Polaris 340 CLASSIC 2006 Manual
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Polaris 340 CLASSIC 2006 Manual

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SPECIFICATIONS
CHAPTER 1
1
SPECIFICATIONS
340 CLASSIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
500 CLASSIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
550 CLASSIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
600 CLASSIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
700 CLASSIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
500 INDY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
SUPERSPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
340 INDY TOURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16
TRAIL TOURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.18
600 EDGE TOURING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20
700 TOURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22
WIDETRAK LX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.24
500 XC SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.26
600 HO STANDARD FUSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.28
600 HO DRAGON FUSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.30
700 FUSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.32
900 FUSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.34
600 HO SWITCHBACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.36
900 SWITCHBACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.38
TRAIL RMK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.40
600 HO RMK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.42
700 RMK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.44
900 RMK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.46
1.1

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Summary of Contents for Polaris 340 CLASSIC 2006

  • Page 1: Table Of Contents

    SPECIFICATIONS CHAPTER 1 SPECIFICATIONS 340 CLASSIC ............1.2 500 CLASSIC .

  • Page 2: 340 Classic

    SPECIFICATIONS 340 CLASSIC Table 1-3: Jetting Ambient Temperature MODEL S06ND3AS Table 1-1: Engine Altitude meters Engine type Fuji (feet) Engine displacement 339cc Bore in/mm 2.45/62.3 Stroke in/mm 2.19/55.6 Piston to cylinder clearance in/ 0-600 .003-.005/.076-.127 (0-2000) 600-1200 Piston ring end gap .008-.014/.20-.35 (2000-4000) Operating RPM±200...
  • Page 3 SPECIFICATIONS Table 1-7: Fluids and capacities Table 1-12: Dimensions Fuel gal/l 11.8/44.7 Width in/cm 48/122 Oil qts/l 3.25/3.1 Length in/cm 113/287 Coolant qts/l Height in/cm 48/122 Chaincase oz/ml 9/266.2 Est dry weight lb/kg 517/234.7 Brake fluid type DOT4 Table 1-13: Electrical Table 1-8: Track Ignition timing 26.5_@3000RPM...
  • Page 4 SPECIFICATIONS 500 CLASSIC Table 1-16: Jetting Ambient Temperature MODEL S06ND4BS Table 1-14: Engine Altitude meters Engine type Fuji (feet) Engine displacement 488cc Bore in/mm 2.83/72 Stroke in/mm 2.36/60 0-600 Piston to cylinder clearance in/ .0035-.0049/.090-.125 (0-2000) 600-1200 Piston ring end gap .0079-.016/.20-.40 (2000-4000) Operating RPM±200...
  • Page 5 SPECIFICATIONS Table 1-20: Fluids and capacities Table 1-24: Dimensions Fuel gal/l 11.8/44.7 Width in/cm 48/122 Oil qts/l 3.25/3.1 Length in/cm 113/287 Coolant qts/l 4.8/4.5 Height in/cm 48/122 Chaincase oz/ml 9/266.2 Est dry weight lb/kg 471/213.8 Brake fluid type DOT4 Table 1-25: Electrical Table 1-21: Track Ignition timing 26_@3000...

  • Page 6: 550 Classic

    SPECIFICATIONS 550 CLASSIC Table 1-28: Jetting Ambient Temperature MODEL S06ND5BS Table 1-26: Engine Altitude meters Engine type Fuji (feet) Engine displacement 544cc Bore in/mm 2.87/73 Stroke in/mm 2.56/65 0-600 300/290 290/280 280/270 270/260 260/250 250/240 Piston to cylinder clearance in/ .0045-.0053/.11-.13 (0-2000) 600-1200...
  • Page 7 SPECIFICATIONS Table 1-32: Fluids and capacities Table 1-37: Dimensions Fuel gal/l 11.8/44.7 Width in/cm 48/122 Oil qts/l 3.25/3.1 Length in/cm 113/287 Coolant qts/l Height in/cm 48/122 Chaincase oz/ml 9/266.2 Est dry weight lb/kg 489/222 Brake fluid type DOT4 Table 1-38: Electrical Table 1-33: Track 27_@3000 Ignition timing...
  • Page 8 SPECIFICATIONS 600 CLASSIC Table 1-41: Jetting Ambient Temperature MODEL S06ND6ES Table 1-39: Engine Altitude meters Engine type Liberty (feet) Engine displacement Bore in/mm 3.04/77.25 Stroke in/mm 2.52/64 Piston to cylinder clearance in/ 0-600 .0045-.0059/.115-.149 (0-2000) 600-1200 Piston ring end gap .014-.020/.0356-.508 (2000-4000) Operating RPM±200...
  • Page 9 SPECIFICATIONS Table 1-44: Chaincase Table 1-49: Dimensions Center distance in/cm 7.92/20.1 Width in/cm 47.25/120 Reverse type PERC Length in/cm 113/287 Height in/cm 48/122 Table 1-45: Fluids and capacities Est dry weight lb/kg 497/255.6 Fuel gal/l 11.8/44.7 Table 1-50: Electrical Oil qts/l 3.25/3.1 Coolant qts/l 5.6/5.3...

  • Page 10: 700 Classic

    SPECIFICATIONS 700 CLASSIC Table 1-54: Clutching DRIVE CLUTCH (P-85) DRIVEN CLUTCH (TEAM) ALTITUDE MODEL S06PD7HS meters Shift Clutch Clutch Driven Gearing (feet) Weight Spring Spring Helix Table 1-51: Engine 0-600 Dark Blue / 62/42-46 10-72 Red/Black 23:39-76 (0-2000) White Engine type Liberty 600-1200 Dark Blue /...
  • Page 11 SPECIFICATIONS Table 1-59: Front Suspension Suspension type IQ 42.5 IFS shocks Arvin/7043054 IFS spring rate lbs-in/kg-mm 120/2.1 Spring installed length in/cm 9.95/25.3 Front vertical travel in/cm 10/25.4 Ski center distance in/cm 42.5/108 Camber in/cm 2.25±.31/5.7±.79 Toe in/mm 0-.12/0-3.0 Table 1-60: M-10 Rear Suspension Suspension type M-10 128 Front track shock (FTS)

  • Page 12: 500 Indy

    SPECIFICATIONS 500 INDY Table 1-65: Jetting Ambient Temperature MODEL S06NB4BS Table 1-63: Engine Altitude meters Engine type Fuji (feet) Engine displacement 488cc Bore in/mm 2.83/72 Stroke in/mm 2.36/60 0-600 Piston to cylinder clearance in/ .0035-.0049/.090-.125 (0-2000) 600-1200 Piston ring end gap .008-.016/.20-.40 (2000-4000) Operating RPM±200...
  • Page 13 SPECIFICATIONS Table 1-69: Fluids and capacities Table 1-74: Dimensions Fuel gal/l 11.8/44.7 Width in/cm 48/122 Oil qts/l 3.25/3.1 Length in/cm 113/287 Coolant qts/l 4.5/4.3 Height in/cm 48/122 Chaincase oz/ml 9/266.2 Est dry weight lb/kg 469/212.9 Brake fluid type DOT4 Table 1-75: Electrical Table 1-70: Track Ignition timing 26_@3000...

  • Page 14: Supersport

    SPECIFICATIONS SUPERSPORT Table 1-78: Jetting Ambient Temperature MODEL S06N(E,P)5BS(A,B) Table 1-76: Engine Altitude meters Engine type Fuji (feet) Engine displacement 544cc Bore in/mm 2.87/73 Stroke in/mm 2.56/65 0-600 300/290 290/280 280/270 270/260 260/250 250/240 Piston to cylinder clearance in/ .0045-.0053/.11-.13 (0-2000) 600-1200 290/280...
  • Page 15 SPECIFICATIONS Table 1-82: Fluids and capacities Table 1-87: M-10 Rear Suspension Fuel gal/l 11.8/44.7 Front track shock Fox/7042224* Oil qts/l 3.25/3.1 Front track shock spring rate 160/2.9 lbs-in/kg-mm Coolant qts/l Spring installed length in/cm 8.375/21.3 Chaincase oz/ml 9/266.2 Rear track shock Fox/7042216* Brake fluid type DOT4...

  • Page 16: 340 Indy Touring

    SPECIFICATIONS 340 INDY TOURING Table 1-92: Jetting Ambient Temperature MODEL S06NT3AS Table 1-90: Engine Altitude meters Engine type Fuji (feet) Engine displacement 339cc Bore in/mm 2.45/62.3 Stroke in/mm 2.19/55.6 Piston to cylinder clearance in/ 0-600 .003-.005/.080-.130 (0-2000) 600-1200 Piston ring end gap .008-.014/.20-.350 (2000-4000) Operating RPM±200...
  • Page 17 SPECIFICATIONS Table 1-96: Fluids and capacities Table 1-101: Dimensions Fuel gal/l 12.25/46.4 Width in/cm 48/121.9 Oil qts/l 3.25/3.1 Length in/cm 128/325.1 Coolant qts/l Height in/cm 49.5/125.7 Chaincase oz/ml 9/266.2 Est dry weight lb/kg 517/234.7 Brake fluid type DOT 4 Table 1-102: Electrical Table 1-97: Track Ignition timing 26.5_@3000RPM...

  • Page 18: Trail Touring

    SPECIFICATIONS TRAIL TOURING Table 1-105: Jetting Ambient Temperature MODEL S06N(T,U)5BS(A) Table 1-103: Engine Altitude meters Engine type Fuji (feet) Engine displacement 544cc Bore in/mm 2.87/73 Stroke in/mm 2.56/65 0-600 300/290 290/280 280/270 270/260 260/250 250/240 Piston to cylinder clearance .0045-.0053/.11-.13 (0-2000) in/mm 600-1200...
  • Page 19 SPECIFICATIONS Table 1-109: Fluids and capacities Table 1-113: Torsion spring Fuel gal/l 12.25/46.4 Torsion spring PNs 7042240/7042241 (LH/RH) Oil qts/l 3.25/3.1 Torsion spring diameter in/mm .405/10.3 Coolant qts/l Torsion spring tail angle Chaincase oz/ml 9/266.2 Brake fluid type DOT4 Table 1-114: Dimensions Table 1-110: Track Width in/cm 48/122...

  • Page 20: 600 Edge Touring

    SPECIFICATIONS 600 EDGE TOURING Table 1-118: Jetting Ambient Temperature MODEL S06PK6FS(A,B) Table 1-116: Engine Altitude meters Engine type Liberty (feet) Engine displacement Bore in/mm 3.04/77.25 Stroke in/mm 2.52/64 Piston to cylinder clearance 0-600 .0045-.0059/.115-.149 (0-2000) in/mm 600-1200 Piston ring end gap .014-.020/.356-.508 (2000-4000) Operating RPM±200...
  • Page 21 SPECIFICATIONS Table 1-121: Chaincase Table 1-126: Torsion spring Center distance in/cm 7.92/20.1 Torsion spring PNs 7042240/7042241 (LH/RH) Reverse type PERC Torsion spring diameter in/mm .405/10.3 Table 1-122: Fluids and capacities Torsion spring tail angle Fuel gal/l 12.25/46.4 Table 1-127: Dimensions Oil qts/l 3.25/3.1 Width in/cm...

  • Page 22: 700 Touring

    SPECIFICATIONS 700 TOURING Table 1-132: Clutching DRIVE CLUTCH (P-85) DRIVEN CLUTCH (TEAM) ALTITUDE MODEL S06PT7HS meters Shift Clutch Clutch Driven Gearing (feet) Weight Spring Spring Helix Table 1-129: Engine 0-600 Dark Blue / 62/42-46 10-72 Red/Black 23:39-76 (0-2000) White Engine type Liberty 600-1200 Dark Blue /...
  • Page 23 SPECIFICATIONS Table 1-136: IQ Track Table 1-139: Dimensions Width in/cm 15/38 Width in/cm 48/121.9 Length in/cm 136/345 Length in/cm 129/327.7 Lug height in/cm 1/2.5 Height in/cm 53/134.6 Track tension sag in/cm with 10 Est dry weight lb/kg 598/271.5 lbs/4.54kg placed 16 in/40.6cm .875-1.13/2.2-2.9 ahead of rear idler shaft Table 1-140: Electrical...

  • Page 24: Widetrak Lx

    SPECIFICATIONS WIDETRAK LX Table 1-143: Jetting Ambient Temperature MODEL S06SU4BS Table 1-141: Engine Altitude meters Engine type Fuji (feet) Engine displacement 488cc Bore in/mm 2.83/72 Stroke in/mm 2.36/60 0-600 Piston to cylinder clearance in/ .0035-.0049/.089-.125 (0-2000) 600-1200 Piston ring end gap in/mm .0070-.016/.18-.41 (2000-4000) Operating RPM±200...
  • Page 25 SPECIFICATIONS Table 1-147: Fluids and capacities Table 1-152: Dimensions Fuel gal/l 11/41.6 Width in/cm 43.5/110 Oil qts/l 2/1.9 Length in/cm 128/325 Coolant qts/l 3.4/3.2 Height in/cm 51/130 Gearcase oz/ml 20/591.5 Est dry weight lb/kg 643/291.9 Brake fluid type DOT4 Table 1-153: Electrical Table 1-148: Track Ignition timing 28_@3000...

  • Page 26: 500 Xc Sp

    SPECIFICATIONS 500 XC SP Table 1-156: Jetting Ambient Temperature MODEL S06NP5CSB Table 1-154: Engine Altitude meters Engine type Liberty (feet) Engine displacement Bore in/mm 2.78/70.5 Stroke in/mm 2.52/64 0-600 Piston to cylinder clearance in/ .0045-.0059/.11-.15 (0-2000) 600-1200 Piston ring end gap .014-.020/.356-.508 (2000-4000) Operating RPM±200...
  • Page 27 SPECIFICATIONS Table 1-160: Fluids and capacities Table 1-165: Dimensions Fuel gal/l 11.8/44.7 Width in/cm 48/122 Oil qts/l 3.25/3.1 Length in/cm 113/287 Coolant qts/l 5.6/5.3 Height in/cm 46/117 Chaincase oz/ml 9/266.2 Est dry weight lb/kg 481/218.4 Brake fluid type DOT4 Table 1-166: Electrical Table 1-161: Track Ignition timing 25_@2500RPM...

  • Page 28: 600 Ho Standard Fusion

    SPECIFICATIONS 600 HO STANDARD FUSION Table 1-169: Jetting Ambient Temperature MODEL S06M(E,P)6FS(A,B) Table 1-167: Engine Altitude meters Engine type 600 Liberty (feet) Engine displacement 599cc Bore in/mm 3.04/77.25 Stroke in/mm 2.52/64 Piston to cylinder clearance 0-600 .0045-.0059/.114-.150 (0-2000) in/mm 600-1200 (2000- Piston ring end gap .014-.020/.36-.51 4000)
  • Page 29 SPECIFICATIONS Table 1-172: Chaincase Table 1-177: M-10 Rear Suspension Center distance in/cm 8.373/21.27 Suspension type M-10 128 Reverse type PERC Front track shock Fox/7043123* Front track shock spring rate 180/3.2 Table 1-173: Fluids and capacities lbs-in/kg-mm Spring installed length in/cm 8.75/22.2 Fuel gal/l 10.8/40.9...

  • Page 30: 600 Ho Dragon Fusion

    SPECIFICATIONS 600 HO DRAGON FUSION Table 1-184: Jetting Ambient Temperature MODEL S06MC6FS Table 1-182: Engine Altitude meters Engine type 600 Liberty (feet) Engine displacement 599cc Bore in/mm 3.04/77.25 Stroke in/mm 2.52/64 Piston to cylinder clearance 0-600 .0045-.0059/.114-.150 (0-2000) in/mm 600-1200 (2000- Piston ring end gap .014-.020/.36-.51 4000)
  • Page 31 SPECIFICATIONS Table 1-187: Chaincase Table 1-192: Torsion spring Center distance in/cm 8.373/21.27 Torsion spring PNs 7043070/7043071 (LH/RH) Reverse type PERC .347/8.8 Torsion spring diameter in/mm Table 1-188: Fluids and capacities Torsion spring tail angle Fuel gal/l 10.8/40.9 Table 1-193: Dimensions Oil qts/l 3/2.8 Width in/cm...

  • Page 32: 700 Fusion

    SPECIFICATIONS 700 FUSION Table 1-198: Clutching DRIVE CLUTCH (P-85) DRIVEN CLUTCH (TEAM) ALTITUDE MODEL NUMBER: S06M(E,P)7HS(A,B) meters Shift Clutch Clutch Driven Gearing (feet) Weight Spring Spring Helix Table 1-195: Engine 0-600 Dark Blue / 62/42-46 10-72 Red/Black 26:40-78 (0-2000) White Engine type Liberty 600-1200...
  • Page 33 SPECIFICATIONS Table 1-202: IQ Track Table 1-207: M-10 Rear Suspension Width in/cm 15/38 Suspension type M-10 128 Length in/cm 121/307 Front track shock (FTS) Fox/7043123 Lug height in/cm 1.25/3.2 FTS spring rate 160/2.9 in-lbs/kg-mm Track tension sag in/cm with 10 lbs/4.54kg placed 16 in/40.6cm .875-1.125/2.2-.9 FTS spring installed length...
  • Page 34 SPECIFICATIONS 900 FUSION Table 1-213: Clutching DRIVE CLUTCH (P-85) DRIVEN CLUTCH (TEAM) ALTITUDE MODEL NUMBER: S06M(E,P)8DS(A,B) meters Shift Clutch Clutch Driven Gearing (feet) Weight Spring Spring Helix Table 1-210: Engine 0-600 Dark Blue / 62/42-46 10-74 Red/Black 25:37-76 (0-2000) White Engine type Liberty 600-1200...
  • Page 35 SPECIFICATIONS Table 1-217: IQ Track Table 1-221: M-10 Rear Suspension Width in/cm 15/38 Suspension type M-10 128 Length in/cm 121/307 Front track shock Fox/7043123* Lug height in/cm 1.25/3.175 Front track shock spring rate 160/2.9 lbs-in/kg-mm Track tension sag in/cm with 10 lbs/4.54kg placed 16 in/40.6cm 7/8”...

  • Page 36: 600 Ho Switchback

    SPECIFICATIONS 600 HO SWITCHBACK Table 1-227: Jetting Ambient Temperature MODEL S06PS6FS(A) Table 1-225: Engine Altitude meters Engine type Liberty (feet) Engine displacement 599cc Bore in/mm 3.04/77.25 Stroke in/mm 2.52/64 Piston to cylinder clearance 0-600 .0045-.0059/.114-.150 (0-2000) in/mm 600-1200 Piston ring end gap .014-.020/.36-.51 (2000-4000) Operating RPM±200...
  • Page 37 SPECIFICATIONS Table 1-230: Chaincase Table 1-235: Torsion spring Center distance in/cm 8.373/21.27 Torsion spring PNs 7041629/7041630 (LH/RH) Reverse type PERC Torsion spring diameter in/mm .359/9.12 Table 1-231: Fluids and capacities Torsion spring tail angle Fuel gal/l 10.8/40.9 Table 1-236: Dimensions Oil qts/l 3/2.8 Width in/cm...

  • Page 38: 900 Switchback

    SPECIFICATIONS 900 SWITCHBACK Table 1-241: Clutching DRIVE CLUTCH (P-85) DRIVEN CLUTCH (TEAM) ALTITUDE MODEL NUMBER: S06PS8DS(A) meters Shift Clutch Clutch Driven Gearing (feet) Weight Spring Spring Helix Table 1-238: Engine 0-600 Dark Blue / 64/42-46 10-74 Red/Black 25:40-78 (0-2000) White Engine type Liberty 600-1200...
  • Page 39 SPECIFICATIONS Table 1-245: IQ Track Table 1-250: Electrical Width in/cm 15/38 Stator output 400w@4000RPM Length in/cm 144/366 Ignition timing @ 9.6-12.7% 16_@3500 throttle Lug height in/cm 1.25/3.2 Spark plug gap in/mm .025/.64 Track tension sag in/cm with 10 lbs/4.54kg placed 16 in/40.6cm .375-.50/1-1.3 Spark plug Champion RN57YCC...

  • Page 40: Trail Rmk

    SPECIFICATIONS TRAIL RMK Table 1-253: Jetting Ambient Temperature MODEL S06NJ5B(E,S)(A) Table 1-251: Engine Altitude Engine type Fuji meters Engine displacement 544cc (feet) Bore in/mm 2.87/73 Stroke in/mm 2.56/65 Piston to cylinder clearance in/ .0045-.0053/.11-.14 Piston ring end gap .0035-.0049/.090-.125 0-600 290/280 280/270 270/260...
  • Page 41 SPECIFICATIONS Table 1-256: Chaincase Table 1-261: Torsion spring Center distance in/cm 7.92/20.1 Torsion spring PNs 7041627/7041628 (LH/RH) Reverse type PERC .347/8.8 Torsion spring diameter in/mm Table 1-257: Fluids and capacities Torsion spring tail angle Fuel gal/l 11.8/44.7 Table 1-262: Dimensions Oil qts/l 3.25/3.1 Width in/cm...

  • Page 42: 600 Ho Rmk

    SPECIFICATIONS 600 HO RMK Table 1-266: Jetting Ambient Temperature MODEL#S06PK6FS(A,B) Table 1-264: Engine Altitude meters Engine type 600 Liberty (feet) Engine displacement 599cc Bore in/mm 3.04/77.25 Stroke in/mm 2.52/64 Piston to cylinder clearance 0-600 .0045-.0059/.114-.150 (0-2000) in/mm 600-1200 (2000- Piston ring end gap .014-.020/.36-.51 4000) Operating RPM±200...
  • Page 43 SPECIFICATIONS Table 1-269: Chaincase Table 1-273: Rear Suspension Center distance in/cm 8.373/21.27 Suspension type IQ RMK 144 Reverse type PERC Front track shock (FTS) Arvin/7043048 FTS spring rate 170/3.0 Table 1-270: Fluids and capacities lbs-in/kg-mm FTS spring installed length Fuel gal/l 10.8/40.9 7.4/18.8 in/cm...

  • Page 44: 700 Rmk

    SPECIFICATIONS 700 RMK Table 1-280: Clutching DRIVE CLUTCH (P-85) DRIVEN CLUTCH (TEAM) ALTITUDE MODEL NUMBER: S06P(K,L,M)7HS(A,B) meters Shift Clutch Clutch Driven Gearing (feet) Weight Spring Spring Helix Table 1-277: Engine 0-600 Black/ 64/36-25 10-74 Red/Black 20:41-76 (0-2000) Green Engine type Liberty 600-1200 Black/...
  • Page 45 SPECIFICATIONS Table 1-284: Track Table 1-287: Torsion spring Width in/cm 15/38 Torsion spring PNs 7041629/7041630 (LH/RH) 144 Length in/cm 144/366 Torsion spring diameter in/mm .359/9.12 151 Length in/cm 151/384 Torsion spring tail angle 159 Length in/cm 159/404 144/151 Lug height in/cm Table 1-288: Dimensions 159 Lug height in/cm 2.4/6.1...
  • Page 46 SPECIFICATIONS 900 RMK Table 1-293: Clutching DRIVE CLUTCH (P-85) DRIVEN CLUTCH (TEAM) ALTITUDE meters MODEL NUMBER: S06PN8DS(A) Shift Clutch Clutch Driven Gearing (feet) Weight Spring Spring Helix 0-600 Black/ 64/38- Table 1-290: Engine 10-78CS Red/Black 20:41-76 (0-2000) Green .25ER 600-1200 Black/ 64/38- Engine type...
  • Page 47 SPECIFICATIONS Table 1-297: Track Table 1-300: Torsion spring Width in/cm 15/38 Torsion spring PNs 7041629/7041630 (LH/RH) Length in/cm 151/384 Torsion spring diameter in/mm .359/9.1 Length in/cm 159/404 Torsion spring tail angle Length in/cm 166/422 151 Lug height in/cm Table 1-301: Dimensions 2.4/6.1 159/166 Lug height in/cm Width in/cm...
  • Page 48 SPECIFICATIONS NOTES 1.48...
  • Page 49 GENERAL CHAPTER 2 GENERAL HOW TO USE THIS MANUAL..........2.2 LOCATING INFORMATION.

  • Page 50: General

    GENERAL HOW TO USE THIS MANUAL LOCATING INFORMATION This manual is divided into chapters that cover each of the main components of the snowmobile. To quickly find the information that you are interested in, the first page of each chapters lists the tale of contents within the chapter.

  • Page 51: Snowmobile Model Number Designation

    GENERAL SNOWMOBILE MODEL NUMBER DESIGNATION EXAMPLE: S06PS8DSA (900 SWITCHBACK STOCK A) Table 2-1: Model Number Designation Model Model Option Identifier Model Type Engine Modifier Year Line Identifier Identifier B=Std D=Classic 1A=121 F/C OHV 4 Cycle Fuji E=M-10 3A=340 F/C Piston Port J=136 RMK 4B=488 L/C Piston Port M=IQ...

  • Page 52: Vin (Vehicle Identification Number)

    VIN EXPLINATION Number) Current snowmobiles have a 17 digit Vehicle Identification Number (VIN). The VIN is organized as follows: Digits 1-3: World Manufacturer Identifier. For Polaris, this is SN1. Digits 4-9: Vehicle Descriptor Section. Digits 10-17: Vehicle Indicator Section. Digits 4-8 of the VIN identify the body style, type, engine type, and series.
  • Page 53 GENERAL Table 2-3: Publication Part Numbers Owner’s Owner’s Parts Assembly Service Model Model Number Manual Microfiche Manual Manual Instruction Manual Supplement FS/FST IQ S06PT7E(F)S 9919673 9919710 9919751 9919752 9916508 9919765 Touring Indy 340 Touring S06NT3AS 9919669 9919690 9919729 9919730 9916508 9919763 Trail Touring S06NT5BS(A)

  • Page 54: General Reference

    GENERAL GENERAL REFERENCE STANDARD BOLT SPECIFICATIONS Grade 2 Grade 5 Grade 8 Table 2-5: Standard Bolt Specifications Bolt Threads/ Grade 2 Grade 5 Grade 8 Size ft-lb(Nm) ft-lb(Nm) ft-lb(Nm) 5 (7) 8 (11) 12 (16) 6 (8) 10 (14) 14 (19) 5/16 11 (15) 17 (23)

  • Page 55: Sae Tap Drill Sizes

    GENERAL SAE TAP DRILL SIZES DECMIAL EQUIVALENTS METRIC TAP DRILL SIZES...

  • Page 56: Mesurement Conversion Chart

    GENERAL MESUREMENT CONVERSION CHART Table 2-6: Measurement Conversion Chart Unit of Measure Multiplied by Converts to ft-lb x 12 = in-lb in-lb x.0833 = ft-lb ft-lb x 1.356 = Nm in-lb x.0115 = kg-m x.7376 = ft-lb kg-m x 7.233 = ft-lb kg-m x 86.796...

  • Page 57: Piston Wash / Spark Plug Reading

    GENERAL PISTON WASH / SPARK PLUG READING color running a distant second. Use the illustrations below to help you establish the EGTs for your machine. Changing temperature, barometer, altitude, and fuel supply are Once the proper jetting is established, you can reference the just a few of the factors that can affect the day to day EGT gauge for your baseline numbers.

  • Page 58: Stroke Gasoline / Oil Pre Mix

    GENERAL pump, or carburetor. This will cause warm engine drive ability problems and hard starting when warm. Some states are limiting the Reid Vapor number to 9.0 PSI year around to help meet evaporative emissions standards. Table 2-7: Gasoline Volatility Maximum Reid Ambient Air Temp Vapor...

  • Page 59: Special Tools

    GENERAL SPECIAL TOOLS Fuel Pressure Gauge (PV-43506-A) Throttle Position Sensor Tester Kit (2201519) Fuel Line Disconnection Tool (PS-47152) Mity-Vac Pressure Test Kit (2870975) 2.11...

  • Page 60: Special Tools

    GENERAL SPECIAL TOOLS 2.12...
  • Page 61 GENERAL 2.13...
  • Page 62 GENERAL 2.14...
  • Page 63 POLARIS RECOMMENDED PROGRAM ........3.3...
  • Page 64 MAINTENANCE AIR FILTER ............3.23 WATER SEDIMENT TRAP .

  • Page 65: Maintenance Program

    1000 mile riding conditions. When inspection reveals the need for (1600 km) intervals. All necessary replacement parts and labor replacement parts, always use genuine Polaris parts, available incurred, with the exception of authorized warranty repairs, from your Polaris dealer.
  • Page 66 MAINTENANCE Table 3-1: Maintenance Intervals Frequency Miles (km) Pre- Item Pre-Ride Season 150 (240) 500 (240) 1000 (1600) 2000 (3200) Brake Disc Parking Brakes Brake System Brake Fluid FUEL MANAGEMENT Pilot Air Screws Carburetor (synchronize) Idle RPM Throttle Lever Oil Pump Lever (synchronize) Throttle Cable Choke Cable...

  • Page 67: Inspectons

    MAINTENANCE Table 3-1: Maintenance Intervals Frequency Miles (km) Pre- Item Pre-Ride Season 150 (240) 500 (240) 1000 (1600) 2000 (3200) Seat Latches Rear Wheel Idler Bolts Idler Bolt Jam Nut Rear Suspension Pivot Shafts Handle Bar U-Joint Camber Alignment Handlebar Centering Track Alignment Track Tension Rail Slide Condition...

  • Page 68: Cylinder Measurement

    MAINTENANCE CYLINDER MEASUREMENT piston pin and 90_ to the pin to determine if the bore is out of round. Repeat the measurements at the middle of the cylinder and the bottom of the cylinder to determine taper or out of Inspect each cylinder for wear, scratches, or damage.

  • Page 69: Honing Procedure

    (transfer port area). Use electrical contact cleaner if necessary to clean these areas. Rinse thoroughly, dry with compressed Wash the cylinder with solvent. air, and oil the bore immediately with Polaris Premium 2 Clamp the cylinder in a soft jawed vise by the exhaust port Cycle Lubricant.

  • Page 70: Piston Ring Installed Gap

    MAINTENANCE PISTON RING INSTALLED GAP RECOMMENDED COOLANT Piston Ring Piston Ring Polaris snowmobiles use a premium 60/40 pre-mix antifreeze. This premium antifreeze is mixed with deionized water for 1/2 (1.3cm.) 1/2 (1.3cm.) Cylinder better protection for aluminum cooling. This pre-mix is good Feeler Gauge for temperatures down to -62_F (-52_C).

  • Page 71: Bearing Fit

    Any time crankshaft bearing failure occurs and the case is to Tighten the bleed screw when coolant starts to come out of be reused, Polaris recommends checking the bearing fit into the screw area. the case halves using the following procedure.

  • Page 72: Main Bearing

    Clean crankshaft thoroughly and oil main and connecting rod bearings with Polaris engine oil. Carefully check each main bearing on the shaft. Due to extremely close tolerances, the bearings must be inspected visually, and by feel.

  • Page 73: Crankshaft Indexing

    • Difficulty calibrating carburetor (repetitive plug fouling on one cylinder with no other cause) Polaris uses crankshafts that are pressed together. The connecting rod journal center lines are indexed 180_(twins). • Unexplained piston failure on one cylinder (i.e. severe...

  • Page 74: Crankshaft Runout Inspection

    MAINTENANCE NOTE: The Rod Pin position in relation to the dial indicator tells you what action is required to straighten the shaft. Table 3-3: Truing Examples HIGH .004 (.1mm) HIGH .004 (.1mm) To correct a situation like this. Strike the shaft at point A with a brass hammer.

  • Page 75: Oil Pump Bleeding

    MAINTENANCE When checking the crankshaft runout on the MAG side. Place reservoir with the appropriate Polaris injector oil. This will the dial indicator end at 1/2” (12.7mm) from the bearing flat add pressure to the oil lines. Loosen the bleed screw (A). After approximately 30 (A).

  • Page 76: Oil / Fuel Filter

    Inspect the reservoir to be sure it contains the correct amount oil sending unit located in the bottom of the oil tank. It should of fluid. Use only Polaris DOT 4 high temperature brake fluid. be replaced every two years or 2400 miles (3862 km).

  • Page 77: Brake Fluid Bleeding

    MAINTENANCE NOTE: A low brake fluid level can be indicated through the sight glass on the cover. If the fluid is low this sight glass will glow a brighter. color. FULL BRAKE FLUID BLEEDING see “BRAKE FLUID REPLACEMENT & BLEEDING” on page 8.3.

  • Page 78: Exhaust System

    MAINTENANCE EXHAUST SYSTEM At approximately 2000 miles, or in preparation for off season Remove the exhaust pipe (C), resonator seal (D) and storage, it is a good idea to check the exhaust system for wear manifold seal (E). or damage. To inspect, allow the engine and exhaust system to Remove the resonator (F).

  • Page 79: Belt Deflection

    This is due to the belt rising too high in the drive clutch sheaves upon engagement Lubricate the following fittings with Polaris Premium All (A). Season grease every 1000 miles (1600 km) and before summer storage.

  • Page 80: Driveshaft Bearing

    To maintain rider comfort and to retard wear of the pivot shafts, the suspension pivot shafts should be lubricated with Polaris Premium All Season Grease at 500 miles (800 km) initially; 1000 miles (1600 km) and before summer storage each year. The riding characteristics of the snowmobile will be affected by lack of lubrication of these shafts.

  • Page 81: Adjustment

    MAINTENANCE ADJUSTMENT CHAINCASE DRIVE TENSION Elevate the rear of the machine so that the track is off the floor. Rotate the driven clutch counterclockwise to move all the chain slack to the tensioner side. Lock the parking brake. Loosen the adjuster bolt jam nut (B) Finger tighten the adjuster bolt (A).

  • Page 82: Track Alignment

    MAINTENANCE TRACK ALIGNMENT NOTE: Track alignment affects track tension. 10. Torque both idler shaft bolts (F) to 35 ft-lb (48Nm). Misalignment of the track will cause excessive wear WARNING to the track, rail slides, and rail. NOTE: Excessive rail slide wear occurs due to Broken track rods can cause a rotating track to come off running in inadequate snow conditions.

  • Page 83: Track Tension

    MAINTENANCE NOTE: Track damage of failure caused by operation speeds, cause rear suspension vibration and cause track and on ice or under other poor lubrication conditions will rear suspension durability problems. void the tracks warranty. Lift the rear of the machine and place a jack stand or secure TRACK TENSION the rear of the machine so that the track is off of the ground.

  • Page 84: Oil Pump Adjustment

    MAINTENANCE OIL PUMP ADJUSTMENT Re-install carburetors, air box and plug in the CDI and On some engines the oil pump is located under the intake coils if they were taken off in step 1. boots and you may have to remove the air box and may Check idle to specification and adjust if needed.

  • Page 85: Handlebar Adjustment

    MAINTENANCE NOTE: On IQ models you can adjust the headlight While holding the handlebar in the desired position tighten by turning the adjustment knob that is located on the the handle bar block bolts and torque to 12 ft-lb (16Nm) top side of the hood, next to the MFD gauge.

  • Page 86: Throttle Lever Free Play

    MAINTENANCE THROTTLE LEVER FREE PLAY TORQUE STOP TORQUE STOP After aligning clutches, adjust torque stop (A) by loosening the lock nut and rotating the stop so that the clearance is .010” gap=.010-.030” - .030” (.25 - .75mm) from the whole surface of the torque .25-.80mm stop.
  • Page 87 NOSEPAN CARE CORROSION If your nosepan becomes dirty with soot, you can use Polaris Carbon Clean (PN 2872890) to remove the soot. To prevent corrosion, always grease jackshaft and drive shaft (clutch side) bearings with Polaris Premium all season grease.
  • Page 88 MAINTENANCE SHOCKS IQ HEADLIGHT BULB REPLACEMENT Use T-9 Metal Protectant (or equivalent) on shock absorber shafts to help prevent corrosion. BATTERY Disconnect and remove the battery. Clean the terminals and cables. Apply dielectric grease to the terminals. Store in a cool dry place for storage.
  • Page 89 CARBURETION CHAPTER 4 CARBURETION WARNINGS ............4.2 WARNINGS .

  • Page 90: Warnings

    When ever servicing the carburetor or fuel use and shop procedures is necessary to perform the service system, it is important to heed the following work safely and satisfactorily. Use only genuine Polaris warnings. service parts. Cleanliness of parts and tools as well as the work area is of WARNING primary importance.

  • Page 91: Gasoline Votalitiy

    CARBURETION Polaris recommends the use of Polaris lubricants and greases, Call physician immediately. Eyes - Flush with water for 15 which have been specially formulated for the top performance minutes and get prompt medical attention. and best protection of our machines. In some applications, such as the engine, warranty coverage may become void if other brands are substituted.

  • Page 92: Fuel Pump (Non-Injected Units)

    CARBURETION FUEL PUMP (non-injected units) When replacing fuel line, be sure to use the correct color line for inside or outside the fuel tank. Also, be very careful not to bend fuel line to a point of kinking it. If it becomes kinked, it must be replaced.

  • Page 93: Maintenance

    CARBURETION MIKUNI JET NEEDLE opening. Whether idling or at full throttle, the pressure built up in the crankcase has enough amplitude to operate the pump. OVERVIEW When the piston is on the upstroke, crankcase pressure in that cylinder becomes less positive. The diaphragm in the fuel This needle (example) is a pump moves toward the engine, causing a negative pressure or 9DH01-57.

  • Page 94: Mikuni Tm 38

    CARBURETION MIKUNI TM 38 CARBURETOR OVERVIEW place. Reach inside with a long nose pliers and pull the needle out. The C-clip can then be adjusted for the desired effect. The advantages of the TM flatslide system include improved Needle Jet (D): The needle jet is press fit into carbs and is not throttle response and a significant reduction in throttle effort replaceable.

  • Page 95: Mikuni Carburetor

    CARBURETION components. The float level is pre-set in the molding and vapor, to mix the fuel with air in a proper ratio, and to deliver cannot be adjusted. the mixture to the engine. A proper ratio means an ideal air/ fuel mixture which can burn without leaving an excess of fuel or air.

  • Page 96: Fuel Metering

    CARBURETION FUEL METERING The mixture is regulated to some degree by adjusting the air screw. When the air screw is closed, the fuel mixture is made richer as the amount of air is reduced. When the air screw is opened, the mixture is made more lean as the amount of air is increased.

  • Page 97: Jetting Guidelines

    CARBURETION PISTON VALVE or THROTTLE VALVE which will pass through it in one minute under controlled conditions. Larger numbers give a greater flow, resulting in a richer mixture. Main jets are screwed directly into the needle jet base. JETTING GUIDELINES Changes in altitude and temperature affect air density, which is essentially the amount of oxygen available for combustion.

  • Page 98: Needle Jet

    CARBURETION provided in the head of the jet needle. The chart at right shows needle jet brings in air measured by the air jet. This air the variation of fuel flow based on the height of the “E" ring. initiates the mixing and atomizing process inside the needle jet.

  • Page 99: Mikuni Tm38 Flat Slide Service

    CARBURETION MIKUNI TM38 FLAT SLIDE installing the needle and e-ring back into the carburetor. SERVICE Inspect the needle (7), e-clip (8), and plastic washer (9) for wear. DISASSEMBLY CAUTION EAR EYE PROTECTION WHEN USING COMPRESSED AIR OR WHEN USING CLEANING SOLVENTS EVIEW ALL FUEL SYS TEM WARNINGS LOCATED AT THE BEGINNING OF THIS CHAP TER BEFORE PROCEEDING...

  • Page 100: Assembly

    CARBURETION 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) and clean them out.

  • Page 101: Carburetor Syncronization

    CARBURETION with float and seat). Remove the carburetor tops. Hold the throttle wide open with the bellcrank on the carburetor. The bottom of the throttle valve should be flush with the top of the carburetor intake area. If they are not flush, hold the PTO carburetor flush with the top of the intake area of the carburetor.

  • Page 102: Throttle Position Sensor

    The TPS comes set form the factory and should not need any adjustments. However, if the TPS was moved or removed for any reason, Polaris has developed a TPS sensor tool that will assist you in correctly setting the TPS to specification.

  • Page 103: Carburetor Cable Adjustments

    CARBURETION CARBURETOR CABLE .250in (.3-.6cm) toggle free play(4). ADJUSTMENTS CHOKE ADJUSTMENT With the dash mounted choke control toggle flipped to the off position, the choke plunger must be seated on the fuel passage way in the carburetor. If the plunger is not seated on the passage way, the engine will flood or run too rich, causing plug fouling and very poor engine performance.

  • Page 104: Carburetor Component Part Numbers

    CARBURETION CARBURETOR COMPONENT MIKUNI JET NEEDLES PART NUMBERS Table 4-4: Mikuni Jet Needles MIKUNI PILOT JETS JET NEEDLE PART NUMBER J8-9FH04-57 3130794 Table 4-2: Mikuni Pilot Jets J8-9EH01-57 3130795 PILOT JET NUMBER PART NUMBER J8-9DH01-54 3130796 3130064 J8-8BEY01 3131250 3130065 J8-9DFH06-57 3131253 3130066...

  • Page 105: Mikuni Pilot Air Jets

    CARBURETION MIKUNI PILOT AIR JETS MIKUNI PISTON VALVES Table 4-6: Mikuni Pilot Air Jets (SHORT) Table 4-8: Mikuni Piston Valves AIR JET PART NUMBER PISTON VALVE PART NUMBER 3130773 3130940 3130774 3131252 3130775 3130790 3130776 3130791 3130777 3130792 3130778 3130793 3130799 3130780 3130781...
  • Page 106 CARBURETION 4.18...
  • Page 107 CLEANFIRE FUEL INJECTION CHAPTER 5 CLEANFIRE FUEL WARNINGS ............5.2 WHEN EVER SERVICING THE CARBURETOR OR FUEL SYSTEM, IT IS IMPORTANT TO HEED THE FOLLOWING WARNINGS.5.2 GENERAL INFORMATION .

  • Page 108: Warnings

    CLEANFIRE FUEL INJECTION WARNINGS 2 STROKE GASOLINE / OIL PRE MIX see “2 STROKE GASOLINE / OIL PRE MIX” on page 2.10 When ever servicing the carburetor or fuel system, it is important to heed the following FUEL DELIVERY SYSTEM warnings.

  • Page 109: Pump Flange Assembly

    CLEANFIRE FUEL INJECTION PUMP FLANGE ASSEMBLY resistance below is from the Violet/White (#2) wire to the Brown (#4) wire located at the front of the fuel pump. FUEL PUMP Table 5-2: Level Sender Resistance TANK LEVEL RESISTANCE (Ω) 2 - 4 Ω FULL 85 - 95 Ω...

  • Page 110: Fuel Rail Bleeding

    CLEANFIRE FUEL INJECTION Torque the fuel rail fasteners to 108 in-lb (12Nm). INJECTOR REPLACEMENT FUEL RAIL BLEEDING If it is verified that a injector needs to be replaced, you must first find out what injector color is on the unit. You can do this The fuel pressure gauge (PN PV-43506-A) is used to check by checking the decal that is located on the top portion of the the pressure in the fuel rail lines or to bleed the fuel rail...
  • Page 111 CLEANFIRE FUEL INJECTION the tip separates from the lever tab. lever. Make sure that both throttle plates are full closed. Idle screw separated form the lever Both throttle plates should be evenly closed Turn the synchronization screw out (counterclockwise) Connect the TPS tool. Make sure it is set up correctly until synchronization lever...

  • Page 112: Setting The Idle Voltage

    CLEANFIRE FUEL INJECTION 15. Lock the idle set screw lock nut. Remove the drive clutch. Loosen the throttle cable lock nut and remove cable from throttle body. Loosen the oil cable lock nut and remove the cable from the throttle body. Remove the coolant lines from the throttle body.
  • Page 113 ENGINE CHAPTER 6 ENGINE GENERAL ENGINE INFORMATION ........6.2 EXHAUST VALVE REMOVAL .

  • Page 114: General Engine Information

    ENGINE GENERAL ENGINE Fold the bellows up and remove the spring (1) and bellows nut (2) from the guillotine. INFORMATION EXHAUST VALVE REMOVAL WARNING Exhaust system temperatures can exceed 900_F (500_C). Serious burns may occur of this inspection is performed without allowing adequate time for the ex- haust system to cool.

  • Page 115: Exhaust Valve Installation

    ENGINE 10. Remove any gasket material from the base mating surface fasteners to 108 in-lb (12Nm). on the cylinder. EXHAUST VALVE INSTALLATION Place a new gasket on the valve base. Place the guillotine in to the cylinder. IMPORTANT: The guillotine is orientated into the cylinder so that the larger shoulder (5) is located at the bottom and matches the cylinder area.

  • Page 116: Reed Valve Assembly

    ENGINE REED VALVE ASSEMBLY THERMOSTAT REPLACEMENT Place the reeds (3) and throttle body adapters (2) onto the engine case. Torque the throttle body adapter fasteners (1) to 108 in-lb (12Nm). EXHAUST VALVE SPRINGS Table 6-1: Exhaust Valve Springs FREE SPRING # COLOR LENGTH 7041704-01...

  • Page 117: 700/900 Engine

    ENGINE 700/900 ENGINE Table 6-2: ENGINE 700/900 700/900 TORQUE SPECIFICATIONS SPARK PLUG 18 ft-lb (24Nm) CYLINDER HEAD 27ft-lb (37Nm)1,3 When tightening bolts, nuts, or screws, a torque pattern should BLEEDER SCREW 48 in-lb (4.5Nm) be followed to ensure uniform equal tension is applied to all THERMOSTAT HOUSING 108 in-lb (12Nm) fasteners.

  • Page 118: 700/900 Liberty Engine Removal

    20. Loosen the throttle adjustment lock nut and remove disassembly. Replace all seals, o-rings, and gaskets throttle cable from the throttle body. with Genuine Pure Polaris parts during assembly. 21. Disconnect the throttle cable from the throttle body. Refer to the ‘INSPECTONS” on page 3.5 for general 22.
  • Page 119 ENGINE wiring harness located under the ECU area. Each injector 31. Disconnect the Crank Position Sensor connector (8). should be labeled. 32. Disconnect the DET sensor harness (9). Injector Connection 26. Locate the fuel filter and remove the filter bracket (4), to make room to remove the fuel line clip (5).

  • Page 120: 700/900 Liberty Engine Installation

    ENGINE cooling hoses, injectors and harness. 11. Orientate these connectors like they were as best you can. 37. Place engine at work station. 700/900 LIBERTY ENGINE INSTALLATION IMPORTANT: ALL Oil lines should have no air present in the lines. Cable Ties Make sure that you have everything on the engine as you had when you removed the engine.
  • Page 121 ENGINE 17. Insert a cable tie (3) around the coolant line and the throttle 27. Orientate the center crankshaft supply line (6) so that it is cable at the top of the coolant line. closer to the engine and the fuel line (7) and the wiring harness away from the engine.
  • Page 122 ENGINE 35. Install a cable strap (9) around the coolant lines and the wiring harness at the relay area of the wiring harness and at the shock tower area. 36. Install the left hand brace onto the left side of the bulkhead in the same manner as the right side.

  • Page 123: 700/900 Engine Rebuilding

    ENGINE 700/900 ENGINE REBUILDING 22(29) 23(31) 700/900 DISASSEMBLY Remove the cylinder bolts (4). Remove the cylinders (5). Remove the recoil housing and stator. See “700/900 10. Remove the MAG side piston c-clips from the pistons. RECOIL/STATOR DISASSEMBLY” on page 6.14 Remove the fuel rail.

  • Page 124: 700/900 Torque Patterns

    23 ft-lb (31Nm). Lubricate the piston pin bearings and the piston pins with Polaris 2 stroke oil and install the piston onto the crankshaft with the piston pin removal/installation tool. Install new c-clips in the piston grooves with the gap...
  • Page 125 ENGINE Remove the water pump cover (2) and gasket (3). With two flat head screw drivers pry the water pump seal out by lifting up on the seal flange. This will crush the flange upward. Pry the mechanical seal out of the case. Remove the impeller nut and washer.

  • Page 126: 700/900 Water/Oil Pump Cross Shaft Assembly

    ENGINE Remove the snap ring from the case. 700/900 RECOIL/STATOR DISASSEMBLY Remove the cross shaft and bearings. Remove the recoil housing fasteners (1). 700/900 WATER/OIL PUMP CROSS SHAFT ASSEMBLY NOTE: Cross shaft assembly (PN) comes with the shaft, gear, seal, snap ring, mechanical seal. Insert the cross shaft and bearings into the crankcase.

  • Page 127: 500/600 Ho Engine

    Torque the flywheel holding nut to 90 ft-lb(122Nm). disassembly. Replace all seals, o-rings, and gaskets Replace the recoil basket fasteners to 108 in-lb (12Nm). with Genuine Pure Polaris parts during assembly. Refer to the ‘INSPECTONS” on page 3.5 for general Replace the recoil housing.
  • Page 128 ENGINE 11. Remove the cable tie (3) that secures the DET wire to the 15. Disconnect the throttle position sensor (TPS) from the exhaust valve vent line. carburetor. 16. Disconnect the Regulator Rectifier (6) and the Stator connections (7). These are located behind the brake disc area.
  • Page 129 ENGINE 22. Move the hose clamp (9) and remove this front radiator 26. Remove the inside motor mount fastener (13), located hose from the coolant bottle, and secure it out of the way. under the PTO carburetor boot. 23. Remove the coolant supply hose that is located at the 27.
  • Page 130 ENGINE 30. Remove the LH nose pan plug located on the nose pan 35. Remove the cable from the engine. Loosen up the lock next to the shock tower. This will allow access to the front nuts (20). fasteners for the LH chassis brace. 31.

  • Page 131: 600 Iq Engine Installation

    ENGINE 600 IQ ENGINE INSTALLATION Insert the LH rear torque stop plate (3) between the motor mount and the bulk head. Make sure that you have the engine assembled so that it is Apply blue Loctite to the fastener (4) and torque all the in the same state as it was when it was removed.
  • Page 132 ENGINE 10. Insert the front torque stop assembly (8) and torque the 14. Connect the thermostat cooling hose and secure it with the fasteners (9) to 28 ft-lb (38Nm). clamp (14). 11. Install the RH rear (10) and front (11) motor mount 15.
  • Page 133 ENGINE 20. Connect the exhaust valve vent lines (18). Secure the DET sensor wire with a cable tie (19). 21. Install the oil supply lines to each of the carburetors. 22. Install the carburetors onto the carburetor boots and tighten the clamps.

  • Page 134: 500/600 Ho Engine Rebuilding

    ENGINE 500/600 HO ENGINE REBUILDING 500/600 LIBERTY ENGINE DISASSEMBLY 22(29.8) 32(43.4) 22(29.8) 5(6.8) Remove reed valve assembly pins, and the piston from the crankshaft (15). Remove the head bolts (1). Remove the water pump cover. Remove the head cover (3) and the rubber head seals (4). 10.
  • Page 135 ENGINE bolts (17,18). 14. Turn the crankcase assembly back over and remove the top of the crankcase (12). 15. Remove the crankshaft, and refer to the General chapter general engine component inspections measurement procedures. 6.23...

  • Page 136: 500/600 Ho/600 Liberty Torque Patterns

    22 ft-lb(30Nm) in the case pattern shown in the left column. Lubricate the small end bearings (13) and the piston pins with Polaris 2 stroke oil and install the piston onto the crankshaft with the piston pin removal/installation tool PN 2870386.

  • Page 137: 500/600 Liberty Water/Oil Pump Cross Shaft Assembly

    ENGINE with Genuine Pure Polaris parts during assembly. Remove the impeller (7) and flat washer (8). Refer General chapter for general inspection Remove the cross shaft (9) by hitting the shaft from the procedures. waterpower side with a rubber hammer.

  • Page 138: 500/600 Recoil/Stator Removal

    17. Remove the engine. 18. Install in reverse order. 500/600 RECOIL/STATOR ASSEMBLY NOTE: Inspect all parts for wear or damage during disassembly. Replace all seals, o-rings, and gaskets with Genuine Pure Polaris parts during assembly. Refer General chapter for general inspection procedures. 6.26...

  • Page 139: 340/550 Engine Rebuilding

    ENGINE 340/550 ENGINE REBUILDING 6.27...

  • Page 140: 340/550 Engine Disassembly

    18. Remove the cylinder base nuts (13) and carefully remove 11. Apply Polaris 2-Stroke engine oil to the wrist pins and the each cylinder. small end bearings and install them onto the crankshaft 19.

  • Page 141: 500 Fuji

    NOTE: Inspect all parts for wear or damage during disassembly. Replace all seals, O-rings, and gaskets •550 = 17-21 ft-lb (23-28 Nm) with Genuine Polaris parts during assembly. Refer to General Section for Inspection Procedures. CYLINDER HEAD TORQUE PATTERN-FUJI Remove carburetors, recoil housing and exhaust manifold.

  • Page 142: Assembly

    ENGINE Mark stator plate and crankcase for reference when component inspection (i.e. crankshaft and crankcase reassembling the engine. inspection, piston clearance, oil pump drive gear end play etc.). ASSEMBLY Grease oil pump drive gear area. Seals should be installed with spring and lip facing inward toward crankshaft. Turn bearing until anti-rotation pins are positioned in the proper location.
  • Page 143 ENGINE Install pistons with F" mark or arrow toward flywheel. Install C-clip using installation tool PN 2870773. Install new base gasket. Mount gasket with the white sealing material facing up. Lubricate rings and pistons with two stroke oil. Install rings with letter, mark, or beveled side facing upward. Lubricate rings and cylinder with Premium 2 Cycle Lubricant and compress rings with fingers, aligning end gaps with locating pins.
  • Page 144 ENGINE 12. Install cylinder head and torque cylinder head nuts to 18 - 20. Adjust tension on water pump belt by loosening mounting 19.5 ft-lb (25-27Nm) following the torque pattern. bolts, applying tension, and re-tightening bolts. 21. Install recoil housing and carburetors. 22.
  • Page 145 DRIVE BELT REMOVAL WITH POLARIS DRIVEN CLUTCH..... 7.5 BELT INSTALLATION (POLARIS DRIVEN CLUTCH)......7.5 DRIVE SYSTEM TERMINOLOGY.
  • Page 146 POLARIS BELT DEFLECTION ........

  • Page 147: Special Clutch Tools

    All drive clutch maintenance, disassembly and assembly must descriptions of all tools. A tool catalog update may be be performed only by an authorized Polaris dealer who has available through the SPX parts department (Phone Number 1- attended current model Dealer Service Seminars, has received 800-328-6657).

  • Page 148: Drive Belt

    CLUTCHING DRIVE BELT • Top Edges have been trimmed on some drive belts. It will be necessary to project the side profiles and measure from corner to corner. BELT INSPECTION • Place a straight edge on each side of the drive belt and measure the distance where the straight edges intersect at the top (A,B).

  • Page 149: Drive Belt Removal With Team Clutch

    CLUTCHING DRIVE BELT REMOVAL WITH TEAM CLUTCH NOTE: Before attempting to remove the drive belt, Remove the “L” wrench. verify the engine is in forward mode, not reverse WARNING (PERC) or, the chaincase is in forward mode (PERC 4). Turn the key to the “OFF” position and allow the It is very important to remove the L wrench after the belt engine to come to a complete stop.

  • Page 150: Drive Belt Removal With Polaris Driven Clutch

    CLUTCHING DRIVE BELT REMOVAL WITH POLARIS DRIVEN CLUTCH BELT INSTALLATION (POLARIS DRIVEN To ensure belt life, install belts so they operate in the same direction of rotation. Position the identification numbers so CLUTCH) that you can read them standing on left side of machine. This Drop the drive belt over the drive clutch and pull back the will keep the belt rotating in the same direction.

  • Page 151: Drive System Terminology

    All clutch maintenance repairs must be performed only the sled will accelerate along the low ratio line until the drive by an authorized Polaris service technician who has at- clutch up shift force overcomes the opposing shift force tended a Polaris sponsored service training seminar generated by the driven clutch.

  • Page 152: Back-Shifting

    CLUTCHING BACK-SHIFTING LOW / HIGH RATIO LINES Back-shifting occurs when the track encounters an increased The low ratio line is the mechanical position when the drive load (demand for more torque). Back-shifting is a function of belt is all the way down into the drive clutch, and all the way a higher shift force within the driven clutch then within the out on the driven clutch.

  • Page 153: Centrifugal Drive System

    Note that the shift out overrev occurs for a tighter tolerance components and refined drive brief amount of time and drops back to the desired engine system calibration in Polaris snowmobiles has virtually eliminated shift out overreving. DRIVE CLUTCH pre-load force, and begin to close the moveable sheave.

  • Page 154: Drive Clutch Identification

    CLUTCHING DRIVE CLUTCH IDENTIFICATION Every clutch will have the last three digits of the clutch part the clutch does not “pop” off, continue to tighten the number etched on to the cover (A). The “X" (B) marking is an clutch puller, and repeat this step. index mark where the clutch cover (C), clutch spider (D) and the stationary sheave (E) should line up when the clutch is assembled.

  • Page 155: Drive Clutch Components

    CLUTCHING DRIVE CLUTCH COMPONENTS NOTE: Replacement clutches come complete and balanced without clutch weights and clutch spring. The clutch cover, spider, and sheaves cannot be purchased separately as replacement parts. 7.11...
  • Page 156 CLUTCHING 7.12...

  • Page 157: Drive Clutch Disassembly

    CLUTCHING 8700220). DRIVE CLUTCH DISASSEMBLY Compress the clutch in the compression tool and lock the compression tool, making sure that all cover bolts (2) are Table 7-3: Drive Clutch Service Components accessible. ITEM DESCRIPTION TORQUE SPECIFICATION/ Remove the cover bolts and washers (2) evenly and NOTES carefully.

  • Page 158: Drive Clutch Spider Removal/Installation

    CLUTCHING removed. Install the head of the weight pin (12) so that it is on the leading side of rotation. This will orientate the nut (11) on the trailing side of rotation. Torque weight pin to 30 in-lb (3Nm). Place the moveable sheave (8) onto the stationary sheave (10). Place the same number of spacers (18) under the stepped washer (17) onto the shaft of the stationary sheave.

  • Page 159: Roller Installation

    CLUTCHING ROLLER INSTALLATION SPIDER INDEXING CAUTION: Use care to start the pin straight. Aluminum burrs could pass through into the roller bushing causing it to bind and stick. Also use care to make sure the roller remains aligned when the pin is driven through. The roller busing could be damaged causing premature wear and roller failure.

  • Page 160: Spring Free Length

    CLUTCHING PN 5210752.020" (.5mm) belt tension, belt to sheave clearance, and internal condition of the drive and driven clutch components. One of the most Install spider washer(s) and spider aligning the “X” with critical and easily serviced parts is the drive clutch spring. Due the moveable sheave’s “X”.
  • Page 161 CLUTCHING Table 7-4: Drive Clutch Springs FORCE LOAD WIRE PART FREE LENGTH LBS.@2.50” - RATE COLOR DIAMETER NUMBER +/-.125” 1.19” (+/- 12 (lbs./ (inches) LBS.) inch) 7041083 .192 3.77 120-245 7041102 Yellow .192 2.92 44-185 7041061 Brown .200 3.14 69-212 7041132 White .177...

  • Page 162: Drive Clutch Weights

    CLUTCHING Table 7-7: 11 Series Weights Drive Clutch Weights WEIGHT GRAMS(+/- .8g) PART NUMBER Table 7-5: Full Tail Weights 11-50 1322589 WEIGHT GRAMS PART NUMBER 11-52 1322595 S43H 1321849 11-64 1322604 S45H 1321850 11-66 1322559 S47H 1321851 11-68 1322558 S49H 1321730 11-70 1322523...

  • Page 163: Drive Clutch Installation

    CLUTCHING DRIVE CLUTCH INSTALLATION NOTE: Always clean the clutch taper before re- taper to corrode, or damage to the crank seal. This may installing clutch on engine. cause difficulty when removing clutch in the future. Place a clutch taper reamer (PN 2870576) in a vise (A) and Clean clutch taper with lacquer thinner or isopropyl lubricate the cutting edges with cutting oil.

  • Page 164: Driven Clutch

    Install the driven clutch bolt with the same amount of washers (B) at removal. Torque the bolt to 17 ft-lb (23Nm). Polaris utilizes two types of driven clutches, the P-85 driven Check for correct belt deflection see page See “BELT clutch and the Team driven clutch.

  • Page 165: Team Ramps Explained

    CLUTCHING TEAM RAMPS EXPLAINED ER RAMP NON ER RAMP The ramps for the Team roller clutch is designated by the angle and length of the angle on the back side of the ramp. You will see that the first number (A) designates the steepest angle, which is the starting angle of the ramp. The second number (B) designates the lowest angle that it progresses to.
  • Page 166 CLUTCHING Table 7-9: Team Driven Ramps for Non Electric Reverse PART NUMBER DESCRIPTION 66/44-46 5133321 70/48-36 74/48-46 5133491 70/48-46 74/48-46 5133492 74/40-46 72/44-46 5133493 72/40-46 70/44-46 5133494 70/40-46 68/44-46 5133495 68/40-46 66/48-46 5133496 66/40-46 64/44-46 5133497 64/40-46 62/44-46 5133498 62/40-46 58/44-46 5133499 58/40-46...

  • Page 167: Polaris P-85 Helix

    54/42-46 ER 5135057 62/38-36 ER 5133904 S36 ER 5133887 S40 ER 5135256 64/42-36 ER 5135242 64/38-25 ER 5135243 64/36-25 ER POLARIS P-85 HELIX Table 7-11: P-85 Helix PART NUMBER DESCRIPTION DEGREES 5130896 34 D 5130895 36 D 5131287 40-32 5131289 45-32...
  • Page 168 Red/Blue .218 7043063 Black/Red .218 7043064 Blue/Black .218 7043060 Red/White .218 7043069 Red/Pink .235 Table 7-13: Polaris Driven Spring Data PART NUMBER COLOR WIRE DIAMETER LOAD @ 2.5″(lbs) LOAD @ 1.375″(lbs) 7041198 .170 7041296 Blue .192 7041499 Silver .188 7041646 Silver/Blue .183...

  • Page 169: Drive System Adjustments

    CLUTCHING DRIVE SYSTEM ADJUSTMENTS CLUTCH ALIGNMENT The engine is mounted into the bulk head so that when the 0 - .060” torque of the belt is under power it, will produce clutches that are aligned. CLUTCH ALIGNMENT INSPECTION Remove drive belt, See “DRIVE BELT REMOVAL WITH TEAM CLUTCH”...
  • Page 170 CLUTCHING POLARIS BELT DEFLECTION 48-72 in-lb 5-8Nm POLARIS CLUTCH Pull belt into driven clutch to slightly open sheaves. Loosen three bolts (A) on adjustment cam. Turn cam (B) counterclockwise to reduce distance between sheaves, and turn it clockwise to increase the distance between the sheaves.
  • Page 171 CLUTCHING DRIVE BELT DATA Table 7-14: Belt Width Side Center to Outer Part (Projected)* Angle Center in/ Circumfere Notes Number in/mm Overall* nce in/cm 3211042 1.375/34.9 12/30 47.25/120 Common production belt. 47.125/ 3211045 1.375/34.9 12/30 Close tolerance version of 3211042 119.7 3211058 1.250/31.75...
  • Page 172 CLUTCHING GENERAL BELT SELECTION GUIDELINES Refer to appropriate parts manual for proper belt fit. Production belt is recommended unless tuning for specific application. • Increased service life for high horsepower and extended high speed running. • Need 1-2 grams heavier drive clutch weight. •...
  • Page 173 FINAL DRIVE CHAPTER 8 FINAL DRIVE GEARING CHARTS........... . 7.2 CHAINCASE SPEED CHARTS .
  • Page 174 FINAL DRIVE GEARING CHARTS CHAINCASE SPEED CHARTS Table 8-1: Chaincase Speed Cart Top Gear Bottom Gear 7.92 8.373 11.35 8.424 Gear Ratio 1.35 1.38 1.50 1.54 1.44 1.48 1.52 1.56 1.60 1.64 1.68 1.72 1.76 1.54 1.58 1.63 1.67 1.71 Jackshaft RPM 6000 6250...
  • Page 175 FINAL DRIVE Table 8-2: Chaincase Speed Cart Top Gear Bottom Gear 7.92 8.373 11.35 8.424 Gear Ratio 1.75 1.79 1.61 1.65 1.70 1.74 1.78 1.83 1.87 2.00 1.68 1.73 1.77 1.82 1.86 1.91 1.95 2.09 Jackshaft RPM 6000 6250 6500 6750 7000 7250...
  • Page 176 FINAL DRIVE Table 8-3: Chaincase Speed Cart Top Gear Bottom Gear 7.92 8.373 11.35 8.424 Gear Ratio 1.76 1.81 1.86 1.90 1.95 2.00 2.05 2.10 2.19 2.24 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.25 Jackshaft RPM 6000 6250 6500 6750 7000 7250...
  • Page 177 FINAL DRIVE Table 8-4: Chaincase Speed Cart Top Gear Bottom Gear 37 7.92 NR NR NR 72 NR 74 8.373 NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR 11.35 NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR 8.424 NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR...

  • Page 178: Gears And Chains

    FINAL DRIVE GEARS AND CHAINS GEARS Table 8-5: Chaincase Gears PART DESCRIPTION CHAINCASE FIT NUMBER 3221093 17T, 3/4W, 15 SPL, HYVO, PM 3221094 18T, 3/4W, 15 SPL, HYVO, PM 3221095 19T, 3/4W, 15 SPL, HYVO, PM 3221096 20T, 3/4W, 15 SPL, HYVO, PM 7.92 3221097 21T, 3/4W, 15 SPL, HYVO, PM...

  • Page 179: Drive Chain

    FINAL DRIVE DRIVE CHAIN Table 8-6: Drive Chains PART DESCRIPTION CHAINCASE FIT NUMBER 3221114 64P, 3/4W, HYVO CHAIN 3221113 66P, 3/4W, HYVO CHAIN 3221112 68P, 3/4W, HYVO CHAIN 7.92 3221115 70P, 3/4W, HYVO CHAIN 8.37 11.35 3221110 72P, 3/4W, HYVO CHAIN 3221109 74P, 3/4W, HYVO CHAIN 3221108...

  • Page 180: 8.37 Chaincase Removal

    FINAL DRIVE Table 8-7: Chaincase ITEM DESCRIPTION TORQUE SPECIFICATION / NOTES Cover bolts 8 ft-lb(11Nm) Chaincase cover Cover gasket make sure that the gasket is not pinched during assembly Cotter pin bend the ends over the nut flats when installing Jackshaft nut 50 ft-lb (62.5Nm) Washer...

  • Page 181: 8.37 Chaincase Installation

    FINAL DRIVE 8.37 CHAINCASE INSTALLATION 31. Check for leaks. 32. Adjust track tension to the specified tension. See “Track Install the seal sleeve and o-ring onto jackshaft. The seal Tension Data” on page 3.21 sleeve goes on first then the o-ring. 33.

  • Page 182: Chaincase Seal/Bearing Replacement

    FINAL DRIVE Insert carriage bolts through the back side of the chassis chain case so that the bearings drop out of the front. If the and install the nylock nuts loosely. bearing pushes out hard, warm the area to expand the chaincase bore slightly.

  • Page 183: Drive Train

    FINAL DRIVE DRIVE TRAIN JACKSHAFT EXPLODED VIEW Table 8-8: Jackshaft ITEM DESCRIPTION TORQUE SPECIFICATION / NOTES Chaincase 7.92, 8.37, 8.47 O-ring 8.37 chaincase - install seal sleeve (C) first, then o-ring (B) on jackshaft 7.92 chaincase - install o-ring (B) first then seal sleeve (C) on jackshaft. Seal Brake Disk Minimum thickness = .193”...

  • Page 184: Jackshaft Removal

    FINAL DRIVE Table 8-8: Jackshaft ITEM DESCRIPTION TORQUE SPECIFICATION / NOTES Speedo Wheel Pick Up and bolt 12-15 ft-lb (8.8-11Nm) Drive Shaft 7.92 chaincase - install o-ring (B) first then seal sleeve (C) on driveshaft. Chaincase Carriage Bolt Nylock Nut 20 ft-lb (27 Nm) JACKSHAFT REMOVAL hole in bearing with hole or fitting in flangette.

  • Page 185: Driveshaft

    FINAL DRIVE DRIVESHAFT DRIVE SHAFT REMOVAL Remove the side panels. Remove the intake plenum. Remove the drain plug (1) and drain the chaincase fluid. Replace the chaincase drain plug and torque it to 8 ft-lb (11Nm). Remove the chaincase cover (2). Loosen the tensioner (3).

  • Page 186: Widetrak Transmission

    FINAL DRIVE WIDETRAK TRANSMISSION 12. Loosen rear idler wheels and bolts. 13. Loosen jam nuts on adjustment bolts on both sides. Back out adjustment bolts to allow rear idler assembly to come REMOVAL forward, relieving track tension. Hood can be removed to prevent damage. Mark hood 14.

  • Page 187: Inspection

    FINAL DRIVE NOTE: Note position of spacer washers behind disc 21. Remove angle drive housing, adaptor key, flangette, gasket, and bearing from drive shaft and tunnel. for proper alignment upon reassembly. NOTE: It is not necessary to remove speedometer Remove detente spring and ball. cable from angle drive.
  • Page 188 FINAL DRIVE Remove output gear assembly (7) and chain (8). Mark 12. Gear, shaft, and chain cluster assembly shown. chain direction for reference during reassembly. Inspect gear teeth for damage. Inspect chain for worn, cracked, or broken link plates. GEAR ASSEMBLY 13.

  • Page 189: Low/Reverse Shaft Disassembly

    FINAL DRIVE 15. Reverse output power flow... Remove low reverse shaft (1), low gear (2), needle bearing (3), thrust washer (4), low/reverse dog gear (5). Remove Snap ring (6), thrust washer (7) (.125”), reverse idler (8), and thrust washer (9) (.065”). REVERSE LOW/REVERSE SHAFT DISASSEMBLY Press bearing from end of shaft using a bearing separator.

  • Page 190: Transmission Assembly

    Install nuts and finger tighten. Tip machine onto its left side. 10. Replace O-rings on input and output shafts. Apply Polaris All Season Grease to drive shaft coupler splines. 11. Reinstall transmission, using care not to damage coolant hoses.
  • Page 191 21. Tip machine back onto floor and tighten all suspension bolts to specification. 22. If jackshaft was removed from unit, grease coupler spline with Polaris Premium All Season Grease and install on transmission. 23. Reattach transmission shift linkage and brake light connector.
  • Page 192 FINAL DRIVE 8.20...
  • Page 193 BRAKES CHAPTER 9 BRAKES HYDRAULIC BRAKE SYSTEM ......... . . 8.2 OVERVIEW .

  • Page 194: Hydraulic Brake System

    WARNING OVERVIEW Contaminated brake discs or brake pads greatly reduce The Polaris snowmobile hydraulic brake system consists of braking performance and increase stopping distance. the following components or assemblies: brake lever, master Do not attempt to clean contaminated pads. Replace cylinder, hydraulic hose, brake caliper (slave cylinder), brake them.

  • Page 195: Brake Fluid Replacement & Bleeding

    BRAKES • Small amounts of air can become trapped in the banjo air, repeat this step until you see only fluid coming out. bolt fittings at the master cylinder(s) and junction points This may take several intervals. of brake lines. These fittings can be purged of air by following a standard bleeding procedure at these fittings (instead of the bleed screw on caliper) if necessary to speed the bleeding process.

  • Page 196: Brake Light Switch Replacement

    BRAKES Attach the other end to a Mity Vac or similar vacuum tool. FLUID REPLACEMENT & BLEEDING” on page 9.3. Bleed the system of brake fluid. Note the orientation of the brake line. The brake line will need to be replaced in the same orientation. Remove the brake line from the caliper.

  • Page 197: Caliper Replacement

    BRAKES CALIPER REPLACEMENT BRAKE PAD REPLACEMENT Brake Pad The only serviceable item in the brake caliper is the brake Brake pads need to be replaced if the total pads. If any service is required of the caliper a new caliper is thickness of the pads and backing are less available.

  • Page 198: Assembly

    BRAKES from the return spring. Install spring and arm with arm located in 2:00 position. Install lower guide bushing and both spring clips. Place pads against lower bushing spring clip and tip into Remove the arm using care not to lose the balls, ball position.
  • Page 199 FRONT SUSPENSION/STEERING CHAPTER 10 FRONT SUSPENSION/ FUSION/IQ RMK ........... . . 10.2 EDGE RMK .

  • Page 200: Fusion/Iq Rmk

    FRONT SUSPENSION/STEERING FUSION/IQ RMK 10.2...

  • Page 201: Edge Rmk

    FRONT SUSPENSION/STEERING EDGE RMK 10.3...

  • Page 202: 42.5 Edge

    FRONT SUSPENSION/STEERING 42.5 EDGE 10.4...

  • Page 203: Widetrak

    FRONT SUSPENSION/STEERING WIDETRAK 10.5...

  • Page 204: Front Suspension Adjustment Procedures

    FRONT SUSPENSION/STEERING FRONT SUSPENSION ADJUSTMENT PROCEDURES SET UP AND ADJUSTMENTS Spring preload is one of the adjustment options which affects ride. Preload is the amount of pressure at which the spring is held. The longer the installed length of the spring, the less the amount of pre-load; the shorter the installed length of the spring, the more the amount of pre-load.

  • Page 205: Ifs Shock Springs

    FRONT SUSPENSION/STEERING IFS SHOCK SPRINGS Table 10-1: IFS Shock Springs Part Total # of Free Rate #/in) Wire Via. I.D." O.D.” Tabbed? Number Coils Length 7041261 10.25 0.312 1.84 7041396 13.35 11.88” .283” 1.89” 2.82 7041398 12.72 11.88” .312” 1.89” 2.88 7041405 13.40...

  • Page 206: Springs

    If the force were 450 pounds, a 100 #/in. spring would compress 4.5 inches. A 150 #/in. Two types of springs are employed in Polaris suspensions, coil spring would only compress 3 inches. If the suspension had 4 springs and torsion springs.

  • Page 207: Shock Information

    FRONT SUSPENSION/STEERING stops. Backing off 1/4 turn counter-clockwise at this point Riding conditions are ever changing. Keep in mind the should give you the best possible ride ensuring use of the full compression damping adjustable screw can be adjusted at any travel of the suspension.

  • Page 208: Ifs Shock Production Valving

    FRONT SUSPENSION/STEERING IFS SHOCK PRODUCTION VALVING Table 10-5: IFS 7043095 .875x.090 The valving charts are listed in compression sections and .625x.065 rebound sections. A compression stack will be located nearest .700x.006 the eyelet of the shock rod. A rebound stack will be located nearest the threaded end of the shock rod.
  • Page 209 FRONT SUSPENSION/STEERING Table 10-7: IFS 7043082 .800x.012 .900x.012 1.000x.012 1.100x.010 1.250x.008 1.300x.010 .900x.006 1.250x.008 1.300x.008 Piston orifice .093 1.250x.006 1.100x.010 1.000x.010 .900x.010 .800x.010 10.11...

  • Page 210: Iq Front Suspension

    FRONT SUSPENSION/STEERING IQ FRONT SUSPENSION 10.12...
  • Page 211 FRONT SUSPENSION/STEERING Table 10-8: IQ Front Suspension ITEM DESCRIPTION TORQUE SPECIFICATION / NOTES Lower A-Arm pivot bolt Flat washer Critical for spacing the bolt from the sway bar. Pivot Shaft Flanged nut 40 ft-lb (54Nm) Pivot Bushing Upper A-Arm pivot bolt Pivot shaft Flanged nut 40 ft-lb (54Nm)

  • Page 212: Spindle Removal

    Some of the fasteners used in the IFS are special and cannot spherical bearing. be purchased at a hardware store. Always use genuine Polaris Place the spindle onto the lower spherical bearing. parts and hardware when replacing front end components.

  • Page 213: Alingment Bar Specifications

    CAMBER &TOE SPECIFICATIONS The following table is the factory specifications for the 2006 Polaris Snowmobile front suspension set up. Maximum width and camber measurements are to be taken with the front end elevated and shocks at full extension. Toe alignment is measured at ride height. This means that the machine is on the ground and resting at normal ride height, not full rebound.

  • Page 214: Alignment Adjustments

    FRONT SUSPENSION/STEERING Table 10-9: 2006 Camber & Toe Disconnect the torsion bar. Specifications Measure spindle to chassis centering and record the measurement. MAXIMUM TOE OUT The spindle centering and set up width is controlled by SET UP CAMBER in/ (At ride SUSPENSION adjusting the radius rod lengths, and must not exceed the WIDTH in/cm...

  • Page 215: Iq Camber Adjustment

    FRONT SUSPENSION/STEERING side. Measure the distance (2) from the top of the bushing(s) removed. Record measurement alignment bar to the top of the ski mount hole with the To adjust the camber, unlock the lock nut (2) and adjust the bushing(s) removed.

  • Page 216: Ski Stance

    FRONT SUSPENSION/STEERING SKI STANCE ADJUSTMENT (RMK ONLY) WIDE SKI STANCE For maximum stability, install both of the spacers to the outside of the spindle NARROW SKI STANCE For maximum maneurverability, install both of the spacers to the inside of the spindle. 10.18...
  • Page 217 REAR SUSPENSION CHAPTER 11 REAR SUSPENSION REAR SUSPENSION SPECIFICATIONS ........11.2 MOUNTING TORQUE SPECIFICATIONS .

  • Page 218: Rear Suspension Specifications

    SUSPENSION COUPLING The shifting of weight from the skis to the track is called On all Polaris snowmobile rear suspensions, there are two weight transfer. As engine torque is applied to the drive axle torque arms that control the movement of the rail beam. Prior the torque is transferred to the track, pulling it forward.

  • Page 219: Rear Torsion Spring Tension Adjustment

    REAR SUSPENSION eliminating kickback. The factory setting are usually adequate The purpose of the front rear scissor stop (FRSS) is to control for all riders in all conditions. the bump attitude of the rear suspension. As the front torque arm (FTA) hits the bump, it forces the rear scissor to collapse a The rear rear scissor stop (RRSS) couples the movement o the predetermined amount, depending on the FRSS block position.

  • Page 220: Setting Rear Suspension Ride Height

    REAR SUSPENSION SETTING REAR SUSPENSION RIDE HEIGHT To set up the rear suspension torsion spring preload, based on rider preference and riding conditions. measure the distance between the ground and rear bumper with out the rider on the seat and the suspension at full SCISSOR STOP ADJUSTMENTS extension.

  • Page 221: Torsion Spring Adjustment

    REAR SUSPENSION TORSION SPRING ADJUSTMENT The dot is an indicator of HIGH the HIGH position. The sides are the LOW To adjust the rear torsion spring, rotate the adjuster cam to the position and the bottom desired adjustment. The cam has three sides, LOW, MEDIUM is the MEDUIUM and HIGH.
  • Page 222 REAR SUSPENSION TORSION SPRINGS The torsion spring tension is determined by the following Wire Diameter (B). factors. Number of coils (F). Degree of the open angle (G). Table 11-1: Square Torsion Springs SPRING PN WIRE # OF DEGREES SPRING LEG 1 LEG 2 COIL ID (last 3 digits...
  • Page 223 REAR SUSPENSION Table 11-1: Square Torsion Springs SPRING PN WIRE # OF DEGREES SPRING LEG 1 LEG 2 COIL ID (last 3 digits DIAMETER COILS OPEN WIDTH inches (C) inches (D) inches (E) inches (B) inches (F) ANGLE (G) inches (H) 7041856 LH .359 16.5...
  • Page 224 REAR SUSPENSION Table 11-1: Square Torsion Springs SPRING PN WIRE # OF DEGREES SPRING LEG 1 LEG 2 COIL ID (last 3 digits DIAMETER COILS OPEN WIDTH inches (C) inches (D) inches (E) inches (B) inches (F) ANGLE (G) inches (H) 7043128 LH .405 14.75...

  • Page 225: Installing Heavier Springs On Afusion Suspension

    REAR SUSPENSION INSTALLING HEAVIER SPRINGS ON A the coil stack of the torsion spring is wide enough to interfere with the suspension arm clamp nut. To work around this issue FUSION SUSPENSION you will need to order two (one for each side) of the following parts.

  • Page 226: M-10 Suspension

    REAR SUSPENSION M-10 SUSPENSION perform well in the moguls would not suit the preference of a groomed trail rider. M-10 OVERVIEW M-10 ADJUSTMENTS The FAST M-10 rear suspension has been designed and set up • Full Range Adjuster (FRA) to deliver a soft ride under average riding conditions. Rider •...

  • Page 227: M-10 Adjustments

    The primary adjustment on the M-10 suspension is the Full Range Adjustment (FRA). Adjusting the FRA will have to 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 228: M-10 Rear Spring Preload

    REAR SUSPENSION M-10 REAR SPRING PRELOAD NOTE: By design, the BIASED COUPLE design of the M-10 suspension displaces the rear arm as the front arm is compressed. This means that when you If FRA position alone does not allow the setup of the proper raise the front limiter strap, at some point you will amount of sag, the center retainer of the rear track shock can collapse the rear suspension arm, which will affect...

  • Page 229: Rail Slider

    Hi-Fax replacement on all Polaris models is similar. When any Remove the suspension from the tunnel. area of the Hi-Fax is worn to 1/8" (3 mm), it should be replaced.

  • Page 230: Shock Information

    REAR SUSPENSION SHOCK INFORMATION Table 11-5: Front Track Shocks Extended Collapsed Stroke Shock IFP Depth SHOCK PN BRAND Shaft PN Length (in) Length (in) (in) Rod (in) (in) 7041939 Arvin 12.16 8.58 3.59 7043096* Walker 12.10 8.60 3.50 .625 2.25 rr 1800227 7042085 Arvin...

  • Page 231: Valving Specifications

    REAR SUSPENSION VALVING SPECIFICATIONS Table 11-8: FTS 7041975 .800x.008 REAR SUSPENSION FRONT TRACK .900x.008 SHOCK (FTS) STOCK VALVING 1.000x.008 1.100x.010 Table 11-7: FTS 7043096 1.300x.008 .875x.090 1.000x.006 1.00xx.025 1.300x.008 1.10x.025 Piston orifice .070 .700x.010 1.250x.008 .800x.010 1.100x.010 .900x.010 1.000x.010 1.00x.008 .900x.010 1.10x.008 .800x.012...
  • Page 232 REAR SUSPENSION Table 11-10: FTS 7041975 Table 11-12: FTS 7043123 .800x.008 1.125x.093 .900x.008 1.100x.006 1.000x.008 1.300x.015 1.100x.010 1.000x.004 1.300x.008 1.300x.015 1.000x.006 1.300x.015 1.300x.008 1.300x.015 Piston orifice .070 Piston orifice .093 1.250x.008 1.250x.010 1.100x.010 1.100x.008 1.000x.010 .900x.008 .900x.010 .800x.008 .800x.012 .620x.093 Table 11-11: FTS 7042224 Table 11-13: FTS 7042335 1.125x.093...

  • Page 233: Rear Suspension Rear Track Shock (Rts) Stock Valving

    REAR SUSPENSION Table 11-14: FTS 7043142 REAR SUSPENSION REAR TRACK SHOCK (RTS) STOCK VALVING 1.125x.093 .700x.012 Table 11-15: RTS 7042129 .700x.012 1.125x.093 .900x.008 .900x.010 1.100x.008 1.000x.010 1.250x.008 1.100x.010 .900x.008 1.250x.012 1.250x.008 1.000x.006 1.300x.008 1.300x.010 Piston orifice .078 Piston orifice .063 1.250x.008 1.250x.015 .800x.008...
  • Page 234 REAR SUSPENSION Table 11-17: RTS 7043097 Table 11-18: RTS 7042216 .875x.090 1.125x.093 .625x.065 .900x.008 .700x.008 1.300x.012 .800x.008 1.300x.012 .900x.010 1.300x.012 1.000x.010 .800x.010 1.100x.008 1.300x.008 .900x.008 1.300x.006 1.100x.008 1.300x.008 .700x.010 Piston orifice .070 1.300x.012 1.250x.010 1.100x.010 1.300x.010 1.250x.012 Piston orifice .040 1.250x.012 1.250x.012 .800x.008...
  • Page 235 REAR SUSPENSION Table 11-19: RTS 7043190 1.125x.093 .900x.008 1.300x.008 1.300x.008 1.300x.010 .800x.010 1.300x.006 1.300x.008 Piston orifice .055 1.250x.012 1.100x.010 1.125x.093 .620x.093 Table 11-20: RTS 7043177 1.125x.093 .900x.010 1.000x.010 1.100x.012 1.100x.010 1.100x.008 1.000x.006 1.300x.008 1.300x.008 Piston orifice .093 1.250x.010 1.250x.010 1.100x.012 1.000x.012 .900x.012 .800x.012...

  • Page 236: Shock Valve Part Numbers

    REAR SUSPENSION SHOCK VALVE PART NUMBERS Shock valves are used in a stack on the top and on the bottom of the shock piston. These stacks can be adjusted so that it can control the amount of fluid that is forced by as the piston travels through its motion.

  • Page 237: Ryde Fxt Shock Valve Part Numbers

    REAR SUSPENSION RYDE FXt SHOCK VALVE PART NUMBERS FOXt SHOCK VALVE PART NUMBERS NOTE: The cart below groups the valves by NOTE: The cart below groups the valves by thickness thickness Table 11-21: RYDE FX VALVE PART Table 11-22: FOX Valve Part Numbers NUMBERS PART NUMBER SIZE...

  • Page 238: Shock Valving Arrangement

    REAR SUSPENSION WALKER EVANS SHOCK VALVE PART SHOCK VALVING ARRANGEMENT NUMBERS Shown below is an example of how valving stacks are Table 11-23: arranged. The Production Shock Information contain production valving specifications and piston orifice sizes. PART NUMBER SIZE THICKNESS Parts in the box below are an example of standard valving.

  • Page 239: Special Tools

    REAR SUSPENSION SPECIAL TOOLS SHOCK REBUILDING TOOLS Table 11-24: Special Tools PART NUMBER DESCRIPTION 2200421 Gas Shock Recharging Kit 2201639 Shock Shaft Seal Protector 1/2” Diameter 2201640 Shock Shaft Seal Protector 5/8” Diameter 2870623 Shock Absorber Spring Compression Tool 2870803 Shock Spring Pre-Load Adjustment Too PS-45259 Gas Fill Tool...

  • Page 240: Ryde Fx Mono-Tube Shock Disassembly

    REAR SUSPENSION rebuilding are also available. Monotube shocks 9917736, Wash the shock body in parts cleaner; then dry with Remote Reservoir 9917737. compressed air to remove sand and dirt. WARNING CAUTION HEN USING COMPRESSED AIR TO DRY COMPONENTS XTREME CAUTION SHOULD BE OBSERVED WHILE HANDLING PROTECTIVE EYE WEAR SHOULD BE WORN TO AVOID RISK AND WORKING WITH HIGH PRESSURE SERVICE EQUIPMENT OF INJURY...

  • Page 241: Ryde Fx Mono-Tube Shock Assembly

    REAR SUSPENSION loosen and remove cylinder head assembly. into the shock body, being careful not to damage I.F.P wear band and O-ring, until the value indicator knob 13. Pour the oil out of the shock body. Discard old oil into an comes in contact with the shock body.

  • Page 242: Fox Ps-5 Assembly

    REAR SUSPENSION remove as much dirt and grime as possible by scrubbing plate and lift upwards. Slide the piston assembly onto the with a soft bristle brush. Never pressure wash your shock, shaft of the screwdriver. Pull the Screwdriver away from as this can force water and debris inside which will shock shaft while supporting the piston assembly.

  • Page 243: Rear Suspension Troubleshooting

    REAR SUSPENSION seated. If a tool is required to aid in proper seating of U- visible. Check to make sure the snap-ring is properly cup seal, use the non-writing end of a pen, or a similar soft, seated. blunt object, to push it in. 10.
  • Page 244 REAR SUSPENSION 11.28...
  • Page 245 CHASSIS / HOOD CHAPTER 12 CHASSIS / HOOD HOOD ............. 12.2 REMOVAL / INSTALLATION .

  • Page 246: Hood

    Currently there is no procedures or materials recommended by INSTALLATION Polaris for repairing hoods. Hoods are made of Thermoplastic Remove the plenum from the bottom of the hood. Olefin (TPO) and cannot be repaired. If a hood is broken it Disconnect the head light connections.

  • Page 247: Coolant/Oil Tank

    Install the fasteners that hold the tank to the chassis. FUEL CLIPS Throttle body Polaris utilizes two different sizes of fuel supply lines. When removing the fuel lines from the chassis use the special fuel Rear coolers line removal tools. The fuel clips will also have the indicated line use labled on the clamp.

  • Page 248: Seat And Fuel Tank

    CHASSIS / HOOD SEAT and FUEL TANK RMK SEAT/FUEL TANK FUSION SEAT AND BASE REMOVAL/ fasteners to 8-12 ft-lb (11-16Nm) INSTALLATION IQ RMK SEAT REMOVAL/INSTALLATION Remove the two bolts (A) that hold the seat base on the RMK seats have a small lever at the rear portion of the tunnel.

  • Page 249: Iq Rmk Seat Base Removal/Installation

    CHASSIS / HOOD IQ FUEL TANK INSTALLATION Replace in reverse order. IQ RMK SEAT BASE REMOVAL/ INSTALLATION Remove seat. Remove the fasteners that hold the base onto the chassis. Install in reverse order, torque the seat base fasteners to 8- 12 ft-lb (11-16Nm).

  • Page 250: Edge Seat Removal / Installation

    Using a staple fun, tack each side of the vinyl cover in Install new taillight assembly and rivet into place. place using two staples (1). If cover has a Polaris" emblem carefully align emblem with the bottom edge of the seat.

  • Page 251: Edge Air Box Installation

    CHASSIS / HOOD of the chassis. If removing the boost box (C), unplug the intake air sensor (D). EDGE AIR BOX INSTALLATION Loosen the narrow clamps (E). Pull the boost box (C) forward from the boots (F), and Place the air box in the chassis. remove it from the machine.

  • Page 252: Handlebar Cover

    CHASSIS / HOOD HANDLEBAR COVER HANDLE BAR COVER REMOVAL/ INSTALTION Slide handle bar covers slide (A) off on each side. Remove the handle bar cover darts (B) on each side. Remove handle bar cover (C). Installation is in reverse order of removal. SKIS SKI REMOVAL Securely lift the front of the machine off the ground.

  • Page 253: Nosepan

    Perform the decal removal procedures carefully! If care is not taken, the possibility exists that paint could peel from the hood. Follow each step thoroughly and completely to avoid hood damage! Polaris is not responsible for any hood or 12.9...

  • Page 254: 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 hood damage resulting from this decal replacement procedure.
  • Page 255 CHASSIS / HOOD to be placed is free of any dirt, debris, or adhesive. CAUTION NCE THE ADHESIVE STICKS IT CAN BE VERY DIFFICULT TO PULL THE DECAL BACK OFF OF THE HOOD SE EXTREME DO NOT CARE F YOU ENCOUNTER AIR BUBBLES ATTEMPT TO USE A STRAIGHT PIN TO POKE THE BUBBLE AND LET THE AIR OUT...
  • Page 256 CHASSIS / HOOD 12.12...
  • Page 257 ELECTRICAL CHAPTER 13 ELECTRICAL MULTIMETER ............13.2 MULTI METER USEAGE .
  • Page 258 OIL LEVEL SENDER ..........13.28 POLARIS ELECTRONIC REVERSE CONTROL (PERC) ....13.29 OPERATION .

  • Page 259: Multimeter

    Any good quality multitester will work. However, due to ease of operation and durability, Polaris recommends the Fluke Model 73 (PN 2870659), or Tektronix DMM155. See photo at right. This instrument will provide a digital readout of the measured value of the test being performed.
  • Page 260 ELECTRICAL to verify timing marks. Disconnect the TPS (Throttle Position Sensor) connector from carburetors on models with TPS. Table 13-1: EH12 EC34-2PM EC50PL EC55PM Domestic 500/600 Domestic 700/900 ROD/ 73mm ROD / 43mm 103mm ROD / 112mm ROD / 60mm 120mm ROD / 128mm ROD / 152mm ROD /...

  • Page 261: Battery

    ELECTRICAL BATTERY can measure state of charge and differences between cells in a multi-cell battery. Readings of 1.270 or greater should be observed in a fully charged battery. Differences of more PREPARING A NEW BATTERY FOR than.025 between the lowest and highest cell readings indicate SERVICE a need to replace the battery.

  • Page 262: Off Season Storage

    ELECTRICAL components of water. Because of the loss of these gases and WARNING the lowering of the electrolyte level, it will be necessary to add pure, clean distilled water to bring the fluid to the proper level. After filling, charge the battery to raise the specific ATTERY ELECTROLYTE IS POISONOUS T CONTAINS AC gravity to1.270 or greater.
  • Page 263 ELECTRICAL must be used. Meter connections are shown later in this chapter. Table 13-4: Electric starter troubleshooting With tester on VDC, place tester black lead on battery negative (-) terminal and tester red lead on battery positive (+) Remove battery, test and/or service. Install a fully terminal.

  • Page 264: Starter Motor Static Testing

    ELECTRICAL STARTER MOTOR STATIC TESTING STARTER HOUSING AND FIELD COIL Remove starter motor and disassemble. (See page 9.14 for exploded view) Mark end covers and housing for proper INSPECTION reassembly. Using a digital multitester, measure resistance between Remove pinion retaining snap ring, spring and pinion starter input terminal and insulated brushes.

  • Page 265: Starter Assembly

    ELECTRICAL STARTER ASSEMBLY STARTER INSTALLATION Slide armature into field coil housing. Lightly grease drive end bushing and install drive end Position starter motor so there is no less than.100, frame on armature. clearance between the ring gear and the starter motor Mount starter vertically in a vice with brush end up.

  • Page 266: Regulated Voltage

    ELECTRICAL EXAMPLE: Short meter leads together, meter reads 0.7 ohms. meter fuse if used on big alternators. Measure stator resistance, meter reads 1.10 ohms. Subtract 0.7 CAUTION ohms (meter/lead resistance) from 1.10 ohms (reading obtained when checking yellow lead to brown lead). True reading is:1.10 ohms (observed reading when checking stator) Can blow meter fuse if used on big alternators.

  • Page 267: Electrical Testing

    ELECTRICAL 340, 550, 600 Classics = 6 pulse ELECTRICAL TESTING Remove the two taillight bulbs and the brake light bulb. Separate the seat harness from the main harness by unplugging the connector at the right rear of the tank. HEADLIGHT BULB FILIMENT CONTINUITY Ω...

  • Page 268: Ignition Switch Testing (Electric Start Models)

    ELECTRICAL IGNITION SWITCH TESTING (ELECTRIC Table 13-5: Temp and Ohms Resistance START MODELS) Range Ω Refer to the appropriate model and year wiring diagram for OHMS RESISTANCE TEMP _F (_C) ignition switch wire colors and connections. RANGE Ω 68 (20) 2189 - 2675 Disconnect wires.

  • Page 269: Auxiliary Shut-Off Switch Testing

    ELECTRICAL FUEL SENDER TESTING throttle lever to throttle block clearance, the engine may misfire or kill upon initial throttle opening. Use the multitester ohmmeter to test the resistance of the fuel CAUTION sender. Table 13-6: Fuel Sender Testing Range FTER ANY IDLE SPEED ADJUSTMENTS ARE MADE THROTTLE LEVER TO THROTTLE BLOCK CLEARANCE AND OHMS OHMS Ω...

  • Page 270: Troubleshooting Charts

    ELECTRICAL TROUBLESHOOTING CHARTS NO SPARK Table 13-7: No Spark Condition Disconnect the single black (black/white) wire from the Check the ignition switch, wire harness, throttle safety CDI Module to the ignition kill circuit. Does it have a switches and kill switch for proper adjustment or short spark? to ground.
  • Page 271 ELECTRICAL IQ BLINK CODES sensor listed. Hook up Digital Wrench to troubleshoot, fix and clear the codes. A warning system is incorporated into the speedometer that The blinking LED can be de-coded for diagnosis and if two or will inform the rider of a code that has been set by a sensor more codes are present at the same time the code will blink in that was operated beyond the normal operating ranges.

  • Page 272: Tps Tool Set Up

    However, upon removal of the TPS, you must mark the TPS position on the carburetor and replace it in the exact same position as removal. Polaris has developed a TPS test kit for aid in setting the Throttle Position Sensor to specification.

  • Page 273: Clean Fire Electrical

    ELECTRICAL CLEAN FIRE ELECTRICAL IQ THROTTLE POSITION SENSOR When the sensor is inoperative or disconnected the system will switch to a LIMP HOME" mode. Limp Home mode reduces performance to a default value and monitors other sensors. IQ TEMPERATURE LIGHT THERMISTOR SENSOR TEST The TEMP light (A) is controlled by the CDI using water At room temperature 68_ F (20_ C) the Thermistor should...

  • Page 274: Iq Detonation Elimination Sensor (Det)

    ELECTRICAL IQ DETONATION ELIMINATION SENSOR (DET) A detonation sensor monitors the engine and responds to detonation by automatically reducing the engine timing and adding fuel. The activated sensor reduces engine detonation by compensation of timing and fuel. This results in decreased engine RPM and performance.

  • Page 275: Det Troubleshooting

    ELECTRICAL DET TROUBLESHOOTING damage. When the detonation returns to a permissible level, the system will incrementally advance the spark to increase the output of the engine in a safe manner. Use this chart to determine causes and solutions for detonation. If none of these conditions exists and the sensor SENSOR FAIL SAFE remains activated you may need to remove the sensor from the engine and test run the unit, and if the conditions are gone you...

  • Page 276: Intake Air Temperature Sensor

    ELECTRICAL below 392_F (200_C). Disconnected or Default temperature 5 tooth pickup is to obtain the following information in is 1100_F (593_C). combination with the 2 tooth pickup. Table 13-13: Exhaust Temperature Sensor • Judge direction of rotation (forward and backward) Specifications •...

  • Page 277: Speed Sensor

    ELECTRICAL SPEED SENSOR This is a hall effect sensor that measures the speed of the drive shaft to give you the speed of the track. Table 13-15: Speed Sensor Testing PIN # COLOR ITEM VALUE Power 5 volts (powered bu Gauge gauge) White...

  • Page 278: Ecu Plug #1

    ELECTRICAL ECU PLUG #1 As viewed unplugged Table 13-16: WIRE COLOR COMPONTENT WIRE COLOR COMPONENT 1 Orange Reg Rec (power) 18 Orange Reg Rec (power) 19 Red/Black External Battery Voltage Exhaust/Air Temp sensor 20 Black/Blue (ground) 4 Yellow/Red Tachometer (signal) 21 Black Auxilary Kill Switch 5 Blue/Red...

  • Page 279: Ecu Plug #2

    ELECTRICAL ECU PLUG #2 As viewed unplugged Table 13-17: WIRE COLOR COMPONTENT WIRE COLOR COMPONENT White CPS (2 tooth) ground White/Red CPS (2 tooth) signal Purple Detonation sensor signal Green CPS (5 tooth) ground Black/Blue Detionation sensor ground Coolant temperature White/Green CPS (5tooth) signal Black/Blue...

  • Page 280: Stator

    ELECTRICAL STATOR The stator supplies the system with 3 Phase AC current to If the gauge and lights cut out above 3500 RPM the charge power the electrical system 300 watts. coils are suspect to failure. When the brown/white wire is disconnected it will have no continuity to ground.

  • Page 281: Ignition Coil

    ELECTRICAL IGNITION COIL Ignition coils provide ignition spark for each spark plug. Below are the values for each coil. Ignition Coil Table 13-19: Ignition Coils PRIMARY COIL #1 (MAG) PRIMARY COIL #2 (PTO) COLOR ITEM VALUE COLOR ITEM VALUE BLACK/ BLACK/RED YELLOW =.38 -.52OHMS...
  • Page 282 ELECTRICAL 13.26...

  • Page 283: Regulator Rectifier

    ELECTRICAL REGULATOR RECTIFIER Chassis connector from Regulator Rectifier From Stator Table 13-22: Chassis connector from Reg Chassis The rectifier converts the AC current to DC current by passing COLOR TO/FROM the AC signal from the stator through diodes in a bridge Red (23) To Chassis Relay configuration.

  • Page 284: Capacitor

    ELECTRICAL CAPACITOR Table 13-23: From Chassis Relay The function of the capacitor is to act like a battery in a non- CONNECTO COLOR TO/FROM battery system. The capacitor makes the chassis side power signal stable. WIth out the capacitor in the system the unit will Red (52) From Regulator not run correctly at idle.

  • Page 285: General Electrical Items

    ELECTRICAL GENERAL ELECTRICAL ITEMS OIL LEVEL SENDER The float (A) moves up and down the sender shaft (B) and ECU sends a signal to the MFD when the level get to the point where you need to add more oil. The oil level signal is measured in resistance, FULL is open and <10Ω...

  • Page 286: Polaris Electronic Reverse Control (Perc)

    ALTITUDE SETTING WARNING If your engine is carbureted, you can adjust the elevation setting of the Polaris electric reverse control (PERC). If your Reverse operation, even at low speeds, may cause engine is a Cleanfire system, this is automatically done loss of control, resulting in serious injury or death.

  • Page 287: Digital Wrench

    ELECTRICAL • Flashing light on the instrument panel indicates that the Apply 12 VDC to this plug by using the M-10 ACE tool (PN system is in reverse. On carbureted units a slow flash PV-46355) and it will power up all the light circuits. This is indicates that the system is set for low elevation, and a helpful for checking any grounds for lights.
  • Page 288 ELECTRICAL 13.32...
  • Page 289 WIRE DIAGRAM 2006 600 FUSION/HO HOOD 14.1...
  • Page 290 WIRE DIAGRAM 2006 HO/RMK HOOD 14.2...
  • Page 291 WIRE DIAGRAM 600 HO/FUSION/RMK CHASSIS 14.3...
  • Page 292 WIRE DIAGRAM 600 HO/FUSION/RMK CHASSIS CALL OUTS 14.4...
  • Page 293 WIRE DIAGRAM 700 / 900 ENGINE 14.5...
  • Page 294 WIRE DIAGRAM 700 / 900 ENGINE AND ENGINE CALL OUTS 14.6...
  • Page 295 WIRE DIAGRAM 700 / 900 CHASSIS 14.7...
  • Page 296 WIRE DIAGRAM 700/900 CHASSIS CALLOUT Table 14-1: Wire # Color From Connector To Conector Wire # Color From Connector To Conector BLK/W ENGINE/CHASSIS CHASSIS/HOOD #1 REGULATOR CHASSIS/HOOD #1 R/W & BRN SPLICE OIL LIGHT SENSOR CHASSIS/HOOD #1 REGULATOR SAVER LEFT HANDLEBAR CHASSIS/HOOD #1 OR/W CHASSIS/HOOD #2...
  • Page 297 WIRE DIAGRAM 340/550 FUJI FAN ENGINE/CHASSIS 14.9...
  • Page 298 WIRE DIAGRAM 500 FUJI ENGINE/CHASSIS 14.10...
  • Page 299 WIRE DIAGRAM 500/600 IBERTY ENGINE/CHASSIS 14.11...
  • Page 300 WIRE DIAGRAM WIDETRAK ENGINE/CHASSIS 14.12...

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