Polaris S09SU4BS Manuals

Manuals and User Guides for Polaris S09SU4BS. We have 1 Polaris S09SU4BS manual available for free PDF download: Service Manual

Polaris S09SU4BS Service Manual

Polaris S09SU4BS Service Manual (266 pages)

2007-2012 EDGE/WIDETRAK LX SNOWMOBILE

Brand: Polaris | Category: Offroad Vehicle | Size: 8.18 MB

Table of Contents

Table of Contents

4
- Specifications
  5
- 2007 340 Lx
  5
- 2007 340 Touring
  7
- 2007 Supersport / 550 Lx
  9
- 2007 Trail Touring Deluxe
  11
- 2007 Trail Rmk
  13
- 2007 Widetrak Lx
  15
- 2007 500 Xcsp
  17
- 2008 340 Transport
  21
- 2008 Supersport / 550 Lx
  23
- 2008 Trail Touring Deluxe
  25
- 2008 Trail Rmk
  27
- 2008 Widetrak Lx
  29
- 2009 550 Transport
  31
- 2009 Trail Touring
  33
- 2009 Trail Rmk
  35
- 2009 Widetrak Lx
  37
- 2010 Trail Rmk
  39
- 2010 Trail Touring
  41
- 2010 Widetrak Lx
  43
- 2011 Widetrak Lx
  45
- 2012 Widetrak Lx
  47
Chapter 2 General Information 2

50
- Model Number Designation
  51
- Snowmobile Number Designations
  51
- Tunnel Decal
  51
- Vehicle Identification Number (Vin)
  51
- Vin Number Designation
  51
- 2007 Publications
  52
- Publication Part Numbers
  52
- Service / Safety Bulletins
  53
- Fuel / Oil Premix Ratios
  54
- Gasoline Volatility
  54
- General Reference
  54
- Standard Bolt Torque Specification
  54
- Decimal Equivalents
  55
- Metric Tap Drill Sizes
  55
- Sae Tap Drill Sizes
  55
- Measurement Conversion Chart
  56
- Piston Wash / Spark Plug Reading
  56
- Glossary of Terms
  57
Chapter 3 Maintenance

60
- Periodic Maintenance
  61
- Periodic Maintenance Schedule
  61
- Maintenance Products
  63
- Belt Deflection Inspection
  64
- Break-In Procedures
  64
- Drive / Driven Clutches
  64
- Drive Belt Break-In Procedure
  64
- Engine Break-In Procedure
  64
- Fuel/Oil Premix Ratio
  64
- Deflection Adjustment - Polaris Driven / P2
  65
- Deflection Adjustment - Spa-P2 / Team Driven
  66
- Torque Stop Adjustment
  66
- Widetrak Torque Stop Adjustment
  66
- Engine Maintenance
  67
- Exhaust Valve Cleaning
  67
- Fill Tube / Pressure Cap
  68
- Surge Tank
  68
- Widetrak Cooling System
  68
- 500 XCSP Cooling System
  69
- Surge Tank
  69
- Cooling System Bleeding
  70
- Oil Pump Adjustment - 340 / 550 Engines
  70
- Oil Pump Adjustment - 488 Lc Engine
  70
- Recommended Coolant
  70
- Water Pump Drive Belt Tension
  70
- Oil Pump Adjustment - 500 Xcsp
  71
- Oil Pump Bleeding
  71
- Oil Pump Bleeding - 550 Engines
  71
- Oil / Fuel Filter
  72
- Oil Pump Bleeding - 550 Engines with Auto Bleed
  72
- Chassis Lubrication
  73
- Water Sediment Trap
  73
- Brake System Maintenance
  76
- Idle Speed Gap / Throttle Free Play Adjustment - VM Carburetors
  77
- Throttle and Choke Cable Adjustments
  77
- Choke Lever Adjustment - Mikuni VM
  78
- Throttle Lever Free Play - Tm Carburetor
  78
- Choke Adjustment - Mikuni Tm
  79
- Handlebars
  79
- Steering / Suspension Maintenance
  79
- Ski / Ski Skag Fasteners
  80
- Track Tension
  80
- Track Alignment
  81
- Electrical Systems
  82
- Headlight Bulb Replacement
  82
- Headlight Height Adjustment
  82
- Off-Season Storage
  83
Chapter 4 Fuel System

84
- Assembly View
  86
- Mikuni VM Carburetor
  86
- Mikuni VM Carburetor Function
  86
- Throttle Opening and Fuel Flow
  87
- Air Screw
  88
- Float System
  88
- Idle Speed Adjustment
  88
- Jetting Guidelines
  88
- Main Jet
  88
- Pilot Jet
  88
- Starting / Enrichment System
  88
- Jet Needle
  89
- Jet Needle/Needle Jet
  89
- Needle Jet
  89
- Piston / Throttle Valve
  89
- VM Carburetor Disassembly
  90
- VM Carburetor Disassembly / Inspection / Assembly
  90
- Float Arm Adjustment
  91
- Needle and Seat Leak Testing
  91
- Disassembly
  92
- Mikuni Tm Carburetor
  92
- Assembly
  94
- Mikuni Tm Carburetor Adjustment
  95
- Throttle Valve Synchronization
  95
- Fuel Pump
  96
- Operation
  96
- Fuel Tank
  97
- Widetrak Fuel Tank Assembly
  97
- Edge Fuel Tank Assembly (Typical)
  98
- Venting System
  98
Chapter 5 Engine Systems

100
- Crankcase Torque Patterns
  101
- Cylinder Head Torque Patterns
  101
- Cylinder Torque Patterns
  101
- Engine Torque Sequences
  101
- Engine Inspections
  102
- Exhaust Valve Maintenance
  110
- Recoil Pulley
  111
- Rope Removal and Installation
  111
- Engine Mounts
  112
- 550 Engine Mounting
  113
- 488 Engine Mounting
  114
- 500Ev Engine Mounting
  115
- 340 Fan Engine
  116
- Blower Housing Assembly
  116
- Cylinder Assembly
  117
- Oil Pump Assembly
  118
- Magneto Assembly
  119
- Crankcase Assembly
  120
- Piston and Crankshaft Assembly
  121
- 550 Fan Engine
  122
- Blower Housing Assembly
  122
- Cylinder Assembly
  123
- Oil Pump Assembly
  124
- Oil Pump Assembly - Fleet Models
  125
- Magneto Assembly
  126
- Crankcase Assembly
  127
- Piston and Crankshaft Assembly
  128
- 488 Liquid-Cooled Engine
  129
- Recoil / Waterpump Housing Assembly
  129
- Water Pump Assembly
  130
- Cylinder Assembly
  131
- Oil Pump Assembly
  132
- Magneto Assembly
  133
- Crankcase Assembly
  134
- Piston and Crankshaft Assembly
  135
- 500Ev Cylinders / Cylinder Head
  136
- 500Ev Liquid-Cooled Engine
  136
- 500Ev Recoil / Magneto
  137
- 500Ev Pistons / Crankshaft
  138
- 500Ev Crankcase
  139
- 500Ev Water / Oil Pump
  140
Chapter 6 Drive and Brake Systems

142
- 7.92 C.D. Chaincase Jackshaft RPM / MPH
  143
- Gear Ratio Tables
  143
- Drive Gears
  146
- Drive Gears and Chains
  146
- 7.92 C.D. Assembly Notes
  147
- 7.92 C.D. Chaincase
  147
- 7.92 C.D. Fastener Torque
  147
- Assembly View
  147
- Chaincase Installation
  148
- Chaincase Removal
  148
- Assembly View
  150
- Driveshaft / Jackshaft Fastener Torque
  150
- Driveshaft and Jackshaft
  150
- Seal Sleeve / O Ring Installation
  150
- Driveshaft Removal/Installation
  151
- Jackshaft Installation
  151
- Jackshaft Removal
  151
- Removal
  152
- Widetrak Gearcase
  152
- Inspection
  153
- Input Shaft Inspection
  155
- Low / Reverse Shaft Inspection
  155
- Output Shaft Inspection
  156
- Shift Drum Inspection
  156
- Gearcase Assembly
  157
- Gearcase Installation
  157
- Compensating Port
  159
- Hydraulic Brake System
  159
- Overview
  159
- Warnings and Cautions
  160
- Brake Fluid Replacement & Bleeding
  161
- Brake Hose Replacement
  162
- Brake Light Switch Replacement
  162
- Brake Caliper
  163
- Brake Caliper Piston and Seal Replacement
  163
- Brake Pad Replacement
  163
- Caliper Removal / Installation
  163
- Brake Disc Replacement
  164
Chapter 7 Pvt System

166
- Clutch Weight
  167
- Drive Spring
  167
- Driven Spring
  167
- Engagement Rpm
  167
- Neutral Speed
  167
- Overview
  167
- Pvt System
  167
- Shift out Over-Rev
  167
- Shift out Rpm
  167
- 1:1 Shift Ratio
  168
- Back-Shifting
  168
- Driven Helix / Ramp
  168
- Final Gearing
  168
- Low / High Ratio
  168
- Pvt System Fastener Torques
  168
- General Information
  169
- Clutch Alignment / Offset
  181
- Offset/Float Adjustment
  181
- Pvt System Adjustments
  181
- Drive Clutch
  182
- Drive Clutch Removal
  182
- Identification
  182
- Drive Clutch Disassembly
  183
- Roller Installation
  184
- Roller Removal
  184
- Spider Button Installation
  184
- Cover Bushing
  185
- Clutch Assembly
  186
- Belt-To-Sheave Clearance Adjustment
  187
- Spider Indexing
  187
- Drive Clutch Installation
  188
- Driven Clutch
  189
- Driven Clutch Installation
  189
- Driven Clutch Removal
  189
- Team Lwt Components
  190
- Widetrak Driven Clutch Components
  191
- Polaris P2 Driven Clutch Components
  192
- Polaris Spa-P2 Driven Clutch Components
  194
Chapter 8 Steering and Suspension Systems

196
- Edge 42.5
  197
- Front Suspension Torque & Specifications
  197
- Edge 41
  198
- Widetrak
  199
- Camber / Toe Specifications
  200
- Inspection
  200
- Overview / Specifications
  200
- Springs
  200
- Adjustable Shocks
  201
- Front Suspension / Steering
  201
- Setup and Adjustments
  201
- Camber
  202
- Front Suspension Alignment Bar
  202
- Handlebar Centering
  203
- Rod End Engagement
  203
- Camber Adjustment
  204
- Maximum Width Adjustment
  204
- Operation
  205
- Rear Suspension
  205
- Toe Adjustment
  205
- Weight Transfer
  205
- Rear Torsion Spring Tension Adjustment
  206
- Suspension Coupling
  206
- Edge Shock Rods
  207
- Rear Track Shock Control Rods
  207
- Adjustment Procedures
  208
- Rear Suspension Adjustments
  208
- Setting the Rear Suspension Ride Height
  208
- Front Torque Arm Limiter Strap Adjustment
  209
- Scissor Stop Adjustments
  209
- Torsion Spring Adjustment
  209
- Widetrak Ski Pressure Adjuster
  210
- Widetrak Torsion Spring Adjustments
  210
- Rear Suspension Assembly Illustrations
  211
- Rebuildable Shocks
  225
- Shock Rebuilding Tools
  225
- Ryde Fx™ Shock Valve Part Numbers
  226
- Piston Orientation
  227
- Valve Shim Arrangement
  227
- Rebuildable Ifs Shock Specifications
  228
- Shock Valve Shim Stack Configurations
  228
- Front Track Shock (Fts) Valving
  229
- Rebuildable Front Track Shock Specifications
  229
- Ryde Fx Mono-Tube Shock Disassembly
  230
- Ryde Fx Mono-Tube Shock Assembly
  231
- Suspension Set-Up
  232
- Troubleshooting
  232
Chapter 9 Chassis

234
- Bumper
  235
- Edge Front Bumper Removal/Installation
  235
- Edge Instrument Removal/Installation
  235
- Hood Assembly
  235
- Hood Removal/Installation
  235
- Hood Repair
  235
- Edge Fuel Tank Removal/Installation
  236
- Edge Headlight Removal/Installation
  236
- Headlight
  236
- Rear Bumper Removal/Installation
  236
- Seat & Base Removal/Installation
  236
- Seat and Fuel Tank
  236
- Seats
  236
- Console
  237
- Console Removal/Installation
  237
- Edge Tail Light Assembly Replacement
  237
- Seat Cover Replacement
  237
- Tail Light
  237
- Tail Light Assembly Replacement
  237
Chapter 10 Battery and Electrical Systems

238
- Battery and Electrical Systems
  239
- Battery Preparation
  239
- Charging System
  239
- Conventional Battery
  239
- Engine Models
  239
- Ignition Timing
  239
- Spark Plugs
  239
- Specifications
  239
- Battery Preparation
  240
- Battery Testing
  240
- Fresh Pack Battery
  240
- Load Test
  240
- Open Circuit Voltage Test (Ocv)
  240
- Refilling a Conventional Battery
  240
- Specifications
  240
- Testing Procedures
  240
- Battery Conductance Analyzer
  241
- Specific Gravity Test (Conventional Battery)
  241
- Off Season Storage
  242
- Ignition Timing
  243
- Timing Procedure - Carbureted Engines
  243
- Ignition Timing Chart
  244
- Throttle Position Sensor (Tps)
  245
- Tps Test Tool Setup
  245
- Using the Tps Test Tool
  245
- Tps Adjustment - Carbureted Models
  246
- Electric Start - Gen II / Edge
  247
- System Schematic
  247
- Starter Motor Assembly (Typical)
  248
- Battery Box
  249
- Dynamic Testing
  250
- Armature Testing
  251
- Starter Housing / Field Coil Testing
  251
- Carbureted Electrical Systems
  252
- No Spark
  253
- Troubleshooting Tables
  253
- Altitude Setting
  254
- Electronic Reverse (Perc)
  254
- Forward Operation
  254
- Important Notes
  254
- Operation
  254
- Hand/Thumb Warmers
  255
- Thumb Warmer Diagnostics
  255
- Thumb Warmer Resistance Checks
  255
- Hand Warmer Diagnostics
  256
- Hand Warmer Resistance Checks
  256
- Left Hand Control
  257
- Left Hand Control Continuity Checks
  257
- Left Hand Control Diagnostics
  257
- Left Hand Control Power Input/Output Check
  257

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