Polaris 500 CLASSIC 2006 ATV Manuals

Manuals and User Guides for Polaris 500 CLASSIC 2006 ATV. We have 1 Polaris 500 CLASSIC 2006 ATV manual available for free PDF download: Manual

Polaris 500 CLASSIC 2006 Manual

Polaris 500 CLASSIC 2006 Manual (300 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 13 MB

Table of Contents

Table of Contents

1
- 340 Classic
  2
- Chapter 1
  2
- 550 Classic
  6
- 700 Classic
  10
- 500 Indy
  12
- Supersport
  14
- 340 Indy Touring
  16
- Trail Touring
  18
- 600 Edge Touring
  20
- 700 Touring
  22
- Widetrak Lx
  24
- 500 XC Sp
  26
- 600 Ho Standard Fusion
  28
- 600 Ho Dragon Fusion
  30
- 700 Fusion
  32
- 600 Ho Switchback
  36
- 900 Switchback
  38
- Trail Rmk
  40
- 600 Ho Rmk
  42
- 700 Rmk
  44
Specifications Notes

49
- Chapter 2 General
  50
- How to Use this Manual
  50
  - Locating Information
    50
  - Explination Method of this Manual
    50
- Snowmobile Model Number Designation
  51
  - Example
    51
- Tunnel Decal
  51
  - Tunnel Decal Located on the Right Hand Side of the Sled
    51
- Publication Part Numbers
  52
  - 2006 Part Numbers
    52
- Vin (Vehicle Identification Number)
  52
  - Vin Explination
    52
- General Reference
  54
  - Standard Bolt Specifications
    54
  - Sae Tap Drill Sizes
    55
  - Metric Tap Drill Sizes
    55
  - Mesurement Conversion Chart
    56
  - Piston Wash / Spark Plug Reading
    57
- Gasoline Information
  57
  - Gasoline Volatility
    57
  - Stroke Gasoline / Oil Pre MIX
    58
- Special Tools
  59
General

63
- Chapter 3 Polaris Recommended Program
  65
- Maintenance Program
  65
- Inspectons
  67
  - Cylinder Head Inspection
    67
  - Cylinder Measurement
    68
  - Cylinder Honing
    68
  - Honing Procedure
    69
  - Honing to over Size (340/550/500 Fuji Engines Only)
    69
  - Cleaning the Cylinder after Honing
    69
  - Piston Inspection
    69
  - Piston Ring Installed Gap
    70
  - Coolant Level
    70
  - Recommended Coolant
    70
  - Cooling System Bleeding
    70
  - Bearing Fit
    71
  - Main Bearing
    72
  - Connecting Rod (Big End) Bearing
    72
  - Wrist Pin Bearing
    72
  - Crankshaft Indexing
    73
  - Checking Crankshaft Index
    73
  - Crankshaft Truing
    73
  - Crankshaft Runout Inspection
    74
  - Oil Pump Bleeding
    75
  - Fitting Types
    75
  - Verifying Check Valve Operation
    75
  - Oil / Fuel Filter
    76
  - Brake Lever Travel
    76
  - Brake Fluid
    76
  - Brake Fluid Bleeding
    77
  - Exhaust System
    78
  - Exhaust Removal
    78
  - Exhaust Installation
    78
  - Belt Deflection
    79
  - Measuring Belt Deflection
    79
- Lubrication
  79
  - Grease Points
    79
  - Jackshaft Bearing
    79
  - Driveshaft Bearing
    80
  - Rear Suspension
    80
  - Chaincase
    80
  - Steering U Joint
    80
- Adjustment
  81
  - Chaincase Drive Tension
    81
  - Track Alignment
    82
  - Track Lubrication
    82
  - Track Tension
    83
  - Oil Pump Adjustment
    84
  - Headlight Adjustment
    84
  - Handlebar Adjustment
    85
  - Handlebar Riding Position Adjustment (Rider Select Only)
    85
  - Throttle Lever Free Play
    86
  - Torque Stop
    86
- Cleaning
  86
Table of Contents

89
- Chapter 4 Warnings
  90
- General Information
  90
  - Service Precautions
    90
  - Gasoline Votalitiy
    91
  - Stroke Gasoline / Oil Pre MIX
    91
- Fuel Delivery System (Carbureted)
  91
  - Carbureted System Overview
    91
- Fuel Pump (Non-Injected Units)
  92
  - Fuel Pump Overview
    92
  - Maintenance
    93
  - Operation
    93
  - Cleaning
    93
  - Inspection
    93
- Mikuni Jet Needle
  93
  - Overview
    93
- Mikuni Tm 38
  94
  - Carburetor Overview
    94
- Mikuni Carburetor
  95
  - Function
    95
  - Float System
    95
  - Fuel Metering
    96
  - Fuel Delivery
    96
  - Pilot Jet
    96
  - Pilot Air Screw
    96
  - Main Jet
    96
  - Jetting Guidelines
    97
  - Piston Valve or Throttle Valve
    97
  - Jet Needle / Needle Jet
    97
  - Jet Needle
    97
  - Needle Jet
    98
  - Throttle Opening Vs Fuel Flow
    98
- Mikuni Tm38 Flat Slide Service
  99
  - Disassembly
    99
  - Assembly
    100
- Carburetor Syncronization
  101
  - Throttle Valve Syncronization
    101
- Throttle Position Sensor
  102
  - Setting the Tps
    102
- Carburetor Cable Adjustments
  103
  - Choke Adjustment
    103
  - Throttle Lever Freeplay
    103
- Carburetor Component Part Numbers
  104
  - Mikuni Pilot Jets
    104
  - Mikuni Main Jets
    104
  - Mikuni Jet Needles
    104
  - Mikuni Starter Jets
    104
  - Mikuni Pilot Air Jets
    105
  - Mikuni Piston Valves
    105
Cleanfire Fuel

107
- Chapter 5 Warnings
  108
- Fuel Delivery System (Cleanfiret)
  108
  - Cleanfire System Overview
    108
- General Information
  108
  - Gasoline Voltality
    108
  - Stroke Gasoline / Oil Pre MIX
    108
- Fuel Rail
  109
  - Fuel Rail/Injector Removal
    109
  - Fuel Rail/Injector Installation
    109
  - Fuel Rail Bleeding
    110
- Pump Flange Assembly
  109
  - Fuel Pump
    109
  - Fuel Level
    109
- Injector
  110
  - Injector Replacement
    110
- Throttle Body
  110
  - Setting the Throttle Body Tps
    110
  - Setting the Base Line Voltage
    110
  - Setting the Idle Voltage
    112
  - Throttle Body Removal
    112
- Fuel Filter
  112
  - Fuel Filter Removal
    112
  - Fuel Filter Installation
    112
Table of Contents

113
- Chapter 6
  114
- Exhaust Valve Removal
  114
- General Engine Information
  114
- Exhaust Valve Installation
  115
- Reed Valve Disassembly
  115
- Exhaust Valve Springs
  116
- Reed Valve Assembly
  116
- Thermostat Replacement
  116
- Water Temperature Sensor Replacement
  116
- 700/900 Engine
  117
- 700/900 Engine Rebuilding
  123
  - 700/900 Disassembly
    123
  - 700/900 Torque Patterns
    124
  - 700/900 Assembly
    124
  - 700/900 Water/Oil Pump Cross Shaft Disassembly
    124
  - 700/900 Water/Oil Pump Cross Shaft Assembly
    126
  - 700/900 Recoil/Stator Disassembly
    126
  - 700/900 Recoil/Stator Assembly
    126
- 500/600 Ho Engine
  127
  - 500/600 Ho Torque Specifications
    127
  - 600 Ho Iq Engine Removal
    127
  - 600 Iq Engine Installation
    131
- 500/600 Ho Engine Rebuilding
  134
- 340/550 Fuji Engine/500 Liberty
  138
  - 340/550 Fuji/500 Liberty Engine Removal/Installation
    138
- 340/550 Engine Rebuilding
  139
  - 340/550 Engine Disassembly
    140
  - 340/550 Engine Assembly
    140
- 500 Fuji
  141
  - Disassembly
    141
  - Assembly
    142
Table of Contents

145
- Chapter 7 Clutch Tools
  147
- Special Clutch Tools
  147
- Drive Belt
  148
  - Belt Inspection
    148
  - Belt Diagnosis
    148
  - Drive Belt Removal with Team Clutch
    149
  - Belt Installation (Team Driven Clutch)
    149
  - Drive Belt Removal with Polaris Driven Clutch
    150
  - Belt Installation (Polaris Driven Clutch)
    150
- Drive System Terminology
  151
  - System Overview
    151
  - Drive Spring
    151
  - Clutch Weight
    151
  - Neutral Speed
    151
  - Engagement Rpm
    151
  - Shift out Overrev
    151
  - Shift out Rpm
    151
  - Driven Spring
    151
  - Back-Shifting
    152
  - Final Gearing
    152
  - 1:1 Shift Ratio
    152
  - Low / High Ratio Lines
    152
  - Driven Helix / Ramp
    152
- Centrifugal Drive System
  153
  - Theory of Operation
    153
- Drive Clutch
  153
  - Operation
    153
  - Drive Clutch Identification
    154
  - Drive Clutch Removal
    154
  - Drive Clutch Components
    155
  - Drive Clutch Disassembly
    157
  - Clutch Assembly
    157
  - Drive Clutch Spider Removal/Installation
    158
  - Roller Removal
    158
  - Roller Installation
    159
  - Spider Indexing
    159
  - Spring Free Length
    160
  - Drive Clutch Weights
    162
  - Drive Clutch Installation
    163
- Driven Clutch
  164
  - Driven Clutch Overview
    164
  - Driven Clutch Types
    164
  - Driven Clutch Removal
    164
  - Driven Clutch Installation
    164
  - Team Ramps Explained
    165
  - Polaris P-85 Helix
    167
- Drive System Adjustments
  169
  - Clutch Alignment
    169
  - Clutch Alignment Inspection
    169
  - Clutch Alignment Adjustment
    169
  - Clutch Offset
    169
  - Off Set Adjustment
    169
Table of Contents

173
- Chapter 8
  178
- Gears
  178
- Gears and Chains
  178
- Chain Case
  179
  - Exploded View
    179
  - 8.37 Chaincase Removal
    180
  - 8.37 Chaincase Installation
    181
  - 7.92 Chaincase Removal
    181
  - 7.92 Chaincase Assembly
    181
  - Chaincase Seal/Bearing Replacement
    182
- Drive Chain
  179
- Drive Train
  183
  - Jackshaft Exploded View
    183
  - Jackshaft Removal
    184
  - Jackshaft Installation
    184
- Driveshaft
  185
  - Drive Shaft Removal
    185
- Widetrak Transmission
  186
  - Removal
    186
  - Inspection
    187
  - Low/Reverse Shaft Disassembly
    189
  - Shift Fork Disassembly
    189
  - Transmission Assembly
    190
  - Transmission Installation
    190
Final Drive

193
- Chapter 9
  194
- Compensating Port
  194
- General Guidelines
  194
- Hydraulic Brake System
  194
- Overview
  194
- Brake Fluid Replacement & Bleeding
  195
- Brake Line Replacement
  195
- Brake Light Switch Replacement
  196
- Caliper
  196
  - Caliper Removal
    196
  - Caliper Replacement
    197
  - Caliper Assembly
    197
  - Brake Pad Replacement
    197
  - Brake Disc Replacement
    197
- Widetrak Brake Caliper
  197
  - Removal
    197
  - Assembly
    198
  - Installation
    198
Front Suspension/

199
- Chapter 10
  200
- Fusion/Iq Rmk
  200
- Edge Rmk
  201
- 42.5 Edge
  202
- Widetrak
  203
- Front Suspension Adjustment Procedures
  204
  - Set up and Adjustments
    204
  - Ifs Shock Springs
    205
  - Springs
    206
  - Compression Damping Adjustable Shocks
    206
- Shock Information
  207
  - Ifs Shock Specifications
    207
  - Ifs Shock Production Valving
    208
- Iq Front Suspension
  210
  - Spindle Removal
    212
  - Spindle Assembly
    212
  - Lower Spherical Bearing Replacement
    212
  - Upper / Lower Control Arm Removal
    212
  - Upper / Lower Control Arm Installation
    212
- Steering
  212
  - Inspection
    212
  - Alingment Bar Specifications
    213
  - Camber Definition
    213
  - Rod End Procedure
    213
  - Rod End Engagement
    213
- Camber &Toe Specifications
  213
- Alignment Adjustments
  214
  - Edge Set up Width
    214
  - Edge Camber Adjustment
    214
  - Iq Camber Adjustment
    215
  - Handlebar Centering
    215
  - Toe Adjustment
    215
- Ski Stance
  216
  - Adjustment (Rmk Only)
    216
Chapter 11 Rear Suspension

217
- Rear Suspension Operation
  218
  - Operation
    218
  - Weight Transfer
    218
  - Suspension Coupling
    218
  - Rear Torsion Spring Tension Adjustment
    219
- Rear Suspension Specifications
  218
- Rear Suspension Adjustments and Settings
  219
- M-10 Suspension
  226
  - M-10 Overview
    226
  - M-10 Adjustments
    226
  - M-10 Terminology
    226
  - M-10 Adjustments
    227
  - M-10 Fra Initial Set up Reference
    227
  - M-10 Rear Spring Preload
    228
  - Ski Pressure
    228
- Rail Slider
  229
  - Rail Slide Wear Limit
    229
  - Rail Slide Removal
    229
  - Rail Slider Break
    229
- Rear Suspension Removal / Installation
  229
  - Rear Suspension Removal
    229
  - Rear Suspension Installation
    229
- Shock Information
  230
- Valving Specifications
  231
  - Rear Suspension Front Track Shock (Fts) Stock Valving
    231
  - Rear Suspension Rear Track Shock (Rts) Stock Valving
    233
- Shock Valve Part Numbers
  236
  - Ryde Fxt Shock Valve Part Numbers
    237
  - Foxt Shock Valve Part Numbers
    237
  - Shock Valving Arrangement
    238
- Shock Maintenance
  239
  - Ryde Fx Mono-Tube Shock Disassembly
    240
  - Ryde Fx Mono-Tube Shock Assembly
    241
  - Fox Ps-5 Assembly
    242
- Special Tools
  239
  - Shock Rebuilding Tools
    239
- Rear Suspension Troubleshooting
  243
Chapter 12 Chassis / Hood

245
- Bumper
  246
  - Iq Front Bumper Removal / Installation
    246
- Headlight
  246
  - Iq Headlight Removal / Installation
    246
- Hood
  246
- Hood Repair
  246
- Instrument / Mfd
  246
  - Edge Instrument Removal / Installation
    246
  - Iq Mfd Removal / Installation
    246
- Removal / Installation
  246
- Coolant/Oil Tank
  247
  - Coolant Tank Removal
    247
  - Coolant Tank Installation
    247
- Fuel Clips
  247
  - Fuel Clip Removal
    247
  - Fuel Clip Installation
    247
- Oil Tank
  247
  - Oil Tank Removal
    247
  - Oil Tank Installation
    247
- Seat and Fuel Tank
  248
  - Fusion Seat and Base Removal/Installation
    248
  - Iq Rmk Seat Removal/Installation
    248
  - Iq Rmk Seat Base Removal/Installation
    249
  - Iq Fuel Tank Removal
    249
  - Iq Fuel Tank Installation
    249
  - Edge Seat Removal / Installation
    250
  - Seat Cover Replacement
    250
  - Iq Seat Cover Replacement
    250
- Air Intake Removal
  250
  - Edge Air Box Removal
    250
  - Edge Air Box Installation
    251
  - Iq 700/900 Air Intake Removal
    251
  - Iq 700/900 Air Intake Installation
    251
  - Iq Carbureted Air Intake Removal
    251
- Console
  250
  - Iq Console Removal / Installation
    250
  - Edge Console Removal / Installation
    250
- Tail Light
  250
  - Tail Light Assembly Replacement
    250
- Handlebar Cover
  252
  - Handle Bar Cover Removal/Instaltion
    252
- Skis
  252
  - Ski Removal
    252
  - Ski Installation
    252
- Decals
  253
  - Decal Removal
    253
  - Decal Installation
    254
- Nosepan
  253
  - Replacement
    253
Chapter 13 Electrical

257
- Ignition Timing (Carbureted Units)
  259
  - Ignition Timing
    259
- Multimeter
  259
- Battery
  261
  - Preparing a New Battery for Service
    261
  - Battery Testing
    261
  - Open Circuit Voltage Testing (Ocv)
    261
  - Load Test
    261
  - Refilling a Low Battery
    261
  - Off Season Storage
    262
  - Charging Procedure
    262
- Starter System
  262
  - Dynamic Testing of the Electric Starter System
    262
  - Starter Motor Static Testing
    264
  - Starter Housing and Field Coil Inspection
    264
  - Armature Testing
    264
  - Starter Assembly
    265
  - Starter Solinoid Bench Test
    265
  - Starter Installation
    265
- Voltage
  265
  - Unregulated Voltage
    265
  - Regulated Voltage
    266
  - Short Circuit Current (Ac Amp Test)
    266
- Alternators
  266
- Electrical Testing
  267
- Troubleshooting Charts
  270
  - No Spark
    270
- Tps Tool Set up
  272
  - Tps Set
    272
  - Tps Adjustment
    272
- Clean Fire Electrical
  273
  - Iq Throttle Position Sensor
    273
  - Iq Temperature Light
    273
  - Lamp Circuit Test
    273
  - Thermistor Sensor Test
    273
  - Iq Detonation Elimination Sensor (Det)
    274
  - Det Troubleshooting
    275
  - Effect of Det
    275
  - Sensor Fail Safe
    275
  - Iq Temerature Sensor
    275
  - Exhaust Temperature Sensor
    275
  - Intake Air Temperature Sensor
    276
  - Barometric Pressure Sensor
    276
  - Crankshaft Position Sensor (Cps)
    276
  - Speed Sensor
    277
  - Ecu Plug #1
    278
  - Ecu Plug #2
    279
  - Stator
    280
  - Ignition Coil
    281
  - Exhaust Valve Solinoid
    281
  - Regulator Rectifier
    283
  - Capacitor
    284
  - Chassis Relay
    284
  - Chassis Ground
    284
- General Electrical Items
  285
  - Oil Level Sender
    285
- Polaris Electronic Reverse Control (Perc)
  286
  - Operation
    286
  - Reverse Operation
    286
  - Forward Operation
    286
  - Altitude Setting
    286
  - Perc Notes
    286
- Digital Wrench
  287
  - Connections
    287

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