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

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

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

Table of Contents

Chapters

Table of Contents

Troubleshooting

Summary of Contents for Polaris 2007 Two Stroke

Page 1 2007 Two Stroke Snowmobile Service Manual PN 9920463 © Copyright 2006 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 Fluke, Registered Trademark of John Fluke Mfg. Co. Mity-Vac, Registered Trademark of Neward Enterprises, Inc. Torx, Registered Trademark of Textron M-10, Registerd Trademark of FAST, Inc Some Polaris factory publications can be downloaded from www.polarisindustires.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer.
Page 3 SPECIFICATIONS GENERAL MAINTENANCE FUEL DELIVERY ENGINE CLUTCHING FINAL DRIVE FRONT SUSPENSION REAR SUSPENSION CHASSIS/HOOD ELECTRICAL...
Page 5: Table Of Contents
MODEL SPECIFICATIONS CHAPTER 1 MODEL SPECIFICATIONS 340 LX ..............1.2 340 TOURING .
Page 6 MODEL SPECIFICATIONS 340 LX Jetting Ambient Temperature MODEL S07ND3AS Body Altitude Body Style EDGE meters (feet) Engine Engine type Fuji Engine displacement 339cc 0-600 (0-2000) Bore (in/mm) 2.45/62.3 600-1200 Stroke (in/mm) 2.19/55.6 (2000-4000) 1200-1800 145# Piston to cylinder clearance (in/mm) .003-.005/.080-.130 (4000-6000) (in/mm)
Page 7: Front Suspension
MODEL SPECIFICATIONS Fluids and Capacities 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) 46/117 Chaincase (oz/ml) 9/266.2 Est dry weight (lb/kg) 457/207.7 Brake fluid type DOT4 Electrical Track Ignition timing 26.5°@3000RPM Width (in/cm) 15/38 Spark plug gap (in/mm)
Page 8: 340 Touring
MODEL SPECIFICATIONS 340 TOURING Jetting Ambient Temperature MODEL S07NT3A(E,S) Body Altitude Body Style EDGE meters (feet) Engine Engine type Fuji Engine displacement 339cc 0-600 (0-2000) Bore (in/mm) 2.45/62.3 600-1200 Stroke (in/mm) 2.19/55.6 (2000-4000) 1200-1800 (4000- Piston to cylinder clearance (in/mm) .003-.005/.080-.130 6000) (in/mm)
Page 9 MODEL SPECIFICATIONS Fluids and Capacities Dimensions Fuel (gal/l) 12.25/46.4 Width (in/cm) 47.25/120 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 Electrical Track Ignition timing 26.5°@3000RPM Width (in/cm) 15/38...
Page 10: Widetrak Lx
MODEL SPECIFICATIONS WIDETRAK LX Jetting Ambient Temperature MODEL S07SU4BS Body Altitude Body Style GENII meters (feet) Engine Engine type Fuji Engine displacement 488cc 0-600 (0-2000) Engine model number EC50PL237 Bore (in/mm) 2.83/72 600-1200 (2000-4000) Stroke (in/mm) 2.36/60 1200-1800 Piston to cylinder clearance (in/mm) .0035-.0049/.090-.125 (4000-6000) Piston ring end gap (in/mm)
Page 11 MODEL SPECIFICATIONS Fluids and Capacities 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 Electrical Track Ignition timing 28°@3000 Width (in/cm) 20/51...
Page 12: 500 Xc Sp
MODEL SPECIFICATIONS 500 XC SP Jetting Ambient Temperature MODEL S07NP5CS(E) Body Altitude Body Style EDGE meters (feet) Engine Engine type Liberty Engine displacement 0-600 (0-2000) Engine model number S3033-5044-PF5F Bore (in/mm) 2.78/70.5 600-1200 (2000-4000) Stroke (in/mm) 2.52/64 1200-1800 (4000- Piston to cylinder clearance (in/mm) .0045-.0059/.11-.15 6000) (in/mm)
Page 13 MODEL SPECIFICATIONS Fluids and Capacities 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 Electrical Track Ignition timing 25°@2500RPM Width (in/cm) 15/38...
Page 14: Super Sport
MODEL SPECIFICATIONS SUPER SPORT Jetting Ambient Temperature MODEL S07NP5B(E,S) Body Altitude Body Style EDGE meters (feet) Engine Engine type Fuji Engine Model EC550PM100 0-600 (0-2000) Engine Displacement 544cc Bore (in/mm) 2.87/73 600-1200 (2000-4000) Stroke (in/mm) 2.56/65 Piston to cylinder clearance (in/mm) .0039-.0053/.10-.135 1200-1800 (4000-6000)
Page 15 MODEL SPECIFICATIONS Fluids and Capacities Dimensions Fuel (gal/l) 11.8/44.7 Est dry weight lb/kg 460/208.7 Oil (qts/l) 3.25/3.1 Electrical Coolant (qts/l) Chaincase (oz/ml) 9/266.2 Ignition timing 27°@3000 Brake fluid type DOT4 Spark plug gap (in/mm) .028/.70 Spark plug NGK BR9ES Track Voltage regulator/output 280watt Width (in/cm)
Page 16 MODEL SPECIFICATIONS 550 LX Jetting Ambient Temperature MODEL S07ND5BS Body Altitude Body Style EDGE meters (feet) Engine Engine type Fuji Engine Model EC550PM110 0-600 (0-2000) Engine Displacement 544cc Bore (in/mm) 2.87/73 600-1200 (2000-4000) Stroke (in/mm) 2.56/65 Piston to cylinder clearance (in/mm) .0039-.0053/.10-.135 1200-1800 (4000-6000)
Page 17 MODEL SPECIFICATIONS Fluids and Capacities Dimensions Fuel (gal/l) 11.8/44.7 Est dry weight lb/kg 460/208.7 Oil (qts/l) 3.25/3.1 Electrical Coolant (qts/l) Chaincase (oz/ml) 9/266.2 Ignition timing 27°@3000 Brake fluid type DOT4 Spark plug gap (in/mm) .028/.70 Spark plug NGK BR9ES Track Voltage regulator/output 280watt Width (in/cm)
Page 18: Trail Rmk
MODEL SPECIFICATIONS TRAIL RMK Jetting Ambient Temperature MODEL S07NJ5B(E,S) Body Altitude Body Style EDGE meters (feet) Engine Engine type Fuji Engine Model EC550PM110 0-600 (0-2000) Engine displacement 544cc Bore (in/mm) 2.87/73 600-1200 (2000-4000) Stroke (in/mm) 2.56/65 Piston to cylinder clearance (in/mm) .0039-.005/.10-.135 1200-1800 (4000-6000)
Page 19 MODEL SPECIFICATIONS Chaincase Torsion Spring Center distance (in/cm) 7.92/20.1 Torsion spring PNs 7041627/7041628 (LH/RH) Reverse type PERC Torsion spring diameter (in/mm) .347/8.8 Fluids and Capacities Torsion spring tail angle 77° Fuel (gal/l) 11.8/44.7 Dimensions Oil (qts/l) 3.25/3.1 Width (in/cm) 45.5/115.6 Coolant (qts/l) Length (in/cm) 124/315...
Page 20: Trail Touring Deluxe
MODEL SPECIFICATIONS TRAIL TOURING DELUXE Jetting Ambient Temperature MODEL S07NT5B(E,S)(A) Body Altitude Body Style EDGE meters (feet) Engine Engine type Fuji Engine Model EC550PM100 0-600 (0-2000) Engine displacement 544cc Bore (in/mm) 2.87/73 600-1200 (2000-4000) Stroke (in/mm) 2.56/65 Piston to cylinder clearance (in/mm) .0039-.005/.10-.135 1200-1800 (4000-6000)
Page 21 MODEL SPECIFICATIONS Fluids and Capacities 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 77° Chaincase (oz/ml) 9/266.2 Brake fluid type DOT4 Dimensions Track Width (in/cm) 48/122 Length (in/cm) 128/325...
Page 22: 600 Ho Iq
MODEL SPECIFICATIONS 600 HO IQ Jetting Ambient Temperature MODEL S07PP6FS(A,B) Body Altitude Body Style meters (feet) Engine Engine type Liberty Engine Model S3273-6044-PF6F 0-600 (0-2000) Engine displacement Bore (in/mm) 3.04/77.25 600-1200 (2000-4000) Stroke (in/mm) 2.52/64 1200-1800 (4000- Piston to cylinder clearance (in/mm) .0045-.0059/.115-.149 6000) (in/mm)
Page 23 MODEL SPECIFICATIONS Chaincase Rear Suspension Center distance (in/cm) 8.373/21.3 Suspension type IQ 121 Reverse type PERC Arvin/7043244* (Std) Front track shock (FTS) Fox/7043267* (Opt) Fluids and Capacities 130-270/2.3-4.8 FTS spring rate (lb/in - kg/mm) (Std & Opt) Fuel (gal/l) 10.8/40.9 FTS installed length (in/mm) 7.97/20.2 (Std &...
Page 24: 600 Ho Iq Cleanfire
MODEL SPECIFICATIONS 600 HO IQ CLEANFIRE Clutching Drive Clutch (P-85) Driven Clutch (TEAM) MODEL S07PP6HS(A,B) Altitude meters Clutch Clutch (feet) Shift Weight Driven Helix Gearing Spring Spring Body 0-600 (64/42-.36) 10-62 Black/Green Red/Black 23:39-76 (0-2000) LW ER 600-1200 (56/42-.36) Body Style 10-60 Black/Green Red/Black...
Page 25 MODEL SPECIFICATIONS Front Suspension Torsion Spring Suspension type Torsion spring PN (LH/RH) 7043070/7043071 Arvin/7043245*(Std.) Torsion spring diameter (in/mm) .374/9.5 Fox/7043268* LH, IFS shocks Torsion spring tail angle 80° 7043269* RH (Opt) Dimensions IFS spring rate (lb/in - kg/mm) 100/1.79 (Std & Opt) IFS Spring installed length (in/cm) 10.55/26.8 (Std &...
Page 26: 600 Ho Iq Lx Cleanfire
MODEL SPECIFICATIONS 600 HO IQ LX CLEANFIRE Clutching Drive Clutch (P-85) Driven Clutch (TEAM) MODEL S07PD6HS Altitude meters Clutch Clutch (feet) Shift Weight Driven Helix Gearing Spring Spring Body 0-600 (64/42-.36) 10-62 Black/Green Red/Black 22:39-76 (0-2000) LW ER 600-1200 (56/42-.36) Body Style IQ Luxury 10-60...
Page 27 MODEL SPECIFICATIONS Front Suspension Suspension type IFS shocks Arvin /7043054 IFS spring rate (lb/in - kg/mm) 120/2.1 IFS Spring installed length (in/cm) 9.95/25.3 Front vertical travel (in/cm) 10/25.4 41.16" Ski center distance (in/cm) 104.5 2.25" ±.31" Camber (in/mm) ± 0-.12" Toe (in/mm) * notes that shock is serviceable Rear Suspension...
Page 28: 600 Ho Switchback
MODEL SPECIFICATIONS 600 HO SWITCHBACK Jetting Ambient Temperature MODEL S07PS6FS(A) Engine Altitude Engine type Liberty meters (feet) Engine displacement 599cc Engine model number S3273-6044-PF6F Bore (in/mm) 3.04/77.25 Stroke (in/mm) 2.52/64 0-600 (0-2000) Piston to cylinder clearance (in/mm) .0045-.0059/.114-.150 600-1200 (2000-4000) (in/mm) Piston ring end gap .014-.020/.36-.51...
Page 29 MODEL SPECIFICATIONS Chaincase 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 Fluids and Capacities Torsion spring tail angle 77° Fuel (gal/l) 10.8/40.9 Dimensions Oil (qts/l) 3.4/3.2 Width (in/cm) 47.25/120 Coolant (qts/l) 6...3/6 Length (in/cm)
Page 30: 600 Ho Switchback Cleanfire
MODEL SPECIFICATIONS 600 HO SWITCHBACK CLEANFIRE Belt Belt part number 3211080 MODEL S07PS6HS(A,B) Belt width (in/cm) 1.438/3.65 Engine Belt side angle 28° Outside diameter (in/cm) 46.625/118.4 Engine type Liberty Clutch center distance (in/cm) 11.5/29.2 Engine displacement 599cc Engine model number S3206-6044-PF6H Chaincase Bore (in/mm)
Page 31 MODEL SPECIFICATIONS Front Suspension Features Suspension type IQ 42.5 Electric Fuel Gauge Standard Fox/7043141* (Std) Electric Start Optional Fox/7043268*, IFS shocks Low Oil Light Standard 7043269*(Option) Parking Brake Standard IFS spring rate 100/1.79 (Std & Opt) Speedometer Standard lbs-in/kg-mm Tachometer Standard Spring installed length (in/cm) 10.55/26.8 (Std &...
Page 32: Ho Rmk 144/155 (F/O)
MODEL SPECIFICATIONS 600 HO RMK 144/155 (F/O) Jetting Ambient Temperature MODEL S07(P,M)(M,K)6FS(A) Body Altitude Body Style meters (feet) Engine Engine type Liberty Engine displacement 599cc 0-600 (0-2000) Engine model number S3274-6044-PF6F 600-1200 (2000- 4000) Bore (in/mm) 3.04/77.25 1200-1800 (4000- Stroke (in/mm) 2.52/64 6000) Piston to cylinder clearance (in/mm)
Page 33 MODEL SPECIFICATIONS Chaincase Rear Suspension Center distance (in/cm) 8.373/21.27 7.4/18.8 (Std) FTS spring installed length (in/cm) No Spring (Premium) Reverse type PERC Rear track shock Arvin/7043047 Fluids and Capacities Rear track shock Premium WE/7043235* 144=14.5/36.8 Fuel (gal/l) 12.1/45.8 Rear travel (in/cm) 155=15.5/39.4 Oil (qts/l) 3/2.8...
Page 34: 600 Ho Iq Touring Cleanfire
MODEL SPECIFICATIONS 600 HO IQ TOURING CLEANFIRE Belt Belt part number 3211080 MODEL S07PT6HS Belt width (in/cm) 1.438/3.65 Body Belt side angle 28° Outside diameter (in/cm) 46.625/118.4 Body Style IQ Touring Clutch center distance (in/cm) 11.5/29.2 Engine Chaincase Engine type Liberty Center distance (in/cm) 7.92/20.1...
Page 35 MODEL SPECIFICATIONS Front Suspension Suspension type IFS shocks Arvin/7043054 IFS spring rate 122-2.1 (lb/in - kg/mm) Spring installed length (in/cm) 9.95/25.3 Front vertical travel (in/cm) 10/25.4 " 41.16 Ski center distance (in/cm) 104.5 " ± " 2.25 Camber (in/mm) 5.7 ±.79 "...
Page 36: Dragon
MODEL SPECIFICATIONS DRAGON Clutching DRIVE CLUTCH (P-85) DRIVEN CLUTCH (TEAM) MODEL NUMBER: S07PC7J(E,S) ALTITUDE meters Shift Clutch Clutch Driven Gearing (feet) Weight Spring Spring Helix Engine 0-600 Dark Blue / 66/44-46 10-64 Red/Black 23:39-76 (0-2000) White LW ER Engine type Liberty 600-1200 Dark Blue /...
Page 37 MODEL SPECIFICATIONS Track Electrical Width (in/cm) 15/38 Stator output 400w Length (in/cm) 121/307 ± 18° @ 1700 RPM ( ± ° F RPM) & 120° F ( Lug height (in/cm) 1.25/3.2 Ignition timing BTDC @ RPM ± ° C 49 ° C ( ) water Manufacturer Camoplast...
Page 38: Dragon Rmk
MODEL SPECIFICATIONS DRAGON RMK Clutching DRIVE CLUTCH (P-85) DRIVEN CLUTCH (TEAM) MODEL NUMBER: S07PL7JS ALTITUDE meters Shift Clutch Clutch Driven Gearing (feet) Weight Spring Spring Helix Engine 0-600 Black/ 56/42-36 10-66 Black 20:41-76 (0-2000) Green LW ER Engine type Liberty 600-1200 Black/ 56/42-36...
Page 39 MODEL SPECIFICATIONS Track Torsion Spring Width (in/cm) 15/38 Torsion spring PNs 7041629/7041630 (LH/RH) Length (in/cm) 155/393.7 Torsion spring diameter (in/mm) .359/9.12 Lug height (in/cm) 2.4/6.1 Torsion spring tail angle 77° Manufacturer Camoplast Track tension sag (in/cm) with 10 lbs/ Dimensions 4.54kg placed 16 in/40.6cm ahead of .375-.50/1-1.3 rear idler shaft...
Page 40 MODEL SPECIFICATIONS NOTES 1.36...
Page 41 GENERAL CHAPTER 2 GENERAL HOW TO USE THIS MANUAL..........2.2 GEARING .
Page 42: How To Use This Manual
GENERAL HOW TO USE THIS MANUAL Gearing Gearing that is called out in the clutching table is stated as TOP GEAR (total number of teeth): BOTTOM GEAR (total number of teeth) - CHAIN PITCH (total number of links) Example 22:39-76 •...
Page 43: Suspension Spring Pre-Load/Installed Length
GENERAL Suspension Spring Pre-Load/Installed Length When installing springs on shocks the specifications will call out “Installed Length” or “Pre-Load”. Installed Length is the length of the spring from end to end when it is ready to be installed on the snowmobile. You should adjust the spring preload ring until you reach your specified spring installed length.
Page 44: Snowmobile Number Designations
GENERAL SNOWMOBILE NUMBER DESIGNATIONS Model Number Designation S07PP6FSA (600 HO IQ STOCK A) ODEL PTION DENTIFIER ODEL ODEL NGINE ODIFIER DENTIFIER DENTIFIER 1st digit 2/3rd digit 4th digit 5th digit 6th digit* 7th digit* 8th digit 9th digit** C=Dragon 121 1A=121 F/C OHV 4 Cycle Fuji D=Classic 3A=340 F/C Piston Port...
Page 45: Vehicle Identification Number (Vin)
GENERAL VEHICLE IDENTIFICATION NUMBER (VIN) Tunnel Decal The Tunnel Decal has the Model Number (1), V.I.N. Number (2), and the Manufactured Date (3).These numbers should be referred to in any correspondence regarding warranty, service or replacement parts.The machine model and V.I.N. number identification decal is located on the right front side of the tunnel.
Page 46: 2007 Service Publications
GENERAL 2007 Service Publications MODEL OWNER'S OWNER'S PARTS ASSEMBLY SERVICE 2007 MODEL NUMBER MANUAL MANUAL BOOK INSTRUCTIONS MANUAL 440 IQ S07MX4CS 9920432 9920433 9920434 9919882 9920436 340 Edge LX S07ND3AS 9920437 9920438 9920442 9916508 9920444 550 Edge LX S07ND5BS 9920437 9920439 9920445 9916508...
Page 47: General Reference
GENERAL GENERAL REFERENCE 1 gallon has 128oz. / 20 = 6.4 oz. of oil needed to mix to each 1 gallon of gasoline. For a 5 gallon mixture, you would need add 32 oz. of oil to the gasoline. Standard Bolt Torque Specification Gasoline Volatility MBIENT AXIMUM...
Page 48: Sae Tap Drill Sizes
GENERAL SAE Tap Drill Sizes Decimal Equivalents 1/64 ....0156 Thread Size/ Drill Size Thread Size / Drill Size 1/32 ....0312.
Page 49: Measurement Conversion Chart
GENERAL Measurement Conversion Chart Piston Wash / Spark Plug Reading Changing temperature, barometer, altitude, and fuel supply are NIT OF EASURE ULTIPLIED BY ONVERTS TO just a few of the factors that can affect the day to day ft-lb x 12 = in-lb performance of your engine.
Page 50: Glossary Of Terms
OD: Outside diameter. Chain Pitch: Distance between chain link pins (No. 35 = Ohm: The unit of electrical resistance opposing current 3/8" or 1 cm). Polaris measures chain length in number of flow. pitches. oz.: Ounce/ounces.
Page 51: Special Tools
GENERAL SPECIAL TOOLS Special Tools 2.11...
Page 52 GENERAL 2.12...
Page 53 GENERAL 2.13...
Page 54 GENERAL 2.14...
Page 55 POLARIS RECOMMENDED PROGRAM........3.3...
Page 56 MAINTENANCE CHASSIS AND HOOD ..........3.22 CLUTCH AND DRIVE SYSTEM.
Page 57: Maintenance Program
Personal safety is critical when attempting to service or adjust your snowmobile. If you're not familiar with safe service or adjustment procedures and the use of tools, or if you don't feel comfortable performing these tasks yourself, contact an authorized Polaris dealer for service.
Page 58 MAINTENANCE REQUENCY ILES REQUENCY ILES EASON EASON 1000 2000 1000 2000 (240) (240) (1600) (3200) (240) (240) (1600) (3200) Exhaust Suspension Retaining Mounting Bolts Springs Steering BRAKES Fasteners Hose Routing Rear Suspension Fasteners Hose Condition Suspension Fluid Leaks Shock Oil Brake Pads Cooling Fins and Shroud...
Page 59: Inspectons
MAINTENANCE INSPECTONS Cylinder Measurement Worksheet Taper limit = Ty - By and Tx - Bx Cylinder Head Inspection Cylinder taper limit is .002"(.051mm) Max Cylinder out of round limit is .002"(.051mm) Inspect each piston dome area of the cylinder head for warping by placing a straight edge across the dome area.
Page 60: Honing Procedure
Rinse thoroughly, dry with compressed air, and oil OVERTIGHTEN). Cylinders may be wet or dry honed the bore immediately with Polaris Premium 2 Cycle Lubricant. depending on the hone manufacturer's recommendations. Wet honing removes more material faster and leaves a NOTE: Always check piston to cylinder clearance more distinct pattern in the bore.
Page 61: Piston Ring Installed Gap
MAINTENANCE Piston Ring Installed Gap Recommended Coolant Polaris snowmobiles use a premium 60/40 pre-mix antifreeze. This premium antifreeze is mixed with deionized water for better protection for aluminum cooling. This pre-mix is good for temperatures down to -62°F (-52°C). Replace coolant every 2 years or if contaminated.
Page 62: Bearing Fit
(4000) to get coolant to flow but not enough RPM to engage the clutch. Clean crankshaft thoroughly and oil main and connecting rod bearings with Polaris engine oil. Carefully check each main bearing on the shaft. WARNING Due to extremely close tolerances, the bearings must be inspected visually, and by feel.
Page 63: Wrist Pin Bearing
Polaris uses crankshafts that 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 64 MAINTENANCE Continue to rotate the crankshaft in the normal direction of rotation until the dial indicator reads .100" (2.54mm) after top dead center (ATDC). Bend the pointer or move the degree wheel until the pointer aligns with a 180° mark on the degree wheel. With the pointer aligned, make sure the degree wheel and pointer are secured and will not move out of position.
Page 65: Crankshaft Trueing
MAINTENANCE Crankshaft Trueing Lubricate the bearings and clamp the crankshaft securely in the holding fixture.If trueing the crankshaft requires striking with a hammer, always be sure to re-check previously straightened areas to verify trueing. Refer to the illustrations below. Use Crankshaft alignment kit PN 2870569.
Page 66: Crankshaft Runout Inspection
1/2” (12.7mm) from the bearing flat (A). MAG END To aid in bleeding the air out of the oil lines, fill oil reservoir with the appropriate Polaris injector oil. This will add pressure to the oil lines. Loosen the bleed screw (A). After approximately 30 seconds oil should flow from beneath the screw head.
Page 67: Brake Lever Travel
Inspect the reservoir to be sure it contains the correct amount of fluid. Use only Polaris DOT 4 high temperature brake fluid. Manifold Fasteners: 18 ft-lb (24 N-m) Change fluid every 2 years or whenever the fluid is dark or contamination is suspected.
Page 68: Belt Deflection Inspection
MAINTENANCE Belt Deflection Inspection Measuring Belt Deflection Belt deflection is critical for optimum belt performance and belt Measure the belt deflection with both clutches at rest and life. It should be checked at 500 miles (800km) and then in 1000 in their full neutral position.
Page 69: Lubrication
LUBRICATION Lack of lubrication will adversely affect your ride and the life of the sleds components. Lubricate with Polaris Premium All Season Grease at 500 miles (800km) initially, every 1000 miles (1600km) after that, and before off-season storage each year. A grease gun kit, complete with grease and adaptors, is available to lubricate all fittings.
Page 70: Front Suspension
Throttle Cable • Lubricate the steering post U-Joint and lower pivot with Lubricate the throttle cable lightly with fresh oil. With the Polaris engine fogging oil. engine off, turn the handlebars to the left and lubricate well as shown. • Grease the center steering arms.
Page 71: Chaincase Oil
MAINTENANCE Chaincase Oil ADJUSTMENTS Check the chaincase oil level at the interval outlined in this Choke Adjustment maintenance section. Change the chaincase oil after the first 500 miles (800 km), then every 1000 miles (1600 km) or seasonally. Flip the choke toggle to the “OFF” position. Maintain the oil level between the “safe”...
Page 72: Throttle Lever Free Play - Non Cfi
MAINTENANCE Throttle Lever Free Play - Non CFI Verify the oil pump index marks are within specification. Check the idle RPM and verify it is within the specified range. 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 kill upon initial throttle opening.
Page 73: Oil Pump Adjustment
MAINTENANCE After setting the throttle lever free play, always verify the oil If they are not aligned, make the necessary adjustments by pump adjustment is set correctly. adjusting the oil pump cable. In small increments, loosen the lock nut that is closest to the oil pump (A). and move Oil Pump Adjustment the mark that is on the oil pump arm by tightening or loosening the adjustment nut (B) as needed to get the line...
Page 74: Track Alignment
MAINTENANCE Track Alignment NOTE: Track alignment affects track tension. After any adjustments are complete, be sure to torque the Misalignment of the track will cause excessive wear locknuts (E) to 35 ft-lb (48 N-m). to the track, rail slides, and rail. NOTE: Excessive rail slide wear occurs due to running in inadequate snow conditions.
Page 75: Track Tension
MAINTENANCE Track Tension NOTE: Track alignment affects track tension. Misalignment will cause excessive wear to the track and slide rails. Excessive slide wear will appear on units with the track tension set too tight (or below measurement specification). SUSPENSION MEASUREMENT 7/8"...
Page 76: Engine Isolator Limiter Setting
Wipe off the residue from the plug and reinstall the clamps. Air Filter Nosepan Care If your nosepan becomes dirty with soot, you can use Polaris Carbon Clean (PN 2872890) to remove the soot. STORAGE Chassis And Hood AIR FILTER CLEANING Proper storage starts by cleaning, washing and waxing the hood, chassis, upholstery and plastic parts.
Page 77: Clutch And Drive System
Lubricate or pack connector blocks with Nyogel™ grease and reconnect. Replace worn or frayed electrical wire and connectors. Carburetor/Throttle Body 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 78: Headlight Bulb Replacement
MAINTENANCE REPLACEMENT Lift spring carefully around the wire harness and flip it to the outside of the housing. Grasp the bulb (4) by the metal base and carefully separate Headlight Bulb Replacement the bulb from the harness. NOTE: Do not touch the bulb with your fingers. The Instal new bulb by the base and reverse the process for grease from body oil will cause a hot spot on the installation.
Page 79: Coolant Draining
MAINTENANCE Coolant Draining WARNING Wait until the engine is cool before removing the pressure cap. Removing the cap while engine is hot and the coolant is under pressure may cause serious scalding. One method of draining coolant from an engine is to use low air pressure to aid the extraction of coolant.
Page 80 MAINTENANCE NOTES 3.26...
Page 81 FUEL DELIVERY CHAPTER 4 FUEL DELIVERY WARNINGS ............4.3 .
Page 82 FUEL DELIVERY 600 CFI FUEL PUMP REPLACEMENT ........4.21 FUEL TANK PRESSURE TEST .
Page 83: Warnings
Because removal damages seals, replace any oil or grease seals removed with new parts. Service Precautions Polaris recommends the use of Polaris lubricants and greases, which have been specially formulated for the top performance In order to perform service work efficiently and to prevent and best protection of our machines.
Page 84: Fuel Delivery System (Carbureted)
FUEL DELIVERY as the engine, warranty coverage may become void if other When replacing fuel line, be sure to use the correct color line for brands are substituted. inside or outside the fuel tank. Also, be very careful not to bend fuel line to a point of kinking it.
Page 85: Maintenance
FUEL DELIVERY Maintenance 9DH01-57 The impulse operated diaphragm fuel pump does not require any specific scheduled maintenance. However, the following procedures should be observed: • Operation The pump may be checked for operation by removing the fuel supply line from the carburetor and placing it into a container. With the engine idling at approximately 2000 RPM, a steady flow of fuel should be visible.
Page 86: Mikuni Tm 38
FUEL DELIVERY MIKUNI TM 38 Carburetor Overview 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 throttle response and a significant reduction in throttle effort Needle Jet (D): The needle jet is press fit into carbs and is not due to rack style carbs and the use of cable cam.
Page 87: Mikuni Carburetor
FUEL DELIVERY Float/Needle & Seat Assembly (H): The float/needle & seat are MIKUNI CARBURETOR sold as an assembly and cannot be replaced as individual components. The float level is pre-set in the molding and cannot be adjusted. WARNING DO NOT pressurize the fuel system by forcing compressed air through the fuel tank.
Page 88: Float System
FUEL DELIVERY Float System Fuel Delivery The float system is designed to maintain a constant height of The pilot system's gasoline during operation. When the fuel flowing from the fuel main function is to pump into the float chamber through the needle valve reaches meter fuel at idle the constant fuel level, the floats rise.
Page 89: Fuel Screw
FUEL DELIVERY Fuel Screw always use the lowest elevation and temperature that is likely to be encountered. The fuel screw controls the fuel mixture from idle to low speeds. The tapered tip of the fuel screw projects into the passage CAUTION leading to the by pass out let.
Page 90: Jet Needle / Needle Jet
FUEL DELIVERY Jet Needle / Needle Jet The jet needle and needle jet have the most effect between 3/8 and 3/4 throttle opening. Some mixture adjustment can be accomplished by changing the location of the “E” clip on the needle. Moving the clip down raises the needle in the jet passage and enriches the mixture.
Page 91: Throttle Opening Vs. Fuel Flow
FUEL DELIVERY Throttle Opening Vs. Fuel Flow VM only 4.11...
Page 92: Mikuni Tm38 Flat Slide Service
FUEL DELIVERY MIKUNI TM38 FLAT SLIDE SERVICE NOTE: Keep track of the plastic washer (9), and place it so it is on the top of the throttle valve when installing the needle and e-ring back into the Disassembly carburetor. CAUTION Inspect the needle (7), e-clip (8), and plastic washer (9) for wear.
Page 93 FUEL DELIVERY 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) on starter jet (22).
Page 94: Assembly
FUEL DELIVERY CARBURETOR SYNCRONIZATION Assembly Install the main jet (20), pilot jet (21), and starter jet (22). Throttle Valve Synchronization Install float/needle & seat assembly (19). Place carburetor in an inverted position. Mikuni TM style carburetors are synchronized at wide open Connect a pressure tester (PN 2870975) to fuel inlet fitting.
Page 95: Carburetor Component Part Numbers
FUEL DELIVERY While holding the PTO carburetor slide flush to the top of Mikuni Main Jets the carburetor, rotate the synchronization nut clockwise to raise the slide and counterclockwise to lower the slide. Lock Screw 3130102 3130118 3130134 3130147 3130103 3130119 3130135 3130148...
Page 96: Mikuni Starter Jets
FUEL DELIVERY Mikuni Starter Jets Mikuni (Long) Pilot Air Jets STARTER JET PART NUMBER AIR JET PART NUMBER 3130805 3131255 3130767 3131249 3130768 3131256 3130769 3131254 3130770 3131203 3130771 3131257 3130772 3131258 3131259 Mikuni (Short) Pilot Air Jets 3131260 3131261 3131262 AIR JET PART NUMBER...
Page 97: Cleanfire Injection (Cfi)
FUEL DELIVERY CLEANFIRE INJECTION (CFI) NOTE: If the injector is on the upper fuel rail, only the air box needs to be removed to gain access to the failed injector. Injector Replacement NOTE: If the injector is on the lower fuel rail, engine The Cleanfire system utilizes 3 different color injectors.
Page 98 FUEL DELIVERY If replacing a lower injector, remove the lower two bolts Crimp the ends of the new injector firmly on to the wire from the lower part of the fuel rail. harness (10). Remove the failed injector(s). NOTE: Make sure that the green rubber washer (9) comes out with the failed injector(s).
Page 99: Cleanfire System Overview
FUEL DELIVERY Cleanfire System Overview Fuel Pump (700) 700 CFI The Cleanfire fuel system uses a fuel pump (A) that is located This fuel pump on this system is non-serviceable and can not be inside the fuel tank, a fuel rail (C) with in-line fuel filter (B), and injectors (D).
Page 100: 2007 Fuel Supply / Return Fittings
FUEL DELIVERY 2007 Fuel Supply / Return Fittings Fuel Rail Bleeding NOTE: Align pump flange so that the arrow is The 2007 600 CFI units will have one of two different styles of Schrader valves. between the two alignment lines. A shallow core valve (1) and will use the adapter that comes with SUPPLY FITTING the fuel pressure gauge (PN PV-43506-A).
Page 101: 600 Cfi Fuel Tank / Fuel Supply
FUEL DELIVERY 600 CFI Fuel Tank / Fuel Supply SUPPLY HOSE RETURN HOSE FUEL FILTER (ARROWS POINTS TO THROTTLE BODY) FUEL RAIL FOAM PAD TPS (PTO SIDE) 600 CFI Pump / Sender Specifications 600 CFI Fuel Pump Replacement Ω WARNING OLOR UNCTION ≤...
Page 102: Fuel Tank Pressure Test
FUEL DELIVERY Using the PFA spanner wrench (PS-48459-1) and nut Fuel Tank Pressure Test socket (PS-48459), carefully remove the PFA nut. Connect a Mity Vac hand pump to the fuel tank vent fitting. Seal the fuel supply and return fittings. Pressurize the tank to 5 PSI.
Page 103: Fuel Filter Removal
FUEL DELIVERY Fuel Filter Removal Carefully remove the fuel filter (A) from the bracket (B). Using the 3/8” fuel line disconnection tool remove the fuel line (C) from the fuel filter. Using the fuel line disconnection tool remove the filter line from the fuel sender.
Page 104 FUEL DELIVERY NOTES 4.24...
Page 105 ENGINE CHAPTER 5 ENGINE GENERAL ENGINE INFORMATION......... 5.2 EXHAUST VALVE EXPLODED VIEW .
Page 106: General Engine Information
ENGINE GENERAL ENGINE INFORMATION Exhaust Valve Exploded View 1. Cover Fasteners 2. Cover 3. Spring 4. Cap Nut 12 ft-lb 5. Bellows 16 ft-lb 6. Bellows Washer (16 N-m) 7. Exhaust Valve Base (22 N-m) 8. Base Gasket 9. Guillotine Clean with Primer “N”...
Page 107: Exhaust Valve Disassembly
ENGINE Exhaust Valve Disassembly Optional Exhaust Valve Springs CAUTION SPRING # COLOR FREE LENGTH 7041704-01 Blue 1.752 EV spring under tension. Use care when removing 7041704-02 Orange 1.729 housing from assembly base. 7041704-03 Pink 1.734 Remove the vent lines from the exhaust valve base(s). 7041704-04 Purple 1.726...
Page 108: Reed Valve Assembly
ENGINE Separate the intake boot(s) (4) from the reed cage (6) Insert the intake boot fasteners (2) and torque to 9 ft-lb (12 N-m). If reed stuffers are used separate the reed stuffer(s) (5) from the reed cage (6) and inspect the reeds (7) before they are removed from the reed cage.
Page 109: Water Temperature Sensor Replacement
ENGINE Water Temperature Sensor Replacement Remove the sensor (1) from the cylinder head. Replace the washer (2) and torque the sensor to specification. Temperature Sensor: 18 ft-lb (24 N-m) Engine Mount Replacement Use the correct Engine Mount Socket (PN PS-45384 or 2871989).
Page 110: 500/600/700 Water/Oil Pump Cross Shaft Disassembly
IMPORTANT: It is very critical to use the Installation tool PN 2872010 to set the operating height of the disassembly. Replace all seals, o-rings, and gaskets mechanical seal. Failure to do so will cause seal to with Genuine Pure Polaris parts during assembly. leak. Refer General...
Page 111: Cylinder Head / Head Components
ENGINE Cylinder Head / Head Components If engine coolant spilled into the cylinder(s), wipe each cylinder dry with a clean shop rag or paper towel. If unsure how much coolant spilled into cylinders and crankcase, Bleed Screw locate the two crankcase drain screws located on the front, lower crankcase halve.
Page 112: Recoil/Stator Assembly
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. Install the stator (10) and the pulse coils (9).
Page 113: Cooling Systems
ENGINE COOLING SYSTEMS 500/600/700 121/Switchback/RMK/DRAGON 500 XC SP 600 HO IQ (LX) 600 HO IQ (LX) CFI 600 HO Switchback To center tunnel cooler 600 RMK/DRAGON...
Page 114: 500/600 Touring / Widetrak Lx
ENGINE 500/600 Touring / WideTrak LX Touring WideTrak 5.10...
Page 115: 340/550 Fuji Engine
ENGINE 340/550 FUJI ENGINE 340/550 Fuji/500 Liberty Engine Removal/installation Turn the fuel valve to the “OFF” position. Remove the exhaust system. Disconnect the battery ground (-) if applicable. Disconnect the CDI box. Remove the spark plug leads form the spark plugs. Disconnect the stator connection(s).
Page 116: 340/550 Engine Disassembly (550 Shown)
ENGINE 340/550 Engine Disassembly (550 shown) NOTE: Inspect all parts for wear or damage during disassembly. Replace all seals, o-rings, and gaskets with Genuine Pure Polaris parts during assembly. 5.12...
Page 117: Engine Assembly
ENGINE Engine Assembly Disconnect the coil pack and CDI from the wiring harness. Loosen the carburetor clamps (1) and remove the Insert the oil pump cross shaft, spacer and bushing. carburetors from the mounting boots. Note where the oil lines are routed and remove the oil lines Gear from the carburetors.
Page 118 10. Turn the crankcase over and lubricate crankshaft main bearings through the access holes. 11. Apply Polaris 2-Stroke engine oil to the wrist pins and the small end bearings and install the pistons with the arrow on the piston crown facing the flywheel (MAG) side. This will orientate the piston so that the piston ring locating pins will be in the intake side of the engine.
Page 119 ENGINE 23. Torque the flywheel nut to: 340 = 61-70 ft.lb. (83-90 N-m) 550 = 58-72 ft.lb. (79-98 N-m) 24. Install the recoil cup onto the flywheel. 25. Install the recoil cover. 26. Insert the vibration dampener in between the cooling fins that are located between the two cylinders on the intake side.
Page 120: Fuji Engine
Disassembly NOTE: Inspect all parts for wear or damage during disassembly. Replace all seals, O-rings, and gaskets with Genuine Polaris parts during assembly. Refer to General Section for Inspection Procedures. Remove carburetors, recoil housing and exhaust manifold. Remove water pump, and starter recoil cup with water pump drive pulley and flywheel nut.
Page 121: Assembly
ENGINE Assembly Install pistons arrow toward flywheel. 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. Apply 3-Bond sealant to crankcase halves. Install C-clip using installation tool PN 2870773.
Page 122 ENGINE 12. Install cylinder head and torque cylinder head nuts to 18 - 20. Adjust tension on water pump belt by loosening water 19.5 ft-lb (25-27 N-m) following the torque pattern. pump mounting bolts, applying tension, and re-tightening bolts. 21. Install recoil housing and carburetors. 22.
Page 123: 500/600 Ho Engine
Engine Removal NOTE: Inspect all parts for wear or damage during disassembly. Replace all seals, o-rings, and gaskets with Genuine Pure Polaris parts during assembly. Remove the side panels (if applicable). Disconnect battery ground (-) if applicable. Turn the fuel valve to the “OFF” position (1).
Page 124 ENGINE 20. Move the hose clamp (7) and remove and secure it out of 24. Remove the inside motor mount fastener (12), located the way. under the PTO carburetor boot. 21. Remove the coolant supply hose that is located at the 25.
Page 125 ENGINE 29. Remove and plug the oil supply line going to the oil pump, and route it through the guide (15). 30. Lift the front of the engine up and then tilt the rear so that the engine straps clear the motor mount studs. 31.
Page 126: 500/600 (Carbureted) Engine Disassembly
ENGINE 500/600 (Carbureted) Engine Disassembly 500 Liberty Engine Shown 22 ft-lb (30 N-m) LOCTITE® 242 70 in-lb (7.9 N-m) If NEW 9 ft-lb Height Installation (12.2 N-m) see page 5.5 18 ft-lb (24 N-m) 32 ft-lb (43 N-m) See Torque sequence on page 5.22 5.22...
Page 127: 500/600 (Carbureted) Torques
ENGINE Remove the spark plugs (1) ENGINE 500/600 Remove reed valve assembly. See “Reed Valve SPARK PLUG 18 ft-lb (24 N-m) Disassembly” on page 5.3. CYLINDER HEAD 22ft-lb (30 N-m)1,3 Remove the recoil and stator assembly. See “Recoil/Stator BLEEDER SCREW 70 in-lb (8 N-m) Removal”...
Page 128: 500/600 (Carbureted) Cylinder Base
ENGINE 500/600 (Carbureted) Cylinder Base Lubricate the small end bearings (21) and the piston pins with Polaris 2 stroke oil and install the piston onto the crankshaft with the piston pin removal/installation tool PN PN PU-45255. Install new c-clips in the piston grooves with the gap facing straight up (12:00 position) or straight down (6:00 position).
Page 129: 500/600 (Carbureted) Recoil/Stator Removal
500/600 (Carbureted) Recoil/Stator Installation 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 general inspection procedures.
Page 130 ENGINE Install the oil supply line through the guide (2) on the MAG Insert the front engine strap washer and Nyloc nut (7) onto intake. the motor mount stud and torque to 28 ft-lb (38 N-m). Place the engine into the bulk head and make sure that it is 10.
Page 131 ENGINE 13. Adjust both torque stops so that you have a clearance of 19. Connect the water temp sensor (16) and secure it to the .010”-.030” (.25-.75mm). thermostat hose with a cable tie. = In. / mm. Torque Stop Clearance: .010"-.030" (.25-.75mm) 14.
Page 132: Torque Specifications
ENGINE Torque Specifications 28. Install drive clutch and belt. See “Driven Clutch Installation” on page 6.21. 29. Route the recoil rope through the console and secure the ENGINE 500/600/600HO recoil handle. SPARK PLUG 18 ft-lb (24 N-m) 30. Install the exhaust system. CYLINDER HEAD 22ft-lb (30 N-m)1,3 31.
Page 133: 600 / 700 Ho Cfi Engine
600/700 CFI Engine Removal NOTE: Inspect all parts for wear or damage during disassembly. Replace all seals, o-rings, and gaskets with Genuine Pure Polaris parts during assembly. Remove the side panels. See “SIDE PANELS” on page 10.2. Disconnect the battery ground (-) cable from the battery if equipped.
Page 134 ENGINE 12. Disconnect the ignition coil connections (9) and EV 16. Remove the recoil rope from the handle and route rope solenoid from the ECU harness. through the guide on the chassis brace and secure the recoil rope by tying a knot (12) so that it does not go into the recoil housing.
Page 135 ENGINE 18. Remove all coolant hoses from the coolant bottle and 24. Remove the four engine mounting fasteners (18) located on secure the loose hoses out of the way for engine removal. the engine straps. 19. Remove the four right hand chassis brace fasteners and remove the brace (13) from the chassis.
Page 136 ENGINE 28. Lift engine out of chassis and carefully place engine on shock tower brace. 29. While holding the engine remove the throttle bodies by loosening up the intake boot clamps and separating the throttle bodies from the intake boots. 30.
Page 137: 600/700 Cfi Engine Disassembly
ENGINE 600/700 CFI Engine Disassembly If new see installation height on page 5.5 5.33...
Page 138: Engine Assembly
Lubricate the small end bearings (21) and the piston pins cylinders (15) with a slight rocking motion. with Polaris 2 stroke oil and install the piston onto the 10. Support one of the pistons with the piston support block PN crankshaft with the piston pin removal/installation tool PN 2870390.
Page 139: 600/700 Cfi Cylinder Head Torque Pattern
ENGINE 600/700 CFI Cylinder Head Torque Pattern Place the engine on the shock tower brace and hold engine at this point. With the throttle bodies separated from the intake adapters, route the throttle cable behind the fuel rail and insert the throttle cable into the throttle pulley located in the center of the throttle bodies.
Page 140 ENGINE 10. Using a 10mm open end wrench tighten the lock nut while 15. Secure the oil bottle to the chassis by installing the two torx holding the other nut with a 10mm open end wrench. Make fasteners located at the top of the bottle (14). sure that the oil cable angle is tilted slightly toward the engine (2).
Page 141 ENGINE 21. Place the engine mount washers and fasteners (8) onto the 23. Apply Blue Loctite™ to the rear fasteners (10), install all engine mount studs. Torque to specification. the rear torque stop fasteners and torque to specification. Engine Mount Fasteners: 28 ft.lb (37.9 N-m) Rear Torque Stop Fasteners: 28 ft.lb (37.9 N-m) 22.
Page 142 ENGINE NOTE: The WHITE connector (17) goes to the MAG 26. Install the front torque stop assembly and torque the plate coil (upper). The BLUE connector (18) goes to the fasteners to specification. PTO coil (lower). Front Torque Stop Fasteners: 28 ft.lb (37.9 N-m) 27.
Page 143 ENGINE 39. Connect the EV solenoid vent lines back onto the EV bases 42. Replace the nosepan plugs were removed to access the front and install the panduit strap (21) around the spark plug chassis brace fasteners. wires as shown. 43.
Page 144: Torque Specifications
ENGINE Torque Specifications When tightening bolts, nuts, or screws, a torque pattern may need to be followed to ensure uniform equal tension is applied to all fasteners. Proper torque application prevents fasteners from loosening or breaking in critical service. It also minimizes wear and eliminates premature or needless repair costs.
Page 145: Specifications
ENGINE Specifications Fastener Torque Specifications OMPONENT PECIFICATION ORQUE ORQUE OMPONENT OTES Engine Model Number - 600 S3206-6044-PF6H Spark Plug - 700 S3322-7044-PF7J Two Stroke CFI/Case Reed Thermostat Engine Type Induction Bleed Screw Cylinder Displacement Thermostat - 600 599cc Cover - 700 700cc Bore - MM (Inches) Cylinder Head...
Page 146 ENGINE NOTES 5.42...
Page 147 CLUTCHING CHAPTER 6 CLUTCHING PVT SYSTEM ............6.2 OVERVIEW.
Page 148: Pvt System
A compression spring (Team driven clutch) or torsional spring pre-load rate will result in a higher engagement RPM. (Polaris P-85 driven clutch) works in conjunction with the helix, and controls the shift rate of the driven clutch. The spring must...
Page 149: Final Drive
CLUTCHING Final Gearing The final drive gear ratio plays an important role in how much vehicle load is transmitted back to the helix. A tall gear ratio (lower numerical number) typically results in lower initial vehicle acceleration, but a higher top-end vehicle speed. A lower gear ratio (higher numerical number) typically results in a higher initial vehicle acceleration, but a lower top-end vehicle speed.
Page 150: General Information
CLUTCHING GENERAL INFORMATION Special Tools Clutch Tools Standard Offset Alignment Tool PS-46998 Team LW Offset Alignment Tool PS-47477 500, 600, 700 Domestic and 4 Stroke Engine Clutch Puller 2872085 2872084 Fuji Engine Clutch Puller Replacement Handle for ALL Clutch Pullers 5020326 Drive Clutch Holding Wrench 9314177-A...
Page 151: Drive Clutch Springs
CLUTCHING Drive Clutch Springs Drive Clutch Springs FORCE LOAD WIRE PART FREE LENGTH LBS.@2.50” - RATE COLOR DIAMETER NUMBER +/-.125” 1.19” (+/- 12 (lbs./ (inches) LBS.) inch) 7041021 No paint color .157” 4.14 70-130 7041022 Black .140” 4.25” 44-77 7041063 Purple .168 4.37...
Page 152: Spring Free Length
CLUTCHING Spring Free Length 10 Series Weights Measure the drive and driven spring free length with the spring WEIGHT GRAMS(+/- 1g) PART NUMBER resting on a flat surface. Replace spring if out of specification. 10M-R Bushed 1321530 10M-W Bushed 1321527 10M Blue Bushed 47.5 1321529...
Page 153: Non-Er Lwt Driven Helixes
CLUTCHING Non-ER LWT Driven Helixes Team Ramp Angles Non-ER LWT Driven Helixes PART NUMBER DESCRIPTION 5135438 70/44 - .46 / 66/44 - .46 5135480 64/38 - .65 / 64/38 - .46 5135486 62/40 - .46 / 64/40 - .55 5135521 74/50 - .46 / 74/48 - .46 5135522 74/44 - .46 / 74/40 - .46...
Page 154: Team Driven Springs
CLUTCHING Team Driven Springs TEAM Driven Springs PART NUMBER COLOR WIRE DIAMETER LOAD @ 2.2″(lbs) LOAD @ 1.1″(lbs) Rate (Lbs. per inch) 7042181 Black/Yellow .200 7043058 Red/Black .218 7043059 Red/Green .218 7042066 Green/Black .200 7043061 Red/Silver .207 7043062 Red/Yellow .207 7043057 Red/Blue .218...
Page 155: Belt Wear / Burn Diagnostics
CLUTCHING Belt Wear / Burn Diagnostics Belt Wear / Burn Diagnostics Table 6-1: POSSIBLE CAUSE SOLUTION Drive at higher RPM if possible. Gear the machine down. Driving at or about engagement RPM for extended periods Make sure belt deflection is at 1 1/4” to achieve optimum of time in any type of snow condition.
Page 156: Drive Belt Removal
CLUTCHING Drive Belt Removal NOTE: Turn the key to the “OFF” position and allow the engine to come to a complete stop. Always install a used belt in the same direction as it was installed before removing. When installing a new belt, position the identification numbers so they can read when viewed from the left-side of machine.
Page 157: Adjusting Belt Deflection
CLUTCHING Adjusting Belt Deflection Loosen the jam nut (E). Using an 1/8” Allen head wrench, turn the stud (F) counter-clockwise to decrease belt deflection and clockwise to increase belt deflection. When the proper belt deflection is achieved torque the lock nut (E) to 90-110 in-lb. (10-12Nm). 6.11...
Page 158: Drive Belts
CLUTCHING Drive Belts Belt Width Side Center to Outer Part (Projected)* Angle Center in/ Circumference Notes Number in/mm Overall* in/cm 3211042 1.375/34.9 12/30 47.25/120 Common production belt. 3211045 1.375/34.9 12/30 47.125/119.7 Close tolerance version of 3211042 3211058 1.250/31.75 11/28 43.313/110 P-90 belt 3211059 1.250/31.75...
Page 159: Blet Pn 3211115 Break -In Proceedure
CLUTCHING Belt PN 3211115 Break -In Procedure This is a new belt for 2007 and is used o the 600 RMK, Dragon RMK and the Dragon IQ sleds. This belt can be used on any sled that has a 11.5” (29.2cm) center to center distance or uses a 3211080 belt.
Page 160: Pvt System Adjustments
CLUTCHING PVT SYSTEM ADJUSTMENTS Clutch Alignment / Offset 0” - .060” The engine is mounted in the bulkhead so the drive and driven clutches self-align under high torque loads. Offset is controlled by the number of washers installed on the jackshaft behind the driven clutch.
Page 161: Drive Clutch
CLUTCHING DRIVE CLUTCH Identification Every clutch will have the last three digits of the clutch part number etched on to the cover (A). The “X” (B) marking is an index mark where the clutch cover (C), clutch spider (D) and the stationary sheave (E) should line up when the clutch is assembled. Drive Clutch Removal (Domestic style) NOTE: All clutch tools can be found at the beginning of this chapter.
Page 162: Drive Clutch Disassembly
CLUTCHING Drive Clutch Disassembly WEIGHT ROLLER WEIGHT PIN WASHER ROLLER PIN SPIDER BUTTON WASHER BEARING SLEEVE MOVEABLE INSERT SPRING JAM NUT COVER SPIDER SPACERS COVER BEARING RETAINER MOVEABLE SHEAVE CLUTCH SPACER STATIONARY SHEAVE Mount the drive clutch securely in a drive clutch holding fixture (PN 2871358).
Page 163: Roller Removal
CLUTCHING Roller Removal 1.496" (37.99mm). ROLLER PIN SPIDER ROLLER WASHER WASHER 11. Measure the width of the moveable sheave towers. Specification is 1.50" (38.1mm). SHIM BUTTON With the spider in a vise start removing the spider buttons by drilling a 0.18" hole in the center of a button on one side of the spider.
Page 164: Clutch Assembly
CLUTCHING Clutch Assembly Spider Indexing NOTE: Spider indexing effects belt to sheave Assemble the rollers, bushings and roller pins if they were removed. clearance and clutch balance. Please read all procedures before proceeding. Install the head of the weight pin so that it is on the leading side of rotation.
Page 165 CLUTCHING Vary the amount and thickness of spacer washers (washer thickness may vary slightly). Re-index marked spider leg to another tower. This can be done because spider has little effect on overall clutch balance. Re-indexing the spider 1/3 turn clockwise, or 1 leg, will allow the realignment of the moveable and stationary sheaves as previously marked (D).
Page 166: Drive Clutch Installation
CLUTCHING Drive Clutch Installation NOTE: Always clean the clutch taper before re-installing clutch on engine. Place a clutch taper reamer (PN 2870576) in a vise (A) and lubricate the cutting edges with cutting oil. Clean the clutch taper by manually rotating the clutch clockwise on the reamer one or two revolutions. Only use the weight of the clutch and do not push down on the clutch while turning.
Page 167: Driven Clutch
CLUTCHING DRIVEN CLUTCH Components (Team LW Clutch Shown) ROLLER ASSEMBLY HELIX SNAP RING SPRING CUP DEFLECTION SPACER SPRING STATIONARY SHEEVE MOVEABLE SHEEVE BELT DEFLECTION SCREW Driven Clutch Installation Helix Fasteners = 60 - 80 In.Lbs. (7 - 9 Nm) Driven Clutch Retaining Fastener = 17 Ft.Lbs. (23 Nm) Driven Clutch Removal Install the driven clutch bolt with the same amount of washers at removal.
Page 168: Driven Clutch Assembly
CLUTCHING Compress the roller assembly to access the snap ring. Lock Install a feeler gage between the belt and moveable sheave the clutch compression tool chain to hold the roller assembly down. Carefully remove the snap ring. Slowly release the compression tool. WARNING Wear eye protection when removing and installing the roller assembly.
Page 169: Belt Deflection Inspection
CLUTCHING Belt Deflection Inspection Belt deflection is critical for optimum belt performance and belt life. It should be checked at 500 miles (800km) and then in 1000 mile (1600km) increments after that. Too much belt deflection is when the belt is too long or the center distance is too short.
Page 170 CLUTCHING NOTES 6.24...
Page 171 FINAL DRIVE/BRAKES CHAPTER 7 FINAL DRIVE/BRAKES GEARING CHARTS............7.2 CHAINCASE SPEED CHARTS .
Page 172: Gearing Charts
FINAL DRIVE/BRAKES GEARING CHARTS Chaincase Speed Charts 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 6500 104 101 6750 108 105...
Page 173 FINAL DRIVE/BRAKES 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 7500 7750 103 101 8000 107 104 101...
Page 174 FINAL DRIVE/BRAKES 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 7500 7750 8000 8250 8500...
Page 175 FINAL DRIVE/BRAKES 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 Gear Ratio 1.95 2.00 2.05 2.11 2.16 2.21 2.26 2.42 2.06 2.11 2.17 2.22 2.28 2.33 2.39 2.18 2.24 2.29 2.35 2.41 2.47 2.53...
Page 176: Gears
FINAL DRIVE/BRAKES GEARS AND CHAINS Drive Chain Gears PART CHAINCASE DESCRIPTION NUMBER PART DESCRIPTION CC FIT 3221114 64P, 3/4W, HYVO CHAIN NUMBER 3221113 66P, 3/4W, HYVO CHAIN 3221093 17T, 3/4W, 15 SPL, HYVO, PM 3221112 68P, 3/4W, HYVO CHAIN 7.92 3221094 18T, 3/4W, 15 SPL, HYVO, PM 3221115...
Page 177: Chain Case
FINAL DRIVE/BRAKES CHAIN CASE Exploded View image depicts 8.373 chaincase, your chaincase may vary slightly Chaincase DESCRIPTIO TORQUE SPECIFICATION / ITEM TORQUE SPECIFICATION / NOTES ITEM DESCRIPTION NOTES Cover bolts 8 ft-lb(11N-m) Breather roll pin Chaincase cover Chaincase make sure that the gasket is not pinched Install so that the lip is facing the Cover gasket Upper seal...
Page 178: Chaincase Removal
FINAL DRIVE/BRAKES Chaincase Removal the way of the chaincase. 23. Remove the rear suspension. Support the rear of the machine and loosen up the track 24. Carefully slide the driveshaft down so that it clears the tension. chaincase, and remove the driveshaft. Remove RH side panel.
Page 179: Chaincase Seal & Bearing Replacement
FINAL DRIVE/BRAKES 17. Install the driveshaft by replacing the flangette nuts on the 30. Install the chaincase cover, and torque the cover bolts to 10 speedo drive side. torque to 19-21 ft-lb (26-28 N-m). ft-lb (13.5 N-m). Speedo Drive Flangette Nuts: 19-21 ft-lb Chaincase Cover Bolts: 10 ft.lb.
Page 180: Drive Train
FINAL DRIVE/BRAKES DRIVE TRAIN Jackshaft Exploded View ITEM DESCRIPTION TORQUE SPECIFICATION / NOTES ITEM DESCRIPTION TORQUE SPECIFICATION / NOTES Chaincase 7.92, 8.37, 8.47 Driven Clutch 8.37 chaincase - install seal sleeve (C) first, then o-ring (B) on jackshaft O-ring Washers Note the placement 7.92 chaincase - install seal sleeve (C) first, then o-ring (B) on jackshaft...
Page 181: Jackshaft Removal
FINAL DRIVE/BRAKES Jackshaft Removal 13. Check clutch alignment. See “Clutch Alignment / Offset” on page 6.14. Remove the drive belt (J). Remove the driven clutch (N) and make note of the ADJUSTMENTS placement of the washers (O). Chaincase Drive Tension Drain the chaincase fluid.
Page 182: Driveshaft
FINAL DRIVE/BRAKES DRIVESHAFT Driveshaft Removal/Installation 14. Assemble in reverse order 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 (11 N-m).
Page 183: Widetrak Transmission
FINAL DRIVE/BRAKES WIDETRAK TRANSMISSION 13. Loosen jam nuts on adjustment bolts on both sides. Back out adjustment bolts to allow rear idler assembly to come forward, relieving track tension. Removal 14. Tighten idler wheel bolts so that spacers on shafts do not Hood can be removed to prevent damage.
Page 184: Inspection
FINAL DRIVE/BRAKES NOTE: It is not necessary to remove speedometer Remove detente spring and ball. cable from angle drive. Replace adaptor key any time drive train assembly is serviced. 22. Tip machine back onto floor. 23. Remove bolt retaining rear of bumper to foot rest. 24.
Page 185 FINAL DRIVE/BRAKES Remove output gear assembly (7) and chain (8). Mark chain 12. Gear, shaft, and chain cluster assembly shown. direction for reference during reassembly. Inspect gear teeth for damage. Inspect chain for worn, cracked, or broken link plates. GEAR ASSEMBLY 13.
Page 186: Low/Reverse Shaft Disassembly
FINAL DRIVE/BRAKES 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 187: 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 188 FINAL DRIVE/BRAKES 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. Check transmission fluid level and fill if necessary 24. Attach brake cable to transmission mounting with bolt, nut and spacer.
Page 189: Hydraulic Brake System
Overview dren. Brake fluid can accumulate moisture, reducing it's effectiveness. The Polaris snowmobile hydraulic brake system consists of the A soft, spongy feeling in the brake lever and/or brake following components or assemblies: brake lever, master cylinder, hydraulic hose, brake caliper (slave cylinder), brake pedal could indicate a hazardous condition in the brake pads, and a brake disc which is secured to the drive line.
Page 190: Brake Fluid Replacement & Bleeding
FINAL DRIVE/BRAKES pressure will cause a surge of fluid through the small orifices of the brake system when the bleeder screw is opened and introduce air into the system by means of cavitation. • Small amounts of air can become trapped in the banjo bolt fittings at the master cylinder(s) and junction points of brake lines.
Page 191: Brake Line Replacement
FINAL DRIVE/BRAKES Brake Line Replacement Repeat steps 7 and 8 until you see new brake fluid coming from the caliper bleeder fitting or if you are bleeding the air, repeat this step until you see only fluid coming out. This may take several intervals.
Page 192: Brake Light Switch Replacement
FINAL DRIVE/BRAKES Brake Light Switch Replacement 11. Torque the caliper banjo bolt to 168-216 in-lb (19-24 N-m). Remove the 4 screws that hold the master cylinder to the handlebar. This will separate the master cylinder from the switch pack. Caliper Banjo Bolt: 168-216 in-lb (18-24 N-m) 12.
Page 193: Caliper
FINAL DRIVE/BRAKES CALIPER Follow Brake Line Replacement. See “Brake Line Replacement” on page 7.21. Install banjo bolt into the caliper and torque it to 168-216 in-lb (19-24 N-m). Bleed the brakes. See “Brake Fluid Replacement & Bleeding” on page 7.20. On a liquid cooled caliper you will need to bleed the cooling system of any trapped air.
Page 194: Widetrak Brake Caliper
FINAL DRIVE/BRAKES WIDETRAK BRAKE CALIPER Assembly Apply a light film of grease to balls and ball spacer. Install Removal in caliper housing. Install lifter ramp. Remove brake cable. Remove retaining bolts, making note of location of hex NOTE: Ramp may be installed in any position. head bolt (with flat washer) and recessed Allen bolt.
Page 195: Front Suspension
FRONT SUSPENSION & STEERING CHAPTER 8 FRONT SUSPENSION & STEERING MODEL FRONT SUSPENSION TYPE ........8.2 FRONT SUSPENSION TYPE BY MODEL .
Page 196: Model Front Suspension Type
FRONT SUSPENSION & STEERING MODEL FRONT SUSPENSION TYPE Front Suspension Type by Model RONT USPENSION ODEL Edge LX 340 LX, 340 Touring 500 XC SP, 550 LX, Edge SuperSport, Trail Touring Deluxe Edge RMK Trail RMK 600 IQ Switchback (Carb and Switchback CFI) 600 RMK 144/155, Dragon...
Page 197: Front Suspension Torque & Specifications
FRONT SUSPENSION & STEERING FRONT SUSPENSION TORQUE & SPECIFICATIONS IQ/IQ LX/IQ RMK/Switchback 1 11 ft-lb (15 N-m) 2 29 ft-lb (39 N-m) 3 40 ft-lb (54 N-m) IQ RMK Specifications EASUREMENT Tie Rod Lock Nuts 11 ft-lb (15 N-m) Camber 2.17"...
Page 198: Edge/Edge Lx
FRONT SUSPENSION & STEERING Edge/Edge LX Edge LX 1 28-30 ft-lb (38-41 N-m) 2 35-40 ft-lb (47-54 N-m) 3 55-60 ft-lb (75-81 N-m) 4 95-100 ft-lb (129-136 N-m) Edge/Edge LX Specifications EASUREMENT Drag link fasteners, Steering arm 28-30 ft-lb Camber .59"...
Page 199: Edge Rmk
FRONT SUSPENSION & STEERING Edge RMK 1 28-30 ft-lb (38-41 N-m) 2 35-40 ft-lb (47-54 N-m) 3 60 ft-lb (81 N-m) 4 150 ft-lb (203 N-m) Edge RMK Specifications EASUREMENT Drag link fasteners, Steering arm 28-30 ft-lb Camber .735" ±.31" / 18.7 ± 8mm fasteners, Tie rod fasteners (38-41 N-m) .12 - .25"...
Page 200: Widetrack Lx
FRONT SUSPENSION & STEERING Widetrack LX 1 29 ft-lb (39 N-m) 2 38 ft-lb (52 N-m) 3 43 ft-lb (58 N-m) 4 48 ft-lb (65 N-m) 5 58 ft-lb (79 N-m) Widetrack LX Specifications EASUREMENT Drag link fasteners, Steering arm 29 ft-lb (39 N-m) Camber .82"...
Page 201: 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 202: Ifs Shock Springs
FRONT SUSPENSION & STEERING IFS SHOCK SPRINGS IFS Shock Springs OTAL I.D." O.D.” ABBED UMBER OILS ENGTH 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 11.88 .306 1.89 2.82 7041489 14.70 74/120 11.30...
Page 203: Springs
2.66 SPRINGS Two types of springs are employed in Polaris suspensions, coil springs and torsion springs. Following is some of the terminology used when referring to coil springs. • Free length - the length of a coil spring with no load applied to the spring •...
Page 204 FRONT SUSPENSION & STEERING If the suspension is “bottoming” tighten the compression screw clockwise in 1/2 turn increments until the bottoming stops. Backing off 1/4 turn counter-clockwise at this point should give you the best possible ride ensuring use of the full travel of the suspension. The opposite procedure should be used if the suspension is too stiff upon initial set-up.
Page 205: Shock Information
FRONT SUSPENSION & STEERING SHOCK INFORMATION IFS Shock Fastener Torques UNIT IFS UPPER IFS LOWER 29 ft-lb (39 N-m) 29 ft-lb (39 N-m) IFS SHOCK SPECIFICATIONS IFS Shocks XTENDED HOCK IFP D OLLAPSED TROKE EPTH SHOCK PN BRAND ENGTH HAFT ENGTH 7041535 Arvin...
Page 206: Ifs Shock Production Valving
FRONT SUSPENSION & STEERING IFS SHOCK PRODUCTION VALVING The valving charts are listed in compression sections and rebound sections. A compression stack will be located nearest the eyelet of the shock rod. A rebound stack will be located nearest the threaded end of the shock rod. SHOCK PN 7042258 7043141...
Page 207: Iq Front Suspension
FRONT SUSPENSION & STEERING IQ FRONT SUSPENSION IQ Front Suspension ITEM DESCRIPTION TORQUE SPECIFICATION / NOTES Lower A-Arm pivot bolt Critical for spacing the bolt from the sway bar. Located Flat washer on the leading edge Pivot Shaft Flanged nut 40 ft-lb (54 N-m) Pivot Bushing Upper A-Arm pivot bolt...
Page 208: Spindle Removal
FRONT SUSPENSION & STEERING IQ Front Suspension ITEM DESCRIPTION TORQUE SPECIFICATION / NOTES Flanged nut 40 ft-lb (54 N-m) Pivot Bushing Upper control arm Camber lock nut 45 ft-lb (61 N-m) Rod end bolt Rod end Flanged nut 40 ft-lb (54 N-m) Screw Jam nut 45 ft-lb (61 N-m)
Page 209: Upper / Lower Control Arm Removal
Some of the fasteners used in the IFS are special and cannot be purchased at a hardware store. Always use genuine Polaris parts and hardware when replacing front end components. Review steering adjustment guidelines before making adjustments.
Page 210: Rod End
FRONT SUSPENSION & STEERING Rod End ALIGNMENT ADJUSTMENTS Rod ends must be parallel to their respective mounting surface Alignment adjustments should be preformed in this order. after tightening jam nut. Hold the rod end and tighten jam nut. If possible, support the edge of the rod end to keep it from Edge/Edge LX/Edge RMK Set Up Width rotating out of position until jam nut is tight.
Page 211: Edge/Edge Lx/Edge Rmk Camber Adjustment
FRONT SUSPENSION & STEERING Edge/Edge LX/Edge RMK Camber IQ/IQ LX/Switchback Camber Adjustment Adjustment WARNING After camber adjustment is complete, be sure to Raise the front of the machine so that the skis are off the measure set up width outlined in this chapter and floor 3”...
Page 212: Handlebar Centering
FRONT SUSPENSION & STEERING Handlebar Centering SKI STANCE Raise the front of the machine off the floor so that the Adjustment (IQ RMK Only) spindles are off the floor 3”(7.62cm). Insert the alignment bar through both ski bolt holes in each spindles.
Page 213: Handlebar
FRONT SUSPENSION & STEERING HANDLEBAR RMK Handlebar Angle RMK Handlebar Position Loosen the four bolts on the top (4) of the adjuster block. Handlebar position and handlebar angle can be adjusted to rider NOTE: If necessary, pry the blocks apart with a preference.
Page 214 FRONT SUSPENSION & STEERING NOTES 8.20...
Page 215 REAR SUSPENSION CHAPTER 9 REAR SUSPENSION REAR SUSPENSION TYPE PER MODEL ........9.2 SPECIAL TOOLS .
Page 216: Rear Suspension Type Per Model
REAR SUSPENSION FOX FTS 7043142 ........... . 9.27 RYDE FX FTS 7041975 .
Page 217: Special Tools
REAR SUSPENSION SPECIAL TOOLS Shock Rebuilding Tools Special Tools PART NUMBER DESCRIPTION 2200421 Gas Shock Recharging Kit 2201639 Shock Shaft Seal Protector .50" Diameter 2201640 Shock Shaft Seal Protector .625" Diameter 2870623 Shock Absorber Spring Compression Tool 2870803 Shock Spring Pre-Load Adjustment Too PS-45259 Gas Fill Tool 9917736...
Page 218: Rear Suspension Torque Specifications
REAR SUSPENSION REAR SUSPENSION TORQUE SPECIFICATIONS Shock Mounting Fasteners Specification NOTE: All bolt heads should be in the left hand side. NOTE: Torque both sides of pivot shaft if applicable UNIT SUSPENSION FTS UPPER FTS LOWER RTS UPPER RTS LOWER 340 LX 500 XCSP Edge 121...
Page 219: Suspension To Chassis Fasteners Specification
REAR SUSPENSION Suspension to Chassis Fasteners Specification UNIT SUSPENSION 340 LX 500 XCSP 45 ft-lb (61 N-m) 45 ft-lb (61 N-m) Edge 121 550 LX SuperSport 340 Touring 45 ft-lb (61 N-m) 45 ft-lb (61 N-m) Edge 136 Trail Touring Trail RMK Edge RMK 136 40 ft-lb (54 N-m)
Page 220: Shock Control Rods
REAR SUSPENSION SHOCK CONTROL RODS Edge Shock Rods Shock rods must be installed in the same orientation as set from the factory. Any changes made to the shock rod orientation other than the factory setting may cause suspension damage. The shock rods that are found on all 2007 Edge rear suspensions are shown below. Shock Rod Assembly Example (Trail RMK Shown) Shock Upper...
Page 221: Rear Suspension Operation
REAR SUSPENSION REAR SUSPENSION OPERATION Suspension Coupling On all Polaris snowmobile rear suspensions, there are two Operation torque arms that control the movement of the rail beam. Prior to the advent of suspension coupling, these torque arms could The primary function of the rear suspension is to provide a move independently of each other.
Page 222: Rear Suspension Adjustments And Settings
REAR SUSPENSION REAR SUSPENSION ADJUSTMENTS measure the distance between the ground and rear bumper with out the rider on the seat and the suspension at full AND SETTINGS extension. This can be achieved by lifting the rear of the machine so that the suspension is off the ground and Rear Suspension Adjustment Procedures carefully setting the machine down.
Page 223: Front Torque Arm Limiter Strap Adjustment
REAR SUSPENSION Torsion Spring Adjustment changed, the ride will be compromised. Always maintain equal adjustment on both sides. To adjust the rear torsion spring, rotate the adjuster cam to the To adjust the scissor stops place the scissor tool onto the scissor desired adjustment.
Page 224: Torsion Spring Detail
REAR SUSPENSION Torsion Spring Detail A. Last 3 digits of PN B. Wire Diameter C. Leg 1 D. Leg 2 E. Coil I.D. F. # of coils G. Degrees open angle H. Spring width The torsion spring tension is determined by the following factors. Wire Diameter (B).
Page 225 REAR SUSPENSION Square Torsion Springs (Continued) WIRE LEG 1 LEG 2 DEGREES SPRING SPRING PN ( COIL ID # OF COILS LAST INCHES DIAMETER OPEN ANGLE WIDTH INCHES INCHES INCHES DIGITS INCHES INCHES 7041856 LH .359 16.5 1.79-1.85 7.71 3.46 7041857 RH 7042079 LH .375...
Page 226: Installing Heaviest Springs On A Iq 121" Suspension
REAR SUSPENSION Installing Heaviest Springs On A IQ 121" Suspension Please reference the following information when installing heavy torsion springs (7043128/7043129) on sleds equipped with IQ 121" suspensions. The issue that arises when installing the heavy spring is that the coil stack of the torsion spring is tall enough to interfere with the suspension arm clamp nut.
Page 227: Widetrak Torsion Spring Adjustments
REAR SUSPENSION Widetrak Torsion Spring Adjustments Rear spring adjustment is primarily a control for riding comfort. To check for the recommended settings: Lift the rear of the machine to relieve the rear springs. Slowly lower the machine and measure the distance between the ground and the running board.
Page 228: M-10 Suspension
REAR SUSPENSION M-10 SUSPENSION M-10 SUSPENSION Remote reservoir detail Full Range Adjuster (FRA) Bottom Bottom M-10 Overview The FAST M-10 rear suspension has been designed and set up to deliver a soft ride under average riding conditions. Rider weight, riding styles, trail conditions, and vehicle speed each affect suspension action. The suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions.
Page 229: M-10 Terminology
REAR SUSPENSION IMPORTANT: The M-10 rear suspension has been Polaris recommends that you allow between 25 to 200 miles for designed to be very sensitive to rider weight. Changes the suspension to break in before performing any adjustments to in rider weight of 25 lbs. or more may require the suspension.
Page 230: M-10 Fra Initial Set Up Reference
REAR SUSPENSION M-10 FRA Initial Set Up Reference M-10 Rear Spring Preload If FRA position alone does not allow the setup of the proper amount of sag, the center retainer of the rear track shock can be replaced with optional retainers to adjust the preload and change the sag.
Page 231: Rail Slider
Rail Slide Wear Limit Hi-Fax replacement on all Polaris models is similar. When any area of the Hi-Fax is worn to the wear indicator (A), it should be replaced. This will save wear on other vital components on the suspension.
Page 232: Rear Suspension Removal / Installation
REAR SUSPENSION REAR SUSPENSION REMOVAL / INSTALLATION Rear Suspension Removal 9.18...
Page 233: Rear Suspension Installation
REAR SUSPENSION Rear Suspension Installation See “Suspension to Chassis Fasteners Specification” on page 9.5. See “Suspension to Chassis Fasteners Specification” on page 9.5. 9.19...
Page 234 REAR SUSPENSION 35 ft-lbs (48 N-m) = In. / mm. See “Track Tension” on page 3.21. 35 ft-lbs (48 N-m) 35 ft-lbs (48 N-m) 35 ft-lbs (48 N-m) 9.20...
Page 235: Shock Information
REAR SUSPENSION SHOCK INFORMATION Serviceable Shocks Extended length is measured form center to center of the mounting holes on the eyelets. Front Track Shocks XTENDED OLLAPSED HOCK IFP D TROKE EPTH SHOCK PN BRAND ENGTH ENGTH HAFT 12.10 8.60 4.61 7041975 Arvin 1700026...
Page 236: Rear Suspension Front Track Shock (Fts) Stock Valving
REAR SUSPENSION Rear Suspension Front Track Shock (FTS) Stock Valving SHOCK PN 7041975 7043142 7043244 7043267 7043204 7043234 1.300x.025 .875x.090 1.125x.093 1.300x.025 .800x.008 1.125x.093 .625x.065 .800x.008 .700x.012 1.300x.025 .900x.010 .700x.012 .700x.012 .900x.008 .700x.012 .700x.010 1.000x.010 .700x.008 .800x.012 1.000x.008 .900x.008 .800x.010 1.100x.008 .800x.008 .900x.012...
Page 237: Rear Suspension Rear Track Shock (Rts) Stock Valving
REAR SUSPENSION Rear Suspension Rear Track Shock (RTS) Stock Valving SHOCK PN 7043177 7043246 7043266 7043205 7043216 7043235 .875x.090 1.125x.093 .700x.015 .625x.065 1.125x.093 .700x.015 .700x.015 .700x.008 1.125x.093 .900x.010 .700x.015 .625x.065 .700x.015 .800x.008 .900x.008 1.000x.010 .700x.015 .700x.010 .900x.010 .900x.010 1.300x.008 1.100x.012 1.000x.010 .800x.010 1.000x.008...
Page 238: Ryde Fx™ Shock Valve Part Numbers
REAR SUSPENSION Ryde FX™ Shock Valve Part Numbers Fox™ Shock Valve Part Numbers NOTE: The cart below groups the valves by NOTE: The cart below groups the valves by thickness thickness PART NUMBER SIZE THICKNESS PART NUMBER SIZE THICKNESS 1700080 0.700 1500055 0.700...
Page 239: Walker Evans Shock Valve Part Numbers
REAR SUSPENSION Walker Evans Shock Valve Part Numbers Shock Valving Arrangement Shown below is an example of how valving stacks are arranged. PART NUMBER SIZE THICKNESS The Production Shock Information contain production valving specifications and piston orifice sizes. 1800051 .700 1800075 .800 Parts in the box below are an example of standard valving.
Page 240: Rear Shock Specifications
REAR SUSPENSION REAR SHOCK SPECIFICATIONS Fox FTS 7043267 Walker Evans FTS 7043204 ITEM NOTE Extended Length 12.07" (30.7 cm) ITEM NOTE Collapsed Length 8.63" (21.9 cm) Extended Length 12.10" (30.7 cm) Stroke 3.44" (8.7 cm) Collapsed Length 8.60" (21.8 cm) Shock Rod .50"...
Page 241: Walker Evans Fts 7043234
REAR SUSPENSION Walker Evans FTS 7043234 Fox FTS 7043142 ITEM NOTE ITEM NOTE Extended Length 12.49" (317.2mm) Extended Length 12.51" (317.8mm) Collapsed Length 8.92" (226.6mm) Collapsed Length 8.92" (226.6mm) Stroke 3.57" (90.7mm) Stroke 3.59" (91.2mm) Shock Rod 1.124" (28.5mm) Shock Rod .50"...
Page 242: Walker Evans Rts 7043205
REAR SUSPENSION Walker Evans RTS 7043205 Fox RTS 7043246 ITEM NOTE ITEM NOTE Extended Length 15.60" (39.6mm) Extended Length 16.60" (421.6mm) Collapsed Length 10.56" (26.8cm) Collapsed Length 10.91" (277.1mm) Stroke 5.04" (12.8cm) Stroke 5.96" (151.4mm) Shock Rod .625" (1.59cm) Shock Rod .50"...
Page 243: Fox Rts 7043266
REAR SUSPENSION Fox RTS 7043266 Fox RTS (M-10) 7043216 ITEM NOTE ITEM NOTE Extended Length 15.65" (39.75cm) Extended Length 14.12" (35.9 cm) Collapsed Length 10.56" (26.2cm) Collapsed Length 9.29" (23.6 cm) Stroke 5.09" (12.9cm) Stroke 4.83" (12.3 cm) Shock Rod .50"...
Page 244: Shock Maintenance
REAR SUSPENSION SHOCK MAINTENANCE CAUTION T IS IMPORTANT THAT THE GAS SHOCK BE RETAINED IN CAUTION THE VISE BY THE LOWER MOUNT NY OTHER METHOD OF SECURING THE CHOCK BODY DURING THESE PROCEDURES MAY DEFORM THE SHOCK BODY XTREME CAUTION SHOULD BE OBSERVED WHILE HANDLING CYLINDER AND WORKING WITH HIGH PRESSURE SERVICE EQUIPMENT EAR A FACE SHIELD...
Page 245: Walker Evans Shocks (7043234, 7043233)
REAR SUSPENSION Walker Evans Shocks (7043234, 7043233) • Fluid level and Nitrogen pressure are critical. Place the body cap (1) of the shock in the vise so that the shock rod (2) is facing downward. Remove the service port screw (3) and release the pressure with the shock charging needle.
Page 246: Ryde Fx Mono-Tube Shock Disassembly
REAR SUSPENSION the gauge will deplete the pressure in the shock and 15. Clean the inside of the shock body using clean parts- will affect performance. cleaning solvent and blow dry using compressed air. 16. Place the shock piston rod upper mount in bench vise, begin 14.
Page 247: Fox Monotube Disassembly
REAR SUSPENSION the thread within the cylinder. Emulsion Shocks: Fill shock Using a blunt object, depress the air valve core to release body with 110cc's of oil. This will allow for the required pressure. air space to properly gas charge the shock with nitrogen gas. When the shock is FULLY DISCHARGED, pull reservoir NOTE: After filling the shock body with oil, allow a away from the Fox Safety Needle in a straight, smooth...
Page 248: Rear Suspension Troubleshooting
REAR SUSPENSION REAR SUSPENSION FIST scraper from the housing. Use a scribe or a dental pick to remove the o-ring from the inside of the FIST TROUBLESHOOTING scraper by "spearing" the seal with the point of the scribe and pulling it out. Use extreme caution when using a scribe to remove seals.
Page 249 CHASSIS & HOOD CHAPTER 10 CHASSIS & HOOD SIDE PANELS ............10.2 SIDE PANEL REMOVAL .
Page 250: Side Panels
CHASSIS & HOOD SIDE PANELS Side Panel Removal Grab the upper portion (1) of the panel and lift straight upwards and out toward you. This will lift it over the tab that is located on the console. Lift the lower portion up and out until the tabs (2) can be released from the fender (4). Pull the panel straight out to release the hinge tabs (3) from the fender.
Page 251: Hood Assembly
CHASSIS & HOOD HOOD ASSEMBLY Edge Hood Removal/Installation Edge Instrument Removal/Installation Remove the plenum (1). WARNING Disconnect the cable or connection (2) from the instrument. Remove the bracket nuts (3). Remove the instrument(s) from the hood. Exhaust system temperatures can exceed 900_ F (500_C).
Page 252: Hood Repair
IQ Front Bumper Removal/Installation Currently there is no procedures or materials recommended by 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 253: Coolant/Oil Tank
CHASSIS & HOOD COOLANT/OIL TANK Oil Tank Installation Attach the supply line to the supply fitting at the bottom of the oil tank. Attach the cross shaft supply line to the fitting on the right Overflow hand side. Line up the centering shafts with the chassis centering bracket.
Page 254: Seat And Fuel Tank
CHASSIS & HOOD SEAT AND FUEL TANK IQ Fuel Tank Installation Replace the vent line (J) at the fitting located at the top of IQ Fuel Tank Removal the tank. Lift the rear of the fuel tank and carefully slide the tank far Remove the seat and seat base.
Page 255: Seat Cover Replacement
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.
Page 256: Handlebar Cover
CHASSIS & HOOD HANDLEBAR COVER NOSEPAN HANDLE BAR COVER REMOVAL/ REPLACEMENT INSTALTION IMPORTANT: When installing replacement nosepan, the open circles represent rivets installed from inside the nosepan through the bottom. The filled in circles represent rivets installed from the under side of nosepan through to the top. NOTE: Rivet holes may require drilling into the bulkhead.
Page 257: Decals
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 258: Decal Installation
CHASSIS & HOOD Once all of the adhesive is removed from the decal area, a squeegee on the decal with the chrome exposed, the follow with a cleaning solution of 99% water to 1% mild chrome will be damaged. dishwasher detergent. Use a non-abrasive cloth with the solution to remove dirt, grease, cleaning solvent, and finger prints.
Page 259 CHASSIS & HOOD 10.11...
Page 260 CHASSIS & HOOD NOTES 10.12...
Page 261 BATTERY & ELECTRICAL SYSTEMS CHAPTER 11 BATTERY & ELECTRICAL SYSTEMS SPECIFICATIONS ............11.3 ENGINE MODELS .
Page 262 BATTERY & ELECTRICAL SYSTEMS CRANKSHAFT POSITION SENSORS (CPS) ....... 11.29 STATOR ASSEMBLY.
Page 263: Specifications
BATTERY & ELECTRICAL SYSTEMS Ignition Timing SPECIFICATIONS Model Specification Engine Models EC34 26.5° @ 3000 RPM EC50PL 28° @ 3000 RPM Model Number Engine 27° @ 3500 RPM EC55PM 14° @ 6500 RPM EC34 Fuji 340cc 25° @ 2500 RPM S3303-5044-PFSC EC50PL Fuji 488cc LC...
Page 264: Conventional Battery
BATTERY & ELECTRICAL SYSTEMS CONVENTIONAL BATTERY Refilling a Conventional Battery The normal charge/discharge cycle of a battery causes the cells NOTE: Do not service the battery unless it will be to give off gases. These gases, hydrogen and oxygen, are the put into regular service within 30 days.
Page 265: Battery Testing
BATTERY & ELECTRICAL SYSTEMS BATTERY TESTING Battery Voltage Per Cell Testing Procedures CONVENTIONAL STATE OF CHARGE YUMACRON TYPE LEAD-ACID Batteries should be kept at or as near full charge as possible. If 100% CHARGED 1.265v 1.275v the battery is stored or used in a partially charged condition, hard crystal sulfication will form on the plates, reducing their 75% CHARGED 1.210v...
Page 266: Ignition Timing
BATTERY & ELECTRICAL SYSTEMS IGNITION TIMING retaining screws can be accessed through the flywheel. Timing Procedure - Carbureted Engines 10. Torque stator plate screws and flywheel nut to specified NOTE: Always verify timing of engine at room torque. Apply Loctite 262 (red) to crankshaft flywheel taper temperature (68°F / 20°C), and at the specified RPM.
Page 267: Ignition Timing Chart
BATTERY & ELECTRICAL SYSTEMS Ignition Timing Chart NOTE: Always disconnect the TPS on carbureted engines prior to checking ignition timing. Convert the ignition timing specification from degrees BTDC to either inches or millimeters, then use a dial indicator to verify timing marks.
Page 268: Throttle Position Sensor (Tps)
BATTERY & ELECTRICAL SYSTEMS THROTTLE POSITION SENSOR (TPS) Connect the test tool to the TPS on the carburetor or throttle body. The following models use a throttle position sensor (TPS): • 500 XC SP • 600 HO Carbureted (All Models) •...
Page 269: Tps Adjustment - Carbureted Models
BATTERY & ELECTRICAL SYSTEMS TPS Adjustment - Carbureted Models Click on the TOOLBOX icon. Click on “TPS INITIALIZATION” NOTE: Always verify the engine idle speed is set at Follow the steps and procedures displayed on the screen. engine operating temperature and the throttle cable freeplay is set to 0.10″...
Page 270 BATTERY & ELECTRICAL SYSTEMS Loosen the idle speed screw until the screw no longer touches the tab and the throttle plates are completely closed. 10. Carefully tighten the screws to 31 In.Lbs. (3.5 Nm) when • A = Idle Speed Screw the voltage is 0.70 +/- 0.01 Vdc.
Page 271: Tps Idle Speed Adjustment - Cfi Models
BATTERY & ELECTRICAL SYSTEMS TPS Idle Speed Adjustment - CFI Models Verify the TPS voltage is 0.70 +/- 0.01 Vdc with the throttle plates closed. Slowly turn the idle speed adjustment screw (A) clockwise until the voltage displayed on the multi meter reads 0.95 +/ - 0.1 Vdc.
Page 272: Electric Start - Gen Ii / Edge
BATTERY & ELECTRICAL SYSTEMS ELECTRIC START - GEN II / EDGE System Schematic 11.12...
Page 273: Starter Motor Assembly (Typical)
BATTERY & ELECTRICAL SYSTEMS Starter Motor Assembly (Typical) COMMUTATOR CAP STARTER SOLENOID ARMATURE 9 Ft.Lbs. (12 Nm) SCREW DRIVE CAP PINION MOTOR BRACKET RETURN SPRING ASM STARTER MOTOR GROUND CABLE 14 - 16 Ft.Lbs. (19 - 21 Nm) 19 - 26 Ft.Lbs. (25 - 35 Nm) MOTOR BRACKET 11.13...
Page 274: Battery Box
BATTERY & ELECTRICAL SYSTEMS Battery Box CIRCUIT BREAKER SOLENOID GROUND WIRE RED LEAD FROM BATTERY RED LEAD TO STARTER BATTERY BOX 11.14...
Page 275: Dynamic Testing
BATTERY & ELECTRICAL SYSTEMS Dynamic Testing NOTE: Be sure the engine crankshaft turns freely before proceeding. Use a digital multimeter during tests. Test battery voltage. Is the battery voltage equal to or greater than Remove battery, test and/or service. Install a fully 12.8 Vdc? charged shop battery to continue the test and continue with left column...
Page 276: Electric Start - Iq Carbureted / Cfi
BATTERY & ELECTRICAL SYSTEMS ELECTRIC START - IQ CARBURETED / CFI System Schematic - 600 HO Carbureted 11.16...
Page 277: System Schematic - 600 / 700 Cfi
BATTERY & ELECTRICAL SYSTEMS System Schematic - 600 / 700 CFI 11.17...
Page 278: Starter Motor / Flex Drive Assembly
BATTERY & ELECTRICAL SYSTEMS Starter Motor / Flex Drive Assembly (+) RED - POSITIVE CABLE FLEX DRIVE STARTER MOTOR PINION / PINION BRACKET WORM GEAR CLAMP END PLATE MOUNTING BRACKET MOUNTING BRACKET 11.18...
Page 279: Iq Battery Box Assembly
BATTERY & ELECTRICAL SYSTEMS IQ Battery Box Assembly CIRCUIT BREAKER SOLENOID BATTERY HOLD-DOWN BRACKET GROUND CABLE BATTERY BATTERY PAD MOUNTING BRACKET 11.19...
Page 280: Clean Fire Fuel Injection
• Diagnostic Connector: The ECU can communicate with the Polaris Digital Wrench software and can be re- • Regulator / Rectifier: Responsible for converting Vac to flashed, monitored and will display trouble codes.
Page 281: Diagnostic Trouble Codes (Dtcs)
BATTERY & ELECTRICAL SYSTEMS Diagnostic Trouble Codes (DTCs) 2007 CFI Diagnostic Trouble Codes MFD B LINK ROUBLE ESCRIPTION TPS signal changes too rapidly to be correct. Can be caused by faulty Throttle Position Sensor Unrealistic Transition P0120 connections or a faulty TPS. TPS signal is above 4.39 Vdc.
Page 282: Mfd Blink Codes
BATTERY & ELECTRICAL SYSTEMS 2007 CFI Diagnostic Trouble Codes MFD B LINK ROUBLE ESCRIPTION Engine is running, but the pulses from the 5 tooth CPS are incorrect. 5 Tooth CPS Signal Intermittent P0336 Can be caused by a faulty stator, wiring harness or ECU. Sensor supply voltage is below an acceptable limit.
Page 283: Cfi Clutch Guard Electrical Center
BATTERY & ELECTRICAL SYSTEMS CFI Clutch Guard Electrical Center COVER / SPARE BELT HOLDER 6 Ft.Lbs. (10 Nm) CAPACITOR REGULATOR / RECTIFIER 6 Ft.Lbs. (10 Nm) IGNITION COILS 6 Ft.Lbs. (10 Nm) COIL MOUNT GUARD PLATE 6 Ft.Lbs. (10 Nm) 11.23...
Page 284: Chassis/Hood
BATTERY & ELECTRICAL SYSTEMS 34 Pin CNA ECU Connector NOTE: Wire Entry View OLOR ONNECTOR UNCTION RED/BLUE SPLICE K LINE POWER ORANGE ECU POWER EXTERNAL POWER WHITE/BLACK EXHAUST TEMP. SENSOR SIGNAL BLUE TBAP AIR TEMP SIGNAL GREEN/BLUE IGNITION SWITCH STARTER LOCKOUT RED/WHITE TBAP 5 VDC POWER SUPPLY...
Page 285: 26 Pin Cnb Ecu Connector
BATTERY & ELECTRICAL SYSTEMS 26 Pin CNB ECU Connector NOTE: Wire Entry View OLOR ONNECTOR UNCTION ORANGE PTO IGNITION COIL COIL POWER BLUE / YELLOW STATOR - FUEL INJECTOR COIL FUEL INJECTOR POWER COIL BLUE / YELLOW STATOR - FUEL INJECTOR COIL FUEL INJECTOR POWER COIL GREEN STATOR - CRANK POSITION SENSOR...
Page 286: Chassis Relay
BATTERY & ELECTRICAL SYSTEMS Chassis Relay 11.26...
Page 287: Throttle / Ignition Kill System
BATTERY & ELECTRICAL SYSTEMS Throttle / Ignition Kill System System Overview The second system is the hardware stop system. The hardware stop system is a direct ignition kill system. That is, whenever the There are two methods for cutting the ignition on CFI systems. operator turns the key to off, pulls the tether, or pushes the safety The first is the software stop system.
Page 288: Vehicle Speed Sensor
BATTERY & ELECTRICAL SYSTEMS Vehicle Speed Sensor 11.28...
Page 289: Exhaust Temperature Sensor
BATTERY & ELECTRICAL SYSTEMS Exhaust Temperature Sensor Crankshaft Position Sensors (CPS) The 5 tooth crank position sensor picks up all 5 flywheel teeth. The 2 tooth crank position sensor picks up 2 off set flywheel teeth. Both crank position sensors will have a gap to the flywheel pick up of 0.031"...
Page 290: Stator Assembly
BATTERY & ELECTRICAL SYSTEMS Stator Assembly REG REC CRANK POSITION SENSORS Stator Specifications RESISTANCE ITEM COLOR SYSTEM FUNCTION +/- 15% @68 F (20 ° ° Chassis and Battery Charge YEL to YEL = 0.13Ω CHARGE YELLOW Coils No continuity to ground. Crank Position Sensor (5 Tooth) GRN to WHT/GRN GRN to WHT/GRN = 190Ω...
Page 291: Exhaust Valve Solenoid
BATTERY & ELECTRICAL SYSTEMS Exhaust Valve Solenoid Regulator / Rectifier Regulator / Rectifier Connections WIRE CONNECTOR ITEM Specifications COLORS STATOR YELLOW Vac from stator charge coils. Coil Resistance 15Ω +/- 15% @ 68°F (20°C) Vdc supplied to ECU to boost power to ORANGE (WHT/YEL to RED) fuel injectors during engine start-up.
Page 292: Engine Coolant Temperature Sensor
BATTERY & ELECTRICAL SYSTEMS Engine Coolant Temperature Sensor replaced with the new color so all four injectors are the same color. After replacing all four injectors, the ECU must be reflashed so the fuel calibration map matches the new color coded fuel injectors.
Page 293: Cfi Power System
BATTERY & ELECTRICAL SYSTEMS CFI Power System CFI Ignition / Injection Power 11.33...
Page 294: Cfi Crank Position System
BATTERY & ELECTRICAL SYSTEMS CFI Crank Position System CFI Safety Stop System 11.34...
Page 295: Cfi Full Load Fuel Injectors
BATTERY & ELECTRICAL SYSTEMS CFI Full Load Fuel Injectors CFI Part Load Fuel Injectors 11.35...
Page 296: Cfi Chassis Power
BATTERY & ELECTRICAL SYSTEMS CFI Chassis Power CFI Ignition Coils 11.36...
Page 297: Cfi Tbap Sensor
BATTERY & ELECTRICAL SYSTEMS CFI TBAP Sensor CFI TPS / Engine Temp. Sensors 11.37...
Page 298: Cfi Exhaust Solenoid
BATTERY & ELECTRICAL SYSTEMS CFI Exhaust Solenoid CFI Knock Sensor 11.38...
Page 299: Cfi Fuel Pump
BATTERY & ELECTRICAL SYSTEMS CFI Fuel Pump CFI Diagnostic Connections 11.39...
Page 300: Cfi Mfd Circuits
BATTERY & ELECTRICAL SYSTEMS CFI MFD Circuits CFI MFD Power Circuits 11.40...
Page 301: Cfi Fuel Level Circuit
BATTERY & ELECTRICAL SYSTEMS CFI Fuel Level Circuit CFI Vehicle Speed Circuit 11.41...
Page 302: Cfi Mode Set Switch
BATTERY & ELECTRICAL SYSTEMS CFI Mode Set Switch CFI PERC Switch 11.42...
Page 303: Digital Wrench Diagnostic Software
BATTERY & ELECTRICAL SYSTEMS DIGITAL WRENCH DIAGNOSTIC Digital Wrench Connections SOFTWARE The access point for the ECU power-up and Digital Wrench connectors is located in the front, left-side of the nosepan. Overview The Digital Wrench diagnostic software allows the technician to CHASSIS POWER-UP perform the following tests and observations: (2- WIRE CONNECTOR)
Page 304: Updating Digital Wrench
Delete the file after performing the update. NOTE: Delete the update file from the desktop when finished. NOTE: Only authorized Polaris dealers distributors can access the dealer Internet website. Log on to www.polarisdealers.com. Locate the “SERVICE AND WARRANTY” drop-down menu.
Page 305: Version / Fileset Identification
BATTERY & ELECTRICAL SYSTEMS Version / Fileset Identification Engine Controller Reprogramming (Reflash) NOTE: New service replacement ECUs Knowing what Digital Wrench or fileset versions are installed will help determine which updates are required. programmed as “no-start” and require a reflash in able to work.
Page 306 BATTERY & ELECTRICAL SYSTEMS A request code will be generated. Record the code. 12. The website will generate an authorization code. Record the code. 13. Enter the authorization number in the box on Digital Wrench. Click on “CONTINUE”. Access www.polarisdealers.com. Locate “REFLASH AUTHORIZATION”...
Page 307: Carbureted Electrical Systems
BATTERY & ELECTRICAL SYSTEMS CARBURETED ELECTRICAL Ignition Coil Packs SYSTEMS NOTE: Specifications listed for all models except EC50PL (488cc) as this model features a CDI / coil EC50PL Stator Specifications pack. NOTE: Use a multimeter to test the stator circuits. Specifications Remember to test the circuits when the engine is cold and after the engine has been running for some...
Page 308: 600Ho Coolant Temperature Sensor
BATTERY & ELECTRICAL SYSTEMS 600HO Coolant Temperature Sensor 600 HO Regulator / Rectifier Sensor Specifications Operating Temperature Range -22_F - +248 _F (-30_C - 120_C) 2.4 - 2.6KΩ@ 68_F (20_C) Resistance (Measure in stirred water) Installation Torque 29 ft.lbs. (39.2Nm) 500 EV Coolant Temperature Sensor Sensor Specifications Circuit Specifications...
Page 309: Troubleshooting Tables
BATTERY & ELECTRICAL SYSTEMS TROUBLESHOOTING TABLES NO SPARK No Spark Condition Disconnect the single black (black/white) wire from the CDI Module to the Check the ignition switch, wire harness, throttle safety switches and kill ignition kill circuit. Does it have a spark? switch for proper adjustment or short to ground.
Page 310: Detonation Control (Det)
Overview Detonation control is achieved by using a knock sensor mounted The Polaris VES system uses exhaust valves (1 per cylinder) to to the cylinder head and an ECU (CFI engines) or the CDI control the exhaust port height. The valves are actuated by (600HO engines).
Page 311: Diagnostic Plugs
CHASSIS POWER-UP PRIME PLUG (2- WIRE CONNECTOR) Some models are equipped with Polaris electric reverse control (PERC). The operation of the electronic reverse system is achieved by automatically reversing the engine rotation with a push of a button. When in reverse you will have an indicator light that will flash, notifying you that the machine is in the reverse mode.
Page 312: Forward Operation
Altitude Setting If your engine is carbureted, you can adjust the elevation setting of the Polaris electric reverse control (PERC). If your engine is a Cleanfire system, this is automatically done through the engine controller unit (ECU), and you do not need to do any setting.
Page 313 Numerics Belt Deflection 3.14, 6.23 2 Stroke Gasoline Pre-Mix Chart 2.7 Measurement 3.14 2 Stroke Gasoline/Oil Pre-Mix chart 2.7 Belt Inspection 6.8 340 Engine Rebuilding 5.12 Belt Installation (TEAM driven clutch) 6.10 340 Engine Removal 5.10 Belt Removal (TEAM driven clutch) 6.10 340/550 Engine Assembly 5.13 Brake Fluid Indicator 3.13 340/550/500 Engine Removal/Installation 5.11...
Page 314 Main bearing 3.8 Crankshaft Runout Inspection 3.12 Edge Headlight Bulb Replacement 3.24 Crankshaft Truing 3.11 EDGE RMK Front Suspension 8.4 Cylinder Head 5.7 Electric Reverse (PERC) 11.51 Cylinder Head Inspection 3.5 Electric Start Cylinder Honing 3.5 Gen II/Edge 11.12 Cylinder Inspections 3.5 IQ 11.16 Cylinder Measurement 3.5 Electrical Specifications 11.3...
Page 315 Piston Inspection 3.6 M-10 Overview 9.14 Piston Ring Installed Gap 3.7 M-10 Ski Pressure 9.16 Piston Wash Reading 2.9 M-10 Suspension 9.14 Polaris Recommended Program 3.3 M-10 Terminology 9.15 Publication Part Numbers Main Bearing 3.8 2007 2.6 Measurement Conversion Chart 2.9 Manuals, Posters, Videos 2.5...
Page 316 Drive Clutch Springs 6.5 Non-ER LW Driven Helixes 6.7 Special Tools 6.4 Team Driven Springs 6.8 PVT System Overview 6.2 Rail Slides 9.17 Rear Suspension Adjustments 9.8 Rear Suspension Operation 9.7 Rear Suspension Removal 9.18 Rear Suspension Torque Specifications 9.4 Rear Suspension Troubleshooting 9.34 Rear Suspension Type per Model 9.2 Recommended Coolant 3.7...
Page 317 Drive System 3.23 Electrical Connections 3.23 Fuel System 3.23 Hood 3.22 Shocks 3.23 Throttle Body 3.23 Suspension Spring Free Length 2.3 Pre-Load 2.3 Tail Light 10.7 Thermostat 5.4 Throttle Body Removal 4.22 Throttle Lever Freeplay 3.18 Throttle Opening vs Fuel Flow 4.11 Throttle Position Sensor 11.8 Torque Stop 3.21 Track Alignment 3.20...
Page 318 Wiring Diagrams 2007 340 / 550 GEN II - EDGE Models 12.1...
Page 319 Wiring Diagrams 2007 Wide Trak 12.2...
Page 320 Wiring Diagrams 2007 500 XCSP 12.3...
Page 321 Wiring Diagrams 2007 600 HO Carbureted 1 of 2 12.4...
Page 322 Wiring Diagrams 2007 600 HO Carbureted 2 of 2 12.5...
Page 323 Wiring Diagrams 2007 600 HO Carbureted Hood Harness 12.6...
Page 324 Wiring Diagrams 2007 600 / 700 CFI 1 of 2 12.7...
Page 325 Wiring Diagrams 2007 600 / 700 CFI 2 of 2 12.8...
Page 326 Wiring Diagrams 2007 600 / 700 CFI Hood Harness 12.9...
Page 327 Wiring Diagrams 12.10...

This manual is also suitable for:

2007 340 lx 2007 340 touring 2007 widetrack lx 2007 500 xc sp 2007 super sport 2007 550 lx ... Show all

Polaris 2007 Two Stroke Service Manual

Model Specifications Chapter 1 1

General Chapter 2 General 2

Maintenance Chapter 3 Maintenance

Fuel Delivery Chapter 4 Fuel Delivery

Engine Chapter 5 Engine

Clutching Chapter 6 Clutching

Final Drive/Brakes Chapter 7 Final Drive/Brakes

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Polaris 2007 Two Stroke