Using the Shock Spring Removal Tool, remove the spring from the shock body by compressing the spring; then remove the spring retainer from the top of the spring. Make sure that the pilot jet is fully tightened. Poor performance at Clogged air vent Remove the air vent hose and clean it. The wear strip must be 0. The valve seat and body must be replaced as a set Power loss Broken float Replace the float. Ground connections dirty — loose 1.
Remove the oil drain plug and drain the oil; then install the oil plug and tighten securely. Check all control wires and cables for signs of Torque Specifications wear or fraying. Remove the lock nut securing the tie-rod ball joint with compressed air. Melted electrodes and possibly a blistered insulator Metallic deposits on insulator Mixture is too lean. This repair manual; a instruction book or service manual will help you fix your snowmobile to factory specifications. Make sure that the main jet is fully tightened. To do this, remove the machine screw and lock nut securing the wear strip at the front of the slide rail;.
Replace the piston and spark plug. Remove the cap screw securing the cross-brace axle 8. Visually inspect all engine components for wear or damage. Align the engine with the scribed line made during the air cleaner case, and with gasket, insulator removing; then measure the distance between the plate, and cap screws, secure the case to the intake crankshaft and the driveshaft. White or gray insulator with small black or grayish brown spots and electrodes having a bluish-burnt appearance Mixture is too lean. Idle fuel adjuster screw out of adjustment 2.
Inspect for cracks, scoring, pitting, imperfections, or warping. After replacing the spark plug with a colder type, tune the carburetors again. Remove the two springs from the governor arm, throttle cable bracket, and retaining bracket. Performing the scheduled maintenance is very important. For consistency purposes, this section shows a complete and thorough progression; however, for efficiency it may be preferable to remove and disassemble only those components needing to be addressed and to service only those components. Replace the main jet with the next smaller size.
Fuel passage is clogged or frozen Check and, if necessary, clean the fuel tank air vent, the fuel filter and all of the fuel passages. Each chapter provides exploded diagrams before each disassembly section to facilitate correct disassembly and assembly procedures. Inspect the keyways in the driveshaft and in the wheel assembly to the tunnel; then remove the chain sprocket for wear or damage. Clogged or loose pilot jet Remove the pilot jet, clean it with compressed air and then install it. Starting with the top ring, slide one end of the ring out of the ring-groove.
Clean the float chamber of any ice or water. Poor acceleration Slow response to res onse throttle. Remove the push rods; then remove the push rod guide plate. Remove the vent hose from the top of the gas tank. All of the procedures in this manual are organized in a sequential, step-by-step format. It contains everything you need to know to fix your polaris snowmobile—including the pilot system.
Place the oil ring expander into the bottom groove of the piston allowing the ends to contact each other. Compress the brake lever fully. Inspect the shock absorber by quickly compressing and extending the shock plunger while firmly holding the shock body. Dirty fuel tank Clean the fuel tank. Recreational Motorsports has designed a new manual chain tensioner that is easy to install and elminates the factory spring loaded tensioners on the Arctic Cat Z120 and the Ski Doo Mini Z 120, this tensioner constantly keeps proper alignment and load on the drive chain under hard braking and acceleration which is very important when trying to reduce chain wear and clutch slippage. Most all service manual chapters start with an assembly or system illustration, diagrams, exploded parts view, quality pictures, service information and troubleshooting for the section.
Remove the engine from the engine compartment. Dirty or clogged fuel line Clean or replace the fuel line. Inspect the wear strip for wear. Inspect the suspension arm axle area for wear. Immediately upon payment you will automatically be forwarded to our secure download page.
If the clearance exceeds the limit, replace the connecting rod or crankshaft. Inspect each idler wheel for cracks or damage. Clogged bypass hole Clean the bypass hole. Check and, if necessary, clean the carburetor air vents, fuel passages and the float valve. Remove the lock nut, washers, and cap screw securing the end cap. Wiring harness shorting — disconnected 2. Inspect the throttle cable for damage or fraying.
The sections cover specific snowmobile components or systems and, in addition to the standard service procedures, includes assembling, disassembling, and inspecting instructions. Wash the ball joint in parts-cleaning solvent. Poor idling Poor performance at low, mid-range, high speeds. Overflow: Clogged air vent Clean the air vent. Dry black or fluffy deposits Mixture is too rich.