Polaris 360 Factory Rebuild Kit

Tools Needed

• Phillips screwdriver
• Needle nose pliers
• Small flathead screwdriver

Disassembly

1. Remove and discard the all-purpose bag, head float, top cover(s), feed pipe/timer blank assembly, and sweep hose assembly.
2. Remove the four screws that secure the frame to the base. Lift the frame off the base at a 45-degree angle, pull back, and lift off. Discard the base. The rebuild kit includes a pre-assembled base unit, so any items still attached to the original base can be discarded.
3. Familiarize yourself with the gears, bearings, and e-clips, noting their location on the shafts before dismantling the frame. Disengage the front and rear belts by pushing the belt off the pulley while turning the wheel.
4. Remove the hub caps, e-clips, wheels, belts, axle blocks, transfer pulley/drive shaft assembly, gears, bearings, and turbine wheel. These parts can be discarded.

Diagram Description: A diagram illustrates the various components of the Polaris 360 cleaner, including gears, bearings, e-clips, shafts, wheels, and the frame. It shows how these parts are interconnected and provides labels for identification during disassembly and reassembly.

Frame Modification

If the frame has not already been notched, file the frame to provide proper clearance for the feed pipe/timer blank assembly.

Diagram Description: A diagram shows the frame of the cleaner with a specific area highlighted for filing. A ruler graphic indicates a 2-inch measurement, suggesting the depth or extent of the required clearance modification.

Assembly

1. Install the new axle blocks using lock washers with screws. Tighten screws loosely to keep them in place.
2. Install bearings with the shield side facing outwards. Insert the compound gear shaft with the inner bearing. Install the new compound gear. Note: The gear may seem tight.
3. Once the gear is installed, attach an e-clip. Push the compound gear shaft through and secure it to the other side with another e-clip. E-clips should snap into place.
4. Place the longest hub of the new drive gear into the new turbine wheel.
5. Push the drive shaft through the new turbine bearing, turbine wheel, and drive gear. Install the single-wheel side wheel with its bearing. Secure with an e-clip.
6. Lay the frame on its single-wheel side and place the drive belts over the axle block shafts. Install the new bearing shields.
7. Install the new double-wheel side wheels with bearings, e-clips, and hub caps. Engage each belt by pushing the belt onto the pulley while turning the wheel. The small belt should be on the inside of the transfer pulley, and the large belt on the outside, with a belt divider separating them.
8. Place the frame on the double-wheel side. Push the axle blocks toward the outside edge of the Polaris until the belts have approximately 1/4 inch of tension, then tighten the axle block screws.
9. Remove two back screws from the pre-assembled new body. Lift off the back plate. Push in the vacuum tube latch to remove the top.
10. Place the lower turbine housing into the base. Place the new base weight on the rear jet retainer, flush against the vacuum tube.
11. Slide the frame onto the new base. Reinstall three of the 3/4-inch screws into the frame. Place the upper turbine housing cover on, then screw in the fourth and final 3/4-inch screw.
12. Install the feed pipe and o-ring. Reinstall the three feed pipe screws.
13. From the back, slide the top assembly in and over the vacuum tube. Align the top and base and snap them into place. IMPORTANT: Ensure the top is secured by the vacuum tube latch.
14. Slide on the back plate and reinstall screws to secure the thrust jet. You may need to create tension on the thrust jet to align the holes.
15. Attach the new head float and push it forward as close to the Polaris as possible.
16. Attach the new bag.
17. Attach the sweep hose using the new attach clamp.

Diagram Description (Belt Tensioning): This diagram shows the frame positioned on the double-wheel side. It illustrates how to adjust the axle blocks to achieve approximately 1/4 inch of belt tension. It depicts a "Same Axle Block in Reverse Position" and a "New Axle Block" to guide this adjustment.

Diagram Description (Top/Base Assembly): This diagram shows the rear of the cleaner, indicating how the top assembly is slid over the vacuum tube and secured by a vacuum tube latch. It also shows the correct placement of the base weight and rear jet retainer.

Replacement of In-line Back-up Valve

1. Remove the existing in-line back-up valve.
2. Install the new float as shown in the diagram. If necessary, trim the end of the hose at an angle and pull the hose through the float using needle-nose pliers. Once the float is installed, retrim the hose square.
3. Attach the back-up valve to the hose with the flow arrow pointing toward the cleaner.
4. Push the new float as close to the back-up valve as possible.

Diagram Description: A diagram provides a detailed view of the in-line back-up valve, showing the float and hose nut. It clearly indicates the direction of water flow with an arrow pointing towards the cleaner, guiding the correct installation.

Polaris 360 Factory Rebuild Kit Limited Warranty

This limited warranty is extended to the original consumer purchaser of the Polaris 360 Rebuild Kit, manufactured by Polaris Pool Systems, Inc. Polaris warrants the parts in this kit to be free of defects in material and workmanship. The warranty does not cover normal replacement items such as tires, bottom plates, belts, or bearings that have worn out from use, nor does it cover damage caused by improper installation.

The Polaris 360 Factory Rebuild Kit is warranted for a period of one year from the date of purchase, with proof of purchase required. This warranty does not apply if failure is caused or contributed to by improper handling, usage, storage, freezing, abuse, unsuitable application, improper maintenance, or repairs/alterations made by anyone other than Polaris or its Authorized Service Centers. Polaris will repair or replace, at its option, any part proven to be defective within the warranty period and under the warranty conditions. To make a warranty claim, consumers must deliver or ship the unit or warranty parts freight prepaid to the nearest Polaris Authorized Service Center or return them freight prepaid after obtaining proper authorization. Contact the Polaris Customer Service Department for authorization and local procedures.

Polaris is not responsible for costs associated with removal, shipping, or installation of units or parts, or any damages incurred during these processes. The consumer bears these expenses. The warranty does not cover pattern removal, abrasion, or markings on a vinyl liner.

This limited warranty is in lieu of all other warranties, express or implied, including implied warranties of merchantability and fitness for a particular purpose. Any implied warranty imposed by state consumer law is limited to one year from the date of purchase. Polaris shall not be liable for incidental or consequential damages.

Limitations on implied warranty duration or exclusion of incidental/consequential damages may not apply in all states. This limited warranty is valid only in the United States of America, Canada, and Australia, and does not apply to kits sold or installed in other countries.

Contact information: Polaris Pool Systems, Inc., 2620 Commerce Way, Vista, CA 92081-8438. Phone: (760) 599-9600 or 1-800-822-7933. Website: www.polarispool.com.

© 2007 Polaris Pool Systems. All Rights Reserved. TL-829 3/07