Polaris 2000 120 XCR, Service Manual

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4.3
ENGINE / CARBURETOR / CLUTCH
4
WARNINGS
WARNINGS
When ever servicing the carburetor or fuel
system, it is important to heed the following
warnings.
GENERAL INFORMATION
SERVICE PRECAUTIONS
In order to perform service work efficiently and to prevent
costly errors, the technician should read the text in this manual,
thoroughly familiarizing him/herself with procedures before
beginning. Photographs and illustrations have been included
with the text as an aid. Notes, cautions and warnings have also
been included for clarification of text and safety concerns.
However, a knowledge of mechanical theory, tool use and shop
procedures is necessary to perform the service work safely and
satisfactorily. Use only genuine Polaris service parts.
Cleanliness of parts and tools as well as the work area is of
primary importance. Dirt and foreign matter will act as an
abrasive and cause damage to precision parts. Clean the
snowmobile before beginning service. Clean new parts before
installing.
Watch for sharp edges which can cause personal injury,
particularly in the area of the tunnel. Protect hands with gloves
when working with sharp components.
If difficulty is encountered in removing or installing a
component, look to see if a cause for the difficulty can be found.
If it is necessary to tap the part into place, use a soft face hammer
and tap lightly.
Some of the fasteners in the snowmobile were installed with
locking agents. Use of impact drivers or wrenches will help
avoid damage to fasteners.
Always follow torque specifications as outlined throughout this
manual. Incorrect torquing may lead to serious machine damage
or, as in the case of steering components, can result in injury or
death for the rider(s).
If a torquing sequence is indicated for nuts, bolts or screws, start
all fasteners in their holes and hand tighten. Then, following the
method and sequence indicated in this manual, tighten evenly to
the specified torque value. When removing nuts, bolts or screws
from a part with several fasteners, loosen them all about 1/4 turn
before removing them.
If the condition of any gasket or O-Ring is in question, replace
it with a new one. Be sure the mating surfaces around the gasket
are clean and smooth in order to avoid leaks.
Some procedures will require removal of retaining rings or
clips. Because removal weakens and deforms these parts, they
should always be replaced with new parts. When installing new
retaining rings and clips use care not to expand or compress
them beyond what is required for installation.
Because removal damages seals, replace any oil or grease seals
removed with new parts.
Polaris recommends the use of Polaris lubricants and greases,
which have been specially formulated for the top performance
and best protection of our machines. In some applications, such
as the engine, warranty coverage may become void if other
brands are substituted.
Grease should be cleaned from parts and fresh grease applied
before reassembly of components. Deteriorating grease loses
lubricity and may contain abrasive foreign matter.
Whenever removing or reinstalling batteries, care should be
taken to avoid the possibility of explosion resulting in serious
burns. Always disconnect the negative (black) cable first and
WARNING
Always stop the engine and refuel outdoors or in a well
ventilated area
WARNING
Do not smoke or allow open flames or sparks in or near
the area where refueling is performed or where
gasoline is stored or used.
WARNING
Do not overfill the tank. Do not fill the tank neck.
WARNING
If you get gasoline in your eyes or if you swallow
gasoline, see your doctor immediately.
WARNING
If you spill gasoline on your skin or clothing,
immediately wash it off with soap and water and
change clothing.
WARNING
Never start the engine or let it run in an enclosed area.
Gasoline powered engine exhaust fumes are
poisonous and can cause loss of consciousness and
death in a short time.