Snowmobile Polaris 2006 - 2007 FS / FST. Instruction - part 12

 

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Snowmobile Polaris 2006 - 2007 FS / FST. Instruction - part 12

 

 

3.9

Maintenance

3

Rev. 1 07/2006

ENGINE MAINTENANCE

FST Air Filter

FST models feature an air filter element to protect the
turbocharger compressor. Replace the air filter if damaged, dirty
or saturated with engine oil.

NOTE:  Do not clean the air filter cartridge.

Alternator Belt Inspection / Adjustment

The alternator belt deflection must be maintained to ensure
trouble-free operation.

1.

Inspect the alternator belt deflection by rotating the belt as
far as possible. The correct amount of deflection is
achieved when the belt can only be twisted 90 degrees
from its operating postion.

2.

Adjust the belt deflection by loosening the upper and lower
alternator fasteners.

3.

Insert a large pry bar between the crankcase and alternator
and pull firmly.

4.

Twist the belt while pulling back on the pry bar.

5.

Have an assistant tighten the two alternator fasteners once
the correct belt deflection is achieved.

Valve Lash Adjustment

1.

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

2.

Remove the key from the ignition switch.

3.

Remove the airbox / clutch guard from the engine
compartment.

4.

Remove the console assembly.

5.

Remove the seat assembly to gain access to the fuel tank.

6.

Remove the fasteners securing the fuel tank to the tunnel.

7.

Cover the supply and return fuel hose connectors with a
clean shop rag. Disconnect the fuel hoses from the fuel
pump flange.

8.

Disconnect the fuel pump wiring harness.

9.

Remove the fuel tank from the snowmobile.

10. Remove the wiring harness connectors from the ignition

coils and cam phase sensor. Verify each connector is
labeled with its position. Label connector for re-assembly
if required.

11. Remove the air intake tube (FST models) that is routed over

the top of the valve cover.

12. Remove the ignition coils, then remove the valve cover.

13. Rotate the drive clutch in the direction of forward vehicle

operation until the rocker arms on the PTO-side of the
engine are at TDC-compression stroke. The TDC-
compression stroke can be identified when the rockers arms
are loose and not contacting the camshaft lobes.

14. Insert a feeler gauge between the valve shim and rocker arm

tappet at each valve location. Write-down each
measurement.

15. Compare each measurement to the specification.

16. If the valve shim clearance is within specification, no

change is required. If the clearance is outside the
specification, the valve shim must be replaced with one that
will satisfy the specification.

Valve Clearance

E

NGINE

 / V

ALVES

S

PECIFICATION

NA
Intake
Exhaust

.08 -.15mm (.003

″ -.006″)

.15 -.22mm (.006

″ -.008″)

Turbo
Intake
Exhaust

.08 -.15mm (.003

″ -.006″)

.18 -.25mm   (.007

″ -.009″)

3.10

Maintenance

Rev. 1 07/2006

17. To remove each valve shim, install the valve shim

guillotine tool, PN: PW-47163, on to the cylinder head.

18. Insert the open-end of a 18mm wrench around one of the

rocker arms. Gently compress the rocker arm and push the
valves downwards.

NOTE: Do not compress the valves into the piston
face. Do not dis-lodge the valve stem keys.

19. Engage the guillotines over the valve assemblies. Remove

the wrench.

20. Extract each shim with a pick, or remove the rocker arm

axle, then rocker arm, and then the shim.

21. Measure the thickness of each shim removed from the

engine and note next to the corresponding valve clearance
measured in previous steps.

22. Select a new valve shim, thicker or thinner, from the table

that will bring the measured valve clearance back into
specification.

CAUTION

DO NOT DROP SHIMS INTO ENGINE.

3.11

Maintenance

3

Rev. 1 07/2006

23. After completing the valve lash adjustment on the PTO

cylinder valve train, remove the valve lash adjustment tool
from the cylinder head.

24. Rotate the drive clutch in the direction of normal rotation

until the MAG piston is at TDC-compression stroke.

25. Perform the valve adjustment procedure on the MAG

cylinder valve train.

26. When completed, re-install the valve cover. Verify the

rocker arm retaining tabs inside the valve cover are seated.
Tighten the valve cover fasteners to 7 ft.lbs. (10 Nm).

27. Re-install the ignition coils and torque fasteners to 7 ft.lbs.

(10 Nm).

COOLING SYSTEM MAINTENANCE

Expansion Tank

When the engine is cold, the coolant level should be at the
COLD FILL LINE. Only add or remove coolant from the system
when the engine is cold.

NOTE: Do not overfill the expansion tank. Coolant
inside the tank will rise as engine temperature
increases.

Engine Coolant Removal

1.

To drain the cooling system, place towels or floor dry
underneath the snowmobile.

2.

Using a siphon, remove as much coolant as possible from
the filler cap location.

Valve Shims

S

HIM

 T

HICKNESS

 (

MM

)

P

ART

 N

UMBER

2.50

0452014

2.55

0452015

2.60

0452016

2.65

0452017

2.70

0452018

2.75

0452019

2.80

0452020

2.85

0452021

2.90

0452022

2.95

0452000

3.00

0452001

3.05

0452023

3.10

0452002

3.15

0452003

3.20

0452004

3.25

0452005

3.30

0452024

3.35

0452006

3.40

0452007

3.45

0452008

3.50

0452009

3.55

0452010

3.60

0452011

3.65

0452012

3.70

0452013

3.12

Maintenance

Rev. 1 07/2006

3.

Remove the hose connecting the main tee to the radiator.
Pour as much coolant out as possible into a container.

4.

Insert the siphon into the tee fitting and into the hose
connected to the water pump. Remove the rest of the
coolant.

Adding Engine Coolant / Air Bleed 

NOTE: When adding coolant after the engine has
been drained or when pockets of air within the
system are suspected, the air must be removed to
prevent serious engine damage.

1.

Verify all of the cooling hoses are secured to each fitting
with a clamp.

2.

Fill the system at the main filler neck with a 60%Propolyne
Glycol / 40% distilled water mixture, Polaris PN 2871323.

3.

Add coolant to bring the level up to the fill tube opening.

4.

Remove the clutch guard / air intake assembly and set aside.
Close the engine compartment door.

5.

Safely raise the front of the snowmobile using a floor jack
or snowmobile lift until the skis are off the ground.

6.

Locate the air bleed screw on the PTO-side of the cylinder
head. Place a towel or shop rag underneath the screw.

7.

Open the screw just enough to allow air and coolant to
escape.

8.

Start the engine.

9.

Run the engine until the temperature displayed on the gauge
is at or above 180°F (82°C). Continue running the engine.

10. Monitor the air bleed screw. Close the screw when a steady

stream of coolant flows out of the hole.

11. Verify the heat exchanges are warm to the touch.

12. Turn off the engine.

13. Top-off the main fill tube, then replace the cap.

14. Allow the engine to cool completely.

15. Reinstall the clutch guard / air intake.

16. Add coolant to the expansion tank to bring the fluid level

up to the COLD FILL LINE.

Cooling System Pressure Test

To test the pressure-holding capability and to check for system
leaks, perform a pressure test.

1.

Remove the filler neck-to-expansion tank hose from the
filler neck (top hose).

2.

Connect a Mity Vac hand pump to the filler neck nozzle.

3.

Pressurize the cooling system to 14 psi (1 bar).

4.

The cooling system should hold the pressure for at least 5
minutes.

5.

During the test, look and listen for leaks. 

Connect Mity Vac to top nozzle.

 

 

 

 

 

 

 

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