2007-2011 IQ Service Manual Chapter 10
Contents
1. strong adhesives and once applied they cannot be removed easily Use a wall paper roller to adhere all surfaces of the urocal Urocal decals are rigid and need to be rolled to ensure good adhesion particularly on the edges 0 19 9922854 2007 2011 IQ Service Manual lt gt POLRHIS 02010 Polaris Sales Inc Chassis NOTES 1 0 2 0 9922854 2007 2011 IQ Service Manual gt POLARIS 2010 Polaris Sales Inc2. Wallpaper seam roller or similar roller 3M citrus based clear 3M PN 62 4615 430 5 the staple sequence above available at most auto parts stores 10 Turn the seat cushion assembly over and inspect for Cleaning solution 99 water 1 mild dish washing wrinkles or imperfections If imperfections are visible detergent remove the staples in the affected area and staple correctly Scotch 233 Performance masking tape 11 Trim excess vinyl from the bottom around the back of Perform the decal removal procedures carefully If care is the seat area only after a satisfactory fit is obtained not taken the possibility exists that paint could peel from the hood Follow each step thoroughly and completely to avoid hood damage Polaris is not responsible for any hood or paint damage resulting from this decal replacement procedure CAUTION USE SAFETY GLASSES AND RUBBER GLOVES WHEN PER FORMING THIS PROCEDURE gt POLARIS 9922854 2007 2011 IQ Service Manual l 0 1 7 02010 Polaris Sales Inc Chassis 1 Using masking tape tape off all decals that are not residue with a clean non abrasive shop towel or going to be replaced If you do not tape off the other cheese cloth that is wet with the 3M cleaner decals the cleaning solution used later in the process 6 Once all of the adhesive is removed from the decal may cause the adhesive to break down in the non area follow with a cleaning solution of 999
3. TPO and cannot be repaired If a hood is broken it must be replaced For small cracks drill a small hole on both ends of the crack to limit spreading Crack 4 Drill hole TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual lt gt POLRHIS 02010 Polaris Sales Inc 10 3 Chassis LWT Hood Hinge Assembly VENT OR BRAKE DUCT HINGE i HINGE COVER FASTENERS NOTE TORQUE FASTENERS HAND TIGHT Front Bumper Assembly Typical HEAT FOIL FABRIC BUMPER 7 ee GRILLE W MESH 44 NOTE TORQUE FASTENERS HAND TIGHT TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc lt gt POLRHRIS 10 4 Chassis LWT Front Bumper Fenders HEAT FOIL FABRIC 6 NYLONRIVETS 4 PANEL des GUA HEAT FOIL FABRIC RD LH FENDER CAUTION Pre coated fasteners must be replaced with new parts when removed TERRAIN DOMINATION gt POLARIS 9922854 2007 2011 IQ Service Manual 10 5 2010 Polaris Sales Inc Chassis IQ Console Assembly Typical FIXED STEERING COVER CONSOLE Q O RING 4 RIDER SELECT STEERING COVERS STORAGE DOOR NOTE TORQUE FASTENERS HAND TIGHT RMK Tunnel REAR BUMPER CLOSE OFF BULKHEAD TUNNEL ASSEMBLY 1 PIECE SNOW FLAP gt Sy CONTROL ARM SUPPORT TERRAIN DOMINATION 992285
4. by lining up the seat cover vinyl side flaps with the indented square location indicators located on the plastic seat base Decal Removal Cheese Cloth Squeegee WARNING Apply staples in the stapling channel only If you apply staples outside the channel you will damage the fuel tank reservoir in the seat base If this happens you will have to replace the entire seat assembly 5 Using a staple gun tack each side of the vinyl cover in place using two staples 1 If cover has a POLARIS emblem carefully align emblem with the bottom edge of the seat This will help ensure that the cover is positioned properly 6 Align the two sewn seams located at the rear of the seat cover with the two back corners of the seat base 7 Pullthe vinyl tight and tackthe seat coverto the plastic seat base in each corner Use two or three staples per Use the following items corner 8 Now that the cover is positioned and tacked to the plastic seat base in for places turn the assembly over an inspect it If the seat cover seems to fit correctly and everything looks straight continue 9 Staple the remainder of the unattached seat cover to the plastic seat base Always staple between two existing staples and follow this procedure until the seat cover is completely stapled to the seat base see Squeegee Cheese Cloth or a non abrasive cloth Paper Shop Towels Hair Drier or Heat Gun
5. the adhesive from the hood Use care not to get the cleaner on any other decals 5 When the bulk of the adhesive is removed from the hood by using the squeegee remove any left over 10 18 TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc gt POLRHRIS Chassis Decal Installation All decals should be applied indoors free from dust dirt cold air and humidity Room temperature must be between 40 and 100 F 4 38 C These decals are to be applied dry 1 Make sure the surface area of the hood where the decal is to be placed is free of any dirt debris or adhesive 2 Place the decal in the area to be installed and make sure that everything lines up properly 3 Carefully peel away the adhesive side of the decal 4 Apply the decal and slowly work the decal down using a clean squeegee to lay the decal straight and to avoid creating air bubbles Do NOT remove the decal mask until the decal is fully applied CAUTION PULL THE DECAL BACK OFF OF THE HOOD USE EXTREME CARE IF YOU ENCOUNTER AIR BUBBLES DO ATTEMPT TO USE A STRAIGHT PIN TO POKE THE BUBBLE AND LET THE AIR OUT HOLE POKED A CHROME DECAL WILL BE VERY NOTICEABLE TERRAIN DOMINATION 5 When finished installing the decal carefully remove the decal mask at a 180 angle Peel the backing off and install the urocals in the appropriate places These also
6. 2007 IQ TOURING SEAT ASSEMBLY 10 14 2008 IQ TOURING SEAT ASSEMBLY 10 15 2011 IQ 550 136 LXT SEAT AND REAR 10 16 SEAT COVER 10 17 DECALS ges div s cedex eer sede SER S d ee 10 17 DECALE REMOVAL Xe Red ili kimi asas RE P E REA 10 17 DECAL 10 19 TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual lt gt POLARIS 2010 Polaris Sales Inc 10 1 Chassis IQ CHASSIS COMPONENTS Steering Hoop Assembly Typical RH UPPER BRACE SPACER kn STS MP CROSS MEMBER 7 BRACKET A 18 Ft Lb 24 Nm B 21 Ft Lbs 28 Nm CAUTION Pre coated fasteners must be replaced with new parts when removed Do not over torque steering hoop fasteners TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual PSLARIS 2010 Polaris Sales Inc 10 2 Chassis Hood Assembly HOOD AROUND HEADLIGHT OPENING AND WHERE POD MEETS WINDSHIELD FLARE HEADLIGHT SEALS ATTACH TO INSIDE OF PRE FILTER BRAKE DUCT NOT ALL MODELS HOOD CONSOLE SEAL FRONT GRILLE HINGE NOTE TORQUE FASTENERS HAND TIGHT Hood Plastic Repair Hoods are made of Thermoplastic Olefin
7. 4 2007 2011 IQ Service Manual 2010 Polaris Sales Inc gt POLRHRIS 10 6 Chassis Fenders and Side Panels HEAT SHIELD RH FENDER M LH SIDE PANEL A TRIM PUSH RIVETS g de RIVETS d 9922854 2007 2011 IQ Service Manual 1 0 x 7 lt gt POLRHIS 2010 Polaris Sales Inc Chassis 600 Widetrak IQ Fender Assembly NYLON RIVETS 8 QTY A 2e 1 amp RH REAR FENDER LS RAS XD 1 RIVETS 22 EXHAUST SEAL 5 L Sh Ca 2 U a SNOW DEFLECTOR i ES 5 gt gt Front R LH FRONT FENDER LH REAR FENDER 10 8 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc TERRAIN DOMINATION POLARIS Chassis 600 Widetrak IQ Console LATCH DOOR HOOD LATCH J ROPE GUIDE e T A 40 In Lbs 4 5Nm TERRAIN DOMINATION gt POLARIS 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 10 9 Chassis 600 Widetrak IQ Nosepan Bumper Assembly BULKHEAD TUNNEL ASM HOOD HARNESS HEAT SHEILD L HINGE COVERS lt 1 U m BE lt gt y A 42 a 2 8 _ BOOT COVER lt 4 i L NOSEPAN 74 A T ou IX v CAP 4 Le SCREEN NOTE Mount L H Boot on R H A Cover Mount R H Boot on L H Cover 9 TIE
8. 6 water to affected decals 196 mild dishwasher detergent Use a non abrasive cloth with the solution to remove dirt grease cleaning solvent and finger prints Always clean the surface where the decal will be applied 2 Usingahair dryer preferable or low setting on a heat gun carefully heat the decal to loosen the adhesive Heat until the decal is warm to touch DO NOT OVER HEAT Overheating may cause damage to the paint and to the integrity of the hood Polaris is not responsible for any hood damage resulting from this decal replacement procedure 3 Once the decal is warm to touch and the adhesive is loose peel the decal off slowly and evenly Use of a hair dryer or heat gun is required If heat is not Itis extremely important to remove all traces of dirt and CAUTION applied the decal will be very hard to remove and debris from the hood where the decal is to be applied paint from the hood may peel off with the decal Left over debris will be magnified through the chrome decals 4 After the decal is removed apply 3M citrus based cleaner to the decal area to remove the adhesive Be sure to follow the instructions and the precautions on the container and use rubber gloves and safety glasses Spray the cleaner on the adhesive and let set for 15 20 seconds Using a squeegee wipe the adhesive from the hood and deposit itin a paper shop towel You may have to repeat this process several times to remove all of
9. Chassis CHAPTER 10 Chassis IQ CHASSIS COMPONENTS 2 cea aem ex c RERO Re SERA XE ERRORS E REA 10 2 STEERING HOOP ASSEMBLY TYPICAL 10 2 HOOD ASSEMBDLY 10 3 HOOD PLASTIG REPAIR nce ERE es dan a ve eem 10 3 LWT HOOD HINGE 10 4 FRONT BUMPER ASSEMBLY TYPICAL 10 4 LWT FRONT BUMPER 6 2 10 5 IQ CONSOLE ASSEMBLY 10 6 2 netu im Ree brise code oeste arn 10 6 FENDERS AND SIDE PANELS 10 7 600 WIDETRAK IQ FENDER ASSEMBLY 10 8 600 WIDETRAK IQ 10 9 600 WIDETRAK IQ NOSEPAN BUMPER ASSEMBLY 10 10 600 WIDETRAK IQ SHOCK TOWER ASSEMBLY 10 11 600 WIDETRAK IQ CHASSIS 10 12 SEAT ASSEMBLIES vaa Sia ee nn dette iR EY 10 13 IQ FIXED SEAT 10 13 IQ RAW SEAT 10 13 IQ REMOVABLE SEAT 10 13
10. ERSION of 2008 VERSION gt POLARIS 9922854 2007 2011 IQ Service Manual l 0 1 3 2010 Polaris Sales Inc Chassis 2007 IQ Touring Seat Assembly SEAT ASSEMBLY LATCH BRACKETS E PASSENGER SEAT ASSEMBLY LUMBAR ADJUSTER x 3150 AL D HAND GUARD 5 5 Ft Lbs 7 5 Nm 10 14 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc TERRAIN DOMINATION POLARIS Chassis 2008 IQ Touring Seat Assembly BACK REST a 0 MCN d ae HAND ARD es GU ra e T A 18 Ft Lbs 24 Nm B Hand Tight Do not crush washers C Hand Tight D 5 5 Ft Lbs 7 5 Nm gt POLARIS 9922854 2007 2011 IQ Service Manual l 0 5 02010 Polaris Sales Inc Chassis 2011 IQ 550 136 LXT Seat and Rear Rack BACKREST PAD LXT HAND HOLD TOURING MOUNT BUSHINGS 2 z 18 Ft Lbs 24 Nm z 10 Ft Lbs 13 5 Nm REAR RACK TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc lt gt POLRRIS 10 16 Chassis Seat Cover Replacement DECALS Remove seat 2 Remove the old covering by removing the staples that hold it on the base Before beginning read these instructions and check to be 3 Drape the new cover over the seat foam sure all parts and tools are accounted for 4 Turn the assembly over and begin upholstering
11. ROD BOOT BUMPER ey T A 25 Ft Lbs 38 Nm CAUTION Pre coated fasteners must be replaced with new parts when removed 10 10 TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc POLARIS Chassis 600 Widetrak IQ Shock Tower Assembly t ov TOWER SUPPORT SHOCK MOUNT 8 lt 2 22 aS VM 4 y BULKHEAD T 22 Ft Lbs 30 Nm CAUTION Pre coated fasteners must be replaced with new parts when removed 0 11 TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual gt POLARIS 2010 Polaris Sales Inc Chassis 600 Widetrak IQ Chassis COOLANT BOTTLE BRACKET ELECTRICAL CENTER AIRBOX STRAP BRACKET 2222 5 BULKHEAD TUNNEL ASSEMBLY ENGINE SUPPORT BRACKET NUT PLATE RIVETED TO BULKHEAD ey T A 22 Ft Lbs 30 Nm CAUTION Pre coated fasteners must be replaced with new parts when removed TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc lt gt POLRRIS 10 12 Chassis SEAT ASSEMBLIES IQ Removable Seat Assembly IQ Fixed Seat Assembly LATCH SEAT 27 SEAT BASE T ey T A 5 5 Ft Lbs 7 5 Nm A 5 5 Ft Lbs 7 5 Nm Plastic crushes at 10 Ft Lbs 13 Nm IQ Raw Seat Assembly 2007 TAILIGHT 2007 V
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