hold the tank to the chassis.

FUEL CLIPS

Polaris utilizes two different sizes of fuel supply lines. When 
removing the fuel lines from the chassis use the special fuel 
line removal tools. The fuel clips will also have the indicated 
line use labled on the clamp.

FUEL CLIP REMOVAL

NOTE:  Note the orentation of the clip for installation

1.

Lift the rear of the clip off the hose.

2.

Push forward to remove the clip from the hose.

FUEL CLIP INSTALLATION

1.

Orentate the clip in its original orentation.

2.

Push backward to insert the locking portion of the clip into
the fuel line.

3.

Push down on the rear of the clip to lock it into place.

Overflow

Throttle body

Radiator

Center cooler

Rear coolers

UP

FORWARD

FUEL CLIP

12.4

CHASSIS / HOOD

SEAT and FUEL TANK

FUSION SEAT AND BASE REMOVAL/
INSTALLATION

1.

Remove the two bolts (A) that hold the seat base on the
tunnel.

2.

Remove the seat (B).

3.

Installation is reverse order of removal. Torque the seat

fasteners to 8-12 ft-lb (11-16Nm)

IQ RMK SEAT REMOVAL/INSTALLATION

1.

RMK seats have a small lever at the rear portion of the
seat.

2.

Lift lever and remove seat.

A

B

C

E

D

F

G

H

I

J

RMK SEAT/FUEL TANK

12.5

CHASSIS / HOOD

3.

Replace in reverse order.

IQ RMK SEAT BASE REMOVAL/
INSTALLATION

1.

Remove seat.

2.

Remove the fasteners that hold the base onto the chassis.

3.

Install in reverse order, torque the seat base fasteners to 8-
12 ft-lb (11-16Nm). 

IQ FUEL TANK REMOVAL

1.

Remove the seat as outlined above.

2.

Remove the seat base. 

3.

Drain any fuel from the fuel tank.

4.

Remove the console. See “IQ CONSOLE REMOVAL /
INSTALLATION” on page 6.

5.

Using the fuel pressure bleeding tool release the pressure
in the fuel rail. See “FUEL RAIL BLEEDING” on page 4.

6.

RMK units will need to remove the bolts (A) that hold the
seat base on the tunnel.

7.

Remove the console see page See “IQ CONSOLE
REMOVAL / INSTALLATION” on page 6.

8.

Remove the fuel line clips, See “FUEL CLIP REMOVAL”
on page 3.

9.

Remove the fuel lines from the ridged fuel lines using the
fuel line removal tool (PS-47152).

10. Remove the two nylock nuts (E) that hold the fuel tank (F)

onto the chassis.

11. Carefully lift the rear of the fuel tank and slide the fuel tank

back so that you can reach the fuel pump harness, and
disconnect the harness.

12. Disconnect the exhaust valve solenoid line from the fuel

tank vent/over flow line at the T fitting.

13. Disconnect the fuel tank vent line (J) from the side of the

tank at the T fitting.

14. Remove the fuel tank from the chassis.

IQ FUEL TANK INSTALLATION

1.

Exhaust Valve Line

Fuel Vent Line

 

 

 

 

 

 

 

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