Polaris 2007 Two Stroke Manuals

Polaris 2007 Two Stroke Manuals

Manuals and User Guides for Polaris 2007 Two Stroke. We have 1 Polaris 2007 Two Stroke manual available for free PDF download: Service Manual

Polaris 2007 Two Stroke Service Manual

Polaris 2007 Two Stroke Service Manual (327 pages)

Two Stroke

Brand: Polaris | Category: Snowmobiles | Size: 24.27 MB

Table of Contents

Model Specifications Chapter 1 1

5
- Table of Contents
  5
- Front Suspension
  7
- Rear Suspension
  7
- 340 Touring
  8
  - Fuel Delivery
    8
- Chapter 1
  8
- Widetrak Lx
  10
- 500 XC Sp
  12
- Super Sport
  14
- Trail Rmk
  18
- Trail Touring Deluxe
  20
- 600 Ho Iq
  22
- 600 Ho Iq Cleanfire
  24
- 600 Ho Iq Lx Cleanfire
  26
- 600 Ho Switchback
  28
- 600 Ho Switchback Cleanfire
  30
- Ho Rmk 144/155 (F/O)
  32
- 600 Ho Iq Touring Cleanfire
  34
- Dragon
  36
- Dragon Rmk
  38
General Chapter 2 General 2

41
- Chapter 2
  42
- Clutch Springs
  42
- Gearing
  42
- How to Use this Manual
  42
- Jetting
  42
- Suspension Spring Pre-Load/Installed Length
  43
- Snowmobile Number Designations
  44
  - Model Number Designation
    44
- Publication Part Numbers
  45
  - Misc. Publications
    45
  - 2007 Service Publications
    46
- Vehicle Identification Number (Vin)
  45
  - Tunnel Decal
    45
  - Vin Number Designation
    45
- General Reference
  47
  - Standard Bolt Torque Specification
    47
  - Stroke Gasoline / Oil Pre MIX
    47
  - Gasoline Volatility
    47
  - Sae Tap Drill Sizes
    48
  - Metric Tap Drill Sizes
    48
  - Measurement Conversion Chart
    49
  - Piston Wash / Spark Plug Reading
    49
  - Glossary of Terms
    50
- Special Tools
  51
Maintenance Chapter 3 Maintenance

55
- Chapter 3 Polaris Recommended Program
  57
- Maintenance Program
  57
- Inspectons
  59
  - Cylinder Head Inspection
    59
  - Cylinder Measurement
    59
  - Cylinder Honing
    59
  - Honing Procedure
    60
  - Honing to over Size (340/500 Fuji Engines Only)
    60
  - Cleaning the Cylinder after Honing
    60
  - Piston Inspection
    60
  - Piston Ring Installed Gap
    61
  - Coolant Level
    61
  - Recommended Coolant
    61
  - Cooling System Bleeding
    61
  - Bearing Fit
    62
  - Main Bearing
    62
  - Connecting Rod (Big End) Bearing
    62
  - Wrist Pin Bearing
    63
  - Crankshaft Indexing
    63
  - Checking Crankshaft Index
    63
  - Crankshaft Trueing
    65
  - Crankshaft Runout Inspection
    66
  - Oil Pump Bleeding
    66
  - Oil / Fuel Filter
    66
  - Brake Lever Travel
    67
  - Brake Fluid
    67
  - Exhaust System Removal/Installation
    67
  - Manifold Installation
    67
  - Belt Deflection Inspection
    68
  - Measuring Belt Deflection
    68
- Lubrication
  69
  - Rear Suspension
    69
  - Front Suspension
    70
  - Steering
    70
  - Jackshaft Bearing
    70
  - Driveshaft Bearing
    70
  - Throttle Cable
    70
  - Choke and Choke Cable
    70
  - Chaincase Oil
    71
- Adjustments
  71
  - Choke Adjustment
    71
  - Throttle Lever Free Play - Non Cfi
    72
  - Throttle Lever Free-Play - Cfi Models
    72
  - Oil Pump Adjustment
    73
  - Track Alignment
    74
  - Track Tension
    75
  - Rear Engine Torque Stop Adjustment
    75
  - Engine Isolator Limiter Setting
    76
- Chassis and Hood
  76
- Cleaning
  76
  - Air Filter
    76
  - Water Sediment Trap
    76
  - Nosepan Care
    76
- Storage
  76
- Carburetor/Throttle Body
  77
- Clutch and Drive System
  77
  - Controls and Linkage
    77
- Electrical Connections
  77
- Fuel System
  77
- Headlight Bulb Replacement
  78
  - Edge Headlight Bulb Replacement
    78
- Iq Headlight Bulb Replacement
  78
- Iq Snow Beam Bulb Replacement
  78
- Coolant Draining
  79
Fuel Delivery Chapter 4 Fuel Delivery

81
- Chapter 4 Service Precautions
  83
- General Information
  83
  - Engine
    83
- Warnings
  83
- Fuel Delivery System (Carbureted)
  84
  - Carbureted System Overview
    84
- Fuel Pump (Carbureted Units)
  84
  - Fuel Pump Overview
    84
  - Maintenance
    85
- Mikuni Jet Needle
  85
  - Overview
    85
- Mikuni Tm 38
  86
  - Carburetor Overview
    86
- Mikuni Carburetor
  87
  - Function
    87
  - Float System
    88
  - Fuel Metering
    88
  - Fuel Delivery
    88
  - Pilot Jet
    88
  - Fuel Screw
    89
  - Main Jet
    89
  - Jetting Guidelines
    89
  - Piston Valve or Throttle Valve
    89
  - Jet Needle / Needle Jet
    90
  - Jet Needle
    90
  - Needle Jet
    90
  - Throttle Opening Vs. Fuel Flow
    91
- Mikuni Tm38 Flat Slide Service
  92
  - Disassembly
    92
  - Assembly
    94
- Carburetor Syncronization
  94
  - Throttle Valve Synchronization
    94
- Carburetor Component Part Numbers
  95
  - Mikuni Pilot Jets
    95
  - Mikuni Main Jets
    95
  - Mikuni Jet Needles
    95
  - Mikuni Starter Jets
    96
  - Mikuni (Short) Pilot Air Jets
    96
  - Mikuni (Long) Pilot Air Jets
    96
  - Mikuni Piston Valves
    96
  - Mikuni (Notched) Piston Valves
    96
- Cleanfire Injection (Cfi)
  97
  - Injector Replacement
    97
  - 600/700 Cfi Injector Replacement
    97
  - 600/700 Cfi Fuel Rail/Injector(S) Removal/Installation
    97
  - Cleanfire System Overview
    99
  - Fuel Pump (700)
    99
  - Fuel Level Indicator
    99
  - 2007 Fuel Supply / Return Fittings
    100
  - Fuel Rail Bleeding
    100
  - 600 CFI Fuel Tank / Fuel Supply
    101
  - 600 CFI Pump / Sender Specifications
    101
- 600 CFI Fuel Pump Replacement
  101
- Fuel Tank Pressure Test
  102
- Throttle Body Removal
  102
- Fuel Filter Installation
  103
- Fuel Filter Removal
  103
Engine Chapter 5 Engine

105
- Chapter 5
  106
- Exhaust Valve Exploded View
  106
- General Engine Information
  106
- Exhaust Valve Assembly
  107
- Exhaust Valve Disassembly
  107
- Optional Exhaust Valve Springs
  107
- Reed Valve Disassembly
  107
- Reed Valve Assembly
  108
- Thermostat Replacement
  108
- Cylinder Stud Installation
  109
- Engine Mount Replacement
  109
- Water Temperature Sensor Replacement
  109
- 500/600/700 Water/Oil Pump Cross Shaft Assembly
  110
- 500/600/700 Water/Oil Pump Cross Shaft Disassembly
  110
- Cylinder Head / Head Components
  111
- Cylinder Head Assembly
  111
- Cylinder Head Disassembly
  111
- Recoil/Stator Removal
  111
- Recoil/Stator Assembly
  112
- Cooling Systems
  113
  - 500/600/700 121/Switchback/Rmk/Dragon
    113
  - 500/600 Touring / Widetrak Lx
    114
- 340/550 Fuji Engine
  115
- Fuji Engine
  120
  - Disassembly
    120
  - Assembly
    121
- 500/600 Ho Engine
  123
- 600 / 700 Ho Cfi Engine
  133
  - 600/700 Cfi Engine Removal
    133
  - 600/700 Cfi Engine Disassembly
    137
  - Engine Assembly
    138
  - 600/700 Cfi Cylinder Head Torque Pattern
    139
  - 600/700 Cfi Cylinder Base
    139
  - 600/700 Cfi Crankcase Torque Pattern
    139
  - 600/700 Cfi Engine Installation
    139
  - Torque Specifications
    144
  - Specifications
    145
  - Fastener Torque Specifications
    145
Clutching Chapter 6 Clutching

147
- Back-Shifting
  148
  - Final Drive
    149
- Chapter 6
  148
- Clutch Weight
  148
- Drive Spring
  148
- Driven Spring
  148
- Engagement Rpm
  148
- Neutral Speed
  148
- Overview
  148
- Pvt System
  148
- Shift out Over-Rev
  148
- Shift out Rpm
  148
- Driven Helix / Ramp
  149
- Final Gearing
  149
- Low / High Ratio
  149
- General Information
  150
  - Special Tools
    150
  - Drive Clutch Springs
    151
  - Spring Free Length
    152
  - Drive Clutch Weights
    152
  - Non-Er Lwt Driven Helixes
    153
  - Team Helix Options with Perc
    153
  - Team Ramp Angles
    153
  - Team Driven Springs
    154
  - Belt Inspection
    154
  - Belt Wear / Burn Diagnostics
    155
  - Drive Belt Removal
    156
  - Drive Belt Installation
    156
  - Adjusting Belt Deflection
    157
  - Drive Belts
    158
  - Blet Pn 3211115 Break -In Proceedure
    159
- Pvt System Adjustments
  160
  - Clutch Alignment / Offset
    160
  - Offset Adjustment
    160
- Drive Clutch
  161
  - Identification
    161
  - Drive Clutch Removal
    161
  - Drive Clutch Disassembly
    162
  - Roller Removal
    163
  - Roller Installation
    163
  - Clutch Assembly
    164
  - Spider Indexing
    164
  - Drive Clutch Installation
    166
- Driven Clutch
  167
  - Components
    167
  - Driven Clutch Removal
    167
  - Driven Clutch Installation
    167
  - Driven Clutch Disassembly
    167
  - Driven Clutch Assembly
    168
  - Belt to Sheave Clearance Inspection
    168
  - Belt to Sheave Clearance Adjustment
    168
  - Belt Deflection Inspection
    169
Final Drive/Brakes Chapter 7 Final Drive/Brakes

171
- Gearing Charts
  172
- Chapter 7
  176
- Gears
  176
- Gears and Chains
  176
  - Drive Chain
    176
- Chain Case
  177
  - Exploded View
    177
  - Chaincase Removal
    178
  - Chaincase Installation
    178
  - Chaincase Seal & Bearing Replacement
    179
- Drive Train
  180
  - Jackshaft Exploded View
    180
  - Jackshaft Removal
    181
  - Jackshaft Installation
    181
- Adjustments
  181
  - Chaincase Drive Tension
    181
- Driveshaft
  182
  - Driveshaft Removal/Installation
    182
- Widetrak Transmission
  183
  - Removal
    183
  - Inspection
    184
  - Low/Reverse Shaft Disassembly
    186
  - Shift Fork Disassembly
    186
  - Transmission Assembly
    187
  - Transmission Installation
    187
- Hydraulic Brake System
  189
  - Overview
    189
  - Compensating Port
    189
  - General Guidelines
    189
  - Brake Fluid Replacement & Bleeding
    190
  - Brake Line Replacement
    191
  - Brake Light Switch Replacement
    192
- Caliper
  193
  - Caliper Removal
    193
  - Caliper Replacement
    193
  - Brake Pad Replacement
    193
  - Brake Disc Replacement
    193
  - Caliper Assembly
    193
- Widetrak Brake Caliper
  194
  - Removal
    194
  - Assembly
    194
  - Installation
    194
Front Suspension & Steering Chapter 8 Front Suspension & Steering

195
- Front Suspension
  195
- Chapter 8 Front Suspension Type by Model
  196
- Model Front Suspension Type
  196
- Front Suspension Torque & Specifications
  197
  - Iq/Iq Lx/Iq Rmk/Switchback
    197
  - Edge/Edge Lx
    198
  - Edge Rmk
    199
  - Widetrack Lx
    200
- Front Suspension Adjustment Procedures
  201
  - Set up and Adjustments
    201
  - Ifs Shock Springs
    202
  - Springs
    203
  - Compression Damping Adjustable Shocks
    203
- Shock Information
  205
  - Ifs Shock Fastener Torques
    205
  - Ifs Shock Specifications
    205
  - Ifs Shock Production Valving
    206
- Iq Front Suspension
  207
  - Spindle Removal
    208
  - Spindle Assembly
    208
  - Lower Spherical Bearing Replacement
    208
  - Upper / Lower Control Arm Removal
    209
  - Upper / Lower Control Arm Installation
    209
  - Alignment Bar Specifications
    209
  - Camber Definition
    209
  - Rod End
    210
  - Rod End Engagement
    210
- Alignment Adjustments
  210
  - Edge/Edge Lx/Edge Rmk Set up Width
    210
  - Edge/Edge Lx/Edge Rmk Camber Adjustment
    211
  - Iq/Iq Lx/Switchback Camber Adjustment
    211
  - Handlebar Centering
    212
  - Toe Adjustment
    212
- Front Suspension Measuring
  210
  - Maximum Width
    210
  - Toe Alignment
    210
  - Camber
    210
- Ski Stance
  212
  - Adjustment (Iq Rmk Only)
    212
- Handlebar
  213
  - Rmk Handlebar Position
    213
  - Rmk Handlebar Angle
    213
Rear Suspension Chapter 9 Rear Suspension

215
- Rear Suspension Type Per Model
  216
- Chapter 9 Shock Rebuilding Tools
  217
- Special Tools
  217
- Rear Suspension Torque Specifications
  218
  - Shock Mounting Fasteners Specification
    218
  - Suspension to Chassis Fasteners Specification
    219
- Shock Control Rods
  220
  - Edge Shock Rods
    220
  - Iq Shock Rod
    220
- Rear Suspension Operation
  221
  - Operation
    221
  - Suspension Coupling
    221
  - Weight Transfer
    221
  - Rear Torsion Spring Tension Adjustment
    221
- Rear Suspension Adjustments and Settings
  222
- M-10 Suspension
  228
  - M-10 Overview
    228
  - M-10 RTS Adjustments
    228
  - M-10 Terminology
    229
  - M-10 Adjustments
    229
  - M-10 FRA Initial Set up Reference
    230
  - M-10 Rear Spring Preload
    230
  - M-10 Ski Pressure
    230
- Rail Slider
  231
  - Rail Slide Wear Limit
    231
  - Rail Slide Removal
    231
  - Rail Slider Break in
    231
- Rear Suspension Removal / Installation
  232
  - Rear Suspension Removal
    232
  - Rear Suspension Installation
    233
- Shock Information
  235
- Shock Valve Part Numbers
  237
- Rear Shock Specifications
  240
  - Walker Evans Fts 7043204
    240
  - Fox Fts 7043267
    240
  - Walker Evans Fts 7043234
    241
  - Ryde Fx Fts 7043244
    241
  - Fox Fts 7043142
    241
  - Ryde Fx Fts 7041975
    241
  - Walker Evans Rts 7043205
    242
  - Fox Rts 7043246
    242
  - Fox Rts 7043266
    243
  - Fox Rts 7043177
    243
  - Walker Evans Rts 7043235
    243
  - Fox Rts (M-10) 7043216
    243
- Shock Maintenance
  244
  - Walker Evans Shocks (7043234, 7043233)
    245
  - Ryde Fx Mono-Tube Shock Disassembly
    246
  - Ryde Fx Mono-Tube Shock Assembly
    246
  - Fox Monotube Disassembly
    247
  - Fox Monotube Assembly
    247
- Rear Suspension Troubleshooting
  248
Chassis & Hood Chapter 10 Chassis & Hood

249
- Chapter 10
  250
- Side Panel Installation
  250
- Side Panel Removal
  250
- Side Panels
  250
- Hood Assembly
  251
  - Hood Removal/Installation
    251
  - Edge Instrument Removal/Installation
    251
  - Iq Mfd Removal/Installation
    251
  - Hood Repair
    252
- Bumper
  252
- Headlight
  252
  - Iq Headlight Removal/Installation
    252
  - Edge Headlight Removal/Installation
    252
- Coolant/Oil Tank
  253
  - Coolant Tank Removal
    253
  - Coolant Tank Installation
    253
- Oil Tank
  253
  - Oil Tank Removal
    253
  - Oil Tank Installation
    253
- Seat Information
  253
  - Seat & Base Removal/Installation
    253
- Seat and Fuel Tank
  254
  - Iq Fuel Tank Removal
    254
  - Iq Fuel Tank Installation
    254
  - Edge Fuel Tank Removal/Installation
    254
  - Seat Cover Replacement
    255
- Console
  255
  - Console Removal/Installation
    255
- Tail Light
  255
  - Edge Tail Light Assembly Replacement
    255
  - Tail Light Assembly Replacement
    255
- Handlebar Cover
  256
  - Handle Bar Cover Removal/Instaltion
    256
- Nosepan
  256
  - Replacement
    256
- Skis
  256
  - Ski Removal
    256
  - Ski Installation
    256
- Decals
  257
  - Decal Removal
    257
  - Decal Installation
    258
Battery & Electrical Systems

261
- Chapter 11
  263
- Charging System
  263
- Engine Models
  263
- Ignition Timing
  263
- Spark Plugs
  263
- Specifications
  263
- Conventional Battery
  264
  - Battery Preparation
    264
  - Specifications
    264
  - Refilling a Conventional Battery
    264
- Fresh Pack Battery
  264
- Battery Testing
  265
  - Testing Procedures
    265
  - Open Circuit Voltage Test (Ocv)
    265
  - Load Test
    265
  - Specific Gravity Test (Conventional Battery)
    265
  - Off Season Storage
    265
- Ignition Timing
  266
  - Timing Procedure - Carbureted Engines
    266
  - Ignition Timing Chart
    267
- Throttle Position Sensor (Tps)
  268
- Electric Start - Gen II / Edge
  272
  - System Schematic
    272
  - Starter Motor Assembly (Typical)
    273
  - Battery Box
    274
  - Dynamic Testing
    275
  - Static Testing
    275
  - Starter Housing / Field Coil Testing
    275
  - Armature Testing
    275
- Electric Start - Iq Carbureted / Cfi
  276
- Clean Fire Fuel Injection
  280
  - System Overview
    280
  - Diagnostic Trouble Codes (Dtcs)
    281
  - Mfd Blink Codes
    282
  - Dtc Troubleshooting
    282
  - Cfi Clutch Guard Electrical Center
    283
  - Chassis/Hood
    284
  - 34 Pin CNA ECU Connector
    284
  - 26 Pin CNB ECU Connector
    285
  - Chassis Relay
    286
  - Throttle / Ignition Kill System
    287
  - Vehicle Speed Sensor
    288
  - Exhaust Temperature Sensor
    289
  - Temperature / Air Pressure Sensor (Tbap)
    289
  - Crankshaft Position Sensors (Cps)
    289
  - Stator Assembly
    290
  - Exhaust Valve Solenoid
    291
  - Cfi Ignition Coils
    291
  - Regulator / Rectifier
    291
  - Chassis Power Capacitor
    291
  - Engine Coolant Temperature Sensor
    292
  - Knock Sensor
    292
  - Fuel Injectors
    292
  - Cfi Power System
    293
  - Cfi Ignition / Injection Power
    293
  - Cfi Crank Position System
    294
  - Cfi Safety Stop System
    294
  - Cfi Full Load Fuel Injectors
    295
  - Cfi Part Load Fuel Injectors
    295
  - Cfi Chassis Power
    296
  - Cfi Ignition Coils
    296
  - Cfi Tbap Sensor
    297
  - Cfi Tps / Engine Temp. Sensors
    297
  - Cfi Exhaust Solenoid
    298
  - Cfi Knock Sensor
    298
  - Cfi Fuel Pump
    299
  - Cfi Diagnostic Connections
    299
  - Cfi Mfd Circuits
    300
  - Cfi Mfd Power Circuits
    300
  - Cfi Fuel Level Circuit
    301
  - Cfi Vehicle Speed Circuit
    301
  - Cfi Mode Set Switch
    302
  - Cfi Perc Switch
    302
- Digital Wrench Diagnostic Software
  303
  - Overview
    303
  - Digital Wrench Connections
    303
  - Updating Digital Wrench
    304
  - Version / Fileset Identification
    305
  - Engine Controller Reprogramming (Reflash)
    305
- Carbureted Electrical Systems
  307
  - Ec50Pl Stator Specifications
    307
  - Ec34 / Ec55 Stator Specifications
    307
  - 500Cc Ev / 600 Ho Stator Specifications
    307
  - Ignition Coil Packs
    307
  - Exhaust Valve Solenoid
    307
  - Knock Sensor
    307
  - 600Ho Coolant Temperature Sensor
    308
  - 500 EV Coolant Temperature Sensor
    308
  - Oil Level Sender
    308
  - 600 HO Regulator / Rectifier
    308
- Troubleshooting Tables
  309
  - No Spark
    309
- Detonation Control (Det)
  310
  - Overview
    310
- Diagnostic Plugs
  311
  - Iq Chassis Power Plug
    311
  - Iq Cfi Fuel Pump Prime Plug
    311
- Electronic Reverse (Perc)
  311
  - Overview
    311
  - Operation
    311
  - Forward Operation
    312
  - Altitude Setting
    312
  - Important Notes
    312

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