improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this

publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting

or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

Table of Contents

Chapters

Table of Contents

Summary of Contents for Polaris IQ 2007

Page 1 2007 - 2008 IQ Snowmobile Service Manual PN 9921044 © Copyright 2007 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
Page 2 MEASUREMENT provides a key for a determined measurement specification. TORQUE provides a key for a required torque value. TRADEMARKS POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL: Loctite, Registered Trademark of the Loctite Corporation Nyogel, Trademark of Wm. F. Nye Co.
Page 3 2007 - 2008 IQ Snowmobile Service Manual Chapters Model Specifications....... 1 General Information........ 2 Maintenance........... 3 Fuel Systems.......... 4 Engine Systems ........5 Final Drive and Brake Systems....6 PVT System ..........7 Suspension and Steering ....
Page 4: Table Of Contents
Model Specifications CHAPTER 1 Model Specifications SPECIFICATIONS ............1.2 2007 600 HO IQ .
Page 5: Specifications
Model Specifications SPECIFICATIONS Carburetor Jetting Ambient Temperature 2007 600 HO IQ Model Number: S07PP6FS (A) (B) Altitude Engine Meters (feet) Liberty Liquid-Cooled / Engine Type Case Reed Induction Model Number S3273-6044-PF6F Displacement / # Cylinders 599cc / 2 0-600 (0-2000) Bore (inches/mm) 3.04 / 77.25 600-1200...
Page 6 Top Gear (Stock) Bottom Gear (Stock) Suspension Type IQ 121 Chain (Stock) Ryde FX HPG w/IFP (STD.) Gear Lube Polaris Synthetic (Rebuildable) Front Track Shock (FTS) Capacity (oz / ml) 11 / 325.3 Fox HPG w/IFP (OPT.) Reverse System Perc...
Page 7: 2007 600 Ho Switchback
Model Specifications 2007 600 HO Switchback Carburetor Jetting Ambient Temperature Model Number: S07PS6FS (A) Engine Altitude Liberty Liquid-Cooled / Engine Type Meters (feet) Case Reed Induction Model Number S3273-6044-PF6F Displacement / # Cylinders 599cc / 2 Bore (inches/mm) 3.04 / 77.25 0-600 Stroke (inches/mm) 2.52 / 64...
Page 8 Suspension Type IQ 144 Bottom Gear (Stock) Fox HPG w/IFP Front Track Shock (FTS) Chain (Stock) (Rebuildable) Gear Lube Polaris Synthetic FTS Spring Rate Capacity (oz / ml) 11 / 325.3 170 (30) lbs/in (N/mm) Reverse System Perc FTS Spring Installed 7.25 (18.4)
Page 9: 2007 600 Ho Rmk
Model Specifications 2007 600 HO RMK Carburetor Jetting Ambient Temperature Model Number: 144 = S07PK6FS / S07PK6FE 155 = S07PM6FS (A) Engine Altitude Meters (feet) Liberty Liquid-Cooled / Engine Type Case Reed Induction Model Number S3273-6044-PF6F Displacement / # Cylinders 599cc / 2 0-600 (0-2000)
Page 10 Top Gear (Stock) Toe Out Inches (cm) 0 - 0.12 (0 - 0.31) Bottom Gear (Stock) Chain (Stock) Rear Suspension Gear Lube Polaris Synthetic Suspension Type IQ 144 / 155 Capacity (oz / ml) 11 / 325.3 Reverse System Perc Ryde FX (STD.)
Page 11: 2007 600 Ho Iq Cfi
Center Distance (inches) 8.373 Top Gear (Stock) Fuel Delivery Bottom Gear (Stock) Chain (Stock) Type Cleanfire Direct Injection Gear Lube Polaris Synthetic Throttle Body Marking 1203213 Capacity (oz / ml) 11 / 325.3 Reverse System Perc Throttle Body Bore 46mm TPS Voltage @ Idle 0.95 +/- 0.01 Vdc...
Page 12 Model Specifications Front Suspension Suspension Type IQ 42.5 Ryde FX HPG w/IFP (STD.) (Rebuidlable) Shocks Fox Compression Adj. Remote Resevoir HPG (OPT.) (Rebuidable) IFS Spring Rate 100 (17.5) lbs/in (N/mm) Spring Installed Length 10.55 (26.8) Inches (cm) Front Vertical Travel 10 (25.4) Inches (cm) Ski Center Distance...
Page 13: 2007 600 Ho Switchback Cfi
Center Distance (inches) 8.373 Top Gear (Stock) Fuel Delivery Bottom Gear (Stock) Chain (Stock) Type Cleanfire Direct Injection Gear Lube Polaris Synthetic Throttle Body Marking 1203213 Capacity (oz / ml) 11 / 325.3 Reverse System Perc Throttle Body Bore 46mm TPS Voltage @ Idle 0.95 +/- 0.01 Vdc...
Page 14 Model Specifications Front Suspension Suspension Type IQ 42.5 Fox HPG w/IFP (STD.) (Rebuidlable) Shocks Fox Compression Adj. Remote Resevoir HPG (OPT.) (Rebuidable) IFS Spring Rate 100 (17.5) lbs/in (N/mm) Spring Installed Length 10.55 (26.8) Inches (cm) Front Vertical Travel 10 (25.4) Inches (cm) Ski Center Distance 42.5 (108)
Page 15: 2007 600 Ho Iq Lx Cfi
Center Distance (inches) 8.373 Top Gear (Stock) Fuel Delivery Bottom Gear (Stock) Chain (Stock) Type Cleanfire Direct Injection Gear Lube Polaris Synthetic Throttle Body Marking 1203213 Capacity (oz / ml) 11 / 325.3 Reverse System Perc Throttle Body Bore 46mm TPS Voltage @ Idle 0.95 +/- 0.01 Vdc...
Page 16 Model Specifications Front Suspension Suspension Type IQ 42.5 Ryde FX Gas Bag Shocks Compression Adjustable IFS Spring Rate 120 (21) lbs/in (N/mm) Spring Installed Length 9.95 (25.3) Inches (cm) Front Vertical Travel 9.92 (25.2) Inches (cm) Ski Center Distance 42.5 (108) Inches (cm) 2.25 ±...
Page 17: 2007 600 Ho Iq Touring Cfi
Center Distance (inches) 8.373 Top Gear (Stock) Fuel Delivery Bottom Gear (Stock) Chain (Stock) Type Cleanfire Direct Injection Gear Lube Polaris Synthetic Throttle Body Marking 1203213 Capacity (oz / ml) 11 / 325.3 Reverse System Perc Throttle Body Bore 46mm TPS Voltage @ Idle 0.95 +/- 0.01 Vdc...
Page 18 Model Specifications Front Suspension Suspension Type IQ 42.5 Ryde FX Gas Bag Shocks Compression Adjustable IFS Spring Rate 120 (21) lbs/in (N/mm) Spring Installed Length 9.95 (25.3) Inches (cm) Front Vertical Travel 10 (25.4) Inches (cm) Ski Center Distance 42.5 (108) Inches (cm) 2.25 ±...
Page 19: 2007 700 Ho Iq Dragon
Center Distance (inches) 8.373 Top Gear (Stock) Fuel Delivery Bottom Gear (Stock) Chain (Stock) Type Cleanfire Direct Injection Gear Lube Polaris Synthetic Throttle Body Marking 1203213 Capacity (oz / ml) 11 / 325.3 Reverse System Perc Throttle Body Bore 46mm TPS Voltage @ Idle 0.95 +/- 0.01 Vdc...
Page 20 Model Specifications Front Suspension Suspension Type IQ 42.5 Walker Evans w/IFP Remote Resevoir Shocks Compression Adjustable (Rebuildable) IFS Spring Rate 100 (17.5) lbs/in (N/mm) Spring Installed Length 10.30 (28.4) Inches (cm) Front Vertical Travel 10.55 (26.8) Inches (cm) Ski Center Distance 42.5 (108) Inches (cm) 2.25 ±...
Page 21: 2007 700 Ho Rmk Dragon
Center Distance (inches) 8.373 Top Gear (Stock) Fuel Delivery Bottom Gear (Stock) Chain (Stock) Type Cleanfire Direct Injection Gear Lube Polaris Synthetic Throttle Body Marking 1203213 Capacity (oz / ml) 11 / 325.3 Reverse System Perc Throttle Body Bore 46mm TPS Voltage @ Idle 0.95 +/- 0.01 Vdc...
Page 22 Model Specifications Front Suspension Suspension Type IQ RMK Shocks Walker Evans Air Oil Volume 95cc Nitrogen Charge Stock 215 psi Optional 220 - 225 psi Front Vertical Travel 9 (22.9) Inches (cm) Ski Center Distance Inches (cm) 39(99.1) / 40(101.6) / 41(104.1) Setup Width 38.67 (98.2) 2.17 ±...
Page 23: 2008 Iq Shift
Model Specifications 2008 IQ Shift Carburetor Jetting Ambient Temperature Model Number: S08PB6FS / S08PB6FE Engine Altitude Liberty Liquid-Cooled / Engine Type Meters (feet) Case Reed Induction Model Number S3466-6044-PU6F Displacement / # Cylinders 599cc / 2 Bore (inches/mm) 3.04 / 77.25 0-600 Stroke (inches/mm) 2.52 / 64...
Page 24 170 (29.75) lbs/in (N/mm) Bottom Gear (Stock) Chain (Stock) Rear Track Shock (RTS) Ryde FX MPV Gear Lube Polaris Synthetic .347 Square / 80_ (Stock) Capacity (oz / ml) 11 / 325.3 - PN 7043070 - 067 Reverse System Perc - PN 7043071 - 067 .347 Square / 77_ (Soft)
Page 25: 2008 600 Rmk 144 / 600 Rmk Shift 155
Model Specifications 2008 600 RMK 144 / 600 RMK Shift 155 Carburetor Jetting Ambient Temperature Model Number: 600 RMK 144: S08PK6FS / S08PK6FE 600 RMK Shift 155: S08PM6FS Altitude Engine Meters (feet) Liberty Liquid-Cooled / Engine Type Case Reed Induction Model Number S3467-6044-PU6F Displacement / # Cylinders...
Page 26 Top Gear (Stock) Bottom Gear (Stock) Ryde AFX Rear Track Shock (RTS) Chain (Stock) Compression Adjustable Gear Lube Polaris Synthetic .359 Square / 77_ (Stock) Capacity (oz / ml) 11 / 325.3 .347 / 77_ / (Soft) Reverse System Perc...
Page 27: 2008 600 Dragon Iq
Center Distance (inches) 8.373 Exhaust Valve Spring Purple Top Gear (Stock) Bottom Gear (Stock) Fuel Delivery Chain (Stock) Gear Lube Polaris Synthetic Type Cleanfire Direct Injection Capacity (oz / ml) 11 / 325.3 Throttle Body Marking 1203213 Reverse System Perc...
Page 28 Model Specifications Front Suspension Suspension Type IQ 42.5 Shocks Ryde FX Air 2.0 Air 2.0 Nitrogen Pressure 36mm Cylinder 145 psi 47mm Cylinder 60 psi Front Vertical Travel 10 (25.4) Inches (cm) Ski Center Distance Inches (cm) 42.5 (108) Setup Width 41.16 (104.5) 2.25 ±...
Page 29: 2008 600 Switchback / 600 Dragon Switchback
8.373 Engagement RPM ±200 3800 Top Gear (Stock) Bottom Gear (Stock) Exhaust Valve Spring Purple Chain (Stock) Gear Lube Polaris Synthetic Fuel Delivery Capacity (oz / ml) 11 / 325.3 Type Cleanfire Direct Injection Reverse System Perc Throttle Body Marking...
Page 30 Model Specifications Front Suspension Suspension Type IQ 42.5 Shocks Base Ryde FX HPG w/IFP Dragon Ryde FX Air 2.0 IFS Spring Rate 100 (17.5) lbs/in (N/mm) Spring Installed Length 10.55 (26.8) Inches (cm) Air 2.0 Nitrogen Pressure 36mm Cylinder 145 psi 47mm Cylinder 60 psi Front Vertical Travel...
Page 31: 2008 600 Iq Lx
Center Distance (inches) 8.373 Top Gear (Stock) Fuel Delivery Bottom Gear (Stock) Chain (Stock) Type Cleanfire Direct Injection Gear Lube Polaris Synthetic Throttle Body Marking 1203213 Capacity (oz / ml) 11 / 325.3 Reverse System Perc Throttle Body Bore 46mm TPS Voltage @ Idle 0.95 +/- 0.01 Vdc...
Page 32 Model Specifications Front Suspension Suspension Type IQ 42.5 Shocks Ryde FX MPV IFS Spring Rate 120 (21) lbs/in (N/mm) Spring Installed Length 9.95 (25.3) Inches (cm) Front Vertical Travel 10 (25.4) Inches (cm) Ski Center Distance Inches (cm) 42.5 (108) Setup Width 41.16 (104.5) 2.25 ±...
Page 33: 2008 600 Iq Touring
Center Distance (inches) 8.373 Top Gear (Stock) Fuel Delivery Bottom Gear (Stock) Chain (Stock) Type Cleanfire Direct Injection Gear Lube Polaris Synthetic Throttle Body Marking 1203213 Capacity (oz / ml) 11 / 325.3 Reverse System Perc Throttle Body Bore 46mm TPS Voltage @ Idle 0.95 +/- 0.01 Vdc...
Page 34 Model Specifications Front Suspension Suspension Type IQ 42.5 Shocks Ryde FX MPV IFS Spring Rate 140 (24.5) lbs/in (N/mm) Spring Installed Length 9.95 (25.3) Inches (cm) Front Vertical Travel 10 (25.4) Inches (cm) Ski Center Distance Inches (cm) 42.5 (108) Setup Width 41.16 (104.5) 2.25 ±...
Page 35: 2008 600 Rmk 155
Center Distance (inches) 8.373 Top Gear (Stock) Fuel Delivery Bottom Gear (Stock) Chain (Stock) Type Cleanfire Direct Injection Gear Lube Polaris Synthetic Throttle Body Marking 1203213 Capacity (oz / ml) 11 / 325.3 Reverse System Perc Throttle Body Bore 46mm TPS Voltage @ Idle 0.95 +/- 0.01 Vdc...
Page 36 Model Specifications Front Suspension Suspension Type IQ RMK Shocks Ryde FX IFS Spring Rate 100 (17.5) lbs/in (N/mm) Spring Installed Length 10.35 (26.3) Inches (cm) Front Vertical Travel 9 (22.9) Inches (cm) Ski Center Distance Inches (cm) 39 - 40 - 41 (99.1 - 101.6 - 104.1) Setup Width 38.67 (98.2) 2.17 ±...
Page 37: 2008 700 Iq / 700 Dragon Iq
Center Distance (inches) 8.373 Exhaust Valve Spring Pink Top Gear (Stock) Bottom Gear (Stock) Fuel Delivery Chain (Stock) Gear Lube Polaris Synthetic Type Cleanfire Direct Injection Capacity (oz / ml) 11 / 325.3 Throttle Body Marking 1203213 Reverse System Perc...
Page 38 Model Specifications Front Suspension Suspension Type IQ 42.5 Shocks Base Ryde FX PRO HPG w/IFP Dragon Ryde FX Air 2.0 IFS Spring Rate 100 (17.5) lbs/in (N/mm) Spring Installed Length 10.55 (26.8) Inches (cm) Air 2.0 Nitrogen Pressure 36mm Cylinder 145 psi 47mm Cylinder 60 psi...
Page 39: 2008 700 Switchback / 700 Dragon Switchback
Center Distance (inches) 8.373 Top Gear (Stock) Exhaust Valve Spring Pink Bottom Gear (Stock) Chain (Stock) Fuel Delivery Gear Lube Polaris Synthetic Type Cleanfire Direct Injection Capacity (oz / ml) 11 / 325.3 Reverse System Perc Throttle Body Marking 1203213...
Page 40 Model Specifications Front Suspension Suspension Type IQ 42.5 Shocks Base Ryde FX PRO HPG w/IFP Dragon Ryde FX Air 2.0 IFS Spring Rate 100 (17.5) lbs/in (N/mm) Spring Installed Length 10.55 (26.8) Inches (cm) Air 2.0 Nitrogen Pressure 36mm Cylinder 145 psi 47mm Cylinder 60 psi...
Page 41 Center Distance (inches) 8.373 Top Gear (Stock) Exhaust Valve Spring Pink Bottom Gear (Stock) Chain (Stock) Fuel Delivery Gear Lube Polaris Synthetic Type Cleanfire Direct Injection Capacity (oz / ml) 11 / 325.3 Reverse System Perc Throttle Body Marking 1203213...
Page 42 Model Specifications Front Suspension Suspension Type IQ RMK Shocks Base Ryde FX Dragon Walker Evans Air IFS Spring Rate 100 (17.5) lbs/in (N/mm) Spring Installed Length 10.35 (26.3) Inches (cm) WE Air Oil Volume 95cc WE Air Nitrogen Charge 220 psi Front Vertical Travel 9 (22.9) Inches (cm)
Page 43: Dragon Rmk 155 / 163
Engagement RPM ±200 3800 Top Gear (Stock) Exhaust Valve Spring Pink Bottom Gear (Stock) Chain (Stock) Fuel Delivery Gear Lube Polaris Synthetic Capacity (oz / ml) 11 / 325.3 Type Cleanfire Direct Injection Reverse System Perc Throttle Body Marking 1203505...
Page 44 Model Specifications Front Suspension Suspension Type IQ RMK Shocks Walker Evans Air Oil Volume 95cc Nitrogen Charge 220 psi Front Vertical Travel 9 (22.9) Inches (cm) Ski Center Distance Inches (cm) 39(99.1) / 40(101.6) / 41(104.1) Setup Width 38.67 (98.2) 2.17 ±...
Page 45 Model Specifications NOTES 1.42...
Page 46 General Information CHAPTER 2 General Information SNOWMOBILE NUMBER DESIGNATIONS ........2.2 MODEL NUMBER DESIGNATION.
Page 47: Snowmobile Number Designations
General Information SNOWMOBILE NUMBER DESIGNATIONS Model Number Designation Example: S08MX6FS ODEL PTION VIN I ROUP ODEL ODEL NGINE ODIFIER DENTIFIER DENTIFIER 1st digit 2/3rd digit 4th digit 5th digit 6th digit* 7th digit* 8th digit 9th digit** B = Basic D = LX G = 155 RMK 1A=121 F/C OHV 4 Cycle Fuji...
Page 48: Vehicle Identification Number (Vin)
General Information VEHICLE IDENTIFICATION NUMBER referred to in any correspondence regarding warranty, service or replacement parts.The machine model and V.I.N. number (VIN) identification decal is located on the right front side of the tunnel. The V.I.N (2) number is permanently stamped into the Tunnel Decal tunnel.
Page 49: Publication Part Numbers
General Information PUBLICATION PART NUMBERS 2008 Publications PARTS BOOK MODEL OWNER'S MANUAL SUPPLEMENT NLINE PART MANUALS AVAILABLE ONLINE AT WWW POLARISINDUSTRIES IQ Shift 9921427 9921067 9921068 600 RMK 144 9921108 9921102 9921112 600 RMK Shift 155 9921545 600 Dragon IQ 9921069 9921075 600 Switchback...
Page 50: Engine Data Formulas
General Information ENGINE DATA FORMULAS Compression Ratio R= (IHV + DISP) IHV= INSTALLED HEAD VOLUME (cc) DISP= CYLINDER DISPLACEMENT (cc) R= COMPRESSION RATIO S= FULL ENGINE STROKE (cm) (DISP x 25.4) I= INCHES PER cc OF IHV B= CYLINDER BORE (cm) PI= 3.1416 DISP = (PI x B x S)
Page 51: Compression Ratio Example
General Information Compression Ratio Example Head cc Removal Example Bore = 6.5cm The total number of cc’s to remove from the head = Old IHV (17.1) - Desired IHV (15.801) = 1.299cc’s Stroke = 6.0 cm Removed cc’s = 1.299cc’s IHV = 17.1cc I = Stroke (6.0cm) / (Displacement (199.098) x 2.54 Displacement = 3.1416 (PI) x 42.25 (Bore squared) x 6.0...
Page 52: Torque Conversion
General Information TORQUE CONVERSION ft.lb - Nm US to Metric 123.4 130.2 124.8 131.5 ft.lb - Nm 126.1 132.9 127.5 134.2 62.4 128.8 135.6 63.7 65.1 66.4 67.8 69.2 70.5 10.8 71.9 12.2 73.2 13.6 74.6 14.9 75.9 16.3 77.3 17.6 78.6 19.0...
Page 53: General Reference
General Information GENERAL REFERENCE Gasoline Volatility Standard Bolt Torque Specification MBIENT AXIMUM APOR ANGE CLASS PRESSURE HIGH 60°F 110°F+ 7.0 psi (0.5 bar) (16°C) (43°C+) Grade 2 50°F 110°F Grade 8 Grade 5 9.0 psi (0.6 bar) (10°C) (43°C) 40°F 10.5psi (0.7 bar) 97°F (36°C) (4°C)
Page 54: Sae Tap Drill Sizes
General Information SAE Tap Drill Sizes Decimal Equivalents 1/64 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .0156 Thread Size/ Drill Size Thread Size / Drill Size - - - - - - 1/32 - - - - - - - - - - - - - - - - - - -.0312 - - 1 mm= .0394"...
Page 55: Measurement Conversion Chart
General Information Measurement Conversion Chart Piston Wash / Spark Plug Reading Changing temperature, barometer, altitude, and fuel supply are NIT OF EASURE ULTIPLIED BY ONVERTS TO just a few of the factors that can affect the day to day ft-lb x 12 = in-lb performance of your engine.
Page 56: Service Precautions
CAUTION face hammer and tap lightly. CAUTION 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 of the fasteners in the snowmobile were installed some applications, such as the engine, warranty coverage with locking agents.
Page 57 General Information NOTES 2.12...
Page 58: Maintenance
Maintenance CHAPTER 3 Maintenance PERIODIC MAINTENANCE ..........3.2 PERIODIC MAINTENANCE SCHEDULE.
Page 59: Periodic Maintenance
Maintenance PERIODIC MAINTENANCE Periodic Maintenance Schedule Periodic Maintenance Table Frequency Item 150 mi. 500 mi. 1000 mi. 2000 mi. Pre-Season (240 km) (800 km) (1600 km) (3200 km) Drive / Driven Clutch Clutch Alignment / Offset Drive Belt Condition Drive / Driven Clutch Condition I / C I / C I / C...
Page 60 Maintenance Periodic Maintenance Table Frequency Item 150 mi. 500 mi. 1000 mi. 2000 mi. Pre-Season (240 km) (800 km) (1600 km) (3200 km) Fuel / Vent Hoses Oil Hoses Air Box Carburetor Drains / Water Traps Electrical System Auxiliary Shut-Off Throttle Safety Switch Ignition Switch Headlights / Brake light / Taillights...
Page 61: Maintenance Products
Maintenance MAINTENANCE PRODUCTS ESCRIPTION UMBER Engine Oils / Lubricants / Misc. Premium All Season Grease 3oz. Grease Gun Kit 2871312 14oz. 2871423 ESCRIPTION UMBER Starter Grease 2871460 Premium 2-Cycle Oil Carbon Clean Plus 2871326 Quart 2875035 Gallon 2875036 Isopropyl 2870505 2.5 Gallon 2874037 Fuel Stabilizer...
Page 62: Drive / Driven Clutches
Maintenance DRIVE / DRIVEN CLUTCHES The measurement should be 1 1/4" (3.2cm). Belt Deflection Inspection = In. / mm. Too much belt deflection is when the belt is too long or the center distance is too short. The initial starting ratio will be too Belt Deflection: 1.25"...
Page 63: Torque Stop Adjustment
Maintenance Torque Stop Adjustment Engine Isolator Limiter Setting Some models use an engine mount strap isolator. The isolator is located on left-front corner of the bulkhead. The isolator should not make contact with the engine strap. If the isolator requires adjustment or replacement, hold the isolator so it is against the bracket, then torque the nut to specification.
Page 64: Engine Maintenance
Severe burns to skin may occur from escaping coolant or steam. Recommended Coolant EV ASSEMBLY Use Polaris Premium 60 / 40 pre-mix antifreeze. This premium GASKET antifreeze is rated for temperatures down to -62°F (-52°C). Cooling System Bleeding Remove the vent hose from the EV base fitting.
Page 65: Oil Pump Adjustment - Carbureted Models
Maintenance 11. Verify that all of the coolers are warm, including the tunnel- going to be replaced, insert the two oil pump cable length cooling system. Turn off the engine once the tunnel wrenches between the bulkhead and the rear of the engine. coolers are sufficiently warmed-up.
Page 66: Oil Pump Adjustment - Cfi Models
Maintenance Oil Pump Adjustment - CFI Models 28mm Lever - Pointer Oil Pump NOTE: Before adjusting oil pump, always verify the POINTER throttle lever free play and idle speed RPM are set to specification. 33mm Lever - No Pointer Oil Pump LEVER MARK INDEX MARK (PUMP BOSS) ARM MARKING...
Page 67 Maintenance NOTE: Some 2008 600 and 700 CFI engines were manufactured with model year 2007 oil pumps (PNs 2520552 and 2520622). Always reference the oil pump adjustment chart to determine the oil pump WRENCHES lever setting based on the oil pump and not the engine model year.
Page 68: Oil Pump Bleeding
Maintenance Oil Pump Bleeding remove it from the sediment tube and drain the contaminated material from the bowl. Repeat for each carburetor. Wipe off the residue from the plug and reinstall the clamps. Fuel Filter - Carbureted Models CAUTION The in-tank fuel filter and fuel lines should be inspected regularly.
Page 69: Fuel Filter - Cfi Models
Maintenance Fuel Filter - CFI Models Oil Filter All models feature an inline oil filter located between the oil WARNING reservoir and oil pump. Always bleed the oil supply hose and oil pump of air after replacing the filter. When removing the fuel filter fuel spillage will occur. Be Install the oil filter so that the directional arrow points towards sure to work in a well ventilated area away from the oil pump.
Page 70: Fuel Tank Vent System
Maintenance Fuel Tank Vent System Air Intake Box / Pre-Filters All models feature a fuel tank vent / vacuum check valve system. Inspect the inside of the air intake box and pre-filters for foreign There are two systems used depending on the model year of the material and/or damage.
Page 71: Chassis Lubrication
Maintenance CHASSIS LUBRICATION M-10 136 Chassis, suspension and mechanical grease points should be lubricated Polaris Premium All Season Grease. Polaris Premium All Season Grease Part Numbers: 3oz. Grease Gun Kit = 2871312 14oz. Tube = 2871423 Rear Suspension IQ RMK Lubricate grease zerks with Premium All Season Grease.
Page 72: Throttle Cable
Chaincase Oil Capacity = 11oz. (325.3 ml) Recommended Lubricants: Chaincase = Polaris Synthetic Chaincase Lubricant Drive Chain Tension Adjustment Rotate the driven clutch counterclockwise to move all of the slack in the chain to the tensioner side. Lock the Choke And Choke Cable parking brake, or have an assistant hold the brake lever.
Page 73: Brake System Maintenance
Inspect the reservoir to be sure it contains the correct amount of (B) and the throttle block (C). This clearance is controlled by the fluid. Use only Polaris DOT 4 high temperature brake fluid. throttle cable (D). Change fluid every 2 years or whenever the fluid is dark or contamination is suspected.
Page 74: Throttle Lever Free-Play - Cfi Models
Maintenance ″ ″ Once you achieve the proper free play of 0.010 -0.030 After setting the throttle lever free play, always verify the oil (.25-.80mm), tighten the lock nuts. pump adjustment is set correctly. Verify the oil pump index marks are within specification. Choke Adjustment Check the idle RPM and verify it is within the specified range.
Page 75: Steering / Suspension Maintenance
Periodically inspect the torque of the handlebar clamp fasteners. APPLY FOGGING OIL CLAMPS The rider select steering U-joint should be lubricated with Polaris fogging oil (PN 2870791). STEERING POST To adjust the handlebar angle, remove the handlebar cover to expose the clamp.
Page 76: Ski / Ski Skag Fasteners
Maintenance Ski / Ski Skag Fasteners Periodically inspect the ski-to-spindle fasteners for proper torque. WASHERS PROVIDED FOR BLOW MOLDED SKIS 16”(41cm) TRACK Lift the rear of the machine and place a jack stand or secure the rear of the machine so that the track is off of the ground.
Page 77: Track Alignment
Maintenance Track Alignment NOTE: Track alignment affects track tension. 10. Torque both idler shaft bolts (F) to 35 ft-lb (48 N-m). Misalignment of the track will cause excessive wear to the track, rail slides, and rail. NOTE: Excessive rail slide wear occurs due to Idler Shaft Bolt: 35 Ft.Lbs.
Page 78: Electrical Systems
Maintenance ELECTRICAL SYSTEMS Carburetor/Throttle Body Fog engine with Polaris Fogging Oil (aerosol type) according to Headlight Bulb Replacement directions on can. NOTE: Do not touch the bulb with your fingers. The Fuel System grease from body oil will cause a hot spot on the bulb and cause bulb failure.
Page 79 Maintenance NOTES 3.22...
Page 80 Fuel Systems CHAPTER 4 Fuel Systems SERVICE WARNINGS AND PRECAUTIONS........4.2 SERVICE WARNINGS .
Page 81: Service Warnings And Precautions
WARNING snowmobile. PROPOSITION 65 WARNING Most Polaris snowmobile engines are calibrated to run Snowmobile engines discharge fuel and exhaust which using 91 octane (oxygenated) or 89 octane (non- contain chemicals known to the State of California to oxygenated) fuels.
Page 82: Carburetor Fuel Systems
Fuel Systems CARBURETOR FUEL SYSTEMS Mikuni Main Jets 3130102 3130118 3130134 3130147 3130103 3130119 3130135 3130148 3130104 3130120 3130136 3130149 3130105 3130121 3130137 510 N 3131400 3130106 3130122 3130138 520 N 3131401 3130107 3130123 3130139 530 N 3131402 3130108 3130124 3130290 540 N 3131408...
Page 83 Fuel Systems Mikuni Jet Needles AIR JET PART NUMBER 3131257 JET NEEDLE PART NUMBER 3131258 J8-9FH04-57 3130794 3131259 J8-9EH01-57 3130795 3131260 J8-9DH01-54 3130796 3131261 J8-8BEY01 3131250 3131262 J8-9DFH06-57 3131253 3131263 J8-9EFH01-60 3131207 3131264 J8-9DFH07-60 3131268 3131265 J8-9DFH10-57 3131313 3131266 J8-9DGI01-60 3131377 3131267 J8-9DGJ02-57...
Page 84 Fuel Systems Carbureted Fuel System (Typical)
Page 85: Mikuni Tm Carburetor
Fuel Systems MIKUNI TM CARBURETOR Fuel Metering Function The function of a carburetor is to produce a combustible air/fuel mixture by breaking fuel into tiny particles in the form of vapor, to mix the fuel with air in a proper ratio, and to deliver the mixture to the engine.
Page 86: Jetting Guidelines
Fuel Systems The main system is designed to deliver fuel between low speed In higher elevations and higher temperatures, the air is less and high speed operation. This system is made up of the jet dense. needle, needle jet, and main jet. The main system begins to take Verify the production setting for your specific model.
Page 87: Jet Needle
Fuel Systems Piston Valve Or Throttle Valve The number following the letters on the jet needle is the serial number and it varies with individual jet needles. The last number, 57 indicates that the outside diameter is 2.57mm. The smaller the O.D., the richer the mixture. 9DH01-57 intake side The throttle valve controls the rate of engine air intake by...
Page 88 Fuel Systems Throttle Opening Vs. Fuel Flow VM only...
Page 89: Fuel Pump
Fuel Systems FUEL PUMP Maintenance The impulse operated-powered fuel pump does not require any Fuel Pump Overview specific scheduled maintenance. However, the following procedures should be observed: FUEL IN (FROM TANK) • Operation The pump may be checked for operation by removing the fuel supply line from the carburetor and placing it into a container.
Page 90: Carburetor Service
Fuel Systems CARBURETOR SERVICE NOTE: Keep track of the plastic washer (9), and place it so it is on the top of the throttle valve when installing the needle and e-ring back into the Disassembly carburetor. CAUTION Inspect the needle (7), e-clip (8), and plastic washer (9) for wear.
Page 91 Fuel Systems Inspect e-rings, plate, spring, and rings (14) connecting the 13. Inspect the contents for wear and debris. slide to the lever if needed. 14. Remove and inspect the main jet (20), pilot jet (21), and 10. Remove water trap/drain plug (15) and single screw (16) starter jet (22).
Page 92 Fuel Systems Assembly Install the main jet (20), pilot jet (21), and starter jet (22). Install float/needle & seat assembly (19). Place carburetor in an inverted position. Connect a pressure tester (PN 2870975) to fuel inlet fitting. Apply 5 psi pressure and observe for one minute. The needle and seat should hold pressure indefinitely.
Page 93: Carburetor Adjustment
Fuel Systems CARBURETOR ADJUSTMENT Once the PTO carburetor slide is flush, loosen the Phillips head screw, located under the top cover on the MAG carburetor. Throttle Valve Synchronization While holding the PTO carburetor slide flush to the top of All throttle valve synchronization adjustments are made to the the carburetor, rotate the synchronization nut clockwise to MAG throttle valve.
Page 94: Cleanfire™ Fuel Injection
Regulates voltage to 14.5 Vdc. Also supplies fuel • Diagnostic Connector: The ECU can communicate with injector “boost” power when engine RPM is 700 RPM the Polaris Digital Wrench software and can be re- or less. flashed, monitored and will display trouble codes.
Page 95: Diagnostic Trouble Codes (Dtcs)
Fuel Systems Diagnostic Trouble Codes (DTCs) CFI Diagnostic Trouble Codes MFD B LINK ROUBLE ESCRIPTION Throttle Position Sensor Unrealistic TPS signal changes too rapidly to be correct. Can be P0120 Transition caused by faulty connections or a faulty TPS. TPS signal is above 4.39 Vdc. Can be caused by a Throttle Position Sensor Voltage High P0123 faulty wire connection or faulty TPS.
Page 96 Fuel Systems CFI Diagnostic Trouble Codes MFD B LINK ROUBLE ESCRIPTION MAG Part Load Injector Circuit Open P0261 MAG Full Load Injector Circuit Open P1261 OPEN circuit or short to ground. Can be caused by faulty wiring, injector, stator or ECU. PTO Part Load Injector Circuit Open P0264 PTO Full Load Injector Circuit Open...
Page 97: Mfd Blink Codes
Fuel Systems MFD Blink Codes The check engine LED will display a blink code whenever the ECU determines there is a current problem with one or more of the sensors. Use Digital Wrench to troubleshoot, fix and clear the codes. When a blink code is displayed, the CHECK ENGINE light will (A) (B) illuminate for 1/2 second “on”...
Page 98: Cfi Clutch Guard Electrical Center
Fuel Systems CFI Clutch Guard Electrical Center COVER / SPARE BELT HOLDER 6 Ft.Lbs. (10 Nm) CAPACITOR REGULATOR / RECTIFIER 6 Ft.Lbs. (10 Nm) IGNITION COILS 6 Ft.Lbs. (10 Nm) COIL MOUNT GUARD PLATE 6 Ft.Lbs. (10 Nm) 4.19...
Page 99: 34 Pin Cna Ecu Connector
Fuel Systems 34 Pin CNA ECU Connector NOTE: Wire Entry View OLOR ONNECTOR UNCTION RED/BLUE SPLICE K LINE POWER ORANGE ECU POWER EXTERNAL POWER WHITE/BLACK EXHAUST TEMP. SENSOR SIGNAL BLUE TBAP AIR TEMP SIGNAL GREEN/BLUE IGNITION SWITCH STARTER LOCKOUT RED/WHITE TBAP 5 VDC POWER SUPPLY GREEN/RED...
Page 100: 26 Pin Cnb Ecu Connector
Fuel Systems 26 Pin CNB ECU Connector NOTE: Wire Entry View OLOR ONNECTOR UNCTION ORANGE PTO IGNITION COIL COIL POWER BLUE / YELLOW STATOR - FUEL INJECTOR COIL FUEL INJECTOR POWER COIL BLUE / YELLOW STATOR - FUEL INJECTOR COIL FUEL INJECTOR POWER COIL GREEN STATOR - CRANK POSITION SENSOR...
Page 101: Chassis Relay
Fuel Systems Chassis Relay 4.22...
Page 102: Throttle / Ignition Kill System
Fuel Systems Throttle / Ignition Kill System System Overview The second system is the hardware stop system. The hardware stop system is a direct ignition kill system. That is, whenever the There are two methods for cutting the ignition on CFI systems. operator turns the key to off, pulls the tether, or pushes the safety The first is the software stop system.
Page 103: Vehicle Speed Sensor
Fuel Systems Vehicle Speed Sensor 4.24...
Page 104: Exhaust Temperature Sensor
Fuel Systems Exhaust Temperature Sensor Crankshaft Position Sensors (CPS) The 5 tooth crank position sensor picks up all 5 flywheel teeth. The 2 tooth crank position sensor picks up 2 flywheel teeth. Both crank position sensors will have a gap to the flywheel pick up of 0.031"...
Page 105: Stator Assembly
Fuel Systems Stator Assembly REG REC CRANK POSITION SENSORS Stator Specifications RESISTANCE ITEM COLOR SYSTEM FUNCTION +/- 15% @68 F (20 ° ° CHASSIS / BATTERY YEL TO YEL = 0.13Ω CHARGE / LIGHTING COIL YELLOW POWER NO CONTINUITY TO GROUND Crank Position Sensor (5 GRN to WHT/GRN GRN to WHT/GRN = 190Ω...
Page 106: Exhaust Valve Solenoid
Fuel Systems Exhaust Valve Solenoid Regulator / Rectifier Regulator / Rectifier Connections WIRE CONNECTOR ITEM Specifications COLORS STATOR YELLOW Vac from stator charge coils. Coil Resistance 15Ω +/- 15% @ 68°F (20°C) Vdc supplied to ECU to boost (WHT/YEL to RED) ORANGE power to fuel injectors during engine start-up.
Page 107: Engine Coolant Temperature Sensor
Fuel Systems Engine Coolant Temperature Sensor Fuel Injectors Specifications Sensor Specifications -22_F - +248 _F (-30_C - Resistance 12Ω @ 68_F (20_C) Operating Temperature Range 120_C) Fuel injectors are flow tested and then color coded (RED, 2.4 - 2.6KΩ@ 68_F (20_C) BLUE, or YELLOW) based on how much fuel the injector flows Resistance (Measure in stirred water)
Page 108: Fuel Rail Bleeding / Pressure Testing
Fuel Systems Fuel Rail Bleeding / Pressure Testing To bleed the fuel system pressure after the engine is stopped, place the tool’s bleed hose into an appropriate fuel- All CFI engine fuel return hoses feature an inline Schrader valve handling container. Open the valve to release the pressure that can be used to bleed the fuel system pressure and observe and residual fuel.
Page 109: Fuel Tank Pressure Test
Fuel Systems Fuel Tank Pressure Test CFI Fuel Rail/Injector(s) Removal/Installation NOTE: Keep the red protective cap on the end of the Connect a Mity Vac hand pump to the fuel tank vent fitting. injector to prevent damage when installed. Follow ″...
Page 110 Fuel Systems Remove the hex screws securing the fuel rail it to the Crimp the ends of the new injector firmly on to the wire cylinders. harness. Tape exposed wire and splices (11). If replacing a lower injector, remove the two bottom screws bolts from the lower fuel rail.
Page 111: 2007 700 Cfi Fuel System
Fuel Systems 2007 700 CFI Fuel System 2007 700 CFI Fuel Pump Service appropriate fuel-holding container. Remove the following components: The fuel pump flange assembly (PFA) can be removed and replaced without replacing the entire fuel tank assembly. • Seat Assembly •...
Page 112 Fuel Systems Remove the fuel tank from the chassis. 15. Carefully slide the pump assembly into the fuel tank until the gasket rests on the tank. Place the fuel tank is a well-ventilated area. 16. Using new screws, supplied with the new gasket, thread in 10.
Page 113: Cfi "Drop In Pump" Fuel Supply (Typical)
Fuel Systems CFI “Drop In Pump” Fuel Supply (Typical) NOTE: 2008 fuel system shown. 2007 models similar. Drop In Fuel Pump Service Disconnect the positive (+) battery cable from the battery if applicable. Some models feature drop in fuel pump and fuel level sender Remove the fasteners securing the fuel tank to the tunnel.
Page 114: Throttle Body Removal
Fuel Systems Using the PFA spanner wrench and nut socket (PS-48459), 16. Using the PFA spanner wrench and nut socket (PS48459), carefully remove the PFA nut. tighten the PFA to specification. PFA Nut Torque = 21 Ft.Lbs. (28 Nm) 17. Fuel tank installation is the reverse of removal. Always test the PFA gasket seal before tank installation by performing a pressure check.
Page 115: Digital Wrench Diagnostic Software
Fuel Systems DIGITAL WRENCH DIAGNOSTIC Digital Wrench Connections SOFTWARE The access point for the ECU power-up and Digital Wrench connectors is located in the front, left-side of the nosepan. Overview The Digital Wrench diagnostic software allows the technician to CHASSIS POWER-UP perform the following tests and observations: (2- WIRE CONNECTOR) ECU POWER-UP...
Page 116: Updating Digital Wrench
Delete the file after performing the update. NOTE: Delete the update file from the desktop when finished. NOTE: Only authorized Polaris dealers distributors can access the dealer Internet website. Log on to www.polarisdealers.com. Locate the “SERVICE AND WARRANTY” drop-down menu.
Page 117: Version / Fileset Identification
Fuel Systems Version / Fileset Identification Engine Controller Reprogramming (Reflash) NOTE: New service replacement ECUs Knowing what Digital Wrench or fileset versions are installed will help determine which updates are required. programmed as “no-start” and require a reflash in able to work. NOTE: Version and fileset versions are subject to change.
Page 118 Fuel Systems A request code will be generated. Record the code. 13. The website will generate an authorization code. Record the code. 14. Enter the authorization number in the box on Digital Wrench. Click on “CONTINUE”. 10. Access www.polarisdealers.com. Locate “REFLASH AUTHORIZATION”...
Page 119 Fuel Systems NOTES 4.40...
Page 120 Engine and Cooling Systems CHAPTER 5 Engine and Cooling Systems ENGINE SPECIFICATIONS ..........5.2 FASTENER TORQUE GUIDE .
Page 121: Engine Specifications
Engine and Cooling Systems ENGINE SPECIFICATIONS Fastener Torque Guide 600 HO 600 / 700 CFI 800 CFI OMPONENT NOTE ARBURETED Spark Plug 18 Ft. Lbs. (24 Nm) Apply Nyogel Head Cover 25 Ft.Lbs. (34 Nm) Loctite 242 Cylinder Head Bypass Fitting 7 Ft.Lbs.
Page 122: Engine Specifications
Engine and Cooling Systems Engine Specifications PISTON INSTALLED HEAD PISTON RING END TRIGGER ENGINE MODEL HEAD SQUISH CYLINDER VOLUME FLYWHEEL GAP NUMBER INCHES CLEARANCE INCHES INCHES S3273-6044-PU6F S3274-6044-PU6F .050 - .060 27.6 - 28.9 .4 - .8 S3466-6044-PU6F (1.283 - 1.544) .004 - .006 .014 - .020 S3467-6044-PU6F...
Page 123: Component Torque Sequences
Engine and Cooling Systems Component Torque Sequences Cylinder Torque Pattern (Monoblock) Cylinder Head Torque Pattern (All) CFI Recoil Cover CFI Crankcase Torque Pattern Carbureted Crankcase Torque Pattern Cylinder Torque Pattern (Except Monoblock)
Page 124: Engine Inspections
Engine and Cooling Systems ENGINE INSPECTIONS Cylinder Head Inspection Using a flat bar and a feeler gauge, inspect each cylinder " head for warping. Replace head if warping exceeds .003 (.08mm). = In. / mm. Cylinder Head Warp Limit = In. / mm. "...
Page 125: Piston Inspection
Engine and Cooling Systems Piston Inspection Piston rings are installed with marking or beveled side up. Check piston for scoring or cracks in piston crown or pin Reed Valve Inspection area. Excessive carbon buildup below the ring lands is an indication of piston, ring or cylinder wear.
Page 126: Main Bearing
Clean crankshaft thoroughly and oil main and connecting Rotate the connecting rod on the crankshaft and feel for rod bearings with Polaris engine oil. Carefully check each any rough spots. Check radial end play in rod by main bearing on the crankshaft.
Page 127: Crankshaft Index
MAG end Crankshaft Index cylinder - simply read the wheel and dial indicator. Polaris crankshafts are pressed together. The connecting Remove the dial indicator and install in PTO cylinder. ° rod journal center lines are indexed 180 apart from each Repeat finding TDC process.
Page 128: Cylinder Honing
(transfer port area). Use electrical contact cleaner if necessary to clean these areas. Rinse thoroughly, dry with compressed air, and oil the bore immediately with Polaris Premium 2 Cycle Lubricant. EXAMPLE OF A CROSS HATCH PATTERN NOTE: Always check piston to cylinder clearance and piston ring installed gap after honing or boring is complete.
Page 129: Crankshaft Truing
Engine and Cooling Systems Crankshaft Truing illustrations below. Use Crankshaft alignment kit PN 2870569. Lubricate the bearings and clamp the crankshaft securely in the holding fixture. If truing the crankshaft requires NOTE: The rod pin position in relation to the dial striking with a hammer, always be sure to re-check indicator tells you what action is required to previously straightened areas to verify truing.
Page 130: Recoil Assembly
Engine and Cooling Systems RECOIL ASSEMBLY Rope Removal and Installation RECOIL PULLEY TAB (ENGAGES INSIDE PULLEY) FRICTION SPRING ROPE FRICTION PLATE RATCHET ROPE GUIDE (HOLE) RATCHET SPRING RECOIL SPRING TAB (ENGAGES INSIDE HOUSING) viewed from the ratchet-side of the pulley. CAUTION Pass the end of the rope through the hole in the housing.
Page 131: Exhaust Valve Maintenance
Engine and Cooling Systems EXHAUST VALVE MAINTENANCE Lubricate the guillotine blade and shaft with engine oil. Actuate the guillotine to ensure full and free motion. Exhaust Valve Assembly Install the spring, and cover. Torque the vertical cover fasteners to specification. VERTICAL SCREWS HORIZONTAL SCREWS Cover/Base Fastener Torque: 12 Ft.Lbs.
Page 132: Engine Mounting Systems
Engine and Cooling Systems ENGINE MOUNTING SYSTEMS 2007 IQ Carbureted Engine Mounting ENGINE ASSEMBLY TORQUE STOP ENGINE MOUNT ENGINE MOUNT SPACER ENGINE MOUNT BRACKET ENGINE MOUNT ISOLATOR CLINCH PLATE A = 28 Ft.Lbs. (38 Nm) B = 15 Ft.Lbs. (20 Nm) C = 45 Ft.Lbs.
Page 133: 2007 Iq 600 Cfi Engine Mounting
Engine and Cooling Systems 2007 IQ 600 CFI Engine Mounting ENGINE ASSEMBLY TORQUE STOP ENGINE MOUNT RH ENGINE STRAP ENGINE MOUNT ENGINE MOUNT BRACKET ENGINE MOUNT LH ENGINE STRAP CLINCH PLATE ISOLATOR A = 28 Ft.Lbs. (38 Nm) B = 15 Ft.Lbs. (20 Nm) C = 30 Ft.Lbs.
Page 134: 2008 Iq Carbureted Engine Mounting
Engine and Cooling Systems 2008 IQ Carbureted Engine Mounting ENGINE ASSEMBLY TORQUE STOP ENGINE MOUNT ENGINE MOUNT SPACER RH ENGINE STRAP ENGINE MOUNT BRACKET ENGINE MOUNT LH ENGINE STRAP CLINCH PLATE A = 28 Ft.Lbs. (38 Nm) B = 15 Ft.Lbs. (20 Nm) C = 45 Ft.Lbs.
Page 135: 2007 700 Cfi / 2008 Iq Cfi Engine Mounting
Engine and Cooling Systems 2007 700 CFI / 2008 IQ CFI Engine Mounting ENGINE ASSEMBLY TORQUE STOP ENGINE MOUNT RH ENGINE STRAP ENGINE MOUNT ENGINE MOUNT BRACKET ENGINE MOUNT LH ENGINE STRAP UPPER ENGINE MOUNT BOTTOM ENGINE MOUNT CLINCH PLATE A = 28 Ft.Lbs.
Page 136: Engine Component Assemblies
Remove the coolant from the engine using a siphon, wet/ Liberally coat the inside of each cylinder and the outside dry vac, or drain pan. of each piston with Polaris two-stroke engine oil. Remove the air box, exhaust pipe and resonator from the engine compartment.
Page 137: 600 Ho Carbureted Recoil / Magneto
Engine and Cooling Systems 600 HO Carbureted Recoil / Magneto RECOIL HUB FRICTION PLATE FRICTION SPRING RECOIL HANDLE RETURN SPRING ROPE REEL RATCHET MAGNETO / STATOR SPRING ROPE GUIDE FLYWHEEL FLYWHEEL NUT RECOIL HOUSING Mark the location of the magneto / stator plate in several places using a scribe.
Page 138: 600 Ho Carbureted Pistons / Crankshaft
180° opposite of the Engine Model Piston PN Piston ID groove opening. Apply a liberal amount of Polaris two-stroke engine oil to S3273-6044-PF6F 2202258 EK-2202b the needle bearings, piston pin and piston assembly.
Page 139: 600 Ho Carbureted Crankcase
Engine and Cooling Systems 600 HO Carbureted Crankcase CYLINDER STUDS INTAKE BOOTS REED STUFFERS OIL INJECTION CHECK VALVES REED ASSEMBLIES IMPULSE FITTING CRANKCASE DRAIN PLUGS WATERPUMP BUSHING SCREW cylinders, pistons, flywheel / recoil housing, and the water / oil pump. Remove the intake boots, and reed assemblies.
Page 140: 600 Ho Carbureted Water / Oil Pump
Engine and Cooling Systems 600 HO Carbureted Water / Oil Pump SEAL WASHER WATER PUMP COVER GASKET MECHANICAL SEAL WATER PUMP COVER WASHER GASKET BUSHING O-RING OIL PUMP CROSS SHAFT WASHER WASHER Always use new seals and gaskets during assembly. To remove the oil pump / cover, remove the two fasteners then pull the pump / cover out of the crankcase bore.
Page 141: 2007 - 2008 600 / 700 Cfi Cylinder Head / Cylinders / Pistons
Engine and Cooling Systems 2007 - 2008 600 / 700 CFI Cylinder Head / Cylinders / Pistons BLEED SCREW THERMOSTAT COVER HEAD COVER O-RINGS THERMOSTAT O-RINGS GASKET KNOCK SENSOR CYLINDERS TEMP. SENSOR BASE GASKETS CYLINDER HEAD PISTON RINGS PISTON BEARING PISTON PIN C-CLIP Piston Matrix...
Page 142 14. Always use new gaskets and o-rings during assembly. Liberally coat the inside of each cylinder and the outside of each piston with Polaris two-stroke engine oil. 15. When installing a piston into a cylinder, verify each piston ring opening is located at each piston ring locating pin.
Page 143: 2008 800 Cfi Cylinder Head / Cylinder / Pistons
Engine and Cooling Systems 2008 800 CFI Cylinder Head / Cylinder / Pistons BLEED SCREW THERMOSTAT COVER THERMOSTAT GASKET SPARK PLUGS HEAD COVER TEMP. SENSOR CYLINDER O-RINGS THROTTLE BODY HOSE CYLINDER HEAD PLUG* BASE GASKET BYPASS NOZZLE* O-RINGS KNOCK SENSOR PISTON RING PISTON PIN PISTON...
Page 144 15. Always use new gaskets and o-rings during assembly. Liberally coat the inside of each cylinder bore and the outside of each piston with Polaris two-stroke engine oil. 16. When installing a piston into a cylinder, verify each piston ring opening is located at each piston ring locating pin.
Page 145 Engine and Cooling Systems 2007 - 2008 600 / 700 / 800 CFI Recoil / Stator Assembly WIRE RETAINER STATOR (MAGNETO) FLYWHEEL NUT FLYWHEEL RATCHET GUIDE REEL w/ROPE HANDLE FRICTION PLATE BUSHING FRICTION SPRING RATCHET RETURN SPRING SPRING RECOIL HOUSING Using the flywheel puller tool, PN 2871043, insert the puller’s three screws into the flywheel.
Page 146: 2007 - 2008 600 / 700 Cfi Crankcase / Crankshaft Assembly
Engine and Cooling Systems 2007 - 2008 600 / 700 CFI Crankcase / Crankshaft Assembly GEAR CLAMPS CYLINDER STUDS INTAKE BOOTS ALIGNMENT DOWELS REED STUFFERS REED BLOCKS OIL INJECTION CHECK VALVE QTY. 5 PTO SEAL NEEDLE BEARINGS FLYWHEEL KEY PTO BEARINGS MAG BEARING CRANKSHAFT MAG SEAL...
Page 147 Install the upper crankcase. Loosely install the crankcase fasteners, then torque to the specifications at the beginning of the chapter. Use the correct torque sequence when tightening the screws. 10. Liberally coat the crankshaft bearings and components with Polaris two-stroke engine oil. 5.28...
Page 148: 2008 800 Cfi Crankcase / Crankshaft
Engine and Cooling Systems 2008 800 CFI Crankcase / Crankshaft GEAR CLAMPS REED STUFFERS ALIGNMENT DOWELS ALIGNMENT DOWELS ADAPTER PLATE SEAL GUARD PTO SEAL REED BLOCKS OIL INJECTION CHECK VALVE QTY. 5 WRIST PIN BEARINGS PTO BEARING FLYWHEEL KEY MAG BEARING MAG SEAL A = 9 Ft.Lbs.
Page 149 Install the upper crankcase. Loosely install the crankcase fasteners, then torque to the specifications at the beginning of the chapter. Use the correct torque sequence when tightening the screws. 10. Liberally coat the crankshaft bearings and components with Polaris two-stroke engine oil. 5.30...
Page 150 Engine and Cooling Systems 2007 - 2008 600 / 700 / 800 CFI Water / Oil Pump Assembly SEAL MECHANICAL SEAL WASTER PUMP COVER GASKET WASHER IMPELLER WASTER PUMP COVER BEARING WASHER OIL PUMP O-RING CROSS SHAFT WASHER TEE FITTING Remove the airbox, exhaust pipe and resonator.
Page 151: 600 / 700 / 800 Cfi Oil Hose Routing
Engine and Cooling Systems gasket. 10. Assembly is the reverse of disassembly. Always use new o-rings, seals and gaskets during assembly. To remove the oil pump / cover, remove the two fasteners then pull the pump / cover out of the crankcase bore. 11.
Page 152: Engine Removal (Typical)
On CFI models, separate the fuel filter from the filter clip that is on the MAG side of the airbox. NOTE: Inspect all parts for wear or damage during disassembly. Replace all seals, o-rings, and gaskets with Genuine Pure Polaris parts during assembly. NOTE: The following removal installation process involves a CFI engine.
Page 153 Engine and Cooling Systems 12. Disconnect the ignition coil connections and EV solenoid 16. Remove the recoil rope from the handle and route rope from the ECU harness on CFI models. through the guide on the chassis brace and secure the recoil rope by tying a knot so that it does not go into the recoil housing.
Page 154 Engine and Cooling Systems oil line so that it can come out with the engine. 25. On CFI models, remove the Schrader valve cover located under the steering hoop, and depressurize the fuel rail. See “Fuel Rail Bleeding” on page 4.20. 23.
Page 155: Engine Installation (Typical)
Engine and Cooling Systems Engine Installation (Typical) 33. Remove the oil cable from the oil pump lever by holding the pump open and rotating the cable and keeper to the slot Make sure that you have the engine assembled in the state in the pump arm.
Page 156 Engine and Cooling Systems 10. Using a 10mm open end wrench tighten the lock nut while 15. Secure the oil bottle to the chassis by installing the two torx holding the other nut with a 10mm open end wrench. Make fasteners located at the top of the bottle.
Page 157 Engine and Cooling Systems 21. Place the engine mount washers and fasteners (8) onto the 23. Apply Blue Loctite™ to the rear fasteners, install all the engine mount studs. Torque to specification. rear torque stop fasteners and torque to specification. Engine Mount Fasteners: 28 ft.lb (37.9 N-m) Rear Torque Stop Fasteners: 28 ft.lb (37.9 N-m) 22.
Page 158 Engine and Cooling Systems 26. Install the front torque stop assembly and torque the plate 37. Connect the regulator rectifier connections. fasteners to specification. Front Torque Stop Fasteners: 28 ft.lb (37.9 N-m) 27. Install the air box onto the carburetor rack. Make sure to line up the air box tabs with the air box plate.
Page 159 Engine and Cooling Systems 39. Connect the EV solenoid vent lines back onto the EV bases 42. Replace the nosepan plugs were removed to access the front and install the panduit strap around the spark plug wires as chassis brace fasteners. shown.
Page 160: Cooling Systems
Engine and Cooling Systems COOLING SYSTEMS Thermostat Orientation The thermostat must be installed in the cylinder head has Thermostat Replacement shown in the illustrations. Center Thermostat Location BLEED SCREW WASHER BRIDGE ALIGNED WITH HOLES HOUSING COVER Offset Thermostat Location THERMOSTAT GASKET 800 CFI Thermostats CAUTION...
Page 161 Engine and Cooling Systems 2007 700 Dragon IQ Cooling System RH PERIMETER COOLER HOSE - THROTTLE BODY REAR TUNNEL COOLER OUT TO SURGE TANK (CFI ONLY) SURGE BOTTLE HOSE - ENGINE OUT TO FRONT COOLER (THERMOSTAT OPEN) FRONT TUNNEL COOLER LH PERIMETER COOLER HOSE - FRT COOLER TO SURGE BOTTLE...
Page 162 Engine and Cooling Systems 2007 600 IQ / Switchback / LX - 2008 CFI LX Cooling System SURGE BOTTLE HOSE - THROTTLE BODY RH PERIMETER COOLER OUT TO SURGE TANK (CFI ONLY) REAR COOLER (REVERSED ON S.B.) HOSE - SURGE BOTTLE TO ENGINE HOSE - ENGINE OUT TO TUNNEL COOLING SYSTEM...
Page 163 Engine and Cooling Systems 2007 - 2008 CFI Touring Cooling System REAR COOLER SURGE TANK RH FOOTBOARD COOLER HOSE - THROTTLE BODY OUT TO SURGE TANK (CFI ONLY) HOSE - ENGINE OUT TO TUNNEL COOLING SYSTEM (THERMOSTAT OPEN) HOSE - BYPASS LH FOOTBOARD COOLER TO RADIATOR FRONT COOLER...
Page 164 Engine and Cooling Systems 2007 - 2008 600 / 700 RMK Cooling System HOSE - TUNNEL COOLER TO SURGE TANK SURGE TANK HOSE - ENGINE OUT TO TUNNEL COOLER (THERMOSTAT OPEN) HOSE - THROTTLE BODY OUT TO SURGE TANK (CFI ONLY) SQUEEZE CLAMPS HOSE - SURGE TANK TO ENGINE IN FOAM PAD...
Page 165 Engine and Cooling Systems 2008 IQ Shift - CFI 600 / 700 121 and Switchback Cooling System CROSS OVER HOSE RH PERIMETER COOLER HOSE - TUNNEL COOLERS OUT TO SURGE TANK HOSE - FRT COOLER OUT TO SURGE TANK HOSE - BYPASS TO FRT COOLER SURGE TANK LH PERIMETER COOLER...
Page 166 Engine and Cooling Systems 2008 800 CFI RMK 155 Cooling System HOSE - TUNNEL COOLER TO SURGE TANK SURGE TANK HOSE - ENGINE OUT TO TUNNEL COOLER (THERMOSTAT OPEN) SQUEEZE CLAMPS HOSE - THROTTLE BODY OUT TO SURGE TANK FRONT TUNNEL COOLER FOAM PAD HOSE - CYLINDER HEAD OUT TO FRONT COOLER HOSE - SURGE TANK TO ENGINE IN...
Page 167: Exhaust Systems
Engine and Cooling Systems EXHAUST SYSTEMS Assembly View (Typical) 600 / 700 SILENCER HEAT SHIELD ZINC-PLATED (YELLOW) SPRINGS ZINC-PLATED (YELLOW) SPRINGS EGT SENSOR 800 SILENCER ZINC-PLATED (YELLOW) SPRINGS GASKETS GASKET 800 MANIFOLD 600 / 700 MANIFOLD SNOW DEFLECTOR EXHAUST PIPE STAINLESS STEEL (GRAY) SPRINGS A = EGT Sensor: 32 Ft.Lbs.
Page 168 Final Drive and Brakes CHAPTER 6 Final Drive and Brakes GEAR RATIO SPEED CHARTS ..........6.2 8.373 CD CHAINCASE SPEED CHARTS .
Page 169: Gear Ratio Speed Charts
Final Drive and Brakes GEAR RATIO SPEED CHARTS 8.373 CD Chaincase Speed Charts Top Gear Bottom Gear Chain Gear 1.38 1.54 1.44 1.48 1.60 1.64 1.76 1.71 1.75 1.70 1.83 1.77 1.82 1.95 1.90 1.95 2.10 2.05 2.25 2.00 2.16 2.21 2.42 Ratio Jackshaft MPH at 1 : 1 Clutch Ratio...
Page 170: Drive Gears And Chains
Final Drive and Brakes DRIVE GEARS AND CHAINS Drive Chains Drive Gears PART DESCRIPTION NUMBER PART NUMBER DESCRIPTION 3221114 64P, 3/4W, HYVO CHAIN 3221107 16T. 3/4W, 15 SPL, HYVO, PM 3221113 66P, 3/4W, HYVO CHAIN 3221093 17T, 3/4W, 15 SPL, HYVO, PM 3221112 68P, 3/4W, HYVO CHAIN 3221094...
Page 171: 8.373 Chaincase
Final Drive and Brakes 8.373 CHAINCASE Assembly View CAUTION A = Cover Fasteners = 10 Ft.Lbs. (12 Nm) Never re-use Cotter pins. Always replace with new B = Lower Gear Fastener = 19 Ft.Lbs. (26 Nm) parts. C = Upper Gear Castle Nut = 50 Ft.Lbs. (62 Nm) Incorrect chain tension may cause the chain to break, D = Fill Plug = 18 - 25 In.Lbs.
Page 172: Chaincase Disassembly
Final Drive and Brakes Chaincase Disassembly 18. Inspect the jackshaft seal sleeve for abnormal wear and tear. Replace the o ring with a new part. Position the vehicle on level ground. Drain the oil out of the chaincase into a suitable container. Replace the drain Chaincase Assembly plug.
Page 173: Pvt System
Final Drive and Brakes 11. Reinstall the chain and upper / lower gears. Install the lower gear washer with the beveled side facing out. Torque castle nut and lower gear fastener to specifications. Upper Gear Castle Nut 50 Ft.Lbs. (68 Nm) (Back nut off only to align cotter pin holes with nut.) Lower Gear Fastener 19 Ft.Lbs.
Page 174: Drive Train
Final Drive and Brakes DRIVE TRAIN Speedometer Cable Type Drive Train Assembly NOTE: Set driven clutch offset following procedure in the PVT System Chapter. Lubricate components as outlined in the Periodic Maintenance Table. A = Driven Clutch Fastener = 17 Ft.Lbs. (23 Nm) Tighten chaincase mounting nuts using a criss- B = Jackshaft Flange Nuts = 17 Ft.Lbs.
Page 175: Electronic Speedometer Drive Train Assembly
Final Drive and Brakes Electronic Speedometer Drive Train Assembly WASHERS BELT SPACER FLANGE WASHERS DRIVEN CLUTCH JACKSHAFT BRAKE DISC FLANGE SEAL SLEEVE SPEEDOMETER FLANGE O RING SNAP RING SPEEDOMETER SENSOR DRIVESHAFT CHAINCASE NOTE: Set driven clutch offset following procedure in the PVT System Chapter. Lubricate components as outlined in the Periodic Maintenance Table.
Page 176: Driveshaft Removal/Installation
Final Drive and Brakes Driveshaft Removal/Installation Remove the side panels. Remove the intake plenum. Remove the drain plug and drain the chaincase fluid. Replace the chaincase drain plug and torque it to 8 ft-lb (11 N-m). Drain Plug: 8 ft-lb (11 N-m) Remove the chaincase cover.
Page 177: Brake System
Master cylinder reservoirs The Polaris snowmobile hydraulic brake system consists of the should be filled to the top of the fluid level mark on the inside following components or assemblies: brake lever, master of the reservoir, 1/4"...
Page 178: General Guidelines
Final Drive and Brakes General Guidelines pressure will cause a surge of fluid through the small orifices of the brake system when the bleeder screw is opened and introduce air into the system by means of WARNING cavitation. • Small amounts of air can become trapped in the banjo An unsafe condition exists when air is trapped in the bolt fittings at the master cylinder(s) and junction points hydraulic brake system.
Page 179: Master Cylinder / Lever Service
Final Drive and Brakes Master Cylinder / Lever Service escape. You will feel the lever release as you let the fluid or air escape. COVER SCREWS Pump the brake lever a few times and hold it again. Repeat steps 7 and 8 until you see new brake fluid coming COVER from the caliper bleeder fitting or if you are bleeding the air, repeat this step until you see only fluid coming out.
Page 180: Brake Line Replacement
Final Drive and Brakes Brake Line Replacement 11. Torque the caliper banjo bolt to 168-216 in-lb (19-24 N-m). 144-192 in-lb (16-22\N-m) Caliper Banjo Bolt: 168-216 in-lb (18-24 N-m) 12. Insert the new brake line and install into the master cylinder. Torque the brake line to 144-192 in-lb (16-21 N-m).
Page 181: Brake Light Switch Replacement
Final Drive and Brakes Caliper Removal 16. Follow the bleeding procedure. See “Brake Fluid Replacement & Bleeding” on page 6.11. Brake Light Switch Replacement Caliper Remove the 4 screws that hold the master cylinder to the Remove the two caliper bolts that hold the caliper to the handlebar.
Page 182: Caliper Assembly
Final Drive and Brakes Caliper Assembly Replace caliper bolts (1) and torque them to 18-20 ft-lb (24-27 N-m). Caliper Bolts: 18-20 ft-lb (24-27 N-m) On a liquid cooled caliper, hook up the coolant lines. Place the brake line on the caliper in the same orientation as it was before it was removed.
Page 183 Final Drive and Brakes NOTES 6.16...
Page 184 PVT System CHAPTER 7 PVT System PVT SYSTEM ............7.2 OVERVIEW.
Page 185: Pvt System
A compression spring (Team driven clutch) or torsional spring pre-load rate will result in a higher engagement RPM. (Polaris P-85 driven clutch) works in conjunction with the helix, and controls the shift rate of the driven clutch. The spring must...
Page 186: Final Gearing
PVT System Final Gearing The final drive gear ratio plays an important role in how much vehicle load is transmitted back to the helix. A tall gear ratio (lower numerical number) typically results in lower initial vehicle acceleration, but a higher top-end vehicle speed. A lower gear ratio (higher numerical number) typically results in a higher initial vehicle acceleration, but a lower top-end vehicle speed.
Page 187: General Information
PVT System GENERAL INFORMATION Special Tools Team “12 Cooling Fin Driven Clutch” Offset Alignment Tool PS-46998 Team “24 Cooling Fin Driven Clutch” Offset Alignment Tool PS-47477 Drive Clutch Puller (3/4 - 16 x 7/16) - All Fuji Fan / Liquid Cooled Engines 2872084 Drive Clutch Puller (3/4 - 16 x 14mm) - Domestic 500 / 600 / 700 / 800 / FS / FST Engines 2872085...
Page 188: Drive Clutch Springs
PVT System Drive Clutch Springs WIRE LOAD FREE LENGTH FORCE LBS.@2.50” - PART NUMBER COLOR DIAMETER RATE +/-.125” 1.19” (+/- 12 LBS.) (inches) (lbs./inch) 7041021 Clear .157” 4.14 70 - 130 7041022 Black .140” 4.25” 44 - 77 7041063 Purple .168 4.37 75 135...
Page 189: Spring Free Length
PVT System Spring Free Length 10 Series Weights Measure the drive and driven spring free length with the spring WEIGHT GRAMS(+/- 1g) PART NUMBER resting on a flat surface. Replace spring if out of specification. 10M - R 1321530 10M - W 1321527 10M - B 47.5...
Page 190: Perc Team Lwt Driven Helixes (24 Fin)
PVT System PERC Team LWT Driven Helixes (24 Fin) Team Ramp Angles PART NUMBER DESCRIPTION 5135401 64 / 42 - .36 5135402 64 / 38 - .25 5135403 56 / 42 - .36 5135503 54 / 38 - .25 5136255 5135504 5135772 66 / 44 - .46...
Page 191: Team Driven Springs
PVT System Team Driven Springs TEAM Driven Springs PART NUMBER COLOR LOAD @ 2.2″(lbs) LOAD @ 1.1″(lbs) Rate (Lbs. per inch) 7042181 Black/Yellow 7043058 Red/Black 7043059 Red/Green 7042066 Green/Black 7043061 Red/Silver 7043062 Red/Yellow 7043057 Red/Blue 7043064 Blue/Black 7043060 Red/White 7043069 Red/Pink 7043363 Black/Purple...
Page 192: Drive Belts
PVT System Drive Belts Belt Width Side Center to Outer Part (Projected)* Angle Center Circumference Notes Number in/mm Overall* in/cm* in/cm 3211080 1.438 / 36.5 11.5 / 29.2 46.625/118.4 Double Cog CVT version of 3211078 3211078 1.438 / 36.5 11.5 / 29.2 46.62 / 118.4 Standard Drive Belt 3211117...
Page 193: Belt Wear / Burn Diagnostics
PVT System Belt Wear / Burn Diagnostics Table 7-1: Belt Wear / Burn Diagnostics POSSIBLE CAUSE SOLUTION Drive at higher RPM if possible. Gear the machine down. Driving at or about engagement RPM for extended periods of Make sure belt deflection is at 1 1/4” to achieve optimum time in any type of snow condition.
Page 194: Drive Belt Removal - Team Driven Clutch
PVT System Drive Belt Removal - Team Driven Clutch Adjusting Belt Deflection - Team Driven NOTE: Turn the key to the “OFF” position and allow Clutch the engine to come to a complete stop. Verify the driven clutch is not in reverse. Open the clutch guard.
Page 195: Pvt System Adjustments
PVT System PVT SYSTEM ADJUSTMENTS Clutch Alignment / Offset 0” - .060” The engine is mounted in the bulkhead so the drive and driven clutches self-align under high torque loads. Offset is controlled by the number of washers installed on the jackshaft behind the driven clutch.
Page 196: Drive Clutch
PVT System DRIVE CLUTCH Identification Every clutch will have the last three digits of the clutch part puller, and repeat this step. number etched on to the cover (A). The “X" (B) marking is an index mark where the clutch cover (C), clutch spider (D) and the CAUTION stationary sheave (E) should line up when the clutch is assembled.
Page 197: Drive Clutch Disassembly
PVT System Drive Clutch Disassembly WEIGHT ROLLER WEIGHT PIN WASHER ROLLER PIN SPIDER BUTTON WASHER BEARING SLEEVE MOVEABLE INSERT SPRING JAM NUT COVER SPIDER SPACERS COVER BEARING RETAINER MOVEABLE SHEAVE CLUTCH SPACER STATIONARY SHEAVE fixture (PN 2871358). 10. Remove the jam nut in a counterclockwise direction (standard thread) using the drive clutch spider nut socket CAUTION (PN 2871358).
Page 198: Roller Removal
PVT System Roller Removal 10. Measure the width of the spider leg with the buttons installed (9) and record the measurement. Specification is 1.496" (37.99mm). ROLLER PIN SPIDER ROLLER WASHER WASHER 11. Measure the width of the moveable sheave towers. Specification is 1.50"...
Page 199: Clutch Assembly
PVT System Clutch Assembly Install the spider jam nut onto the shaft and torque to specification. Assemble the rollers, bushings and roller pins if they were removed. Install the head of the weight pin so that it is on the leading side of rotation.
Page 200: Spider Indexing
PVT System Spider Indexing NOTE: Spider indexing effects belt to sheave clearance and clutch balance. Please read all procedures before proceeding. Remove and disassemble clutch Add or remove spider washers as required to achieve desired belt to sheave clearance. Make sure that the stepped washer (A) is on the bottom of the spacer stack (B).
Page 201: Drive Clutch Installation
PVT System Drive Clutch Installation Driven Clutch Installation NOTE: Always clean the clutch taper before re- installing clutch on engine. Place a clutch taper reamer (PN 2870576) in a vise and lubricate the cutting edges with cutting oil. Clean the clutch taper by manually rotating the clutch clockwise on the reamer one or two revolutions.
Page 202: Team Lwt Components
PVT System Team LWT Components SCREWS ROLLER ASSEMBLY HELIX SNAP RING SPRING CUP DEFLECTION SPACER SPRING STATIONARY SHEEVE MOVEABLE SHEEVE BELT DEFLECTION SCREW 10. Install and torque helix fasteners to 60 - 80 in. lbs. (7 - 9 Nm). Helix Fasteners = 60 - 80 In.Lbs. (7 - 9 Nm) Driven Clutch Retaining Fastener = 17 Ft.Lbs.
Page 203 PVT System NOTES 7.20...
Page 204: Shocks
Steering and Suspensions CHAPTER 8 Steering and Suspensions OVERVIEW / SPECIFICATIONS..........8.2 INSPECTION .
Page 205: Overview / Specifications
57 ± 7.9 Some of the fasteners used in the IFS are special and cannot be 0 -.12 purchased at a hardware store. Always use genuine Polaris parts 0 -3.05 2.17 ± .31 and hardware when replacing front end components. Review IQ RMK 38.67 / 98.2...
Page 206: Adjustable Shocks
Steering and Suspensions Adjustable Shocks Front Suspension Type by Model Snowmobiles equipped with adjustable Ryde FX shocks allow RONT USPENSION ODEL the driver to make adjustments to the compression valving by turning the screw on the shock. ALL IQ, IQ Switchback, IQ LX, IQ 42.5 and IQ Touring Models By turning the screw clockwise (a small screwdriver or dime...
Page 207: Iq Rear Suspension Shock Rod
Steering and Suspensions IQ Rear Suspension Shock Rod Orientate the shock rod with the reinforcement plate facing down. REINFORCEMENT PLATE DOWN IQ Rear Track Shock Pivot Orientation The rear track shock pivot must be properly located on all IQ RMK and race rear suspensions, the shock pivot is orientated rear suspensions when installing the rear skid into the tunnel.
Page 208: Front Suspension Assembly Illustrations
Steering and Suspensions FRONT SUSPENSION ASSEMBLY ILLUSTRATIONS IQ Front Suspension NOTE: 2008 IQ Front Suspension Shown • Orientate rod ends so they are parallel with mating component. CAUTION Never re-use lock nuts. Always re-assemble using new lock nuts. A = 29 Ft.Lb. (39 Nm) (Shock Mounting Fastener Nuts) B = 40 Ft.Lb.
Page 209: Iq Fixed Steering Post Assembly
Steering and Suspensions IQ Fixed Steering Post Assembly (Where Applicable) FASTENERS UPPER POST BRACKET UPPER POST BRACKET BUSHINGS STEERING POST LOWER POST BRACKET SUPPORT PLATE MOUNT SUPPORT BUSHING BUSHINGS CAUTION Never re-use lock nuts. Always re-assemble using new lock nuts. A = 16 Ft.Lbs.
Page 210: Iq Rider Select Steering Post Assembly
Steering and Suspensions IQ Rider Select Steering Post Assembly ADJUSTING LEVER STEERING BLOCK ADJUSTER BLOCK NUTSERT STEERING POST STEERING POST MID BRACKET FASTENER BUSHING BRACKET BUSHING BRACKET STEERING POST LOWER BRACKET BUSHINGS NOTE: Assembly Notes CAUTION • Torque steering post lower bracket fasteners first, then torque the steering post mid bracket fasteners.
Page 211: Iq Steering Linkage
Steering and Suspensions IQ Steering Linkage FIXED DRAG LINK TIE ROD FIXED-LENGTH STEERING LINK BUSHING BEARING SPACER BEARING TIE ROD JAM NUT BUSHING BUSHING BEARING TIE ROD SPACER PITMAN ARM ASSEMBLY BEARING BUSHING ROD END IDLER ARM ASSEMBLY NOTE: 2008 IQ steering linkage shown. 2007 models Linkage Assembly Measurements feature adjustable steering links.
Page 212: Handlebar Assemblies
Steering and Suspensions Handlebar Assemblies THROTTLE LEVER COVER MIRRORS SAFETY SWITCH HANDWARMER THROTTLE CABLE GRIP CLAMPS 16 Ft.Lbs. (21 Nm) HEADLIGHT LOW/HIGH SWITCH BLOCK BRAKE ASSEMBLY 25 - 30 In.Lbs. (2.9 - 3.4 Nm) HOOK MOUNTAIN BAR GRIP E CLIP 16 Ft.Lbs.
Page 213: Adjustment Procedures
Steering and Suspensions ADJUSTMENT PROCEDURES Alignment Bar Specifications • DIAMETER: .623”-.625” (15.824-15.875mm) ETUP AND DJUSTMENTS • LENGTH: 45” (114.3cm) Spring preload is the amount of pressure at which the spring is held. The longer the installed length of the spring, the less the •...
Page 214: Rod Ends
Steering and Suspensions Rod Ends Determine which spindle requires the greatest amount of correction my installing the alignment bar through one Rod ends must be parallel to their respective mounting surface spindle to the other spindle. Measure the distance from the after tightening jam nut.
Page 215: Disassembly And Assembly
Steering and Suspensions Upper / Lower Control Arm Removal Record the measurements from the edge of the straight edge to the forward ski mark and the rearward ski mark. Remove the fastener securing the control arm being Adjust the tie rod so that both measurements are the same. removed from the spindle.
Page 216: Rear Suspension Assembly Illustrations
Assembly Notes • Never re-use Nylock nuts. Always replace with new parts. • All pivots must rotate freely after tightening fasteners. • Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table. 8.13...
Page 217 Assembly Notes • Never re-use Nylock nuts. Always replace with new parts. • All pivots must rotate freely after tightening fasteners. • Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table. 8.14...
Page 218 Assembly Notes • Never re-use Nylock nuts. Always replace with new parts. • All pivots must rotate freely after tightening fasteners. • Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table. 8.15...
Page 219 Assembly Notes • Never re-use Nylock nuts. Always replace with new parts. • All pivots must rotate freely after tightening fasteners. • Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table. 8.16...
Page 220 SLEEVE SHOCK ROD CARRIER WHEEL MOUNTING ARM TORSION SPRING • Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table. A = 12 Ft.Lb. (16 Nm) CAUTION B = 35 Ft.Lb. (47 Nm) C = 45 Ft.Lb.
Page 221 Assembly Notes • Never re-use Nylock nuts. Always replace with new parts. • All pivots must rotate freely after tightening fasteners. • Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table. 8.18...
Page 222 Assembly Notes • Never re-use Nylock nuts. Always replace with new parts. • All pivots must rotate freely after tightening fasteners. • Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table. 8.19...
Page 223 SHOCK ASSEMBLY UPPER SHAFT REAR TORQUE ARM LOWER SHAFT • Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table. A = 12 Ft.Lb. (16 Nm) CAUTION B = 35 Ft.Lb. (47 Nm) C = 70 Ft.Lb.
Page 224 Assembly Notes • Never re-use Nylock nuts. Always replace with new parts. • All pivots must rotate freely after tightening fasteners. • Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table. 8.21...
Page 225 Assembly Notes • Never re-use Nylock nuts. Always replace with new parts. • All pivots must rotate freely after tightening fasteners. • Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table. 8.22...
Page 226 MID TRACK SHOCK SET SCREW (M-10 ACE ONLY) SPACER • Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table. A = 12 Ft.Lb. (16 Nm) CAUTION B = 35 Ft.Lb. (47 Nm) C = 70 Ft.Lb.
Page 227 Assembly Notes • Never re-use Nylock nuts. Always replace with new parts. • All pivots must rotate freely after tightening fasteners. • Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table. 8.24...
Page 228 Assembly Notes • Never re-use Nylock nuts. Always replace with new parts. • All pivots must rotate freely after tightening fasteners. • Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table. 8.25...
Page 229 ADJUSTER SLEEVE SHOCK ROD SPACER / SET SCREW SPRING • Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table. A = 12 Ft.Lb. (16 Nm) CAUTION B = 19 Ft.Lb. (26 Nm) C = 45 Ft.Lb.
Page 230 Assembly Notes • Never re-use Nylock nuts. Always replace with new parts. • All pivots must rotate freely after tightening fasteners. • Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table. 8.27...
Page 231 Assembly Notes • Never re-use Nylock nuts. Always replace with new parts. • All pivots must rotate freely after tightening fasteners. • Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table. 8.28...
Page 232 BUSHING CARRIER WHEEL SLEEVE BUSHING TORSION SPRING • Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table. A = 12 Ft.Lb. (16 Nm) CAUTION B = 40 Ft.Lb. (54 Nm) C = 35 Ft.Lb. (47 Nm)
Page 233 Assembly Notes • Never re-use Nylock nuts. Always replace with new parts. • All pivots must rotate freely after tightening fasteners. • Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table. 8.30...
Page 234 Assembly Notes • Never re-use Nylock nuts. Always replace with new parts. • All pivots must rotate freely after tightening fasteners. • Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table. 8.31...
Page 235 SLEEVE SHOCK ROD CARRIER WHEEL MOUNTING ARM TORSION SPRING • Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table. A = 12 Ft.Lb. (16 Nm) CAUTION B = 35 Ft.Lb. (47 Nm) C = 45 Ft.Lb.
Page 236 Assembly Notes • Never re-use Nylock nuts. Always replace with new parts. • All pivots must rotate freely after tightening fasteners. • Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table. 8.33...
Page 237 Assembly Notes • Never re-use Nylock nuts. Always replace with new parts. • All pivots must rotate freely after tightening fasteners. • Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table. 8.34...
Page 238 ADJUSTER SLEEVE SHOCK ROD SPACER / SET SCREW SPRING • Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table. A = 12 Ft.Lb. (16 Nm) CAUTION B = 19 Ft.Lb. (26 Nm) C = 45 Ft.Lb.
Page 239: Rear Suspension Operation
The suspension can be adjusted to Coupling suit rider preference and deliver excellent performance for a On all Polaris snowmobile rear suspensions, there are two given set of conditions. However, suspension adjustments torque arms that control the movement of the rail beam. Prior to always involve compromises.
Page 240: Rear Suspension Adjustments
Steering and Suspensions REAR SUSPENSION ADJUSTMENTS Adjustment Procedures NOTE: Break-in the suspension for at least 150 miles (240 km) before making adjustments. All settings will vary from rider to rider, and are dependant on rider weight, vehicle speed, riding style, and trail conditions. Always start with the factory settings.
Page 241: Limiter Strap Adjustment
Steering and Suspensions rear torsion springs. Second, it prepares the rear portion of the • DEEP POWDER SNOW: Limiter strap in LOW suspension for the bump, reducing secondary kick back. position for maximum lift and flotation • POWDER-HARDPACK: Limiter strap in STANDARD The FRSS is made of a resilient material allowing smooth action position for overall handling and speed over snow.
Page 242: Iq 121 Heavy Torsion Spring Installation
Steering and Suspensions IQ 121 Heavy Torsion Spring Installation suspension arm clamp nut. To work around this issue you will need to order two (one for each side) of the following parts. Please reference the following information when installing Relocate the two washers that are next to the clamp nut to the heavy torsion springs on IQ sleds.
Page 243: M-10 Suspension
The primary adjustment on the M-10 suspension is the Full Range Adjustment (FRA). Adjusting the FRA will have the MOST effect on rear suspension performance. Polaris recommends that you allow between 25 to 200 miles for the suspension to break in before performing any adjustments to the suspension.
Page 244 Steering and Suspensions M-10 136 will be softer and may require FRA adjustment. Rider weight with gear Suggested FRA Range M-10 REAR SPRING PRELOAD (lbs.) (Lower number is softer) If FRA position alone does not allow the setup of the proper Under 100* 1 to 1 1/2 amount of sag, the center retainer of the rear track shock can be...
Page 245: Rail Sliders
Steering and Suspensions NOTE: By design, the BIASED COUPLE design of Break-In the M-10 suspension displaces the rear arm as the After installing new rail sliders they must be “broke in” for front arm is compressed. This means that when you longer life and better wear patterns.
Page 246 Shocks CHAPTER 9 Shocks SPECIAL TOOLS ............9.2 SHOCK REBUILDING TOOLS .
Page 247: Special Tools
Shocks SPECIAL TOOLS Shock Rebuilding Tools Special Tools PART NUMBER DESCRIPTION 2200421 Gas Shock Recharging Kit 2201639 Shock Shaft Seal Protector .50" Diameter 2201640 Shock Shaft Seal Protector .625" Diameter 2870623 Shock Absorber Spring Compression Tool 2870803 Shock Spring Pre-Load Adjustment Tool PS-45259 Gas Fill Tool 9917736...
Page 248: Valve Shims
Shocks VALVE SHIMS motion. Refer to the appropriate parts manual for a complete listing of shock parts. Shock shim stacks can be adjusted to control the amount of fluid that is forced by as the piston travels through its Ryde FX™ Shock Valve Part Numbers PART NUMBER SIZE THICKNESS...
Page 249: Fox™ Shock Valve Part Numbers
Shocks Fox™ Shock Valve Part Numbers PART NUMBER SIZE THICKNESS 1500055 0.700 1500054 0.800 1500053 0.900 1500048 1.000 0.006 1500049 1.100 1500050 1.250 1500052 1.300 1500029 0.700 1500028 0.800 1500033 0.900 1500032 1.000 0.008 1500031 1.100 1500051 1.250 1500030 1.300 1500044 0.700 1500047...
Page 250: Walker Evans Shock Valve Part Numbers
Shocks Walker Evans™ Shock Valve Part Numbers PART NUMBER SIZE THICKNESS 1800051 .700 1800075 .800 1800076 .900 1800077 1.000 .006 1800078 1.100 1800079 1.200 1800080 1.300 1800081 .700 1800082 .800 1800083 .900 1800084 1.000 .008 1800085 1.100 1800086 1.200 1800087 1.250 1800088 1.300...
Page 251: Walker Evans Shock Valve Part Numbers - 7/16 I.d
Shocks Walker Evans™ Shock Valve Part Numbers - 7/16″ I.D. PART NUMBER SIZE THICKNESS 1800244 .900 1800245 1.000 1800246 1.100 1800247 1.200 .010 1800248 1.300 1800249 1.450 1800250 1.500 1800251 1.550 1800252 .900 1800253 1.000 1800254 1.100 1800255 1.200 .012 1800256 1.300 1800257...
Page 252: Valve Shim Arrangement
Shocks Valve Shim Arrangement NOTE: The rebound and compression valve stacks will always be positioned as shown in the Shown below is an example of how valving stacks are illustration, regardless of how the shock assembly is arranged. installed on the snowmobile. FULLY COMPRESSED SHOCK ROD FULLY EXTENDED...
Page 253: Specifications
Shocks SPECIFICATIONS 2007 Shock Specifications Front Suspension Shocks XTENDED OLLAPSED HOCK IFP D TROKE EPTH SHOCK PN ODEL ENGTH ENGTH OLUME 7042258 Ryde FX 18.00 11.8 6.92 Full 7043245 Ryde FX 18.00 11.8 6.92 Full 7043141 18.00 11.8 1.42 Full 7043268 (LH) 18.00...
Page 254 Shocks 2007 Shock Valve Shim Stack Configurations NOTE: All measurements are in inches. 2007 IFS Shocks 7043268 7043233 7043233 SHOCK 7042258 7043141 7043095 7043090 7043082 7043206 7043269 (Stock) (Optional) .625 x .065 .700 x .010 .620 x .093 .620 x .093 .625 x .065 .625 x .065 .700 x .010...
Page 255 Shocks 2007 Front Track Shocks SHOCK 7041975 7043142 7043244 7043267 7043204 7043234 .620 x .093 .620 x .093 .625 x .065 .700 x .015 .700 x .015 .625 x .065 .800 x .012 .700 x .010 .700 x .015 .800 x .015 .800 x .015 .700 x .012 .900 x .012...
Page 256 Shocks 2007 Rear Track Shocks SHOCK 7043177 7043246 7043266 7043205 7043216 7043235 .950 x .050 .625 x .065 .620 x .093 .950 x .050 .625 x .065 .950 x .050 .700 x .010 .800 x .012 .950 x .050 .700 x .010 .800 x .008 .800 x .010 .620 x .093...
Page 257 Shocks 2008 Shock Specifications 2008 Front Suspesion Shocks XTENDED OLLAPSED HOCK IFP D TROKE EPTH SHOCK PN ODEL ENGTH ENGTH OLUME 7043245 Ryde FX 17.98 11.77 6.21 6.92 Full 36mm (Rod) Cylinder= 145 PSI 7043315 Ryde FX 18.00 11.80 6.20 5.75 Full 47mm (Body) Cylinder= 60 PSI...
Page 258 Shocks 2008 Shock Valve Shim Stack Configurations NOTE: All measurements are in inches. 2008 Front Track Shocks 2008 IFS Shocks SHOCK 7043244 7043365 .625 x .065 SHOCK 7043245 7043315 7043364 .7 x .015 .625 x .065 .8 x .015 .700 x .010 .700 x .012 .9 x .015 .700 x .008...
Page 259 Shocks 2008 Rear Track Shocks SHOCK 7043177 7043216 7043316 7043366 .625 x .065 .620 x .093 .700 x .015 .800 x .012 .800 x .015 .620 x .093 .900 x .012 .900 x .015 1.125 x .093 1.000 x .012 1.00 x .015 1.100 x .010 1.100 x .012...
Page 260: Optional Shock Settings
Currently, there is not an optional nitrogen gas pressure setting for the 2008 Walker Evans FST Air Shock. • Polaris calibrates all shocks at 30°F ride temperature. Ryde FX Air 2.0 Shock • Any IFS shock service that requires gas recharging...
Page 261: Shock Maintenance
Shocks pressure in 5 PSI increments until the desired Secure shock in a soft-jawed table vise. performance level is achieved. Again, always reset the shock body chamber pressure to the factory specification charge. If one shock appears to be too soft, place the vehicle on flat, level ground.
Page 262 Shocks After all of the nitrogen gas has been allowed to escape Place the 36mm piston (shock) rod upper mount in a soft- from the shock, remove both pressure valve assemblies. jawed bench vise. Remove the piston valve and valve shim assembly from the rod in the sequence of disassembly.
Page 263: Ryde Fx Air 2.0 Shock Assembly
Shocks Ryde FX Air 2.0 Shock Assembly Apply a light film of grease to the 36mm rod assembly pressure valve port counter bore where the pressure valve Place the 36mm piston rod upper mount in a soft-jawed assembly o-ring meets. bench vise.
Page 264 Shocks 12. Apply a thin layer of oil to the IFP, wearband, and o-ring. 16. Invert the 36mm piston rod assembly and pour a small Insert the IFP, o-ring side first, into the shock body. amount of shock oil into the center of the locking piston bolt until the oil flows back out of the hole.
Page 265: Walker Evans Air Shock Disassembly
Shocks 20. Pressurize the shock body cylinder with nitrogen gas to is facing upward. specification. Slowly loosen the shock rod bearing cap (4) and remove 21. Install the small button-head screws back into each valve from the shock. assembly. Empty all the shock oil from the shock body and discard 22.
Page 266: Walker Evans Remote Reservoir / Piggy Back Shock Disassembly
Shocks Walker Evans Remote Reservoir / Piggy Back Shock Disassembly NOTE: Remote reservoir shock shown. IMPORTANT: To prevent damage or marks to the shock, the use of soft jaws on a vise is recommended. Clean and carefully remove shock from the suspension. Remove button head screw (1) from reservoir cap (if applicable).
Page 267: Walker Evans Remote Reservoir / Piggy Back Shock Assembly
Shocks 13. Inspect the valves for kinks, waves, pits or foreign material. 14. Inspect the piston wear band and replace if damaged or worn. Secure the shock body by its lower mount. Set the compression damping adjustment selector to Walker Evans Remote Reservoir / Piggy position “1”.
Page 268: Ryde Fx Remote Reservoir Shock Disassembly
Shocks 18. Set the IFP to specification, then close the bleed screw. 19. Pour out any remaining shock oil from the reservoir. 20. Install the cap making sure the o-ring does not flip-over. Install the snap ring. 21. Charge the shock to the specified pressure. 22.
Page 269: Ryde Fx Remote Reservoir Shock Assembly
Shocks When all of the gas has escaped the reservoir, carefully 11. With the shock disassembled, inspect the following items: push the reservoir cap down to expose the c-clip. Using a • Piston rod for straightness, nicks, or burrs. pick, remove the c-clip from the reservoir body. •...
Page 270 Shocks Fill the shock body with new Ryde FX shock oil. Fill until 12. Using an adjustable wrench, secure the bearing cap the level of the oil is one inch below the top of the reservoir assembly to the shock body. body.
Page 271: Ryde Fx Mono-Tube Shock Disassembly
Shocks RYDE FX MONO-TUBE SHOCK Depressurize the shock. DISASSEMBLY WARNING Procedures for the proper disassembly and assembly of Ryde FX gas charged IFP and emulsion mono-tube shock ITROGEN GAS IS UNDER EXTREME PRESSURE absorbers. CAUTION WHEN RELEASING NITROGEN GAS FROM SHOCK ROTECTIVE EYE WEAR SHOULD BE WORN TO CAUTION...
Page 272: Ryde Fx Mono-Tube Shock Assembly
Shocks RYDE FX MONO-TUBE SHOCK ASSEMBLY shop cloth around shock body to catch possible oil overflow. Fast installation of the piston rod and assembly Place the piston rod upper mount into the vise. Reassemble may displace the floating piston from its original position. damper rod assembly in the reverse order of disassembly.
Page 273: Fox Ps-5 Assembly
Shocks 12. Clamp the shock in the vice using the body clamp blocks. Thoroughly clean the FIST scraper, bearing housing, and If the bearing is still in the body, use the 1 3/8” end wrench piston assembly with solvent. Dry with compressed air in to loosen and un-thread the bearing.
Page 274 Chassis CHAPTER 10 Chassis IQ CHASSIS COMPONENTS ..........10.2 STEERING HOOP ASSEMBLY (TYPICAL) .
Page 275: Iq Chassis Components
Chassis IQ CHASSIS COMPONENTS Steering Hoop Assembly (Typical) STEERING HOOP RH UPPER BRACE FUEL TANK BUMPER SPACER LH UPPER BRACE CROSS MEMBER BRACKET A: 18 Ft.Lb. (24 Nm) B: 21 Ft.Lbs. (28 Nm) 10.2...
Page 276: Hood Assembly
Chassis Hood Assembly HEADLIGHT SEALS (ATTACH TO INSIDE OF HOOD AROUND HEADLIGHT OPENING AND WHERE POD MEETS WINDSHIELD FLARE.) PRE FILTER INSTRUMENT POD BRAKE DUCT (NOT ALL MODELS) HOOD - CONSOLE SEAL INTAKE / ACCESS COVER FRONT GRILLE / HINGE NOTE: TORQUE FASTENERS HAND TIGHT Hood / Plastic Repair Hoods are made of Thermoplastic Olefin (TPO) and cannot be...
Page 277: Front Bumper Assembly (Typical)
Chassis Front Bumper Assembly (Typical) HEAT FOIL / FABRIC PANEL NOSEPAN BUMPER GRILLE W/MESH NOTE: TORQUE FASTENERS HAND TIGHT IQ Console Assembly (Typical) FIXED STEERING COVER IGNITION SWITCH CONSOLE NUT O-RING RIDER SELECT STEERING COVERS ROPE GUIDE CONSOLE STORAGE DOOR NOTE: TORQUE FASTENERS HAND TIGHT 10.4...
Page 278: Rmk Tunnel
Chassis RMK Tunnel REAR BUMPER CLOSE OFF RIVETS BULKHEAD/TUNNEL ASSEMBLY (1 PIECE) SNOW FLAP RIVETS CONTROL ARM SUPPORT 10.5...
Page 279: Fenders And Side Panels
Chassis Fenders and Side Panels RH SIDE PANEL HEAT SHIELD FOAM EXHAUST SEAL RH FENDER FOAM LH SIDE PANEL TRIM LH FENDER RIVETS PUSH RIVETS 10.6...
Page 280: Seat Assemblies
Chassis SEAT ASSEMBLIES IQ Removable Seat Assembly IQ Fixed Seat Assembly LATCH SEAT SEAT SEAT BASE SEAT BASE A: 5.5 Ft.Lbs. (7.5 Nm) A: 5.5 Ft.Lbs. (7.5 Nm) Plastic crushes at 10 Ft.Lbs. (13 Nm). IQ Raw Seat Assembly 2007 TAILIGHT 2007 VERSION 2008 VERSION 10.7...
Page 281: 2007 Iq Touring Seat Assembly
Chassis 2007 IQ Touring Seat Assembly PASSENGER SEAT ASSEMBLY COVER LUMBAR ADJUSTER SEAT LATCH LATCH BRACKETS SEAT ASSEMBLY HAND GUARD A: 5.5 Ft.Lbs. (7.5 Nm) 10.8...
Page 282: 2008 Iq Touring Seat Assembly
Chassis 2008 IQ Touring Seat Assembly BACK REST BACK REST ADJUSTER RIVETS MOUNT HAND GUARD A: 18 Ft.Lbs. (24 Nm) B: Hand Tight (Do not crush washers.) C: Hand Tight D: 5.5 Ft.Lbs. (7.5 Nm) 10.9...
Page 283: Seat Cover Replacement
Hair Dryer Using a staple gun, tack each side of the vinyl cover in place using two staples (1). If cover has a “POLARIS” emblem carefully align emblem with the bottom edge of the seat. This will help ensure that the cover is positioned properly.
Page 284: Decal Installation
Heat until the decal is warm to touch. DO NOT OVER HEAT! Overheating may cause damage to the paint and to the integrity of the hood. Polaris is not responsible for any CAUTION hood damage resulting from this decal replacement procedure.
Page 285 Chassis Apply the decal and slowly work the decal down using a clean squeegee to lay the decal straight and to avoid creating air bubbles. Do NOT remove the decal mask until the decal is fully applied. CAUTION NCE THE ADHESIVE STICKS IT CAN BE VERY DIFFICULT TO PULL THE DECAL BACK OFF OF THE HOOD SE EXTREME...
Page 286 Battery and Electrical Systems CHAPTER 11 Battery and Electrical Systems SPECIFICATIONS ..............11.2 ENGINE MODELS .
Page 287: Battery And Electrical Systems
Battery and Electrical Systems SPECIFICATIONS WARNING Engine Models PROPOSITION 65 WARNING BATTERY POSTS TERMINALS AND RELATED ACCESSORIES Model Number Engine CONTAIN LEAD AND LEAD COMPOUNDS CHEMICALS KNOWN S3273-6044-PF6F TO THE STATE OF CALIFORNIA TO CAUSE CANCER AND RE S3274-6044-PF6F Liberty 600cc HO Carbureted PRODUCTIVE HARM WASH HANDS AFTER HANDLING S3466-6044-PU6F...
Page 288: Conventional Battery
Battery and Electrical Systems CONVENTIONAL BATTERY Refilling a Conventional Battery The normal charge/discharge cycle of a battery causes the cells NOTE: Do not service the battery unless it will be to give off gases. These gases, hydrogen and oxygen, are the put into regular service within 30 days.
Page 289: Battery Testing
Battery and Electrical Systems BATTERY TESTING Battery Voltage Per Cell Testing Procedures CONVENTIONAL STATE OF CHARGE YUMACRON TYPE LEAD-ACID Batteries should be kept at or as near full charge as possible. If 100% CHARGED 1.265v 1.275v the battery is stored or used in a partially charged condition, hard crystal sulfication will form on the plates, reducing their 75% CHARGED 1.210v...
Page 290: Ignition Timing
Battery and Electrical Systems IGNITION TIMING retaining screws can be accessed through the flywheel. Timing Procedure - Carbureted Engines 10. Torque stator plate screws and flywheel nut to specified NOTE: Always verify timing of engine at room torque. Apply Loctite 262 (red) to crankshaft flywheel taper temperature (68°F / 20°C), and at the specified RPM.
Page 291: Ignition Timing Chart
Battery and Electrical Systems Ignition Timing Chart NOTE: Always disconnect the TPS on carbureted engines prior to checking ignition timing. Convert the ignition timing specification from degrees BTDC to either inches or millimeters, then use a dial indicator to verify timing marks.
Page 292: Throttle Position Sensor (Tps)
Battery and Electrical Systems THROTTLE POSITION SENSOR (TPS) Connect the test tool to the TPS on the carburetor or throttle body. The TPS is located on the carburetor rack (carbureted engines) or on the throttle body (CFI engines). The TPS is set at the time of manufacture and should only require adjustment when: •...
Page 293: Tps Adjustment - Carbureted Models
Battery and Electrical Systems TPS Adjustment - Carbureted Models Click on the TOOLBOX icon. Click on “TPS INITIALIZATION” NOTE: Always verify the engine idle speed is set at Follow the steps and procedures displayed on the screen. engine operating temperature and the throttle cable freeplay is set to 0.10″...
Page 294 Battery and Electrical Systems Loosen the idle speed screw until the screw no longer touches the tab and the throttle plates are completely closed. 10. Carefully tighten the screws to 31 In.Lbs. (3.5 Nm) when • A = Idle Speed Screw the voltage is 0.70 +/- 0.01 Vdc.
Page 295: Tps Idle Speed Adjustment - Cfi Models
Battery and Electrical Systems TPS Idle Speed Adjustment - CFI Models Verify the TPS voltage is 0.70 +/- 0.01 Vdc with the throttle plates closed. Slowly turn the idle speed adjustment screw (A) clockwise until the voltage displayed on the multi meter reads 0.95 +/ - 0.1 Vdc (.93 +/- 0.1 Vdc for 800 CFI engines).
Page 296: Electric Start - Iq Carbureted / Cfi
Battery and Electrical Systems ELECTRIC START - IQ CARBURETED / CFI System Schematic - 600 Carbureted 11.11...
Page 297: System Schematic - Cfi
Battery and Electrical Systems System Schematic - CFI 11.12...
Page 298: Starter Motor / Flex Drive Assembly
Battery and Electrical Systems Starter Motor / Flex Drive Assembly (+) RED - POSITIVE CABLE FLEX DRIVE STARTER MOTOR PINION / PINION BRACKET WORM GEAR CLAMP END PLATE MOUNTING BRACKET MOUNTING BRACKET 11.13...
Page 299: Iq Battery Box Assembly
Battery and Electrical Systems IQ Battery Box Assembly CIRCUIT BREAKER SOLENOID BATTERY HOLD-DOWN BRACKET GROUND CABLE BATTERY BATTERY PAD MOUNTING BRACKET 11.14...
Page 300: Carbureted Electrical Systems
Battery and Electrical Systems CARBURETED ELECTRICAL Knock Sensor SYSTEMS 600 HO Stator Specifications NOTE: Use a multimeter to test the stator circuits. Remember to test the circuits when the engine is cold and after the engine has been running for some time.
Page 301: 2007 600 Ho Regulator / Rectifier
Battery and Electrical Systems 2007 600 HO Regulator / Rectifier Circuit Specifications This regulator / rectifier performs the following functions: HARNESS / J / RED/ REGULATED DC MFD POWER • Regulates AC Voltage to 14.3 volts. HARNESS / K / RED REGULATED DC BATTERY POWER •...
Page 302: 2008 Iq Shift Regulator / Rectifier
Replace the regulator / rectifier if the AC Voltage is above 14.8 V or when there is no 12 Vdc supply on the RED / GREEN The Polaris VES system uses exhaust valves (1 per cylinder) to circuit. control the exhaust port height. The valves are actuated by...
Page 303: Diagnostic Plugs
CHASSIS POWER-UP PRIME PLUG (2- WIRE CONNECTOR) Some models are equipped with Polaris electric reverse control (PERC). The operation of the electronic reverse system is achieved by automatically reversing the engine rotation with a push of a button. When in reverse you will have an indicator light that will flash, notifying you that the machine is in the reverse mode.
Page 304: Altitude Setting
Altitude Setting If your engine is carbureted, you can adjust the elevation setting of the Polaris electric reverse control (PERC). If your engine is a Cleanfire system, this is automatically done through the engine controller unit (ECU), and you do not need to do any setting.
Page 305 Battery and Electrical Systems NOTES 11.20...
Page 306 4.34 CFI Drop-In Fuel Pump Service 4.27 CFI Ignition Coils 4.27 CFI Regulator / Rectifier Adjustments 4.27 Chassis Power Capacitor 3.17 Choke 4.22 Chassis Relay Arvin Monotube Assembly ..... 9.27 4.19 Clutch Guard Electrical Center 4.25...
Page 307 Belt Deflection Adjustment Cooling System Bleeding Belt Deflection Inspection Exhaust Valves Engine Isolator Limiter Setting Oil Pump Adjustment - Carbureted Models Torque Stop Adjustment Oil Pump Adjustment - CFI Models Drive Clutch Recommended Coolant Engine Mounting Systems ..... 5.13 7.16 Assembly 7.14...
Page 308 Ryde FX Handlebar Assemblies ......8.9 Walker Evans Honing Procedure ......5.9 Walker Evans 7/16 Cleaning the cylinder after honing Hood...
Page 309 Reed Valve ........5.6 Reed Valve Disassembly ..... . .5.6 Variable Exhaust Systems (VES) .
Page 310 Wiring Diagrams 2007 600 HO Carbureted 1 of 2 12.1...
Page 311 Wiring Diagrams 2007 600 HO Carbureted 2 of 2 12.2...
Page 312 Wiring Diagrams 2007 600 HO Carbureted Hood Harness 12.3...
Page 313 Wiring Diagrams 2007 600 / 700 CFI Chassis Harness 1 of 2 12.4...
Page 314 Wiring Diagrams 2007 600 / 700 CFI Chassis Harness 2 of 2 12.5...
Page 315 Wiring Diagrams 2007 600 / 700 CFI Hood Harness 12.6...
Page 316 Wiring Diagrams 2007 600 / 700 CFI Engine Harness 12.7...
Page 317 Wiring Diagrams 2008 IQ Shift 1 of 2 12.8...
Page 318 Wiring Diagrams 2008 IQ Shift 2 of 2 12.9...
Page 319 Wiring Diagrams 2008 IQ Shift Hood Harness 12.10...
Page 320 Wiring Diagrams 2008 IQ Shift RMK 1 of 2 12.11...
Page 321 Wiring Diagrams 2008 IQ Shift RMK 2 of 2 12.12...
Page 322 Wiring Diagrams 2008 IQ Shift RMK Hood Harness 12.13...
Page 323 Wiring Diagrams 2008 IQ CFI Chassis Harness 1 of 2 12.14...
Page 324 Wiring Diagrams 2008 IQ CFI Chassis Harness 2 of 2 12.15...
Page 325 Wiring Diagrams 2008 IQ CFI Engine Harness 12.16...

This manual is also suitable for:

Iq 2008

Polaris IQ 2007 Service Manual

Model Specifications Chapter 1 1

General Information Chapter 2 General Information 2

Maintenance Chapter 3 Maintenance

Fuel Systems Chapter 4 Fuel Systems

Engine and Cooling Systems

Final Drive and Brakes Chapter 6 Final Drive and Brakes

Pvt System Chapter 7 Pvt System

Steering and Suspensions Chapter 8 Steering and Suspensions

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Summary of Contents for Polaris IQ 2007