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MY21 650 SBA 146, ES, ICE Storm 1.5
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Discussion Starter · #1 ·
Well the season is off to a good start.

******* TRACK TENSION ********* Oct. 7, 2005

After some seesawing Polaris has decided that some of the track tension specs on the 05 and 06 sleds are incorrect.

the tech department is now in agreement that the track tension on the
121" IQ rear suspension
and
128" or 136" M-10 should be the same:

7/8" to 1 1/8" of slack between hifax and track clip, with 10 lb. of pull down force at the track window, 16" ahead of rear idler shaft.

Some of you with '06 owners manuals should make a correction to page 107. The specs in the '06 Snowmobile Quick Reference Manual for 121 and 128 machines that I checked did have the above correct specs.

A track tension addendum sheet will be added to later '06 machines coming out of the factory.

Previously owner/service and tip printed information recommended considerably tighter. This change will help fuel economy, acceleration in some conditions and top end, as well as hifax life.


*********** TOE OUT ************ Oct. 1, 2005

The correct Toe Out measurement for the IQ front end should be

1/8" to 1/4" toe OUT measured from 10 inches in front to 10 inches behind the ski mounting bolt. Do this with the weight of the sled distributed normally on the ground/floor between the skis and the track, NOT with the skis lifted up in the air. This spec is misprinted in many of the publications, including the '06 Snowmobile Quick Reference Manual (It has everything listed as toe IN)

If anybody finds out about other significant corrections or additions, please let me know, I will try to keep this accurate. A lot of us, especially those without easy access to a good dealer, depend on the Polaris printed and website information. It is a pain in the (fill in your favorite word) when that information is wrong or misleading. Thanks.
 

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MY21 650 SBA 146, ES, ICE Storm 1.5
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Discussion Starter · #3 ·
**** 900 high altitude clutching specs *****

A mistake is in some of the glove box spec sheets for the 900 Fusion.

for 6000 ft. elevation and higher, the recommended helix is 62/38-.36 ER


**** Lubrication ****

every 1000 miles and at the start and end of the season, Polaris is advising to spray fogging oil or another preservative type oil on the U-Joint found on the IQ 2 stroke steering post. The FS/FST type steering arrangement is very different, and very sturdy.

How has it been going, greasing the jackshaft bearing behind the secondary clutch? I know everybody has been following the directions printed on that white greasing decal under the hood. :dunno:

**** 128/136 M-10 setup *** Nov. 14, 2005

There have been some changes in how major adjustments for rider/cargo weight are made. Polaris is now using a spring retainer to do an initial preload starting point.

Retainer:
5135077 is least preload standard on the 128 M-10
5134923 is medium preload
5135080 is most preload standard on the 136 M-10

Below is the 5 page .pdf which is missing from the 600 Fusion owners manual
 

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From what I've been told by the Polaris Engineer and it has been mentioned on this site but I thought I post it here.

***************Outside Temperature****************

600 HO Models

This bolt on will not work today. They are having a voltage issue with the wiring harness so it will not work on the 600 HO. Spoke with the Engineer at Polaris and he said they are working on the problem and it should be resolved in a few weeks. Until then do not buy this accesory for your 600HO.

UPDATE 11/7/05 spoke with a very helpful Polaris rep and said that they are still working on the fix for the 600HO outside temp sensor kit.
 

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MY21 650 SBA 146, ES, ICE Storm 1.5
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Discussion Starter · #5 ·
************* Service Manual ***************

The 2006 Snowmobile Service manual for...

IQ/Edge/Gen II 700 Classic/Touring/600HO Switchback/600 HO RMK/700 RMK 900 etc. etc. (basically all 2006 except FS or FST or 120)

9919763 Is now available from Polaris. It is $40US.

It no longer has a CD-ROM of the service manual included. ??why??


************ Install of Cleanfire 7/900 primary clutch *******

Polaris is now recommending that whenever the primary clutch is removed from a 700 or 900 Cleanfire motor, that...

1. the clutch be put on the tapered reaming tool, spun a turn or so just resting on its own weight,
2. then put on a clean crankshaft end and
3. torqued to 96 foot pounds,
4. run the sled some and
5. then retorque to 96 foot pounds.



************* Skags for 2006 ****************


2875676 Kit, Dual IQ Skag, 4 inch 60 degree (pair) Is not yet available.

It is used on the 2006 M-10 and 2006 Touring. It has 4 mounting studs, in a pattern not used previously. A pair is used on each ski.

2875716 Pair, Single 4 inch 60 degree (pair) $55US will be available 12/30/05.

It is used on the 121 inch IQ sleds, and on the Switchback.
 

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MY21 650 SBA 146, ES, ICE Storm 1.5
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Discussion Starter · #8 ·
I added infomation (see post #4 ) about M10 128/136 setup and adjustment which was omitted from the 600 HO Fusion Owners manual.
 

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Just so everyone knows...if you want a 90° brake lever you can get one from Powermadd. It is listed as the GEN II only brake lever but it does work on the Fusions.
 

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MY21 650 SBA 146, ES, ICE Storm 1.5
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Discussion Starter · #11 ·
Polaris is advising that after a belt failure for any reason, it is necessary to clean the reed cage in case any debris has entered the intake system.

It is also important to check the plenum on top of the belt guard for any cracks or damage, this could continue to admit dirt or debris into the intake system.

You should use your own judgement to decide if you may have a poor seal either between the hood and the plenum, or between the plenum and the air intake box attached to the throttle bodies. This would be where debris could enter and get to the reeds.

You need to continue to check belt tension and alignment, engine mounts, engine torque stops, and proper clutch operation. Also, breakin a new belt, and warm up a cold belt before heavy use.
 

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MY21 650 SBA 146, ES, ICE Storm 1.5
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Discussion Starter · #12 ·
Series 11 Drive Clutch Weights March of 2005 announcement:

A new series of drive clutch flyweights have been developed and are now available for purchase from Polaris. The new “Series 11” flyweights feature an aggressive shift curvature, and thinner profile.

Each flyweight is priced individually. Drive weights are matched within .5 grams of each other and packaged in packs of three.

part# type weight each list price
1322594 11-38 bushed 38 grams (1) $28US
1322593 11-40 bushed 40 grams (1) $28US
1322592 11-42 bushed 42 grams (1) $28US
1322591 11-44 bushed 44 grams (1) $28US
1322596 11-46 bushed 46 grams (1) $18US
1322590 11-48 bushed 48 grams (1) $18US
1322589 11-50 bushed 50 grams (3) $28US
1322595 11-52 bushed 52 grams (3) $28US
1322604 11-64 bushed 64 grams (1) $28US
1322559 11-66 bushed 66 grams (3) $28US
1322558 11-68 bushed 68 grams (3) $28US
1322523 11-70 bushed 70 grams (3) $28US
1322524 11-72 bushed 72 grams (3) $28US
1322525 11-74 bushed 74 grams (3) $28US
1322526 11-76 bushed 76 grams (3) $28US

When compared to a series 10 weight, the series 11 weight has more weight distributed at the beginning of the profile curve and does not tuck under as much as the series 10 weight. Because of this difference, the belt--to--sheave clearance must be checked and washers may need to be added to increase the belt--to--sheave clearance after installing any series 11 weight into a drive clutch that was previously equipped with series 10 weights.

The procedure for increasing the belt--to--sheave clearance by adding washer(s) to the spider is outlined in all Polaris snowmobile service manuals.

When cross--referencing between series 10 and series 11 flyweights, a series 11 flyweight will function similarly to a 2--gram heavier series 10 weight. For example, use a 11--68 when replacing a 10--70 flyweight.
 

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MY21 650 SBA 146, ES, ICE Storm 1.5
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Discussion Starter · #13 ·
Here is an updated tip on Installing the extra firm springs on the 2005 or 2006 IQ 121" rear suspension.

Soft - 7043240-067 / 7043241-067
Std. - 7043070-067 / 7043071-067
Firm - 7043079-067 / 7043080-067
Extra Firm - 7043128-067 / 7043129-067 (requires extra parts listed below)

Please reference the following information when installing 7043128-067 / 7043129-067 extra heavy torsion springs on 2005 Fusion sleds. The issue that arises when
installing the heavy spring on a 2005 Fusion sled is that the coil stack of the torsion spring is wide enough to interfere with the suspension arm clamp nut. To work around this issue you will need to order two (one for each side) of the following parts. Relocate the two washers that are next to the clamp nut to the outside of the link arm. These parts are basically what was used on the 2004 PRO-X and similar.

The attached .PDF file has drawings which will make this easier to understand.
 

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Discussion Starter · #14 ·
2006 600 HO ENGINE TORQUE STOP CLEARANCE AND ADJUSTMENTS

The front torque stop should not be adjusted and if needed should be replaced. Replace the rubber isolator so that it is bottomed out against the bracket, and tighten the jam nut to 15-17 ft-lbs (21-24Nm). This will give you a gap of .100” (2.54mm) between the rubber isolator and the PTO engine strap. Reinstall the torque stop assembly into the bulk head. Torque the bracket fasteners to 28ft-lb (38Nm).

The rear torque stop should have a clearance of .010-.030” (.25-.75mm) from the rubber isolator to the engine case.

Service manual Error!
On page 6.20 in the 2006 IQ snowmobile manual (9919763) step 12 states to adjust both front and rear torque stops to have a clearance of .010-.030 (.25-.75mm). Please make a change to adjust the front torque stop to have a clearance of .100” (2.54mm) on page 6.20.



Clearance
Front torque stop 0.100"
Rear torque stop .010-.030"
 

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MY21 650 SBA 146, ES, ICE Storm 1.5
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Discussion Starter · #15 ·
There has been a correction to the Service Manual for 2005, the 2006 Service Manual has the same mistake!

Here it is:

This is the second version of the correction.

12 Head torque is 22 ft. lb.
16 crank case torque is 22 ft. lb.
8 cylinder base bolts 34 ft. lb. (not 40, manual is wrong)
 

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Discussion Starter · #16 ·
*** 600 HO VES solenoid wire burning/melting.

On all the 600 HO's a vent solenoid releases combustion chamber pressure that goes to the Variable Exhaust System valve. In some cases the wire that goes to this solenoid has gotten too close to the exhaust pipe, near the joint to the Y pipe, and the wire was damaged.

I would recommend taking that black wiring harness that goes to the VES solenoid, and routing it over the top of the black square tubing brace which runs between the shock towers. Secure the harness with some cable ties, and it will keep it's cool!

If this wire fails or is disconnected, combustion chamber pressure will never be allowed to build up behind the VES bellows, and they will never open the exhaust valves. You will start losing power before 7000 rpm and will not get to maximum rpm under load.
 

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Discussion Starter · #17 ·
I had misplaced a third correction regaring the crank case bolt torque, sorry.

Head torque is 22 ft. lb.
8mm bolt crank case torque is 25 ft. lb.
10mm bolt crank case torque is 28 ft. lb.
cylinder base bolts 34 ft. lb. (not 40, manual is wrong)
 

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Discussion Starter · #18 ·
CANNOT REMOVE P-85 CLUTCH on 2006 Snowmobile

Some of the P-85 primary clutches on 2006 Polaris snowmobiles, do not have the internal threads inside the hub, tapped deeply enough for the clutch puller to thread all the way in and make contact with the crankshaft. This causes the threads of the puller to bottom out and maybe get damaged, without putting any outward pressure to pull the clutch off the crank.

If you think this is occurring, remove the puller, put a small dab of grease on the end of the puller, and thread it back in until it stops turning easily. Then remove the puller and see if the dab of grease on the tip of the puller shows any signs of actually hitiing the crankshaft. Also look to see if the leading threads of the puller, look like they are being damaged by running out of tapped and threaded area in the clutch. When this occurs, you will be almost 1/2 inch away from touching the crankshaft. Have the dealer contact Polaris tech support, they will instruct you on how to remove the clutch, and will replace the clutch with a new one.

I am guessing they may be using the method where you tip the sled on its side, pour some oil into the center of the clutch hub, so that there is just enough air left that you can thread the puller in a few threads before it starts to hydaulically push on the end of the crankshaft and push off. When people do this, they say the clutch CAN JUMP INTO THE AIR DUE TO TRAPPED AIR PRESSURE.
 

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I'm going to copy this post from TC1, and put it in here.

600 ho rpm fix, different spring


after many hours of testing on PRODUCTION UNITS epi has determined that there purple seconary spring and ther gold primary spring works much better than the ones supplied in the kit. the test units that glen developed the kit for must have been a little different than the production units. this is in no way anyone's fault. the kits currently being shipped to polaris contain the different springs. glen will handle each case on a one to one basis. i know for a fact the purple driven spring works much better on a m10 unit. i have been running one all year and pull 8200 rpm's everytime using the 64 gram weight's. if your sled is working ok there is no need to contact glen, if it's not, call him.
 

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MY21 650 SBA 146, ES, ICE Storm 1.5
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Discussion Starter · #20 ·
Polaris announced today that there is a problem with all 700/900 Cleanfire electric start kits, factory installed or dealer installed.

The electric motors may come loose and it is possible they could jam the steering mechanism.

Letters are going out to those who bought sled with E/S standard: Classics, Tourings.

It is advised that snowmobiles equipped with this E/S not be operated, until the Electric Start motor is emoved or the factory fix is installed.

The factory fix is expected to be available mid-April.
 
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