Changing The Fuel Filter In A Polaris 800 (2006 Model)

If your Polaris Cleanfire snowmobile is running rough or is down on power, it may be time to change the fuel filter. While hard starting is not a symptom, run quality—especially top-end performance—suffers if fuel has to pass through a dirty filter. Polaris recommends that the filter be replaced every 2,000 miles as part of regular maintenance. To change the fuel filter on a 2006 Polaris 800, you will need common hand tools like wrenches, sockets, screwdrivers and pliers, and a fuel-line disconnect tool. The fuel filter is located under the frame, just behind and above the radiator. Once you have located the filter, remove any parts blocking access to it. Then, use the fuel-line disconnect tool to unhook the line. Install the new filter and route the attached hose to the fitting on the fuel tank. Make sure the fuel line is routed correctly and secure it with zip ties if necessary. Finally, test run the sled.

Finding the fuel filter

To find the fuel filter on a 2006 Polaris 800, you'll need to locate it behind and below the fuel tank. On a Polaris Sportsman 800, the fuel filter is under the front rack, mounted to the frame. It is silver in colour.

If you are still unsure where the fuel filter is located, you can follow the fuel supply line from the fuel injector rail near the engine back to the filter. This will help you locate it.

Once you have found the fuel filter, you will need to remove any parts blocking access to it. This may include removing the airbox, plastic cover on the clutch guard, and any screws from the right side of the cowling.

The fuel filter on a Polaris 800 is a sock-style filter. It is a good idea to replace it every 2,000 miles as part of regular maintenance.

Accessing the filter

To access the fuel filter on a 2006 Polaris 800, you will first need to locate it. The fuel filter is located under the frame, just behind and above the radiator. To get a good look at it, you'll need to remove the front box.

Once you've found the fuel filter, the next step is to remove any parts blocking access to it. This may include removing the airbox, plastic cover on the clutch guard, and any screws from the right side of the cowling. For Pro-Ride models, you may also need to reposition the oil tank to gain access.

It is important to note that the fuel filter is a quick-disconnect filter, so you will need to be careful when removing it to avoid any leaks. Make sure you have a rag or container ready to catch any fuel that may leak out during the removal process.

Now that you have located the fuel filter and removed any obstructing parts, you should be able to access it and proceed with the next steps of replacing the fuel filter on your 2006 Polaris 800.

Removing the filter

To remove the fuel filter from a 2006 Polaris 800, first locate the filter. The location of the fuel filter varies between models, but generally speaking, the filter for one Polaris model is in the same place as other similar models. The surest way to find the fuel filter is to follow the fuel supply line from the fuel injector rail near the engine back to the filter.

Once you've found the fuel filter, remove any parts that block access to it. This may include removing the airbox, plastic cover on the clutch guard, and screws from the right side of the cowling.

Now that you have access to the fuel filter, it's time to disconnect the fuel lines. Place a rag around the end of the hose to catch any leaking fuel. Use a fuel-line disconnect tool to unhook the line. Do this for both connectors.

Finally, remove the fuel filter from the sled and dispose of it according to your local regulations. It is important to maintain cleanliness when working on fuel system components, so ensure that ice or dirt is cleared away, and use clean tools.

Installing the new filter

To install the new fuel filter, first plug the new filter into the fuel supply line. Then, route the attached hose to the fitting on the fuel tank and plug that end in, too. You should hear a 'click' when the metal tabs inside the coupler engage on the fuel filter. This means the parts are securely attached so the filter won't disconnect within the coupler.

Next, spray a lightweight lubricant like WD-40 on the rubber airbox boots so they are easier to install on the throttle bodies.

With the new filter installed, make sure the fuel line that's attached to the filter is routed correctly so the airbox can be reinstalled. If necessary, secure the line between the fuel tank and fuel filter with a zip tie or two, but don't pull the tie so tightly that it could restrict flow.

Finally, reinstall the airbox and other parts you removed, then test run the sled. A few pulls on the rope will be required to fill the line and restore fuel pressure.

Securing the fuel lines

To secure the fuel lines when changing the fuel filter on a 2006 Polaris 800, you should first inspect the route of the fuel line to ensure it is correctly positioned. This will ensure there are no kinks or bends that could restrict the flow of fuel. Once you are satisfied with the routing, you can then secure the line in place using zip ties.

It is important to note that while zip ties are a convenient and effective way to secure fuel lines, they should not be overtightened as this could restrict the flow of fuel. As a general rule, the zip tie should be tight enough to hold the fuel line in place but still allow for some movement. This will help to prevent any unnecessary strain on the fuel line.

Additionally, when securing the fuel line, it is important to consider the location of the fuel filter. The fuel filter should be easily accessible for future maintenance or replacement. Therefore, the fuel line should be secured in a way that provides easy access to the fuel filter without placing unnecessary strain on the line or any other components.

In some cases, it may be necessary to reposition or remove certain parts to gain access to the fuel filter and properly secure the fuel lines. For example, the oil tank may need to be repositioned on some models to provide better access. It is also important to consider the length of the fuel line when securing it, as you want to ensure there is enough slack to allow for movement and vibration without placing strain on the line or any connections.

Finally, once the fuel line is secured, it is a good idea to test the sled to ensure proper function. A few pulls on the rope will be necessary to fill the line and restore fuel pressure, allowing you to check for any leaks or issues.

Frequently asked questions