Seat Cover Replacement; Console; Console Removal/Installation; Tail Light - Polaris 2007 Two Stroke Service Manual

Seat Cover Replacement

1. Remove seat.
2. Remove the old covering by removing the staples that hold
it on the base.
3. If replacing the tail light assembly. See "Tail Light
Assembly Replacement" on page 10.7.
4. Drape the new cover over the seat foam.
5. Turn the assembly over and begin upholstering by lining up
the seat cover vinyl side flaps with the indented square
location indicators located on the plastic seat base.
WARNING
Apply staples in the stapling channel only. If you apply
staples outside the channel, you will damage the fuel
tank reservoir in the seat base. If this happens you will
have to replace the entire seat assembly.
6. Using a staple fun, tack each side of the vinyl cover in place
using two staples (1). If cover has a Polaris emblem
carefully align emblem with the bottom edge of the seat.
This will help ensure that the cover is positioned properly.
7. Align the two sewn seams located at the rear of the seat
cover with the two back corners of the seat base.
8. Pull the vinyl tight and tack the seat cover to the plastic seat
base in each corner. Use two or three staples per corner.
9. Now that the cover is positioned, and tacked to the plastic
seat base in for places, turn the assembly over an inspect it.
If the seat cover seems to fit correctly and everything looks
straight, including the tool compartment flap, continue.
10. Staple the remainder of the unattached seat cover to the
plastic seat base. Always staple between two existing
staples and follow this procedure until the seat cover is
completely stapled to the seat base see the staple sequence
above.
11. Turn the seat cushion assembly over and inspect for
wrinkles or imperfections. If imperfections are visible,
remove the staples in the affected area and staple correctly.
12. Trim excess vinyl from the bottom around the back of the
seat area only after a satisfactory fit is obtained.
CHASSIS & HOOD

CONSOLE

Console Removal/Installation

1. Place the adjustable steering in the center (if equipped).
2. Remove the two T25 Torx screws (A).
3. Remove filler cap and the threaded filler retainer (B).
4. Remove the two T25 Torx screws on each side of the shroud
(C).
5. You can set the console aside with the starter rope still
installed or you can carefully un-tie the knot in the recoil
handle and route it through the chassis, then secure a knot
and let the rope rest on the recoil housing.

TAIL LIGHT

Edge Tail Light Assembly Replacement

1. Remove the tail light lens.
2. Remove the taillight assembly.
3. Replace taillight assembly.
4. Replace seat.

Tail Light Assembly Replacement

1. After removal of seat cover, drill out three rivets from top
of taillight.
2. Remove taillight assembly and wire harness.
3. Install new taillight assembly and rivet into place.
4. Connect taillight wire harness. Taillight harness wires must
be routed away from any possible contact with seat cover
staples to prevent electrical shorts.
5. Pull seat cover tightly and evenly into position and re-staple
to seat pan.
6. Inspect cover for a wrinkle-free finish before reinstalling on
the snowmobile.
10
10.7