Polaris 340 LX 2007 Service Manual
  1. Manuals
  2. Brands
  3. Polaris Manuals
  4. Offroad Vehicle
  5. 340 LX 2007
  6. Service manual

Polaris 340 LX 2007 Service Manual

2007-2012 edge/widetrak lx snowmobile
Hide thumbs Also See for 340 LX 2007:
Table of Contents

Advertisement

Quick Links

2007-2012 EDGE/WIDETRAK LX SNOWMOBILE
SERVICE MANUAL
FOREWORD
The information printed within this publication includes the latest product information at time of print. The most recent
version of this Service Manual is available in electronic format at www.polarisdealers.com.
This Service Manual is designed primarily for use by certified Master Service Dealer® technicians in a properly equipped
shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator's
perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the
service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper
tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this service manual,
contact an authorized dealer for service.
We value your input and appreciate any assistance you can provide in helping make these publications more useful.
Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask
Polaris'. Click on 'Ask Polaris', and then click on 'Publications Question'.
Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department,
2100 Hwy 55, Medina, MN 55340.
2007-2012 EDGE/Widetrak LX Snowmobile Service Manual PN 9923396
© Copyright 2011 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting
or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

Advertisement

Table of Contents
loading

Related Manuals for Polaris 340 LX 2007

Summary of Contents for Polaris 340 LX 2007

  • Page 1 2007-2012 EDGE/Widetrak LX Snowmobile Service Manual PN 9923396 © Copyright 2011 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
  • Page 2 MEASUREMENT provides a key for a determined measurement specification. TORQUE provides a key for a required torque value. TRADEMARKS POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL: Loctite, Registered Trademark of the Loctite Corporation Nyogel, Trademark of Wm. F. Nye Co.
  • Page 3 2007-2012 EDGE/Widetrak LX Service Manual Chapters Model Specifications....... 1 General Information........ 2 Maintenance........... 3 Fuel Systems.......... 4 Engine Systems ........5 Final Drive/Brake Systems..... 6 PVT System ..........7 Front/Rear Suspensions......8 Chassis..........

  • Page 4: Table Of Contents

    2012 WIDETRAK LX........... . 1.44 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 5: Specifications

    Drive Clutch Bolt Torque: 50 lb.ft. (68Nm) Re-torque after running engine. Valve Seat 1.5 Viton Starter Jet Pilot Air Jet Air Screw (Turns Out) Fuel Octane (R+M/2) (Minimum) 87 Non-Oxygenated (Recommended) 89 Oxygenated 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 6 121 (307) Lug Height - Inches (cm) .66 (1.7) Track tension sag in/cm with 10 lbs/4.54kg placed 3/8” - 1/2” (1 - 1.3cm) 16 in/40cm ahead of rear idler shaft 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 7: 2007 340 Touring

    Drive Clutch Bolt Torque: 50 lb.ft. (68Nm) Starter Jet Re-torque after running engine. Pilot Air Jet Air Screw (Turns Out) Fuel Octane (R+M/2) (Minimum) 87 Non-Oxygenated (Recommended) 89 Oxygenated 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 8 Lug Height - Inches (cm) 1 (2.5) Track tension sag in/cm 1 1/8” - 1 3/8” with 10 lbs/4.54kg placed 16 in/40cm ahead of rear (2.9 - 3.5cm) idler shaft 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 9: 2007 Supersport / 550 Lx

    Starter Jet Drive Clutch Bolt Torque: 50 lb.ft. (68Nm) Re-torque after running engine. Pilot Air Jet Air Screw (Turns Out) Fuel Octane (R+M/2) (Minimum) 87 Non-Oxygenated (Recommended) 89 Oxygenated 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 10 121 (307) Lug Height - Inches (cm) .82 (2.08) Track tension sag in/cm with 10 lbs/4.54kg placed 3/8” - 1/2” (1 - 1.3cm) 16 in/40cm ahead of rear idler shaft 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 11: 2007 Trail Touring Deluxe

    3000-3600 (10,000-12,000) Pilot Air Jet Drive Clutch Bolt Torque: 50 lb.ft. (68Nm) Air Screw (Turns Out) Re-torque after running engine. Fuel Octane (R+M/2) (Minimum) 87 Non-Oxygenated (Recommended) 89 Oxygenated 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 12 Lug Height - Inches (cm) 1.0 / (2.5) Track tension sag in/cm with 10 lbs/4.54kg placed 7/8” - 1 1/8” (2.2 - 2.9cm) 16 in/40cm ahead of rear idler shaft 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 13: 2007 Trail Rmk

    (10,000-12,000) Pilot Air Jet Drive Clutch Bolt Torque: 50 lb.ft. (68Nm) Air Screw (Turns Out) Re-torque after running engine. Fuel Octane (R+M/2) (Minimum) 87 Non-Oxygenated (Recommended) 89 Oxygenated 1.10 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 14 Lug Height - Inches (cm) 1.25 (3.175) Track tension sag in/cm with 10 lbs/4.54kg placed 3/8” - 1/2” (1 - 1.3cm) 16 in/40cm ahead of rear idler shaft 1.11 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 15: 2007 Widetrak Lx

    Starter Jet Drive Clutch Bolt Torque: 50 lb.ft. (68Nm) Pilot Air Jet Re-torque after running engine. Air Screw (Turns Out) Fuel Octane (R+M/2) (Minimum) 87 Non-Oxygenated (Recommended) 89 Oxygenated 1.12 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 16 Lug Height - Inches (cm) 1.0 / (2.5) Track tension sag in/cm with 10 lbs/4.54kg placed 3/4” - 1” (1.9 - 2.5cm) 16 in/40cm ahead of rear idler shaft 1.13 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 17: 2007 500 Xcsp

    Re-torque after running engine. Fuel Screw (Turns Out) Air Screw (Turns Out) 1.25 Fuel Octane (R+M/2) (Key Switch - Regular) 87 Non-Oxygenated (Key Switch - Premium) 91 Oxygenated 1.14 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 18 Lug Height - Inches (cm) Euro = 1.25 (3.175) Track tension sag in/cm with 10 lbs/4.54kg placed 3/8” - 1/2” (1 - 1.3cm) 16 in/40cm ahead of rear idler shaft 1.15 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 19 Drive Clutch Bolt Torque: 50 lb.ft. (68Nm) Starter Jet Re-torque after running engine. Pilot Air Jet Air Screw (Turns Out) Fuel Octane (R+M/2) (Minimum) 87 Non-Oxygenated (Recommended) 89 Oxygenated 1.16 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 20 Lug Height - Inches (cm) .82 (2.08) Track tension sag in/cm with 10 lbs/4.54kg placed 3/8” - 1/2” (1 - 1.3cm) 16 in/40cm ahead of rear idler shaft 1.17 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 21: 2008 340 Transport

    Drive Clutch Bolt Torque: 50 lb.ft. (68Nm) Starter Jet Re-torque after running engine. Pilot Air Jet Air Screw (Turns Out) Fuel Octane (R+M/2) (Minimum) 87 Non-Oxygenated (Recommended) 89 Oxygenated 1.18 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 22 Lug Height - Inches (cm) 1.25 (3.175) Track tension sag in/cm 1 1/8” - 1 3/8” with 10 lbs/4.54kg placed 16 in/40cm ahead of rear (2.9 - 3.5cm) idler shaft 1.19 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 23: 2008 Supersport / 550 Lx

    Starter Jet Drive Clutch Bolt Torque: 50 lb.ft. (68Nm) Re-torque after running engine. Pilot Air Jet Air Screw (Turns Out) Fuel Octane (R+M/2) (Minimum) 87 Non-Oxygenated (Recommended) 89 Oxygenated 1.20 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 24 Lug Height - Inches (cm) .82 (2.08) Track tension sag in/cm with 10 lbs/4.54kg placed 3/8” - 1/2” (1 - 1.3cm) 16 in/40cm ahead of rear idler shaft 1.21 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 25: 2008 Trail Touring Deluxe

    (10,000-12,000) Drive Clutch Bolt Torque: 50 lb.ft. (68Nm) Pilot Air Jet Re-torque after running engine. Air Screw (Turns Out) Fuel Octane (R+M/2) (Minimum) 87 Non-Oxygenated (Recommended) 89 Oxygenated 1.22 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 26 Lug Height - Inches (cm) 1.0 / (2.5) Track tension sag in/cm with 10 lbs/4.54kg placed 7/8” - 1 1/8” (2.2 - 2.9cm) 16 in/40cm ahead of rear idler shaft 1.23 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 27: 2008 Trail Rmk

    (10,000-12,000) Drive Clutch Bolt Torque: 50 lb.ft. (68Nm) Pilot Air Jet Re-torque after running engine. Air Screw (Turns Out) Fuel Octane (R+M/2) (Minimum) 87 Non-Oxygenated (Recommended) 89 Oxygenated 1.24 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 28 Lug Height - Inches (cm) 1.25 (3.175) Track tension sag in/cm with 10 lbs/4.54kg placed 3/8” - 1/2” (1 - 1.3cm) 16 in/40cm ahead of rear idler shaft 1.25 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 29: 2008 Widetrak Lx

    Starter Jet Drive Clutch Bolt Torque: 50 lb.ft. (68Nm) Pilot Air Jet Re-torque after running engine. Air Screw (Turns Out) Fuel Octane (R+M/2) (Minimum) 87 Non-Oxygenated (Recommended) 89 Oxygenated 1.26 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 30 Lug Height - Inches (cm) 1.0 / (2.5) Track tension sag in/cm with 10 lbs/4.54kg placed 3/4” - 1” (1.9 - 2.5cm) 16 in/40cm ahead of rear idler shaft 1.27 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 31: 2009 550 Transport

    (10,000-12,000) Pilot Air Jet Drive Clutch Bolt Torque: 50 lb.ft. (68Nm) Air Screw (Turns Out) Re-torque after running engine. Fuel Octane (R+M/2) (Minimum) 87 Non-Oxygenated (Recommended) 89 Oxygenated 1.28 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 32 Lug Height - Inches (cm) 1.25 / (3.175) Track tension sag in/cm with 10 lbs/4.54kg placed 7/8” - 1 1/8” (2.2 - 2.9cm) 16 in/40cm ahead of rear idler shaft 1.29 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 33: 2009 Trail Touring

    (10,000-12,000) Pilot Air Jet Drive Clutch Bolt Torque: 50 lb.ft. (68Nm) Air Screw (Turns Out) Re-torque after running engine. Fuel Octane (R+M/2) (Minimum) 87 Non-Oxygenated (Recommended) 89 Oxygenated 1.30 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 34 Lug Height - Inches (cm) 1.0 / (2.5) Track tension sag in/cm with 10 lbs/4.54kg placed 7/8” - 1 1/8” (2.2 - 2.9cm) 16 in/40cm ahead of rear idler shaft 1.31 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 35: 2009 Trail Rmk

    (10,000-12,000) Drive Clutch Bolt Torque: 50 lb.ft. (68Nm) Pilot Air Jet Re-torque after running engine. Air Screw (Turns Out) Fuel Octane (R+M/2) (Minimum) 87 Non-Oxygenated (Recommended) 89 Oxygenated 1.32 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 36 Lug Height - Inches (cm) 1.25 (3.175) Track tension sag in/cm with 10 lbs/4.54kg placed 3/8” - 1/2” (1 - 1.3cm) 16 in/40cm ahead of rear idler shaft 1.33 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 37: 2009 Widetrak Lx

    10M-W (9000-12,000) Starter Jet Drive Clutch Bolt Torque: 50 lb.ft. (68Nm) Air Screw (Turns Out) Re-torque after running engine. Fuel Octane (R+M/2) (Minimum) 87 Non-Oxygenated (Recommended) 89 Oxygenated 1.34 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 38 Lug Height - Inches (cm) 1.0 / (2.5) Track tension sag in/cm with 10 lbs/4.54kg placed 3/4” - 1” (1.9 - 2.5cm) 16 in/40cm ahead of rear idler shaft 1.35 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 39: 2010 Trail Rmk

    (10,000-12,000) Pilot Air Jet Drive Clutch Bolt Torque: 50 lb.ft. (68Nm) Air Screw (Turns Out) Re-torque after running engine. Fuel Octane (R+M/2) (Minimum) 87 Non-Oxygenated (Recommended) 89 Oxygenated 1.36 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 40 Lug Height - Inches (cm) 1.25 (3.175) Track tension sag in/cm with 10 lbs/4.54kg placed 3/8” - 1/2” (1 - 1.3cm) 16 in/40cm ahead of rear idler shaft 1.37 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 41: 2010 Trail Touring

    (10,000-12,000) Pilot Air Jet Drive Clutch Bolt Torque: 50 lb.ft. (68Nm) Air Screw (Turns Out) Re-torque after running engine. Fuel Octane (R+M/2) (Minimum) 87 Non-Oxygenated (Recommended) 89 Oxygenated 1.38 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 42 Lug Height - Inches (cm) 1.0 / (2.5) Track tension sag in/cm with 10 lbs/4.54kg placed 7/8” - 1 1/8” (2.2 - 2.9cm) 16 in/40cm ahead of rear idler shaft 1.39 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 43: 2010 Widetrak Lx

    10M-W (9000-12,000) Starter Jet Drive Clutch Bolt Torque: 50 lb.ft. (68Nm) Air Screw (Turns Out) Re-torque after running engine. Fuel Octane (R+M/2) (Minimum) 87 Non-Oxygenated (Recommended) 89 Oxygenated 1.40 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 44 Lug Height - Inches (cm) 1.0 / (2.5) Track tension sag in/cm with 10 lbs/4.54kg placed 3/4” - 1” (1.9 - 2.5cm) 16 in/40cm ahead of rear idler shaft 1.41 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 45: 2011 Widetrak Lx

    10-56 (9000-12,000) Starter Jet Drive Clutch Bolt Torque: 50 lb.ft. (68Nm) Air Screw (Turns Out) Re-torque after running engine. Fuel Octane (R+M/2) (Minimum) 87 Non-Oxygenated (Recommended) 89 Oxygenated 1.42 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 46 Lug Height - Inches (cm) 1.0 / (2.5) Track tension sag in/cm with 10 lbs/4.54kg placed 3/4” - 1” (1.9 - 2.5cm) 16 in/40cm ahead of rear idler shaft 1.43 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 47: 2012 Widetrak Lx

    10-56 (9000-12,000) Starter Jet Drive Clutch Bolt Torque: 50 lb.ft. (68Nm) Air Screw (Turns Out) Re-torque after running engine. Fuel Octane (R+M/2) (Minimum) 87 Non-Oxygenated (Recommended) 89 Oxygenated 1.44 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 48 Lug Height - Inches (cm) 1.0 / (2.5) Track tension sag in/cm with 10 lbs/4.54kg placed 3/4” - 1” (1.9 - 2.5cm) 16 in/40cm ahead of rear idler shaft 1.45 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 49 Model Specifications NOTES 1.46 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 50 GLOSSARY OF TERMS..........2.8 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 51: Snowmobile Number Designations

    Number (2), and the Manufactured Date (3). These model number is embossed on the decal. numbers should be referred to in any correspondence regarding warranty, service or replacement parts. The 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 52: Publication Part Numbers

    9922310 9922311 9922312 2011 Publications MODEL OWNER'S MANUAL SUPPLEMENT PARTS BOOK Widetrak LX 9922897 9922898 9922899 2012 Publications MODEL OWNER'S MANUAL SUPPLEMENT PARTS BOOK Widetrak LX 9923393 9923394 9923395 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 53: Service / Safety Bulletins

    Widetrak LX Fuel Tank Inspection / Replacement (Select Models Only) 550LX / 2008 S-08-03 550 Fan Electric Start Drive Clutch Ring Gear Replacement (All w/electric start). Trail Touring DLX / 2008 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 54: General Reference

    • 128 / 40 (40:1 Ratio) = 3.2 ounces of oil for every 1 gallon of fuel. Always mix ratio in 5 gallon increments. NOTE: A 40:1 premix should always be used during engine break-in or after re-building the engine. 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 55: Sae Tap Drill Sizes

    13/32 0.406 13/32 ....15/16........9375 ..24 mm = .9449" 61/64..........9531 12x1.75 13/32 0.406 13/32 ....31/32 .........9688 ..25 mm = .9843" 63/64..........9844 ....1 ... 1.0 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 56: Measurement Conversion Chart

    = liter liter x.264 = US gallon Pounds force per = Kilo pascals x 6.895 square inch (psi) (kPa) = Pounds force per Kilo pascals (kPa) x.145 square inch (psi) 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 57: Glossary Of Terms

    Chain Pitch: Distance between chain link pins (No. 35 = in-lb: (inch pounds) A force of one pound at the end of a 3/8" or 1 cm). Polaris measures chain length in number of lever one foot in length, applied in a rotational direction. 12 pitches.
  • Page 58 Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit. Watt: Unit of electrical power. Watts = amperes x volts. WOT: Wide open throttle. 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 59 General Information NOTES 2.10 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 60 BELT DEFLECTION INSPECTION ......... 3.5 DEFLECTION ADJUSTMENT - POLARIS DRIVEN / P2 ......3.6 DEFLECTION ADJUSTMENT - SPA-P2 / TEAM DRIVEN.

  • Page 61: Periodic Maintenance

    Fluid Level / Leaks / Fluid Condition Brake Pads / Brake Disc Parking Brake Brake Fluid Fuel System Idle RPM Carburetor Adjustments Throttle Lever / Chock Lever Oil Pump Arm 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 62 Bogie / Wheel Condition / Fastener Bolts Hood / Seat / Chassis / Engine Compartment L = Lubricate / I = Inspect or Adjust / R = Replace / C = Clean 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 63: Maintenance Products

    Shock Oil - 5W - Fox Quart 2870995 Gallon 2872279 Shock Oil - 5W - Ryde FX / Arvin 2873716 Brake Fluid - DOT 4 2872189 Fogging Oil Aerosol 2870791 Quart 2871517 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 64: Break-In Procedures

    Oil when the engine is either new or refurbished (new pistons, crankshaft, cylinder, etc.). Polaris semi-synthetic engine oil will seat the rings faster than when using Polaris VES Gold Plus oil. After the break-in period use Polaris VES Gold Plus engine oil for normal operation for snowmobiles equipped with VES engines.

  • Page 65: Deflection Adjustment - Polaris Driven / P2

    (increase deflection) rotate the cam towards position 4. Torque cam fasteners to 10 ft.lbs. (12 Nm) on the Polaris P-85. Torque P2 deflection cam screws to 12 ft.lbs. (16 Nm). 5. Raise rear of snowmobile up off of the ground using a track stand to allow the track to spin.

  • Page 66: Deflection Adjustment - Spa-P2 / Team Driven

    Torque Stop Jam Nut: 15-17 ft-lb. (21-24 Nm) Set torque stop bumper gap to specification after aligning drive and driven clutches. = In. / mm. Torque Stop Bumper-to-Engine Gap .010 - .030 (.25 - .75mm) 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 67: Engine Maintenance

    12 Ft.Lbs. (16 Nm) - Apply Loctite 242 NOTE: To obtain maximum exhaust valve performance, Polaris recommends using Polaris VES Gold Synthetic Two-Stroke engine oil. Never mix different brands of engine oil. 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 68: Widetrak Cooling System

    Severe burns to skin may occur from escaping coolant or steam. Fill Tube / Pressure Cap The fill tube is the primary cooling system fill location. Always add and remove coolant from the fill tube. 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 69: 500 Xcsp Cooling System

    Always add coolant when the cooling system is COLD. CAUTION Never remove the fill tube pressure cap when the cooling system is warm. Severe burns to skin may occur from escaping coolant or steam. 3.10 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 70: Recommended Coolant

    Maintenance Recommended Coolant Oil Pump Adjustment - 340 / 550 Engines Use Polaris Premium 60 / 40 pre-mix antifreeze. This premium antifreeze is rated for temperatures down to - 62°F (-52°C). Cooling System Bleeding 1. Allow the cooling system to cool completely.

  • Page 71: Oil Pump Adjustment - 500 Xcsp

    10mm wrench. and oil pump. 7. When adjusting the lever, make adjustments in small increments, then re-check the timing mark alignment. 3.12 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 72: Oil Pump Bleeding - 550 Engines With Auto Bleed

    4. To stop the flow of oil, loosen the oil tank cap. 5. Reinstall the auto-bleed hose on the tank fitting. 6. Pour the oil in the container into the storage tank. 3.13 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 73: Water Sediment Trap

    CHASSIS LUBRICATION bowl water / sediment traps located at the bottom of each carburetor. Most chassis, suspension and mechanical grease points should be lubricated using Polaris Premium All Season Grease. Polaris Premium All Season Grease Part Numbers: 3oz. Grease Gun Kit = 2871312 14oz.
  • Page 74 Maintenance Rear Suspension Lubricate grease zerks with Premium All Season Grease. EDGE WIDETRAK 3.15 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 75 2. Remove the dipstick (1). Verify level is in SAFE zone. 3. Add the recommended oil as needed. Do not overfill. 4. Clean the magnetic tip (2) on the dipstick. 5. Reinstall the dipstick. 3.16 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 76: Brake System Maintenance

    Inspect the reservoir to be sure it contains the correct tighten the drain plug. amount of fluid. Use only Polaris DOT 4 high temperature 6. Fill chaincase or gearcase at the dipstick hole. brake fluid. Change fluid every 2 years or whenever the fluid is dark or contamination is suspected.

  • Page 77: Throttle And Choke Cable Adjustments

    NOTE: If the idle speed screw is adjusted inward and the cable sleeve is not adjusted to take up the throttle lever clearance, the engine may misfire or quit upon initial throttle opening. 3.18 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 78: Throttle Lever Free Play - Tm Carburetor

    4. Tighten adjustment lock nut. carburetors and adjust the throttle free play by adjusting the barrel nut (E) and lock nuts (F). 5. Repeat steps on the other carburetor. 3.19 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 79: Choke Adjustment - Mikuni Tm

    Handlebar Clamp Fastener Torque 11 - 13 Ft.Lbs. (15 - 18 Nm) 4. Tighten adjustment locknut (2). 5. Reinstall the handlebar cover. 3.20 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 80: Ski / Ski Skag Fasteners

    3/8" - 1/2" EDGE 121 durability problems. (1-1.3cm) 3/4" "- 1" Widetrak (1.9-2.5cm) 1 1/8" - 1 3/8" EDGE 136 (2.9-3.5cm) 3/8" - 1/2" EDGE RMK (1-1.3cm) 3.21 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 81: Track Alignment

    It may be necessary to check this with the engine rotating the track. Be sure to SHUT THE MACHINE before making further adjustments. 8. Loosen up the rear idler shaft (F). 3.22 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 82: Electrical Systems

    2. Slide the access panel down to gain access to the bulb. 3. Squeeze and move the bulb clip up. 4. Replace the bulb, clip and access panel. 3.23 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 83: Off-Season Storage

    Fog engine with Polaris Fogging Oil (aerosol type) according to directions on can. Fuel System Treat the fuel system with Polaris Carbon Clean. If Polaris Carbon Clean is not used, fuel tank, fuel lines, and carburetor should be completely drained of gasoline.
  • Page 84 VENTING SYSTEM ........... . 4.15 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 85 3130146 condition and may cause serious engine damage. Jet according to the jetting charts provided for each snowmobile. Never use fuel containing more than 10% ethanol or E85 fuels. 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 86: Mikuni Vm Carburetor

    Mikuni type carburetors. A Mikuni VM carburetor uses several components and fuel metering circuits to deliver fuel at all throttle opening positions. These components and circuits include: • Starting (Enrichment) Circuit 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 87: Throttle Opening And Fuel Flow

    For example, changing main jets to resolve an off-idle moved from position 2 to position 4. hesitation or rich condition would do nothing as the main jet’s effect on total fuel output is minimal at idle speeds. 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 88: Starting / Enrichment System

    Always set the idle speed after the engine reaches in warm weather. As the weather turns colder it will be operating temperature. necessary to re-jet to prevent engine damage. When 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 89: Piston / Throttle Valve

    The throttle valves are numbered 1.0, 1.5, 2.0, etc., according to the size of the cutaway in millimeters. The higher the number, the leaner the gasoline/air mixture. 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 90: Vm Carburetor Disassembly / Inspection / Assembly

    3. Check the choke plunger and cable movement. Plunger must move up and down in bore without binding. 4. Remove the float bowl. Inspect the choke fuel supply passage. 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 91: Float Arm Adjustment

    3. Apply approximately 5 PSI of pressure and wait for at least one minute. The needle and seat should hold the pressure indefinitely. If the pressure drops rapidly, replace the needle and seat assembly. 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 92: Mikuni Tm Carburetor

    3. Locate the arm screw (4) and loosen it just enough to move the arm (5) out of the way so that you can remove the needle (6) e-clip and the plastic washer from the throttle slide. 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 93 12. Remove the two screws (18) holding the float/needle 18. Repeat steps 1-18 for disassembly for the other and seat assembly (19) in position and remove this carburetor if needed. assembly. 4.10 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 94: Assembly

    12. Install carburetors on engine. 13. Replace top cap gaskets (3), cover (2) and screws (1). 14. Check throttle lever free play. 4.11 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 95: Mikuni Tm Carburetor Adjustment

    9. Once this is flush, lock the locking screw. 10. Replace the carburetor covers. 11. If removed, reinstall the fuel, vent, throttle, and choke hose and cable connections. 12. Verify and set throttle cable free play. 4.12 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 96: Fuel Pump

    To inspect the diaphragm, connect a Mity Vac hand pressure pump to the impulse fitting. Apply 4 - 6 PSI. The diaphragm should hold the pressure indefinitely. 4.13 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 97: Fuel Tank

    Fuel System FUEL TANK Widetrak Fuel Tank Assembly GAS CAP FUEL TANK VENT GASKET FITTING FUEL FILTER FUEL SHUTOFF VALVE FUEL PUMP 4.14 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 98: Edge Fuel Tank Assembly (Typical)

    Additionally, warm ambient temperatures may cause the fuel tank to expand if the fuel vapors are not allowed to vent into the atmosphere. 4.15 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 99 Fuel System NOTES 4.16 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 100 500EV WATER / OIL PUMP ..........5.41 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 101: Engine Torque Sequences

    Cylinder Torque Patterns 340 / 550 / 500EV Engines Crankcase Torque Patterns 340 Engine 488 Engine 550 Engine Cylinder Head Torque Patterns 340 Engine 488 Engine 550 Engine 500EV Engine 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 102: Engine Inspections

    Using a flat bar and a feeler gauge, inspect each cylinder head for warping. Replace head if warping exceeds .003" (.08mm). = In. / mm. Cylinder Head Warp Limit .003" (.08mm) 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 103 • MAG end = 1/2" from bearing flat. 3. Runout deflection cannot exceed .0025" (.07mm). 4. If the runout deflection exceeds the maximum specification, crankshaft trueing may correct the deflection. 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 104 Piston Ring Installed Gap Main Bearing Clean crankshaft thoroughly and oil main and connecting rod bearings with Polaris engine oil. Carefully check each main bearing on the crankshaft. Due to extremely close tolerances, the bearings must be inspected visually and by feel. Look for signs of Position the ring 1/2"...
  • Page 105 Engine Systems any up and down movement detectable in the big end Crankshaft Index bearing. Polaris crankshafts are pressed together. The connecting rod journal center lines are indexed 180° apart from each other. It is sometimes necessary to check multi-cylinder crankshafts to verify that one cylinder has not been forced out of position relative to the other cylinder.
  • Page 106 It should be 180° (+/-2°) from the MAG cylinder mark. 6. Continue to rotate the crankshaft in the normal direction of rotation until the dial indicator reads .100" (2.54mm) after top dead center (ATDC). 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 107 Rinse thoroughly, dry with compressed air, and oil the bore immediately with Honing Procedure Polaris Premium 2 Cycle Lubricant. 1. Wash the cylinder with cleaning solvent. NOTE: Always check piston to cylinder clearance 2. Clamp the cylinder in a soft jawed vise by the cylinder and piston ring installed gap after honing or boring is studs.
  • Page 108 A position as shown in illustration 3. When rebuilding and straightening a crankshaft, straightness is of utmost importance. Runout must be as close to zero as possible. 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 109 = In. / mm. Oil Pump Oil Pump Bushing End Play .008" - .016" (.203 - .406mm) Available Shims 30803671 - .006" (.15mm) 30803672 - .012" (.30mm) 30803673 - .024" (.60mm) 5.10 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 110: Exhaust Valve Maintenance

    Orange 5. Separate the cap nut, bellows and bellows washer from the guillotine. 7041704-03 Pink 6. Remove the guillotine from the base. 7041704-04 Purple 7041704-05 Yellow 7041704-06 White 5.11 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 111: Recoil Pulley

    6. Lubricate the center shaft and spring with Premium grease. 7. Wind the rope counterclockwise around the pulley as viewed from the ratchet-side of the pulley. 5.12 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 112: Engine Mounts

    Vibration dampeners must be installed Engine Plate-to-Engine Bolts 45 ft.lbs. (61 Nm) perpendicular to plate and centered in bushings and caps. Exhaust Manifold Nuts 15 ft.lbs. (20 Nm) 5.13 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 113: 550 Engine Mounting

    Rear Engine Mount Mounting Nuts 18 ft.lbs. (24 Nm) Engine Strap Mounting Nuts 28 ft.lbs. (38 Nm) Exhaust Manifold Screws 18 ft.lbs. (24 Nm) Engine Strap-to-Crankcase Bolts 45 ft.lbs. (61 Nm) 5.14 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 114: 488 Engine Mounting

    Note Engine Plate Mounting Nuts 28 ft.lbs. (38 Nm) Engine Plate-to-Crankcase Bolts 45 ft.lbs. (61 Nm) Apply Loctite 262 to threads. Exhaust Manifold Nuts 18 ft.lbs. (24 Nm) 5.15 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 115: 500Ev Engine Mounting

    Mounting Strap-to-Crankcase Bolts 45 ft.lbs. (61 Nm) Apply Loctite 262 to threads. Mounting Strap-to-Rubber Mount Nuts 28 ft.lbs. (38 Nm) Rear Engine Mount Bracket Bolts 28 ft.lbs. (38 Nm) 5.16 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 116: 340 Fan Engine

    4. Lock recoil hub with a large screwdriver. Remove Housings in place and recoil hub fasteners. snapped together. 5. Reference RECOIL PULLEY section for recoil disassembly / assembly information. 5.17 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 117: Cylinder Assembly

    4. When re-installing a cylinder, coat the piston and Intake Boots 5 ft.lbs. (7 Nm) cylinder walls with Polaris Two-Stroke engine oil. 5. Verify the piston rings are centered around each piston ring locating pin before inserting the piston into the cylinder.

  • Page 118: Oil Pump Assembly

    3. Extract bushing and inspect. Replace if abnormal wear and tear is found. 4. Remove drive gear using a needle nose pliers. 5. Lubricate all parts with Polaris Two-Stroke engine oil during re-assembly. 6. Install the exact amount of shim(s) that were removed.

  • Page 119: Magneto Assembly

    NOTE: Do not thread the flywheel puller bolts into the Magneto Plate (7 - 9 Nm) magneto (stator) located behind the flywheel. 4. Thoroughly clean the crankshaft nose and flywheel 5.20 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 120: Crankcase Assembly

    6. Apply a thin bead of Three Bond 1215 to both (32 - 35 Nm) crankcase mating surfaces. 7. Lubricate the oil pump drive gear with two-stroke engine oil and install into crankcase. 5.21 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 121: Piston And Crankshaft Assembly

    4. Inspect the crankshaft as outlined in the Engine Inspection section within this chapter. 5. Install the piston rings with the beveled edge facing 5.22 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 122: 550 Fan Engine

    Housings in place and 4. Reference RECOIL PULLEY section for recoil snapped together. disassembly / assembly information. 5. The fan / flywheel and stator must be removed to 5.23 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 123: Cylinder Assembly

    5. During assembly, the reed valve assembly is installed under the cylinder base gasket. Install the base gasket with the sealing strip facing upwards. 6. Lubricate cylinder walls and piston with two-stroke 5.24 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 124: Oil Pump Assembly

    3. Extract bushing and inspect. Replace if abnormal wear and tear is found. 4. Remove drive gear using a needle nose pliers. 5. Lubricate all parts with Polaris Two-Stroke engine oil during re-assembly. 6. Install the exact amount of shim(s) that were removed.

  • Page 125: Oil Pump Assembly - Fleet Models

    Oil Pump Screws (5.5 - 8.3 Nm) serviceable. 4. Remove drive gear using a needle nose pliers. 5. Lubricate all parts with Polaris Two-Stroke engine oil during re-assembly. 6. Install the exact amount of shim(s) that were removed. 5.26 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual...

  • Page 126: Magneto Assembly

    NOTE: Do not thread the flywheel puller bolts into the Magneto Plate (7 - 9 Nm) magneto (stator) located behind the flywheel. 4. Thoroughly clean the crankshaft nose and flywheel 5.27 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 127: Crankcase Assembly

    6. Apply a thin bead of Three Bond 1215 to both crankcase mating surfaces. 7. Lubricate the oil pump drive gear with two-stroke engine oil and install into crankcase. 5.28 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 128: Piston And Crankshaft Assembly

    4. Inspect the crankshaft as outlined in the Engine Inspection section within this chapter. 5. Install the piston rings with the beveled edge facing 5.29 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 129: 488 Liquid-Cooled Engine

    3. Reference RECOIL PULLEY section for recoil disassembly / assembly information. 4. Lock the ratchet hub with a large screwdriver and remove the fasteners that secure the hub and waterpump pulley to the flywheel. 5.30 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 130: Water Pump Assembly

    2. O ring, belt, cover castings, cover gasket and belt pulley can be replaced with service parts. 3. Set belt tension to 1/8" to 3/16" at the midpoint of the belt. 5.31 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 131: Cylinder Assembly

    7. Apply a liberal amount of two-stoke engine oil to each to threads. piston assembly and each cylinder bore. Carefully install each piston while making sure each piston ring is centered at each piston ring locating pin. 5.32 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 132: Oil Pump Assembly

    4. Remove the oil pump drive gear using a needle nose pliers. 5. Lubricate all parts with Polaris Two-Stroke engine oil during re-assembly. 6. Install the exact amount of shim(s) that were removed. Verify return spring works and applies tension to the lever.

  • Page 133: Magneto Assembly

    4. Thoroughly clean the crankshaft nose and flywheel nut threads. Inspect the flywheel key for damage. Replace if damage is found. 5. Scribe a line in the magneto plate and crankcase to 5.34 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 134: Crankcase Assembly

    6. Apply a thin bead of Three Bond 1215 to both (32 - 35 Nm) crankcase mating surfaces. 7. Lubricate the oil pump drive gear with two-stroke engine oil and install into crankcase. 5.35 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 135: Piston And Crankshaft Assembly

    4. Inspect the crankshaft as outlined in the Engine Inspection section within this chapter. 5. Install the piston rings with the beveled edge facing 5.36 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 136: 500Ev Liquid-Cooled Engine

    13. Always use new gaskets and o-rings during CYLINDER HEAD assembly. Liberally coat the inside of each cylinder and the outside of each piston with Polaris two-stroke engine oil. O-RINGS 14. When installing a piston into a cylinder, verify each piston ring opening is located at each piston ring locating pin.

  • Page 137: 500Ev Recoil / Magneto

    NOTE: Do not thread the puller screws into the magneto/stator located behind the flywheel. 6. Turn the puller center bolt in until the flywheel “pops” 5.38 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 138: 500Ev Pistons / Crankshaft

    NOTE: Always use new cylinder base gaskets. removing the cylinder head and cylinders from the engine. 9. Apply a liberal amount of Polaris two-stroke oil to the 2. To remove the crankshaft, follow the process for cylinder wall. Align the piston ring gaps around the disassembling the crankcase assembly.

  • Page 139: 500Ev Crankcase

    1. Remove the engine from the engine compartment. 2. Follow the process for removing the cylinder head, cylinders, pistons, flywheel / recoil housing, and the water / oil pump. 5.40 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 140: 500Ev Water / Oil Pump

    Discard the water pump cover gasket. 4. Remove the impeller nut, impeller and washers from the cross shaft. 5. Carefully pry the mechanical seal and seal out of the 5.41 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 141 Engine Systems NOTES 5.42 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 142 BRAKE DISC REPLACEMENT ......... . . 6.23 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 143: Gear Ratio Tables

    104 101 107 104 105 100 8500 107 104 110 108 100 109 103 100 8750 107 114 103 101 112 106 103 9000 114 106 103 115 109 106 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 144 Gear Ratio 1.76 1.90 1.95 2.05 1.85 1.90 2.05 2.10 2.00 2.05 2.16 2.21 2.26 Jackshaft 6000 6250 6500 6750 7000 7250 7500 7750 8000 8250 8500 8750 9000 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 145 Bottom Gear 7.92 Chain Gear Ratio 2.17 2.22 2.33 2.39 2.18 2.29 2.35 2.41 2.53 Jackshaft 6000 6250 6500 6750 7000 7250 7500 7750 8000 8250 8500 8750 9000 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 146: Drive Gears And Chains

    40T, 3/4W, 15 SPL, HYVO, PM 3222101 41T, 3/4W, 15 SPL, HYVO, PM 3221188 43T, 3/4W, 15 SPL, HYVO, PM CM = Cut Metal Sprocket PM = Powder Metal Sprocket 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 147: 7.92 C.d. Chaincase

    D = 62 ft.lbs. (84Nm) 7.92 C.D. Assembly Notes • Never re-use cotter pins. Always replace with new parts. • Install upper gear washer with dome (raised side) facing locknut. 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 148: Chaincase Removal

    17. Remove the loosely placed lower gear and retaining bolt. 18. Place the upper sprocket, lower sprocket into the chain, and install it on the shafts in the chaincase. 19. Lock the parking brake. 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 149 Chaincase Cover Bolts: 10 ft.lb. (13.5 N-m) 27. Remove the fill cover and fill chaincase to the appropriate level. 28. Check for leaks. 29. Adjust track tension to the specified tension. 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 150: Driveshaft And Jackshaft

    B = 15 - 17 ft.lbs. (21 - 23 Nm) Verify the o- ring sits inside the sleeve. C = 28 - 30 ft.lbs. (38 - 41 Nm) (Chaincase Mounting Fasteners) 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 151: Jackshaft Removal

    10. Place the same amount of washers on the drive clutch end of the jackshaft. 11. Install the driven clutch, spacer, and washers and torque the retaining bolt to 17 ft-lb (23 N-m). 12. Install the belt. 6.10 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 152: Widetrak Gearcase

    10. Tighten idler wheel bolts so that spacers on shafts do the drive sprocket. not rotate and lose alignment. 11. Remove carrier shaft bolts, and front and rear 6.11 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 153: Inspection

    Rounded edges will cause gears to disengage under load. Replace both dog gear and mating gear if edge of dog and/or slot is rounded. Inspect gears for chipped, cracked, or broken teeth. 6.12 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 154 12. Gear, shaft, and chain cluster assembly shown. Reverse output power flow. INPUT SHAFT LOW/RVS SHAFT OUTPUT SHAFT Low gear output power flow. High gear output power flow. 6.13 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 155: Input Shaft Inspection

    3. Inspect needle bearings for wear or cracks on cage. Shiny spots on cage indicate wear and the bearing should be replaced. Inspect shaft and thrust washers for galling or wear. Always replace snap rings if removed. 6.14 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 156: Output Shaft Inspection

    6. When installing shift forks, press dowel pins up to  .100 (2.5mm) below top of bore. Verify pins do not bottom-out on shift groove. SHAFT MUST BE IN PLACE WHEN INSTALLING SPRING SHIFT INDEX 6.15 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 157: Gearcase Assembly

    (11-14 N-m) using a criss-cross pattern. 18. Install and hand tighten suspension bolts (1). 7. Install brake disc. Install detent ball, spring, and plug. Fill with 20 ounces (600cc) Polaris Premium Synthetic 2W-50 Oil. Gearcase Installation 1. Tip unit onto right side.
  • Page 158 34. Lift and support rear of unit and align track to specifications found in the Maintenance section. Make sure rear idler wheel spacer location is correct before tightening idler wheels. 6.17 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 159: Hydraulic Brake System

    During system service, be The Polaris snowmobile hydraulic brake system consists sure this port is open. Due to the high temperatures of the following components or assemblies: brake lever,...

  • Page 160: Warnings And Cautions

    In addition, the fluid stored in a pressure bleeder may be contaminated. Al- ways use fresh DOT 4 brake fluid from a sealed con- tainer. 6.19 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 161: Brake Fluid Replacement & Bleeding

    10. After removing the air or replenishing the brake fluid, actuate the lever. If the lever feels “spongy”, further bleeding is required. If the lever feels “stiff”, the system is fully bled. 6.20 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 162: Brake Hose Replacement

    6. Replace the master cylinder to the switch pack and cylinder. insert the smaller screws on the top, the longest one 9. Remove the brake hose from the master cylinder. goes into the lower right side. 6.21 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 163: Brake Caliper

    3. Rotate and remove the brake pad retaining pin and 11. Test the snowmobile at low speed to verify operation. then remove the brake pads. Remove the caliper from the chaincase. 6.22 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 164: Brake Disc Replacement

    13. Coat the piston thoroughly with new brake fluid. Evenly insert each piston into the bores, working each in by hand carefully and slowly. Push each piston down until bottomed out. 6.23 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 165 Drive and Brake Systems NOTES 6.24 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 166 WIDE TRAK DRIVEN CLUTCH COMPONENTS ......7.26 POLARIS P2 DRIVEN CLUTCH COMPONENTS ......7.27 POLARIS SPA-P2 DRIVEN CLUTCH COMPONENTS .

  • Page 167: Pvt System

    RPM, but never below, after the driven or repairs. clutch begins to open. The Polaris drive system is a centrifugally actuated Shift Out RPM variable speed belt drive unit. The drive clutch, driven clutch, and belt make up the torque converter system.

  • Page 168: Back-Shifting

    High ratio represents when the drive belt is all the way out on the drive clutch, and all the way in on the driven clutch. 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 169: General Information

    Universal Drive/Driven Clutch Compressor (Screw Down Type) PU-50518 Spring-Loaded Roller Pin Installation Roller/Bushing Alignment Tool 8700221 Drive Clutch Compression Tool (Compresses drive clutch without removing clutch from engine.) 2871173 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 170 NOTE: Springs listed as color - #### will have the last four digits of the part number painted on the spring coil. Tag each spring with the part number and spring force when not in use. 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 171 10-54 1321685 1321589 10-56 1321684 10-58 1321588 10-60 1321587 10-62 1321586 10-64 1321585 10-66 1321584 10-68 1322427 10-70 1322414 10-72 1322428 10-74 1322429 10-76 1322585 10-78 1322586 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 172 When cross referencing 10 and 11 series weights, select a 2 gr. lighter 11 series weight (10-66 = 11-64). 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 173 NOTE: Team driven springs listed with a color - ### / ### will have the beginning and ending spring rates painting on the spring coils. Tag each spring with the part number when not in use. 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 174 PVT System Polaris P2 Driven Non-Tabbed Springs TEAM PART Free Length COLOR LOAD @ 2.2(lbs) LOAD @ 1.1(lbs) Rate (Lbs./In.) EQUIVALENT NUMBER Inches (cm) COLOR RED/YELLOW 7043397 4.4 (11.2) RED/SILVER 7043398 4.95 (12.6) 7043151 4.76 (12.1) RED/BLUE BLACK 7043150 Black 4.2 (10.6)
  • Page 175 PVT System Polaris P2 Driven Helixes 1st Angle at .100” from Horizontal / 2nd Angle - Vertical Distance to Transition PART NUMBER DESCRIPTION 5136975 5137154 5137155 5137160 5137142 58/40 - .35 5137150 40/38 - .45 5137157 44/38 - .45 5137176 58/42 - .45...
  • Page 176 Hour glassing occurs when the drive train does not move and the drive clutch engages the belt. 7.11 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 177 Check for correct clutch components, or damage on the Clutch malfunction clutch Slow, easy belt engagement - easing on the throttle Use fast, effective throttle to engage the clutch. 7.12 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 178 2. Remove the wrench. “Wiggle” the belt to remove slack while removing the wrench. 3. Close the clutch guard. 7.13 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 179 2. Insert the L wrench, PN 2874857, into one of the threaded holes located on the driven clutch. Turn it clockwise until the clutch sheaves are in the open position. 3. Remove the drive belt. DEFLECTION CAM 7.14 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 180 (B). 3. Firmly push on the moveable sheave while pulling the belt down into the sheaves from the rear. 4. Close the clutch guard. 7.15 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 181: Pvt System Adjustments

    4. After adjusting the offset, add or remove shim washers from behind the driven clutch bolt and washer to provide a .060" (.1.5mm) driven clutch float on the jackshaft. (PN: PS-46998 Shown) 7.16 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 182: Drive Clutch

    3. Remove the drive clutch retaining bolt. Note the placement and number of washers on retaining bolt. 4. Insert the correct clutch puller into the retaining bolt hole. 7.17 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 183: Drive Clutch Disassembly

    1.40 (28.95mm) 6. Remove the spring. 7. Mount the drive clutch securely in a drive clutch holding fixture (PN 2871358-1). 8. Remove the jam nut in a counterclockwise direction 7.18 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 184: Roller Removal

    6. Install pin centering tool (PN 2870910-A or 8700221). 7. Drive the roller pin through the second land of the spider. 8. Repeat process for the other two rollers. 7.19 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 185: Cover Bushing

    10. Apply a thin film of Loctite 648 to the leading edge of the new bushing. Push a new bushing into center of sheave by hand. NOTE: Verify no retaining compound is deposited on the I.D. of the bushing. 7.20 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 186: Clutch Assembly

    8. Apply Loctite 243 to the spider threads. Using the spider tool (PN 2870341) torque to specification. Spider Torque 280-300 Ft.Lbs. (380-406 Nm) Apply Loctite 243 to Threads 7.21 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 187: Belt-To-Sheave Clearance Adjustment

    “X”. Notice as the spider seat location is changed, the sheave marks made before disassembly no longer align (C). There are two ways to bring the sheave marks into alignment. 7.22 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 188: Drive Clutch Installation

    1" (25.4mm) after final assembly and torquing. When assembling a new clutch with all of the same components, it is not uncommon for the marks not to line up. 7.23 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 189: Driven Clutch

    Driven Clutch Installation 1. Install the driven clutch bolt with the same amount of washers at removal. 2. Torque the bolt to specification. 3. Check for correct belt deflection. 7.24 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 190: Team Lwt Components

    8. Align the notch in the roller assembly with row of double splines on the shaft. Slowly compress the spring and roller assembly down on to the shaft. Install 7.25 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 191: Widetrak Driven Clutch Components

    7. Insert one leg of the spring into the hole in the sheave. Insert the other spring leg into the #2 hole in the helix. 7.26 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 192: Polaris P2 Driven Clutch Components

    PVT System Polaris P2 Driven Clutch Components STATIONARY SHEAVE MOVEABLE SHEAVE SPRING CUPS* WASHER DRIVEN COVER SPRING HELIX SPACER BUSHING WASHER BUSHING (NO SERVICE) RETAINING RING (NO SERVICE) ROLLER DEFLECTION PINS / CAM * = See Note companies such as Team Industries Inc.
  • Page 193 15. Carefully release the clutch compressor. 16. Align the two “X” marks and install the cover. Torque fasteners to specification. 7.28 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 194: Polaris Spa-P2 Driven Clutch Components

    PVT System Polaris SPA-P2 Driven Clutch Components SPACER STATIONARY SHEAVE MOVEABLE SHEAVE DRIVEN COVER WASHER SPRING w/TAB HELIX SPRING CUP w/TAB HOLES BUSHING SPACER ROLLER BUSHING (NO SERVICE) RETAINING RING (NO SERVICE) WASHER ADJUSTER SCREW / LOCK NUT 3. Remove the snap ring. Verify the washer is not lodged inside the snap ring groove.
  • Page 195 16. Carefully release the clutch compressor. 17. Align the two “X” marks and install the cover. Torque fasteners to specification. P2 Cover Fastener Torque 12 Ft.Lbs. (16 Nm) 7.30 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 196 SUSPENSION SET-UP ..........8.37 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 197: Front Suspension Torque & Specifications

    NOTE: Drag link, tie rod, and steering rack length Rod end jam nuts 8 - 14 ft-lb measurements are assembled with rod ends and (11 - 19 N-m) center-to-center. 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 198: Edge 41

    NOTE: Drag link, tie rod, and steering rack length Rod end jam nuts 8 - 14 ft-lb measurements are assembled with rod ends and (11 - 19 N-m) center-to-center. 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 199: Widetrak

    48 ft-lb (65 N-m) measurements are assembled with rod ends and center-to-center. Center Steering Arm 58 ft-lb (79 N-m) Rod end jam nuts 8 - 14 ft-lb (11 - 19 N-m) 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 200: Overview / Specifications

    Always use suspension had 4 inches of spring travel, the 100 #/in. genuine Polaris parts and hardware when replacing front spring would bottom out, while the 150 #/in. spring would end components. Review steering adjustment guidelines have one inch of travel remaining.

  • Page 201: Adjustable Shocks

    Remove the existing spring and install the next highest rate spring, or reduce the preload on the existing spring and change the shock valving to obtain the desired effect. 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 202: Front Suspension Alignment Bar

    • + = Positive camber. The bottom of the spindle is canted inward toward the chassis. • - = Negative camber. Spindle bottom is canted outward from the chassis. 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 203: Rod End Engagement

    Rod ends must engage (B) the rod a minimum of 2x the fasteners to specification. Remove the alignment bar. thread diameter (A) when adjustment is complete. Reinstall the upper radius rod bolts and torque to specification if removed. 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 204: Maximum Width Adjustment

    5. Re-check the set up width and compare to specification. Maximum Setup Width 5. Using a tape measure, measure the distance between the centers of each spindle. This measurement is the maximum setup width. 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 205: Toe Adjustment

    Soft springs/preload will increase ski pressure, but may bottom out. Stiff springs/preload will provide more track pressure (reduced ski pressure), but may result in a less comfortable ride 8.10 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 206: Suspension Coupling

    Rear Scissor blocks also have a big effect on weight transfer. Suspension Coupling On all Polaris snowmobile rear suspensions, there are two torque arms that control the movement of the rail beam. Prior to the advent of suspension coupling, these torque arms could move independently of each other.

  • Page 207: Rear Track Shock Control Rods

    Trail RMK (lower end is smaller than the upper end) Upper Lower .475" (12 mm) .475" (12 mm) Facing Shock 340-, SuperSport (both ends are the same size) 8.12 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 208: Rear Suspension Adjustments

    • EDGE RMK / EDGE = 4” (10cm) • Widetrak = 1.5” (4cm) 5. Adjust for the desired ride height by rotating the torsion spring cams located on the rear of the torsion spring. 8.13 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 209: Scissor Stop Adjustments

    The limiter strap is normally mounted in the fully extended position. Both limiter straps must be adjusted evenly and remain equal in length to avoid improper Hi-Fax and track wear. 8.14 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 210: Widetrak Torsion Spring Adjustments

    NOTE: Rear spring settings will affect ski-to-ground pressure. If ski pressure is too light it may be desirable to tighten the rear springs for an increase in ski-to-ground pressure. 8.15 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 211: Rear Suspension Assembly Illustrations

    REAR PIVOT SHAFT H BRACKET SHAFT SPACER C - Both Sides • Apply Polaris Premium All Season Grease to all grease zerks as outlined in the maintenance table. A = 45 Ft.Lbs. CAUTION B = 35 Ft.Lbs. C = 36 Ft.Lbs.
  • Page 212 Always replace with new parts. • All pivots must rotate freely after tightening fasteners. • Apply Polaris Premium All Season Grease to all grease zerks as outlined in the maintenance table. CAUTION Some rail shaft fasteners are pre-coated with locking agent.
  • Page 213 LIMITER STRAP MOUNTING ARM SHOCK ASSEMBLY TORSION SPRING SPACER SHOCK ROD • Apply Polaris Premium All Season Grease to all grease zerks as outlined in the maintenance table. A = 12 Ft.Lbs. CAUTION B = 45 Ft.Lbs. C = 35 Ft.Lbs.
  • Page 214 Always replace with new parts. • All pivots must rotate freely after tightening fasteners. • Apply Polaris Premium All Season Grease to all grease zerks as outlined in the maintenance table. CAUTION Some rail shaft fasteners are pre-coated with locking agent.
  • Page 215 Always replace with new parts. • All pivots must rotate freely after tightening fasteners. • Apply Polaris Premium All Season Grease to all grease zerks as outlined in the maintenance table. CAUTION Some rail shaft fasteners are pre-coated with locking agent.
  • Page 216 SHOCK RODS SHAFT • All pivots must rotate freely after tightening fasteners. • Apply Polaris Premium All Season Grease to all A = 12 Ft.Lbs. grease zerks as outlined in the maintenance table. B = 40 Ft.Lbs. C = 35 Ft.Lbs.
  • Page 217 Always replace with new parts. • All pivots must rotate freely after tightening fasteners. • Apply Polaris Premium All Season Grease to all grease zerks as outlined in the maintenance table. CAUTION Some rail shaft fasteners are pre-coated with locking agent.
  • Page 218 Always replace with new parts. • All pivots must rotate freely after tightening fasteners. • Apply Polaris Premium All Season Grease to all grease zerks as outlined in the maintenance table. CAUTION Some rail shaft fasteners are pre-coated with locking agent.
  • Page 219 SHOCK ROD TORSION SPRING • All pivots must rotate freely after tightening fasteners. • Apply Polaris Premium All Season Grease to all A = 40 Ft.Lbs. grease zerks as outlined in the maintenance table. B = 19 Ft.Lbs. C = 12 Ft.Lbs.
  • Page 220 INNER SHAFT SPACER INNER / OUTER SHAFTS INNER / OUTER SHAFTS • Apply Polaris Premium All Season Grease to all grease zerks as outlined in the maintenance table. • Thoroughly grease all inner shafts prior to A = 45 Ft.Lbs.
  • Page 221 Always replace with new parts. • All pivots must rotate freely after tightening fasteners. • Apply Polaris Premium All Season Grease to all grease zerks as outlined in the maintenance table. 8.26 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual...
  • Page 222 Always replace with new parts. • All pivots must rotate freely after tightening fasteners. • Apply Polaris Premium All Season Grease to all grease zerks as outlined in the maintenance table. CAUTION Some rail shaft fasteners are pre-coated with locking agent.
  • Page 223 INSIDE COUPLER LINK CLEVIS OUTER COUPLER INNER SHAFT OUTER SHAFT • Apply Polaris Premium All Season Grease to all grease zerks as outlined in the maintenance table. A = 45 Ft.Lbs. CAUTION B = 19 Ft.Lbs. Some rail shaft fasteners are pre-coated with locking Assembly Notes agent.
  • Page 224 RH INNER ADJUSTER ADJUSTER ASSEMBLY A = 19 Ft.Lbs. Assembly Notes • Apply Polaris Premium All Season Grease to all grease zerks as outlined in the maintenance table. • Never re-use Nylock nuts fasteners with locking agent. Always replace with new parts.

  • Page 225: Rebuildable Shocks

    Shock Rod Holding Tool .50" Diameter Rod 2872429 Shock Rod Holding Tool .625" Diameter Rod 2871232 Fox Shock Spanner 2871351 Fox Shock IFP Depth Tool PS-44925 Fox Inner Tube Puller PS 2 8.30 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 226: Ryde Fx™ Shock Valve Part Numbers

    1700090 0.800 1700096 0.900 1700127 1.000 0.012 1700132 1.100 1700137 1.250 1700142 1.300 1700085 0.700 1700091 0.800 1700120 0.900 1700128 1.000 0.015 1700133 1.100 1700138 1.250 1700143 1.300 8.31 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 227: Valve Shim Arrangement

    The face of the piston with the greater number of relief Blue = COMPRESSION SIDE ports will always face the rebound valve stack Red = REBOUND SIDE. = Relief Port Faces Rebound Stack Faces Compression Stack 8.32 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 228: Rebuildable Ifs Shock Specifications

    .8 x .012 NOTE: Valve shim stacks listed as they would appear on the shaft when shock rod is locked in a table vise (eyelet down, threaded end up). 8.33 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 229: Rebuildable Front Track Shock Specifications

    .8 x .008 NOTE: Valve shim stacks listed as they would appear on the shaft when shock rod is locked in a table vise (eyelet down, threaded end up). 8.34 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 230: Ryde Fx Mono-Tube Shock Disassembly

    Teflon piston and 6. Remove the small button head screw from the I.F.P wear band for cuts, chipped or nicked edges, or pressure valve assembly. 8.35 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 231: Ryde Fx Mono-Tube Shock Assembly

    NOTE: After filling the shock body with oil, allow a couple of minutes for all air bubbles to rise to the top. 8.36 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 232: Troubleshooting

    Change worn rail slides. Increase front limiter strap length Setting up for deep snow operation. Based on rider preference, RRSS may be removed to increase weight transfer 8.37 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 233 Steering and Suspension Systems NOTES 8.38 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 234 TAIL LIGHT ASSEMBLY REPLACEMENT........9.4 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 235: Hood Assembly

    Polaris for repairing hoods. Hoods are made of Thermoplastic Olefin (TPO) and cannot be repaired. If a hood is broken it must be replaced. For small cracks you may drill a small hole on both ends of the crack to limit spreading.

  • Page 236: Rear Bumper Removal/Installation

    2. Remove the fasteners (2) that hold the seat base onto the tunnel or rear seat brace. 3. Unplug the tail light harness if applicable and remove the seat base. 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 237: Seat Cover Replacement

    6. Using a staple fun, tack each side of the vinyl cover in place using two staples (1). If cover has a Polaris emblem carefully align emblem with the bottom edge of the seat. This will help ensure that the cover is positioned properly.
  • Page 238 LEFT HAND CONTROL CONTINUITY CHECKS......10.20 LEFT HAND CONTROL POWER INPUT/OUTPUT CHECK ....10.20 10.1 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 239: Battery And Electrical Systems

    25° @ 2500RPM S3303-5044-PF5C 5. Check specific gravity of each cell with a hydrometer (TPS Disconnected) to ensure each has a reading of 1.270 or higher. 6. Install vent covers. 10.2 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 240: Specifications

    4. Charge battery at 1/10 of its amp/hour rating. Example:1/10 of 9 amp battery =.9 amps, 1/10 of 14 amp battery = 1.4 amps, 1/10 of 18 amp battery = 1.8 10.3 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 241: Specific Gravity Test (Conventional Battery)

    The Authorized Polaris dealers/distributors are required to use hydrometer can measure state of charge and differences the conductance analyzer when testing 12V Polaris between cells in a multi-cell battery.

  • Page 242: Off Season Storage

    Specific Gravity Freezing Point Specific Gravity of Freezing Point Electrolyte 1.265 -75_F (-59_C) 1.225 -35_F (-37_C) 1.200 -17_F (-27_C) 1.150 5_F (-15_C) 1.100 18_F (-8_C) 1.050 27_F (-3_C) 10.5 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 243: Ignition Timing

    9. If the pointer is outside the variance, the stator will have to be rotated either with crankshaft rotation (to retard the timing) or against rotation to advance it. 10.6 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 244: Ignition Timing Chart

    7.3253 0.2884 7.8931 0.3108 8.5696 0.3374 8.3089 0.3271 6.0562 0.2384 7.6920 0.3028 8.2883 0.3263 8.9986 0.3543 8.7254 0.3435 6.3501 0.2500 8.0659 0.3176 8.6912 0.3422 9.4360 0.3715 9.1501 0.3602 10.7 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 245: Throttle Position Sensor (Tps)

    O.L. momentarily when throttle flipper is moving. 3. Connect the test tool to the TPS on the carburetor or 8. If the signal readings are erratic, replace the TPS sensor. 10.8 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 246: Tps Adjustment - Carbureted Models

    3. Have an assistant hold the throttle flipper in the WOT position. 4. Turn the TPS clockwise to decrease voltage, or counterclockwise to increase voltage. 5. Carefully tighten the TPS screws when the WOT Vdc is 4.00Vdc. 10.9 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 247: Electric Start - Gen Ii / Edge

    Battery and Electrical Systems ELECTRIC START - GEN II / EDGE System Schematic 10.10 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 248: Starter Motor Assembly (Typical)

    NOTE: The starter motor bracket fasteners on 550 engines are treated with Loctite 262. Apply heat to each fastener to soften the threadlock prior to removing fastener. Apply Loctite 262 to threads during assembly. 10.11 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 249: Battery Box

    Battery and Electrical Systems Battery Box CIRCUIT BREAKER SOLENOID GROUND WIRE RED LEAD FROM BATTERY RED LEAD TO STARTER BATTERY BOX 10.12 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 250: Dynamic Testing

    7. Clean and inspect starter components. NOTE: Some cleaning solvents may damage the insulation in the starter. Care should be exercised when selecting an appropriate solvent. The brushes 10.13 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 251: Starter Housing / Field Coil Testing

    1/8, (.03 cm) above armature coil laminates. Rotate armature 360_. If hacksaw blade is drawn to the armature on any pole, the armature is shorted and must be replaced. 10.14 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 252: Carbureted Electrical Systems

    68_F / 20_C 2189 - 2675 BLK or WHT TO ENGINE 0 149_F / 6_C 455 - 556.2 WHT / RED TO WHT 185 221_F / 105_C 152.8 - 186.8 10.15 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 253: Troubleshooting Tables

    Check the resistance of the coils under the flywheel. Check the wiring connecting the coils and/or replace  Compare these to values on wiring diagram. Are they the coils as necessary. within limits? 10.16 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 254: Electronic Reverse (Perc)

    1. Ensure that the path ahead is clear, then push and release the reverse button. The engine will automatically change direction form reverse to forward and the reverse light on the instrument panel will stop flashing. 10.17 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.

  • Page 255: Hand/Thumb Warmers

    Battery and Electrical Systems HAND/THUMB WARMERS MOLEX CONNECTOR Thumb Warmer Diagnostics The thumb warmer on all Polaris snowmobiles is a thermistor-type warming element pad. This means its resistance will change based on temperature. Thumb Warmer Resistance Checks RESISTANCE @ ROOM CIRCUIT (Wire Color) TEMP.

  • Page 256: Hand Warmer Diagnostics

    There are two types of hand warmer element pads used NOTE: Hand warmer pads do not feature a high on Polaris snowmobiles. One version is used on steel/ temperature circuit. On snowmobiles featuring a left- painted handlebars and touring model rear passenger...

  • Page 257: Left Hand Control

    8. If there is a drop in voltage or no voltage at all, there is an issue (broken wire, short circuit) in between the left-hand control connector (AA-FF) and handlebar connectors. 10.20 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 258 Wiring Diagrams 2007 340/550 Models 11.1 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 259 Wiring Diagrams 2007 Widetrak 11.2 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 260 Wiring Diagrams 2007 500 XCSP 11.3 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 261 Wiring Diagrams 2008 340 / 2008-2010 550 Models 11.4 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 262 Wiring Diagrams 2008-2012 Widetrak 11.5 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc.
  • Page 263 Crankshaft Indexing ......5.6 5.36 488 L/C Piston and Crankshaft Crankshaft Inspection 5.30 488 L/C Recoil and Waterpump Housing IX.1 9922876 - 2007-2011 EDGE/Gen II/Widetrak LX Service Manual ©2010 Polaris Sales Inc.
  • Page 264 Front Track Shock Specifications ....8.34 Assembly View Fuel / Intake System Maintenance Disassembly and Inspection IX.2 9922876 - 2007-2011 EDGE/Gen II/Widetrak LX Service Manual ©2010 Polaris Sales Inc.
  • Page 265 SAE Tap Drill Sizes ......2.6 IX.3 9922876 - 2007-2011 EDGE/Gen II/Widetrak LX Service Manual ©2010 Polaris Sales Inc.
  • Page 266 Widetrak Gearcase ......6.11 Assembly 6.16 Input Shaft 6.14 Inspection 6.12 Installation 6.16 Low / Reverse Shaft 6.14 Output Shaft 6.15 Removal 6.11 Shift Drum 6.15 IX.4 9922876 - 2007-2011 EDGE/Gen II/Widetrak LX Service Manual ©2010 Polaris Sales Inc.

This manual is also suitable for:

340 touring 2007Supersport 2007550 lx 2007Trail touring deluxe 2007Trail rmk 2007Widetrak lx 2007 ... Show all

Table of Contents