Polaris Supersport 2007 Offroad Vehicle Manuals

Manuals and User Guides for Polaris Supersport 2007 Offroad Vehicle. We have 2 Polaris Supersport 2007 Offroad Vehicle manuals available for free PDF download: Service Manual, Owner's Manual

Polaris Supersport 2007 Service Manual (266 pages)

2007-2012 EDGE/WIDETRAK LX SNOWMOBILE

Brand: Polaris | Category: Offroad Vehicle | Size: 8 MB

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

Polaris Supersport 2007 Owner's Manual (148 pages)

Polaris 2007 Snowmobile Owner's Manual

Brand: Polaris | Category: Offroad Vehicle | Size: 2 MB

Table of Contents

6
- Introduction
  7
- Vehicle Identification Numbers
  7
- Safety
  9
  - Operator Safety
    9
  - Riding Position
    12
  - Riding Apparel
    12
  - Survival Preparation
    13
  - Disabled Operators
    14
  - Rider Capacity
    14
  - Excessive Speed
    14
  - Driver Awareness
    15
  - Driving on Slippery Surfaces
    17
  - Ice and Snow Build-Up
    17
  - Driving Downhill
    18
  - Driving in Hilly Terrain
    19
  - Cold Weather Drive-Away
    19
  - Intake Silencer
    20
  - Clutch Guard
    20
  - Drive Belt
    20
  - Inadequate Snow Conditions
    21
  - Driving Responsibly
    22
  - Clutch Cover Warning
    24
  - Airbox Warning
    24
  - Pressure Cap Warning
    24
  - Safety Decals and Locations
    24
  - Track Warning
    25
  - "No Passenger" Warning
    25
  - Reverse Warning
    26
  - Safety Decals and Locations
    27
  - Operation Warning
    27
- Features
  28
  - Ifs Components
    31
  - Ifs Adjustment Options
    31
- The Perfect Fit
  31
  - Front Suspension Adjustments
    31
  - Shock Components
    32
  - Indy Select Shock
    33
  - Shock Damping
    33
  - Front Springs
    33
  - Front Suspension Adjustments
    34
  - Spring Preload
    34
  - Rear Suspension Adjustments
    35
  - Suspension Performance Tips
    36
  - Track Tension
    36
  - Torsion Spring Tension
    38
  - Suspension Coupling
    40
  - Weight Transfer During Acceleration
    42
  - Handlebar Adjustments
    43
  - Handlebar Angle
    43
  - Traction Products
    45
  - Wear Strips
    47
Pre-Ride Inspections Pre-Ride Checklist

48
- Pre-Ride Checklist
  
  48
  - Pre-Ride Inspections
    48
    
    Item See Page
    48
    
    Before Starting the Engine
    49
    
    Brake Lever Travel
    50
    
    Parking Brake Lever Lock
    51
    
    Start the Engine and Check
    55
    
    Starting the Engine
    56
  - Operation
    56
    
    Engine Break-In
    57
    
    Slide Rail and Track Cooling
    58
    
    Oil Injection System
    58
    
    Oil Recommendations
    58
    
    Track Warm-Up
    59
    
    Fuel Valve
    60
    
    Premium Fuel Switch
    61
    
    Fuel System Deicers
    62
    
    Low Oil Indicator Light
    63
    
    Jetting Guidelines
    65
    
    Engine Stop Switch
    66
    
    Emergency Stopping
    68
    
    Emergency Starting
    69
    
    Mechanical Reverse
    70
    
    Reverse Operation
    70
    
    Altitude Setting
    72
    
    Daily Storage
    73
    
    Emission Control Information
    75
  - Maintenance
    75
    
    Emission Control Label
    75
    
    Polaris Recommended Maintenance Program
    77
- Item See Page
  
  78
  - Coolant Level
    78
  - Drive Belt Condition
    78
  - Recoil Rope
    78
  - Ignition Switch
    79
  - Taillight/Brakelight/Headlight
    79
  - Hood Straps/Latches
    80
  - Rear Wheel Idler Bolts
    80
  - Skags (Wear Bars)
    80
  - Ski Saddle and Spindle Bolts
    80
  - Suspension Mounting Bolts
    80
  - Tether Switch/Strap
    80
    
    Suspension and Steering
    81
    
    Driveshaft Bearing
    83
    
    Jackshaft Bearing
    83
    
    Choke and Choke Cable
    84
    
    Throttle Cable
    84
    
    Oil Check
    85
    
    Spark Plugs
    86
    
    Spark Plug Removal and Replacement
    87
    
    Intake Filters
    88
    
    Oil Filter
    89
    
    Water/Sediment Trap Service
    90
    
    Carburetor Adjustments
    91
    
    Exhaust System
    92
    
    Cooling System
    93
    
    Cooling System Coolant
    94
    
    Flushing the Cooling System
    95
    
    Bleeding the Cooling System
    96
    
    Drive Chain Tension
    97
    
    Brake Components
    98
    
    Brake Fluid
    99
    
    Bleeding the Hydraulic Brake System
    100
    
    Headlight Adjustment
    101
    
    Headlight Bulb Installation
    102
    
    Headlight Bulb Removal
    102
    
    Taillight/Brakelight Replacement
    102
    
    Clutch System
    103
    
    Clutch Alignment Offset
    104
    
    Clutch Center Distance
    104
    
    Drive Belt Removal
    106
    
    Drive Belt Installation
    107
    
    Drive Belt Adjustment
    108
    
    Drive Belt Deflection
    108
    
    Reverse Kit Maintenance
    109
    
    Torque Stop
    109
    
    Chain Tension
    110
    
    Tool Kit
    110
    
    Track Inspection
    111
    
    Track Lubrication
    112
    
    Track Tension
    113
  - Track Alignment/Condition
    115
    
    Steering Inspection and Adjustment
    116
    
    Steering System
    116
    
    Ski Alignment
    117
    
    Skag Replacement
    118
    
    Ski Skags
    118
    
    Pre-Ride Suspension Inspection
    119
  - Rail Slide Condition
    119
    
    Rail Slide Wear
    119
    
    Suspension Maintenance
    119
    
    Cleaning and Preservation
    120
    
    Controls and Linkage
    120
    
    Extended Storage
    120
    
    Clutch and Drive System
    121
    
    Engine and Carburetor Protection
    122
    
    Electrical Connections
    123
    
    Track and Suspension
    123
    
    Transporting the Snowmobile
    123
    
    Battery Fluid
    124
    
    Battery Connections
    125
    
    Battery Removal
    125
    
    Battery Installation
    126
    
    Battery Storage
    127
  - Polaris Products
    128
  - Troubleshooting
    129
    
    Engine Troubleshooting
    129
    
    Drive Belt Troubleshooting
    133
    
    Service and Warranty Information
    134
  - Warranty
    134
    
    Limited Warranty
    136
    
    Engine Oil
    137
    
    Limitations of Warranties and Remedies
    137
    
    How to Obtain Warranty Service
    137
    
    Conditions and Exclusions
    138
  - Maintenance Log
    145
  - Index
    147

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Polaris Supersport 2007 Offroad Vehicle Manuals

Polaris Supersport 2007 Service Manual (266 pages)

Table of Contents

Table of Contents

Chapter 2 General Information 2

Chapter 3 Maintenance

Chapter 4 Fuel System

Chapter 5 Engine Systems

Chapter 6 Drive and Brake Systems

Chapter 7 Pvt System

Chapter 8 Steering and Suspension Systems

Chapter 9 Chassis

Chapter 10 Battery and Electrical Systems

Polaris Supersport 2007 Owner's Manual (148 pages)

Table of Contents

Table of Contents

Pre-Ride Inspections Pre-Ride Checklist

Pre-Ride Checklist

Item See Page

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