2007-2011 IQ Service Manual Chapter 03
Contents
1. 2010 Polaris Sales Inc Maintenance BREAK IN PROCEDURES Engine Break In Procedure The first tank of fuel is considered the break in period for the engine During this time it is critical to not operate the engine at full throttle for more than a few seconds Vary the throttle speed as much as possible Monitor engine temperatures and fluid levels often during the break in period NOTE During the engine break in period verify the oil injection system is functioning by monitoring the oil level in the oil tank If the oil level does not drop inspect the oil injection system Polaris recommends filling the oil tank and pre mixing the first full tank of fuel with Premium 2 Cycle Semi Synthetic Oil when the engine is either new or refurbished new pistons crankshaft cylinder s etc Polaris semi synthetic engine oil will seat the rings faster than when using Polaris VES Gold Plus oil After the break in period use Polaris VES Gold Plus engine oil for normal operation Fuel Oil Premix Ratio During the break in period premix the first tank a fuel 10 US gallons using a 40 1 fuel oil ratio Formula 1 US Gallon 1280z 40 Desired Ratio 3 20z for every 1 US gallon of fuel 10 US gallons of fuel requires 320z of oil to achieve a 40 1 premix ratio Always mix fuel and oil 5 gallons at a time Never fill the tank with fuel and then add oil Drive Belt Break In Procedure The break in period for a new dri2. ARK NOTE Before adjusting oil pump always verify the throttle lever free play and idle speed RPM are set to specification 1 Verify the oil pump MAX OIL FLOW in line marker is aligned with the oil pump body mark at WOT Wide Open Throttle Lever adjustment is accomplished by loosening the two oil pump cable jam nuts then moving the threaded barrel up or down until the two marker lines are aligned at WOT Apply Loctite 262 to barrel threads and secure jam nuts when adjustment is set Oil Pump Bleeding 550 Engines 1 The oil pumps on IQ 550s feature an air bleed hose conencting the oil pump with the oil tank Verify the presence of oil in the bleed hose and air bubbles migrating up to the oil tank while the engine is running NOTE Any time that the engine is disassembled or repaired it is important to purge air within the hoses and oil pump TERRAIN DOMINATION gt POLARIS Oil Pump Adjustment Carbureted Models NOTE Before adjusting oil pump always verify the throttle lever free play and idle speed RPM are set to specification T Always verify the throttle cable free play is set to specification 010 030 NOTE The oil pump lever arm line mark MUST be aligned with the oil pump boss index mark at the exact moment when the throttle slides begin to lift from the idle position 2 Remove the air box drive belt drive clutch and driven clutch from the engine compartment
3. applicable when installing a new torque stop position bumper so the tip is just touching crankcase TERRAIN DOMINATION gt POLARIS Maintenance Engine Isolator Limiter Setting Some models use an engine mount strap isolator The isolator is located on left front corner ofthe bulkhead The isolator should not make contact with the engine strap Ifthe isolator requires adjustment or replacement hold the isolator so it is against the bracket then torque the nut to specification NOTE Do not adjust this engine isolator limiter as a torque stop or damage may occur The approximate distance from the face of the isolator to the face of the engine strap is 0 107 2 72mm BRACKET ISOLATOR AGAINST BRACKET E T Jam Nut 15 17 ft lb 21 24 Nm TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual lt gt POLARIS 2010 Polaris Sales Inc 3 7 Maintenance ENGINE MAINTENANCE Exhaust Valve Cleaning The exhaust valve guillotines must be cleaned to ensure maximum engine performance and throttle response FASTENERS A EV ASSEMBLY 1 Remove the vent hose from the EV base fittings 2 Remove the two fasteners that secure the valve assembly to the cylinder Remove the cover after the assembly is removed from the engine 3 Using a clean rag or shop towel remove the oil residue from the cylinder guillotine and EV base 4 Inspection Inspect the
4. guillotine for signs of damage Replace guillotine if damage is found Inspect the cylinder and piston for damage if guillotine is damaged Inspect the spring Replace if rusted damaged or bent Inspect bellows Replace if damaged or excessively worn Submerse the assembly in parts cleaner Thoroughly flush the EV housing base bellows and mating surfaces Verify no carbon is in the gas transfer ports 3 8 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Clean the guillotine with brake cleaner and a piece of fine steel wool Clean only to remove hardened carbon deposits Once clean rinse blade with mild detergent and water Dry completely Install a new gasket then reinstall the EV assembly Apply Loctite 242 to the fastener threads then torque to specification TERRAIN DOMINATION gt POLARIS Maintenance NOTE Always install a new EV base gasket Never re use the gasket or modify a new gasket E T Exhaust Valve Housing Fasteners 12 Ft Lbs 16 Nm Apply Loctite 242 7 Reconnect the vent hoses Exhaust Valve Springs CAUTION Do not substitute different color springs on solenoid controlled EV engines SPRING COLOR FREE LENGTH INCHES NOTE To obtain maximum exhaust valve 7041704 01 Blue 1 752 e a S a lores LE Never mix different brands of engine oil 704
5. required 8 Reinstall the pressure cap to one click only 9 Disconnect the radiator fan power connector 10 Verify the transmission is in neutral N and start the engine in a well ventilated area 11 Monitor the engine coolant temperature on the MFD Push the MODE SET switch up once to access the engine temperature display 3 12 12 13 14 15 16 17 18 19 20 21 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Refill the coolant reservoir as required to the 3 4 level while allowing the engine to warm up to 120 F 50_C Increase engine RPM to 4000 intermittently 1 to 2 seconds for step 14 Pinch off the coolant hose connecting the bypass fitting to the brake caliper Use a soft jawed pliers to prevent hose damage This step will assist in removing air from the rear coolers Close the thermostat housing bleed screw when a steady stream of coolant is evident Remove the pliers from the hose when the tunnel coolers become warm to the touch Reconnect the radiator fan motor harness Shut off the engine and allow it to cool for several hours while keeping the front of the vehicle elevated Lower the vehicle to the ground Fill the coolant recovery bottle to the COLD FILL line Monitor the coolant levels during operation and add coolant if necessary TERRAIN DOMINATION gt POLARIS Maintenance Oil Pump Adjustment 550 Engines IL
6. that is attached to the carburetors and adjust the throttle free play by 3 24 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc CAUTION When adjusting throttle lever free play always verify the engine RPM does not rise with bars in the full low and full up right Rider Select positions if applicable and while turning the handlebars to the full left and full right positions ax NN Fi In mm Throttle Lever Free Play 0 010 0 030 25 8mm The inline adjuster should only be used to set free play and to remove cable slack that occurs if the cable has stretched over time ADJUSTER LOCK NUT NOTE Never use the in line adjuster to adjust engine idle speed and never adjust the cable so that TERRAIN DOMINAT gt POLARIS the throttle plate cam on the throttle body no longer rests against the idle air gap screw Turning the in line adjuster inwards clockwise will increase throttle lever free play Turning the in line adjuster outwards counter clockwise will decrease throttle lever free play After setting the throttle lever free play always verify the oil pump adjustment is set correctly Choke Adjustment 1 Flip the choke toggle to the OFF position 2 Loosen locknuts 1 on the carburetor 3 Turn sleeve adjusting nut 2 counter clockwise until the choke toggle shows no free play when pulled then rotate it clockwise until there is between
7. the parking brake or have an assistant hold the brake lever 2 Loosen the adjuster bolt jam nut 1 An Mann memo ges 3 Finger tighten the adjuster bolt 2 until it con no longer 3 Add the recommended oil as needed at the fill plug peraiusted by hand MER BACK YET Do riar ovarii 4 Tighten the jam nut while holding the adjuster bolt torque to 21 ft lbs 28 Nm 5 Release the brake lever lock A p lt gt POLARIS 9922854 2007 2011 IQ Service Manual 3 21 2010 Polaris Sales Inc Maintenance BRAKE SYSTEM MAINTENANCE Brake Lever Travel 1 2 1 27cm y PA The gap between the brake lever and handlebar grip should be equal to or more than 1 2 1 27cm when depressing the brake lever If the gap is less than 1 2 1 27cm the brake system should be inspected and bled of any air within the fluid Brake Fluid A WARNING Do not over fill the master cylinder Fluid expansion could cause brakes to lock resulting in serious injury or death Once a bottle of brake fluid is opened use what is necessary and discard the rest Do not store or use a partial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air This causes the boiling temperature of the brake fluid to drop leading to early brake fade and the possibility of serious injury Inspect the reservoir to be sure it contains the correct amount of fluid U
8. the pressure cap 3 Open the thermostat housing bleed screw Wrap a clean shop towel around the housing to absorb any coolant that may flow out of the bleed screw 4 Elevate the front of the machine slightly 5 Apply the parking brake and start the engine 6 Allow the engine idle time to stabilize 7 Immediately add coolant to the surge tank if the coolant level dropped significantly after the engine started Watch the level and add more coolant until the level stops dropping NOTE Squeeze the coolant hoses to purge air from the cooling system 8 Secure the pressure cap and bleed screw after the thermostat begins to open and coolant begins to flow out of the bleed screw 9 Verify the tunnel coolers begin to warm up as the engine continues to run TERRAIN DOMINATION gt POLARIS 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 10 To remove air from the tunnel cooling system the vehicle should be pivoted upwards in four directions nose up left side up rear bumper up and right side up to move any air pockets in the system to the surge tank 11 Verify that all of the coolers are warm including the tunnel length cooling system Turn off the engine once the tunnel coolers are sufficiently warmed up Release the parking brake CAUTION Always verify all tunnel coolers radiator are warm to the touch A tunnel cooler or return hose that is significantly colder than ano
9. turn the ignition off Inspect track alignment by carefully looking through the track window B to make sure the rails C are evenly spaced on each side If the track runs to the left loosen the left locknut and tighten the left adjusting bolt D If the track runs to the right loosen the right locknut and tighten the right adjusting bolt It may be necessary to check this with the engine rotating the track Be sure to SHUT THE MACHINE OFF before making any further adjustments 8 Loosen the rear idler shaft F 9 After any adjustments are complete be sure to torque the locknuts E to 35 ft lb 48 N m Adjuster Lock Nuts 35 ft lb 48 N m 10 Torque both idler shaft bolts F to 35 ft lb 48 N m e T Idler Shaft Bolt 35 Ft Lbs 48 Nm A WARNING Broken track rods can cause a rotating track to come off the machine Never operate or rotate a damaged track under power with a broken rod Serious injury or death may occur Stay clear of all moving parts to avoid personal injury Never make any adjustments with the engine running as serious personal injury can result TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual gt POLARIS 2010 Polaris Sales Inc Maintenance ELECTRICAL SYSTEMS Headlight Bulb Replacement NOTE Do not touch the bulb with your fingers The grease from body oil will cause a hot spot on the bulb and cause bulb failure If you do to
10. 1 8 1 4in 3 2 6 4mm free play 3 NOTE Verify the cable does not lift the plungers when checking the free play TERRAIN DOMINATION E gt POLARIS Maintenance 4 Tighten adjustment locknut 2 STEERING SUSPENSION MAINTENANCE Handlebars Periodically inspect the torque of the handlebar clamp fasteners STEERING POST 1 To adjust the handlebar angle remove the handlebar cover to expose the clamp 2 Loosen the four clamp fasteners Slightly pry the upper clamp up with a flat blade screwdriver 3 Adjust handlebars to desired position Verify the wiring harness brake hose and throttle cable do not kink 4 Secure the front clamp fasteners first to specification Finish by securing the two rear clamp fasteners to the same torque setting E T Handlebar Clamp Fastener Torque 16 Ft Lbs 21 Nm 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 5 If equipped reinstall the handlebar cover 3 25 Maintenance Rider Select Steering U Joint Ski Ski Skag Fasteners Periodically inspect the ski to spindle fasteners for proper torque WASHERS PROVIDED FOR BLOW MOLDED SKIS APPLY FOGGING OIL The rider select steering U joint should be lubricated with Polaris fogging oil PN 2870791 Ski to Spindle Fastener Torque 36 Ft Lbs 49 Nm Inspect ski skags and skag fasteners for abnormal wear and tear Re
11. 1704 03 Pink 1 734 Exhaust Valve Assembly 7041704 04 Purple 1 726 gt 7041704 05 Yellow 1 734 s 7041704 06 White 1 537 e A EV Cap B Spring e C Cap Nut e D Bellows e E Spacer e F EV Base G Gasket e H Guillotine POLARIS e ge dd Maintenance Spark Plugs Inspect replace the spark plugs as outlined in the periodic maintenance table The spark plugs can be serviced by opening the left and right door panels Replace a spark plug when the following occurs e Spark plug is damaged insulator is cracked or missing e Plug electrode insulator is fouled e Replace at interval in maintenance table When inspecting a spark plug take note of the electrode and insulator color A light brown dark tan color indicates the engine is running properly If the spark plug electrode insulator is white the engine may be running lean Inspect the engine throttle body boots etc for air leaks Ifthe spark plug electrode insulator is black oily or shows heavy soot the engine may be running rich Inspect the engine fuel system and lubrication system for problems Set the electrode gap to specification before installing a new spark plug pi h K n mm Spark Plug Gap 027 70mm E T Spark Plug Torque 18 21 6 Ft Lbs 24 30 Nm Apply anti seize to threads 3 10 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Spark Plug Caps Spark Plug Terminals In
12. E The rollover check valve is not serviceable When inspecting the system verify the hose is not kinked TERRAIN DOMINATION gt POLARIS Air Intake Box Pre Filters Inspect the inside of the air intake box and pre filters for foreign material and or damage ONE PIECE CFI AIR BOX ADAPTOR NOTE All 2007 and some 2008 CFI models were manufactured with a two piece airbox where an adapter plate was secured to the throttle body The airbox then snapped into the adapter plate to make the airbox assembly The two piece air box is no longer available A one piece air box is the direct replacement The new air box features adaptor boots that are pinned to the air box A set of gear clamps secure the boots to the throttle body assembly Inspect the console mounted pre filters for damage and foreign material Replace filter s or clean if required 3 19 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Maintenance CHASSIS LUBRICATION M 10 136 Chassis suspension and mechanical grease points should be lubricated Polaris Premium All Season Grease gt 0 Polaris Premium All Season Grease Part Numbers 30z Grease Gun Kit 2871312 140z Tube 2871423 Rear Suspension Lubricate grease zerks with Premium All Season Grease IQ 121 136 Coupled 136 Comfort IQ 121 Shown Driveshaft Bearing Lubricate wi
13. G FASTENERS 000000 c cece eee 3 26 TRACK TENSION od oes Se Ga ee ae ee ks 3 27 TRACK ALIGNMENT 00000 has eee cee Mite eels ha Va ete he ee Ad en 3 28 ELEGTRICAL SYSTEMS cera eh eid oP e a 3 29 HEADLIGHT BULB REPLACEMENT 2 0 0000000002000 3 29 MED SERVICE INTERVAL erminig siter ci imdietwd is ee eed 3 29 FUNCTION peizan an cta ll shane ale o ate iat ita Te 3 29 OFF SEASON STORAGE ets aie dt deere ex 3 30 n DOMINATION 9922854 2007 2011 IQ Service Manual lt gt POLARIS 2010 Polaris Sales Inc 3 1 Maintenance PERIODIC MAINTENANCE Periodic Maintenance Schedule Periodic Maintenance Table ltem Frequency 150 mi 240 km 500 mi 800 km 1000 mi 1600 km 2000 mi 3200 km Pre Season Drive Driven Clutch Clutch Alignment Offset Drive Belt Condition Drive Driven Clutch Condition Drive Belt Tension Clutch Sheaves Engine Engine Mounts Recoil Handle Rope Function Engine Torque Stop Engine Isolator Cylinder Head Bolts Cylinder Base Nuts Ignition Timing Spark Plug Condition Exhaust System Retaining Springs VES Valves Solenoid I C I C Cooling System Hoses Coolant Level Heat Exchangers Oil Filter Brake System Hose Condition Routing Fluid Level Leaks Fluid Condition Brake Pads Brake Disc Parking Brake Brake Fluid Fuel System Idle RPM CFI Fuel Filter Replac
14. Lever Free Play Non CFI adjusting the barrel nut E and lock nuts F 4 Once you achieve the proper free play of 0 010 0 030 25 80mm tighten the lock nuts 5 Verify the oil specification pump index marks are within 6 Check the idle RPM and verify it is within the specified range NOTE If the idle speed screw is adjusted inward and the cable sleeve is not adjusted to take up the throttle lever clearance the engine may misfire or kill upon initial throttle opening Throttle Lever Free Play CFI Models Ly ae In mm Throttle Lever Free Play 0 010 0 030 25 8mm CAUTION When adjusting throttle lever free play always verify the engine RPM does not rise with bars in the full low and full up right Rider Select positions if applicable and while turning the handlebars to the full left and full right positions Throttle lever free play must always be at a specified clearance A 0 010 0 030 0 25 0 80 mm between the throttle lever B and the throttle block C This clearance is controlled by the throttle cable D If adjustment is needed follow these steps CAUTION After any idle speed adjustments are made the throttle lever clearance and the oil pump adjustment must be checked and adjusted 1 Check the idle RPM and verify it is within the specified range 2 Shut off engine 3 Locate the throttle cable
15. MENT 550 ENGINES 0 00 0 0 00000 0005 3 13 OIL PUMP BLEEDING 550 ENGINES 0 0 000 000 0000 005 3 13 OIL PUMP ADJUSTMENT CARBURETED MODELS 3 13 OIL PUMP ADJUSTMENT CFIMODELS 0 0 0000000005 3 14 Ol PUMP BLEEDING vrscig once shail ta Beane need Spade Secale 3 16 600 IQ WIDETRAK SELF BLEEDING OIL TANK 0 00 0 0 05 3 16 FUEL JINTAKESYSTEM 2 sce cdg pre pad bm r sa ds EN eee eee 3 17 CHASSIS LUBRICATION Les Sie 20 bles o Bh aan E BAe eee Bek 3 20 REAR SUSPENSI N piae siaaa od di cetacean dts 3 20 DRIVESHAFT BEARING 0 000000000 cece eee 3 20 THROTTLE GABLES ete ct it nece a o re ORE OG ae eek 3 21 CHOKE AND CHOKE CABLE 000 000 c eee 3 21 CHAINCASE OIL LEVEL CHECK 0 0 000 000 02 c eee eee eee 3 21 CHAINCASE OIL REPLACEMENT 0 00002 e eee eee eee 3 21 DRIVE CHAIN TENSION ADJUSTMENT 0 0 000000002 e eee ee 3 21 BRAKE SYSTEM MAINTENANCE 0 0 2 cee eee eee 3 22 BRAKE LEVER TRAVEL siii taeda ida Gas bie lee a eto ate Soa Biel ai ake 3 22 BRAKEELUID ico 2 io Sep tle oa bad ih bast ik aM a a cence rane de odas 3 22 THROTTLE AND CHOKE CABLE ADJUSTMENTS 000000 e eee eee 3 22 STEERING SUSPENSION MAINTENANCE 0 00000 e eee ee eee 3 25 HANDLEBARS o Tenen eu ids Se cet Sh kaa teal DE etek eee ta ee ie 3 25 RIDER SELECT STEERING U JOINT ooo 3 26 SKI SKI SKA
16. Maintenance CHAPTER 3 Maintenance PERIODIC MAINTENANCE Sine a heed wade s a a ews 3 2 PERIODIC MAINTENANCE SCHEDULE 0 0 000000000000 0005 3 2 MAINTENANCE PRODUCTS us nara eden dt eeu edited A we een tee 3 4 ENGINE OILS LUBRICANTS MISC 0 0 0000000000002 eee eee 3 4 BREAKIN PROCEDURES jean naea Us be sierra o E ee ela dae 3 5 ENGINE BREAK IN PROCEDURE 0 0 000000022 eee eee eee 3 5 FUEL OIL PREMIX RATIO inaran aiden ia Beet ge ty ke 3 5 DRIVE BELT BREAK IN PROCEDURE 0 0 00000000 e eee eae 3 5 DRIVE DRIVEN CLUTCHES usara tn as 3 5 BELT DEFLECTION INSPECTION 0 000000 eee eee eee 3 5 DEFLECTION ADJUSTMENT SPA P2 TEAM DRIVEN 3 6 TORQUE STOP ADJUSTMENT 0 000 000 c eee eee 3 6 ENGINE ISOLATOR LIMITER SETTING 0 0 00000 nnne 3 7 ENGINE MAINTENANCE fess dpa en hoe cok ty eee ee ee ae ae a eek Ste wt 3 8 EXHAUST VALVE CLEANING 0 000000 cece eee 3 8 EXHAUST VALVE SPRINGS 0 000 0002 e ee eee 3 9 SPARK PLUGS e022 see o dae eee ve ee Oe esd 3 10 SPARK PLUG CAPS SPARK PLUG TERMINALS 0 0 0005 3 10 SURGE TANK RECOVERY BOTTLE 0 000 002 ee eee eee eee 3 11 RECOMMENDED COOLANT 0 0 0 0022 e eee 3 11 COOLING SYSTEM BLEEDING 0 000 002 02 e eee eee 3 11 600 WIDETRAK IQ COOLING SYSTEM FILL AIR BLEED 3 12 OIL PUMP ADJUST
17. OTTLE CABLE LOCK NUT IDLE SPEED ADJUSTMENT SCREW 5 Secure the adjuster lock nut s 6 Slowly turn each idle speed screw inward until the tip begins to touch the throttle slide Remove the drill bit s 7 Set the throttle lever free play by loosening both carburetor adjuster lock nuts Turn each adjuster out equally until the throttle lever free play is set A gt Im mm 8 Secure the adjuster lock nuts TERRAIN DOMINATION gt POLARIS 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc NOTE If the idle speed screw is adjusted inward and the cable sleeve is not adjusted to take up the throttle lever clearance the engine may misfire or kill upon initial throttle opening Choke Lever Adjustment Mikuni VM 1 Flip the choke toggle to the OFF position 1 8 1 4 3 6 cm Freeplay CTT 2 Loosen choke cable lock nut s THROTTLE CABLE LOCK NUT IDLE SPEED ADJUSTMENT SCREW 3 Turn cable sleeve adjuster counterclockwise on the carburetor until choke toggle has zero free play then rotate it clockwise until 1 8 to 1 4 3 6 toggle free play is evident NOTE Verify the plunger does not lift when checking the free play Throttle Lever Free Play 010 030 25 80mm 4 Tighten adjustment lock nut 5 Repeat steps on the other carburetor 3 23 Maintenance Throttle
18. Pointer NOTE Some 2008 600 and 700 CFI engines were manufactured with model year 2007 oil pumps PNs 2520552 and 2520622 Always reference the oil pump adjustment chart to determine the oil pump lever setting based on the oil pump and not the engine model year All service parts will be the 28mm w Pointer oil pumps A CAUTION Failure to properly set the oil pump lever arm may cause severe engine damage 3 Remove the air box throttle body adapter plate drive belt drive clutch and driven clutch from the engine compartment 4 Remove the rear engine torque stop plate from the bulkhead the bulkhead TERRAIN DOMINATION gt POLARIS Remove the 2 left hand console mounting screws and electrical center cover piece Remove the rear 2 lower clutch guard mounting screws and 3 forward mounting nuts and plate Remove the 3 screws securing the lower clutch guard to the upper plate leaving the electrical center components in place Loosen and remove the throttle body assembly and set aside Using a mirror or a bore scope and a light visually inspect the current oil pump setting The oil pump lever and pump boss marks must be CAUTION observed straight on to yield accurate results 3 15 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Maintenance NOTE The oil pump jam nuts can be manipulated using the special tool set part number PS 49001 Oil Pump Ca
19. Rebuild or Replace C Clean gt POLARIS 9922854 2007 2011 IQ Service Manual 3 3 2010 Polaris Sales Inc Maintenance MAINTENANCE PRODUCTS PRODUCTS DESCRIPTION PART NUMBER Engine Oils Lubricants Misc Premium All Season Grease 30z Grease Gun Kit 2871312 DESCRIPTION PART NUMBER 14oz Tube 2871423 Premium 2 Cycle Semi Synthetic Oil la dida Non Variable Exhaust Engines Carbon Clean Plus 2871326 Quart 2875035 Gallon 2875036 Isopropyl 2870505 2 5 Gallon 2875038 Fuel Stabilizer 16 Gallon 2875037 Quart 2870652 55 Gallon 2875039 2 5 Gallon 2872280 330 Gallon 2875040 Three Bond Sealant 50z 2871557 VES Gold Plus 2 Cycle Oil All Variable Exhaust Engines SANS ARIAS Quart 2877882 Gallon 2877883 2 5 Gallon 2877884 16 Gallon 2877885 55 Gallon 2877886 330 Gallon 2877892 Liter 2877887 4 Liter 2877888 25 Liter 2877889 208 Liter 2877890 PS 4 4 Cycle 2W 50 Oil Quart 2876244 Gallon 2876245 16 Gallon 2876247 55 Gallon 2876246 Synthetic Chaincase Lubricant Quart 2873105 Gallon 2873106 2 5 Gallon 2872952 Antifreeze 60 40 Premix Quart 2871534 Gallon 2871323 55 Gallon 2872278 Shock Oil 5W Walker Evans 2874522 Shock Oil 5W Fox Quart 2870995 Gallon 2872279 Shock Oil 5W Ryde FX Arvin 2873716 Brake Fluid DOT 4 2872189 Fogging Oil Aerosol 2870791 Quart 2871517 3 4 9922854 2007 2011 IQ Service Manual gt POLARIS
20. Remove the rear engine torque stop plate from the bulkhead the bulkhead Remove the 2 left hand console mounting screws and electrical center cover piece Remove the rear 2 lower clutch guard mounting screws and 3 forward mounting nuts and plate Remove the 3 screws securing the lower clutch guard to the upper plate leaving the electrical center components in place Loosen and remove the throttle body assembly and set aside Using a mirror or a bore scope and a light visually inspect the current oil pump setting The oil pump lever and pump boss marks must be 4h CAUTION observed straight on to yield accurate results NOTE The oil pump jam nuts can be manipulated using the special tool set part number PS 49001 Oil Pump Cable Wrenches 9 10 If the oil pump lever requires adjustment or the cable is going to be replaced insert the two oil pump cable wrenches between the bulkhead and the rear of the engine If the oil pump lever requires adjustment or the cable is going to be replaced insert the two oil pump cable wrenches between the bulkhead and the rear of the engine 3 13 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Maintenance NOTE The wrench with the large opening is designed to fit around the cable sheath while the wrench with the small opening is designed to fit around the inner cable wire Y WRENCHES 11 When adjusting the lever make adjust
21. ant to purge air within the hoses and oil pump 600 IQ Widetrak Self Bleeding Oil Tank In addition to an oil pump air bleed the 600 IQ Widetrak features a self bleeding oil supply hose TO OIL pump A i FILTER ARROW TO PUMP amp GHECK VALVE VAC TOWARDS TANK amp IS S VENTED CAP Si b A AS LEVEL SENSOR TERRAIN DOMINATION gt POLARIS Maintenance FUEL INTAKE SYSTEM Water Sediment Trap A WARNING When draining the traps fuel spillage will occur Be sure to work in a well ventilated area away from anything which may cause the fuel to ignite such as an open flame heaters trouble lights or cigarettes Vehicles with carburetors incorporate a patented float bowl water sediment traps located at the bottom of each carburetor A os 1 Turn the fuel tank supply valve to the OFF position 2 Position a container or shop towels under the work area to help catch some of the contaminated gasoline 3 Slide the clamp A away from the drain plug B and remove it from the sediment tube and drain the contaminated material from the bowl Repeat for each carburetor 4 Wipe off the residue from the plug and reinstall the clamps TERRAIN DOMINATION gt POLARIS Fuel Filter Carbureted Models The in tank fuel filter and fuel lines should be inspected CAUTION regularly Special attention should be given to
22. ar engine strap a on y 2520552 Pump used on all 2007 600 CFls and Set lever line mark to 1 full line width 050 above original oil pump boss index some early build 2008 600 CFls mark Subs to 2520831 600 28mm w Pointer 2520831 Lever will clear engine strap Lever mark is a pointer Oil pump lever pointer is set POINTER TO LINE Pump phased in for 2008 600 CFls 700 33mm No Pointer Lever will not clear engine strap Set lever line mark set to 1 full line width 050 above original oil pump boss 2520622 Pumpusedonall 2007 700 CFls and index mark Some 2007 700 CFI models had a second line scribed above some early build 2008 700 CFls original pump boss mark and were marked with red paint Subs to 2520832 700 28mm w Pointer Lever will clear engine strap 2520832 Pump phased in Tor 2006 700 CFs Lever mark is a pointer Oil pump lever pointer is set POINTER TO LINE Service replacement pump for ALL 700 CFls 600 IQ Widetrak Oil Pump 2008 Early Build Engines Oil pump index mark boss is scribed with 2 lines 2520833 800 28mm w Pointer from the factory Oil pump lever pointer is set BETWEEN the 2 scribe lines Subs to 2520901 Late Build Engines Oil pump index mark boss features 1 scribe line Oil pump lever pointer is set POINTER TO LINE 2520901 800 28mm w Pointer rae Subs to 2521165 Oil pump index mark boss features 1 scribe line Oil pump lever pointer is set POINTER TO LINE 2521165 800A 28mm w
23. are secure by firmly pulling on the two hose connections Push the filter cartridge back into the bracket 4 To prime the fuel system after installing a new filter connect a 12 volt Vdc battery to the fuel pump prime plug See Diagnostic Plugs on page 11 18 3 18 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Oil Filter All models feature an inline oil filter located between the oil reservoir and oil pump Always bleed the oil supply hose and oil pump of air after replacing the filter Install the oil filter so that the directional arrow points towards the oil pump VENTED CAP OIL LEVEL SENDER TERRAIN DOMINATION gt POLARIS Maintenance Fuel Tank Vent System All models feature a fuel tank vent vacuum check valve system There are two systems used depending on the model year of the snowmobile On some models the vent vacuum check valve system resembles the illustration below When inspecting the system verify the hoses are not cut or kinked VENT CHECK VALVE ARROW POINTS AWAY FROM TANK REGIO Ces een dits Saeed siss S gt e SAY See EE gt VACUUM CHECK VALVE VAC FACES Y FITTING Some models feature a rollover check valve vent vacuum check valve assembly bonded to the inside of the fuel tank The rollover check valve prevents fuel from escaping the tank in the event of a vehicle rollover ROLLOVER VALV
24. ble Wrenches 10 If the oil pump lever requires adjustment or the cable is going to be replaced insert the two oil pump cable wrenches between the bulkhead and the rear of the engine NOTE The wrench with the large opening is designed to fit around the cable sheath while the wrench with the small opening is designed to fit around the inner cable wire Y WRENCHES 11 When adjusting the lever make adjustments in small increments then re check the timing mark alignment Reference the OIL PUMP ADJUSTMENT SETTING TABLE to verify where the oil pump lever is set in relation to the oil pump boss index mark 12 After setting the oil pump lever correctly apply a small drop of Loctite 242 to the cable barrel threads then secure the jam nuts 13 Re check the oil pump alignment marks after securing the jam nuts to verify the marks are set correctly 14 Re assemble the removed components in the reverse they were removed Reference the appropriate service manual chapter for component assembly fastener torques 3 16 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Oil Pump Bleeding 1 Verify oil tank is filled with oil 2 Loosen the bleed screw A Verify a stream of oil flows from the bleed screw 3 After bleeding oil pump secure bleed screw and wipe up oil residue NOTE Any time that the engine is disassembled or repaired it is import
25. e every 2 000 miles Carburetor Adjustments Throttle Lever Choke Lever L L Oil Pump Arm 3 2 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc TERRAS n DOMINATI Maintenance Periodic Maintenance Table Frequency Item 150 mi 500 mi 1000 mi 2000 mi 240 km 800km 1600km 3200 km Throttle Choke Cables L L L L Fuel Vent Hoses Oil Hoses Air Box Carburetor Drains Water Traps Pre Season Electrical System Auxiliary Shut Off Throttle Safety Switch Ignition Switch Headlights Brake light Taillights Hand Thumbwarmers l l Perc Reverse System Chassis Ski Toe Alignment Suspension Mounting Bolts Steering Fasteners Linkage Handlebars Driveshaft Jackshaft Bearings L L L L Ski Fasteners l High performance shocks should have oil changed and AI ea recharged at the end of every riding season Drive Chain Tension l l l l Chaincase Gearcase Oil l l l R Track Alignment Track Tension Rail Slide Condition Bogie Wheel Condition Fastener Bolts Hood Seat Chassis Engine Compartment C C L Lubricate Inspect or Adjust R
26. elt Deflection 1 25 3 2cm 5 Ifthe measurement is not correct adjust driven clutch Deflection Adjustment SPA P2 Team Driven 1 Verify the drive system is FWD drive by rotating the driven clutch forward 2 While holding the set screw with an Allen wrench loosen the jam nut 3 Turn the set screw clockwise while holding the jam nut stationary to increase the distance between the clutch sheaves increase belt deflection 4 Turn the set screw counter clockwise while holding the jam nut stationary to decrease the distance between the clutch sheaves decrease belt deflection 5 Secure the jam nut while holding the set screw stationary 6 Raise the rear of the snowmobile using a track stand to allow the track to spin 7 Start the engine and apply enough throttle to spin the track 8 Turn off then engine then re check the belt deflection NOTE Do not adjust the belt deflection to the point where the drive belt cord line is visible when the belt is seated in the driven clutch 3 6 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Torque Stop Adjustment GAP Set torque stop bumper gap to specification after aligning drive and driven clutches AS a In mm Torque Stop Bumper to Engine Gap 010 030 25 75mm After setting gap torque jam nut to specification e T Torque Stop Jam Nut 15 17 ft lb 21 24 Nm NOTE Where
27. er drive adaptor until grease purges out inside or outside the bearing seal Lubricate both front ski pivots at bushings and spindles Shocks Use T 9 Metal Protectant or equivalent on shock absorber shafts to help prevent corrosion Battery Disconnect and remove the battery Clean the terminals and cables Apply dielectric grease to the terminals Store in a cool dry place for storage TERRAIN DOMINATION gt POLARIS
28. ht at point A Point A is 16 41cm ahead of the rear idler shaft E 5 Measure the distance D between the rail slider and the track This measurement should fall with in the measurement range for the appropriate vehicle see chart o this page 6 If adjustment is needed loosen up the lock nuts B on each side 7 Loosen up the idler shaft bolts F gt POLARIS 9922854 2007 2011 IQ Service Manual 3 27 2010 Polaris Sales Inc Maintenance Track Alignment NOTE Track alignment affects track tension Misalignment of the track will cause excessive wear to the track rail slides and rail NOTE Excessive rail slide wear occurs due to running in inadequate snow conditions Periodically check that the track is centered and running evenly on the slide rails Misalignment will cause excessive wear to the track and slide rails 1 3 28 Safely lift and support the rear of the snowmobile off the ground Rotate the track by hand to check for any possible damage Inspect the track rods A carefully and examine the track along the entire length of each rod bending the track edge and inspecting it for breakage If any rod damage is found the track should be replaced Warm up the track by starting the engine and apply a small amount of throttle so the track runs slowly at least five complete revolutions Stop the engine and
29. lutches with light oil or rust inhibitor All lubrication applied as arust preventative measure must be cleaned off before installing belt for service and operating machine Controls And Linkage All bushings spindle shafts and tie rod ends should be coated with a light coat of oil or grease Throttle controls and cables should be lubricated Force a small amount of lubricant down cables Electrical Connections Separate electrical connector blocks and clean corrosive build up from connectors Lubricate or pack connector blocks with Nyogel grease and reconnect Replace worn or frayed electrical wire and connectors Carburetor Throttle Body Fog engine with Polaris Fogging Oil aerosol type according to directions on can Fuel System Treat the fuel system with Polaris Carbon Clean If Polaris Carbon Clean is not used fuel tank fuel lines and carburetor should be completely drained of gasoline 3 30 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Corrosion To prevent corrosion always grease jackshaft and drive shaft clutch side bearings with Polaris Premium all season grease Loosen driven clutch retaining bolt and pull clutch outward to expose bearing Use a point type grease gun fitting to inject grease through hole in flangette into bearing until grease purges out inside or outside bearing seal Push clutch back on shaft and replace clutch retaining bolt Inject grease into fitting on speedomet
30. ments in small increments then re check the timing mark alignment 12 After setting the oil pump lever correctly apply a small drop of Loctite 242 to the cable barrel threads then secure the jam nuts 13 Re check the oil pump alignment marks after securing the jam nuts to verify the marks are set correctly 14 Re assemble the removed components in the reverse they were removed Reference the appropriate service manual chapter for component assembly fastener torques 3 14 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Oil Pump Adjustment CFI Models NOTE Before adjusting oil pump always verify the throttle lever free play and idle speed RPM are set to specification 33mm Lever No Pointer Oil Pump LEVER MARK INDEX MARK PUMP BOSS ARM MARKING 1 Always verify the throttle cable free play is set to specification 010 030 and the throttle lever is synchronized to the throttle plates NOTE The oil pump lever arm MUST begin to move at the exact moment the throttle plates move from the throttle stop position 2 The oil pump part number and or lever marking determines where to set the oil pump lever TERRAIN DOMINATION gt POLARIS Maintenance Oil Pump Adjustment Settings CFI Models Only PART NUMBER ARM MARKING LENGTH A MM LEVER SETTING 600 33mm No Pointer Lever will not cle
31. place skags when carbide edge is worn away Always use new Nylok nuts and secure hand tight TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual gt POLARIS 2010 Polaris Sales Inc 3 26 Maintenance Track Tension 8 Turn each adjuster bolt C clockwise to tighten track Turn the adjuster bolt counterclockwise to loosen Track tension is critical for maintaining correct suspension track tension operation If the track tension is too loose it may cause the track to slip or ratchet If the track is too tight it will wear 9 Torque the lock nuts B and idler shaft bolts on each down the rail slides reduce top speeds cause rear side to 35 ft lb 48 N m suspension vibration and cause track and rear suspension durability problems SUSPENSION MEASUREMENT IQ 121 4 4 8 136 Coupled e k a aa 136 Comfort 7 8 1 1 8 MES 2 2 2 9cm 3 4 1 0 E dis 1 9 2 5cm IQ RMK Switchback 3 8 1 2 Widetrak Assault 1 1 3cm E N Es D _ _ p Ti 16 410m 1 Lift the rear of the machine and place a jack stand or secure the rear of the machine so that the track is off of the ground 2 Start the engine and slowly let the engine turn the track over This will warm up the track for a correct measurement 3 Shut off the engine 4 Place a 10 lb 4 54kg weig
32. se only Polaris DOT 4 high temperature brake fluid Change fluid every 2 years or whenever the fluid is dark or contamination is suspected NOTE A low brake fluid level can be indicated through the sight glass on the cover If the fluid is low this sight glass will glow a brighter color 3 22 THROTTLE AND CHOKE CABLE ADJUSTMENTS Idle Speed Gap Throttle Free Play Adjustment VM Carburetors CAUTION When adjusting throttle lever free play always verify the engine idle RPM does not increase when turning the handle bar to the full left or full right positions After idle speed adjustments are made the throttle lever clearance and oil pump adjustment must be checked and adjusted 1 Always set the idle speed when the engine is at operating temperature 2 Turn the idle speed adjustment screws on each carburetor out at least 2 turns 3 Reference the throttle gap drill bit size specification for each engine Insert the drill bit s under each of the throttle slide cutaway s MIKUNI a Center of slide under cutaway See chart E for size E _ E Forward 4 Loosen lock nut s on top of carburetor and turn the throttle cable adjuster in clockwise or out counterclockwise until a slight drag can be felt on the drill bit TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual gt POLARIS 2010 Polaris Sales Inc Maintenance THR
33. spect the spark plug caps when performing spark plug maintenance Visually inspect the terminal ring inside the cap and the spark plug tip for oblonging uneven wear Replace the spark plug and corresponding cap if the wear patterns on the cap terminal ring and spark plug terminal resemble the photos below Spark Plug Cap Terminal Ring Wear TERMINAL OBLONGED REPLACE CAP PLUG Spark Plug Cap Terminal Wear WEAR ON ABOVE INDENTATION REPLACE WEAR BELOW INDENTATION GOOD Use gentle force and a slight twisting motion when installing plug caps An audible click should be heard when the terminal ring is properly seated below terminal tip indentation TERRAIN DOMINATION gt POLARIS Maintenance Surge Tank Recovery Bottle Keep the level of the coolant inside the surge tank at the FULL COLD level mark when the coolant is at room temperature Always add coolant when the cooling system is COLD CAUTION cooling system is warm Severe burns to skin may occur from escaping coolant or steam Never remove the surge tank pressure cap when the Recommended Coolant Use Polaris Premium 60 40 pre mix antifreeze This premium antifreeze is rated for temperatures down to 62 F 52 C Cooling System Bleeding 1 Allow the cooling system to cool completely 2 Verify the coolant level in the surge tank is at the COLD mark Fill the surge tank if required Loosely install
34. ss the button again up to five times to advance the reminder in 50 hour increments The maximum interval is 250 hours 4 Press and release the MODE button to save the new settings Press and release the MODE button until the history program is displayed To disable the service interval reminder 1 Press the SET button once after reaching 250 hours on the display The gauge will display OFF 3 29 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Maintenance OFF SEASON STORAGE Chassis And Hood Proper storage starts by cleaning washing and waxing the hood chassis upholstery and plastic parts Clean and touch up with paint any rusted or bare metal surfaces Ensure that all corrosive salt and acids are removed from surfaces before beginning preservation with waxes and rust inhibitors grease oil or paint If the machine is equipped with a battery disconnect the battery cables and clean the cables and battery posts Fill battery to proper level with distilled water and charge to full capacity Remove and store the battery in a cool dry place The machine should be stored in a dry garage or shed out of the sunlight and covered with a fabric snowmobile cover Do not use plastic to cover the machine moisture will be trapped inside causing rust and corrosion problems Clutch And Drive System Remove drive belt and store in a cool dry location Lubricate sheave faces and ramps of drive and driven c
35. th Premium All Season Grease IQ Shift Shown TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual gt POLARIS 2010 Polaris Sales Inc 3 20 Maintenance Throttle Cable Lubricate the throttle cable lightly with fresh oil With the engine off turnthe handlebars to the left and lubricate well as shown Choke And Choke Cable Lubricate the choke slide and cables lightly with oil or grease Before turning the engine off operate the choke intermittently to draw moisture out of the choke plunger area and reduce the possibility of the choke becoming frozen Chaincase Oil Level Check Maintain the oil level at the mid point of the sight glass 1 Position the vehicle on a level surface Chaincase Oil Replacement 1 Locate the chaincase drain plug on the bottom of the nosepan Place an oil catch pan under the drain plug Remove the drain plug and drain the oil into the catch pan Clean the magnetic plug to remove metal shavings Install drain plug and hand tighten Do not over tighten the drain plug Fill chaincase with oil at the fill plug location Chaincase Oil Capacity 110z 325 3 ml Recommended Lubricants Chaincase Polaris Synthetic Chaincase Lubricant Drive Chain Tension Adjustment 1 Rotate the driven clutch counterclockwise to move all of the slack in the chain to the tensioner side Lock
36. the fuel line condition after periods of storage Normal deterioration from weather and fuel can occur during this storage period Do not damage fuel lines when removing them If a fuel line has been damaged or kinked it must be replaced All models feature a fuel pick with filter located inside the fuel tank To inspect and replace 1 Remove the gas cap 2 Use a coat hanger to carefully pickup the fuel hose inside the tank 3 Inspect and replace the pickup filter at the end of the hose 3 17 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Maintenance Fuel Filter CFl Models A WARNING When removing the fuel filter fuel spillage will occur Be sure to work in a well ventilated area away from anything which may cause the fuel to ignite such as an open flame heaters trouble lights or cigarettes 1 The fuel filter should be replaced as outlined in the periodic maintenance table For information involving de pressurizing the fuel system and disconnecting fuel hoses See Fuel Rail Bleeding Pressure Testing on page 4 37 FUEL FILTER SUPPLY SN FUEL FILTER BRACKET re gr A ee ARS Ro a aay 2 After de pressurizing the fuel system and disconnecting the fuel hoses remove the fuel filter cartridge from the bracket Dispose of any fuel in an appropriate container then discard assembly 3 When re connecting the fuel hoses verify the connections
37. ther cooler or hose is an indication of trapped air within the cooling system 12 Allow time for the coolant temperature to cool Re check the coolant level in the surge tank Add more coolant if required 3 11 Maintenance 600 Widetrak IQ Cooling System Fill Air Bleed A CAUTION Steam and hot liquids will cause burns to your skin Never bleed the cooling system or remove the pressure cap when the engine is warm or hot This procedure is intended for use after service or repair where the cooling system has been completely drained NOTE Read and understand all procedure before starting steps of the CAUTION Do not start the engine until instructed to do so 1 Shift the transmission into neutral N 2 Move the snowmobile into a well ventilated area Elevate the front of the vehicle 30 inches 76cm using a jack or lift 3 Open the bleed screws on the engine thermostat housing elbow and radiator Do not misplace the bleed screws washers if removed 4 Remove the pressure cap from the coolant reservoir 5 Fill the coolant reservoir with new coolant 60 40 mixture Propylne Glycol distilled water until coolant drains from the radiator bleed opening 6 Close the radiator bleed screw 7 Continue filling the coolant reservoir until coolant drains from the thermostat housing bleed screw NOTE Monitor the coolant level throughout the following steps Add coolant as
38. uch the bulb clean the bulb with isopropyl alcohol 1 Push in on the PUSH section of the plenum 2 Slide the access panel down to gain access to the bulb 3 Squeeze and move the bulb clip up 4 Replace the bulb clip and access panel MFD SERVICE INTERVAL Function mn ENG SE UCE i The gauge logs the number of engine hours accumulated between service reminders When the logged hours reaches the designated service interval set by the user the gauge provides a reminder that service is due SErVCE will flash in the odometer area and ENG will flash in the icon area for five seconds each time the engine is started until the service reminder is reset Use the following procedures to reset the reminder To reset the reminder at the existing interval 1 Press and release the MODE button until the history program is displayed 2 Press and release the SET button until the service interval screen is active 3 Press and hold the SET button for ten seconds continuing to hold even after the display begins to flash 4 When the display stops flashing release the button TERRAIN DOMINATION gt POLARIS The service interval has been reset To reset the reminder at a new interval 1 Press and release the SET button until the service interval screen is active 2 Press and hold the SET button for five seconds until the hours begin to flash Immediately release the button 3 Pre
39. ve belt is 30 miles During this time vary the throttle position under 50 and limit full throttle use New drive belts that feature a sanded finish should be first washed with warm soapy water and allowed to air dry prior to use Always take time to warm up the belt and driveline prior to operating the snowmobile Free track and skis from the ground before engaging throttle TERRAIN DOMINATION gt POLARIS DRIVE DRIVEN CLUTCHES Belt Deflection Inspection Too much belt deflection is when the belt is too long or the center distance is too short The initial starting ratio will be too high resulting in performance loss This is due to the belt rising too high in the drive clutch sheaves upon engagement A Not enough belt deflection B is when the belt is too short or the center distance is too long The initial starting ratio will be too low In addition the machine may creep when the engine idles causing damage to the internal face of the drive belt Belt too high on initial engagement 1 Measure the belt deflection with both clutches at rest and in their full neutral position 2 Place a straight edge across the tow clutches on top the belt 3 Apply downward pressure to the belt and measure the distance at point D 3 5 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Maintenance 4 The measurement should be 1 1 4 3 2cm LAN PN Fi In mm B
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