Polaris IQ 2008 Manuals

Manuals and User Guides for Polaris IQ 2008. We have 1 Polaris IQ 2008 manual available for free PDF download: Service Manual

Polaris IQ 2008 Service Manual

Polaris IQ 2008 Service Manual (325 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 13.91 MB

Table of Contents

Model Specifications Chapter 1 1

4
- Table of Contents
  4
- 2007 600 Ho Iq
  5
- Chapter 1
  5
- Model Specifications
  5
- Specifications
  5
- 2007 600 Ho Switchback
  7
- 2007 600 Ho Rmk
  9
- 2007 600 Ho Iq Cfi
  11
- 2007 600 Ho Switchback Cfi
  13
- 2007 600 Ho Iq Lx Cfi
  15
- 2007 600 Ho Iq Touring Cfi
  17
- 2007 700 Ho Iq Dragon
  19
- 2007 700 Ho Rmk Dragon
  21
- 2008 Iq Shift
  23
- 2008 600 Rmk 144 / 600 Rmk Shift 155
  25
- 2008 600 Dragon Iq
  27
- 2008 600 Switchback / 600 Dragon Switchback
  29
- 2008 600 Iq Lx
  31
- 2008 600 Iq Touring
  33
- 2008 600 Rmk 155
  35
- 2008 700 Iq / 700 Dragon Iq
  37
- 2008 700 Switchback / 700 Dragon Switchback
  39
- Dragon Rmk 155 / 163
  43
General Information Chapter 2 General Information 2

46
- Chapter 2 Model Number Designation
  47
- Snowmobile Number Designations
  47
- Vehicle Identification Number (Vin)
  48
  - Tunnel Decal
    48
  - Vin Number Designation
    48
- Publication Part Numbers
  49
  - 2008 Publications
    49
- Engine Data Formulas
  50
  - Compression Ratio
    50
  - Compression Ratio Example
    51
  - Head CC Removal Example
    51
  - Port Opening Duration
    51
- Torque Conversion
  52
  - Us to Metric
    52
- General Reference
  53
  - Standard Bolt Torque Specification
    53
  - Fuel / Oil Premix Ratios
    53
  - Gasoline Volatility
    53
  - Sae Tap Drill Sizes
    54
  - Metric Tap Drill Sizes
    54
  - Decimal Equivalents
    54
  - Measurement Conversion Chart
    55
  - Piston Wash / Spark Plug Reading
    55
- Service Precautions
  56
  - General Precautions
    56
Maintenance Chapter 3 Maintenance

58
- Maintenance
  58
  - Periodic Maintenance
    59
  - Chapter 3 Periodic Maintenance Schedule
    59
  - Fuel Systems
    59
- Maintenance Products
  61
  - Engine Oils / Lubricants / Misc
    61
- Drive / Driven Clutches
  62
- Engine Maintenance
  64
  - Exhaust Valve Cleaning
    64
  - Surge Tank
    64
  - Recommended Coolant
    64
  - Cooling System Bleeding
    64
  - Oil Pump Adjustment - Carbureted Models
    65
  - Oil Pump Adjustment - Cfi Models
    66
  - Oil Pump Bleeding
    68
- Fuel / Intake System
  68
  - Water Sediment Trap
    68
  - Fuel Filter - Carbureted Models
    68
  - Fuel Filter - Cfi Models
    69
  - Oil Filter
    69
  - Fuel Tank Vent System
    70
  - Air Intake Box / Pre-Filters
    70
- Chassis Lubrication
  71
  - Rear Suspension
    71
  - Driveshaft Bearing
    71
  - Throttle Cable
    72
  - Choke and Choke Cable
    72
  - Chaincase Oil Level Check
    72
  - Chaincase Oil Replacement
    72
  - Drive Chain Tension Adjustment
    72
- Brake System Maintenance
  73
  - Brake Lever Travel
    73
  - Brake Fluid
    73
- Throttle and Choke Cable Adjustments
  73
- Steering / Suspension Maintenance
  75
  - Handlebars
    75
  - Rider Select Steering U-Joint
    75
  - Ski / Ski Skag Fasteners
    76
  - Track Tension
    76
  - Track Alignment
    77
- Electrical Systems
  78
  - Headlight Bulb Replacement
    78
- Fuel System
  78
  - Clutch and Drive System
    78
    
    Controls and Linkage
    78
    
    Electrical Connections
    78
    
    Carburetor/Throttle Body
    78
- Off-Season Storage
  78
  - Chassis and Hood
    78
Fuel Systems Chapter 4 Fuel Systems

80
- Chapter 4 Service Warnings
  81
- Service Warnings and Precautions
  81
- Carburetor Fuel Systems
  82
- Mikuni Tm Carburetor
  85
  - Float System
    85
  - Jetting Guidelines
    86
  - Jet Needle
    87
  - Needle Jet
    87
- Fuel Pump
  89
- Carburetor Service
  90
- Carburetor Adjustment
  93
- Cleanfire™ Fuel Injection
  94
  - System Overview
    94
  - Diagnostic Trouble Codes (Dtcs)
    95
  - Mfd Blink Codes
    97
  - Dtc Troubleshooting
    97
  - Cfi Clutch Guard Electrical Center
    98
  - 34 Pin CNA ECU Connector
    99
  - 26 Pin CNB ECU Connector
    100
  - Chassis Relay
    101
  - Throttle / Ignition Kill System
    102
  - Vehicle Speed Sensor
    103
  - Exhaust Temperature Sensor
    104
  - Temperature / Air Pressure Sensor (Tbap)
    104
  - Crankshaft Position Sensors (Cps)
    104
  - Stator Assembly
    105
  - Exhaust Valve Solenoid
    106
  - Cfi Ignition Coils
    106
  - Regulator / Rectifier
    106
  - Chassis Power Capacitor
    106
  - Engine Coolant Temperature Sensor
    107
  - Knock Sensor
    107
  - Fuel Injectors
    107
  - Fuel Rail Bleeding / Pressure Testing
    108
  - Disconnect Fittings
    108
  - Fuel Tank Pressure Test
    109
  - Cfi Fuel Rail/Injector(S) Removal/Installation
    109
  - 2007 700 Cfi Fuel System
    111
  - 2007 700 Cfi Fuel Pump Service
    111
  - Cfi "Drop in Pump" Fuel Supply (Typical)
    113
  - Drop in Fuel Pump Service
    113
  - Drop in Fuel Pump Replacement
    113
  - Throttle Body Removal
    114
- Digital Wrench Diagnostic Software
  115
  - Overview
    115
  - Digital Wrench Connections
    115
  - Updating Digital Wrench
    116
  - Version / Fileset Identification
    117
  - Engine Controller Reprogramming (Reflash)
    117
Engine and Cooling Systems

120
- Chapter 5
  121
- Engine Specifications
  121
- Fastener Torque Guide
  121
- Engine Service Specifications - All Engines
  122
- Engine Specifications
  122
- Component Torque Sequences
  123
- Engine Inspections
  124
  - Cylinder Head Inspection
    124
  - Cylinder Measurement
    124
  - Crankshaft Runout Inspection
    124
  - Piston Inspection
    125
  - Piston Ring Installed Gap
    125
  - Reed Valve Inspection
    125
  - Bearing Fit
    125
  - Main Bearing
    126
  - Connecting Rod Lower Bearing
    126
  - Piston Needle Bearing
    126
  - Crankshaft Index
    127
  - Checking Crankshaft Index
    127
  - Cylinder Honing
    128
  - Honing Procedure
    128
  - Cleaning the Cylinder after Honing
    128
  - Crankshaft Truing
    129
- Recoil Assembly
  130
- Exhaust Valve Maintenance
  131
  - Exhaust Valve Assembly
    131
  - Exhaust Valve Disassembly
    131
  - Optional Exhaust Valve Springs
    131
- Engine Mounting Systems
  132
- Engine Component Assemblies
  136
- Cooling Systems
  160
- Exhaust Systems
  167
  - Assembly View (Typical)
    167
Final Drive and Brakes Chapter 6 Final Drive and Brakes

168
- CHAPTER 6 8.373 CD Chaincase Speed Charts
  169
- Gear Ratio Speed Charts
  169
- Drive Gears and Chains
  170
  - Drive Gears
    170
- 8.373 Chaincase
  171
  - Assembly View
    171
  - Chaincase Disassembly
    172
  - Chaincase Assembly
    172
  - PVT System
    173
- Drive Train
  174
- Brake System
  177
  - Overview
    177
  - Compensating Port
    177
  - General Guidelines
    178
  - Brake Fluid Replacement & Bleeding
    178
  - Master Cylinder / Lever Service
    179
  - Brake Line Replacement
    180
  - Brake Light Switch Replacement
    181
  - Caliper Removal
    181
  - Caliper Replacement
    181
  - Caliper Assembly
    182
  - Brake Pad Replacement
    182
  - Brake Disc Replacement
    182
Pvt System Chapter 7 Pvt System

184
- Back-Shifting
  185
- Chapter 7
  185
- Clutch Weight
  185
- Drive Spring
  185
- Driven Spring
  185
- Engagement Rpm
  185
- Neutral Speed
  185
- Overview
  185
- Pvt System
  185
- Shift out Over-Rev
  185
- Shift out Rpm
  185
- 1:1 Shift Ratio
  186
- Driven Helix / Ramp
  186
- Final Gearing
  186
- Low / High Ratio
  186
- General Information
  187
  - Special Tools
    187
  - Drive Clutch Springs
    188
  - Spring Free Length
    189
  - Drive Clutch Weights
    189
  - Perc Team Lwt Driven Helixes (24 Fin)
    190
  - Non-Perc Team Lwt Driven Helixes (24 Fin)
    190
  - Team Ramp Angles
    190
  - Team Driven Springs
    191
  - Drive Belts
    192
  - Belt Inspection
    192
  - Drive Clutch Bolt Torque
    192
  - Belt Wear / Burn Diagnostics
    193
  - Drive Belt Removal - Team Driven Clutch
    194
  - Drive Belt Installation - Team Driven Clutch
    194
  - Adjusting Belt Deflection - Team Driven Clutch
    194
- Pvt System Adjustments
  195
  - Clutch Alignment / Offset
    195
- Drive Clutch
  196
  - Identification
    196
  - Drive Clutch Removal
    196
  - Drive Clutch Disassembly
    197
  - Roller Removal
    198
  - Roller Installation
    198
  - Clutch Assembly
    199
  - Spider Indexing
    200
  - Drive Clutch Installation
    201
- Driven Clutch
  201
  - Driven Clutch Removal
    201
  - Driven Clutch Installation
    201
  - Team Lwt Components
    202
Steering and Suspensions Chapter 8 Steering and Suspensions

204
- Shocks
  204
  - Overview / Specifications
    205
- Camber / Toe Specifications
  205
- Chapter 8
  205
- Inspection
  205
- Springs
  205
- Adjustable Shocks
  206
- Front Suspension Type by Model
  206
- Rear Suspension Type by Model
  206
- Suspension Mounting Fastener Torque
  206
- Iq Rear Suspension Shock Rod
  207
- Iq Rear Track Shock Pivot Orientation
  207
- Front Suspension Assembly Illustrations
  208
  - Iq Front Suspension
    208
  - Iq Fixed Steering Post Assembly
    209
  - Iq Rider Select Steering Post Assembly
    210
  - Iq Steering Linkage
    211
  - Handlebar Assemblies
    212
- Adjustment Procedures
  213
  - Setup and Adjustments
    213
  - Alignment Bar Specifications
    213
  - Camber
    213
- Chassis
  213
  - Rod Ends
    214
    
    Rod End Engagement
    214
    
    Camber Adjustment
    214
    
    Handlebar Centering
    214
    
    Toe Adjustment
    214
  - Disassembly and Assembly
    215
    
    Spindle Removal
    215
    
    Spindle Assembly
    215
    
    Spherical Bearing Replacement
    215
    
    Upper / Lower Control Arm Removal
    215
    
    Upper / Lower Control Arm Installation
    215
  - Rear Suspension Assembly Illustrations
    216
  - Rear Suspension Operation
    239
    
    Operation
    239
    
    Weight Transfer
    239
    
    Coupling
    239
  - Rear Suspension Adjustments
    240
    
    Adjustment Procedures
    240
    
    Rear Suspension Ride Height
    240
    
    Scissor Stop Adjustment
    240
    
    Limiter Strap Adjustment
    241
    
    Torsion Spring Adjustment
    241
    
    Iq 121 Heavy Torsion Spring Installation
    242
  - M-10 Suspension
    243
  - Rail Sliders
    245
    
    Wear Limit
    245
    
    Removal
    245
    
    Break-In
    245
  - Rear Suspension Removal and Installation
    245
    
    Installation
    245
Shocks Chapter 9 Shocks

246
- Chapter 9 Shock Rebuilding Tools
  247
- Special Tools
  247
- Valve Shims
  248
  - Ryde Fx™ Shock Valve Part Numbers
    248
  - Fox™ Shock Valve Part Numbers
    249
  - Walker Evans Shock Valve Part Numbers
    250
  - Walker Evans Shock Valve Part Numbers - 7/16 I.D
    251
  - Valve Shim Arrangement
    252
  - Piston Orientation
    252
- Specifications
  253
  - 2007 Shock Specifications
    253
- Optional Shock Settings
  260
  - Walker Evans Air Shock
    260
  - Ryde Fx Air 2.0 Shock
    260
- Shock Maintenance
  261
Chassis Chapter 10 Chassis

274
- Chapter 10
  275
- Iq Chassis Components
  275
- Steering Hoop Assembly (Typical)
  275
- Hood / Plastic Repair
  276
- Hood Assembly
  276
- Front Bumper Assembly (Typical)
  277
- Iq Console Assembly (Typical)
  277
- Rmk Tunnel
  278
- Fenders and Side Panels
  279
- Seat Assemblies
  280
  - Iq Fixed Seat Assembly
    280
  - Iq Raw Seat Assembly
    280
  - Iq Removable Seat Assembly
    280
  - 2007 Iq Touring Seat Assembly
    281
  - 2008 Iq Touring Seat Assembly
    282
  - Seat Cover Replacement
    283
- Decals
  283
  - Decal Removal
    283
  - Decal Installation
    284
Battery and Electrical Systems Chapter 11 Battery and Electrical Systems

286
- Battery and Electrical Systems
  287
- Chapter 11
  287
- Charging System
  287
- Engine Models
  287
- Ignition Timing
  287
- Spark Plugs
  287
- Specifications
  287
- Conventional Battery
  288
  - Battery Preparation
    288
  - Specifications
    288
  - Refilling a Conventional Battery
    288
- Fresh Pack Battery
  288
- Battery Testing
  289
  - Testing Procedures
    289
  - Open Circuit Voltage Test (Ocv)
    289
  - Load Test
    289
  - Specific Gravity Test (Conventional Battery)
    289
  - Off Season Storage
    289
- Ignition Timing
  290
  - Timing Procedure - Carbureted Engines
    290
  - Timing Procedure - Cfi Engines
    290
  - Ignition Timing Chart
    291
- Throttle Position Sensor (Tps)
  292
- Electric Start - Iq Carbureted / Cfi
  296
  - System Schematic - 600 Carbureted
    296
  - System Schematic - Cfi
    297
  - Starter Motor / Flex Drive Assembly
    298
  - Iq Battery Box Assembly
    299
- Carbureted Electrical Systems
  300
  - 600 HO Stator Specifications
    300
  - Ignition Coil Packs
    300
  - Exhaust Valve Solenoid
    300
  - Knock Sensor
    300
  - 600Ho Coolant Temperature Sensor
    300
  - Oil Level Sender
    300
  - 2007 600 Ho Regulator / Rectifier
    301
  - 2008 Rmk Shift 155 Regulator / Rectifier
    301
  - 2008 Iq Shift Regulator / Rectifier
    302
- Detonation Control (Det)
  302
  - Overview
    302
- Variable Exhaust System (Ves)
  302
- Diagnostic Plugs
  303
  - Iq Chassis Power Plug
    303
  - Iq Cfi Fuel Pump Prime Plug
    303
- Electronic Reverse (Perc)
  303
  - Altitude Setting
    304
  - Important Notes
    304

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