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Polaris 2007 2008 IQ Service Manual

1. u 311108 110 853229 HOLIMS NI 431 201 USHLSL bx MOSN3S fm a 14 440 Luvs 11 1025 328151538 QU HM 8 5 010049 Na 5 S81 QH HM 01 HM s 5 and OL 90 d ay 90 9001 90 HOLIMS I 8 38 OL 90 NOILIN9I 5170 GN OL 34 O SHI S t 50 31 801915 A COP Ng 5102 INDI i
2. LEFT RIGHT HANDWARMER HANDWARMER THUMBWARMER 3 13 BRAKE LEVER SIMPLIFY TRACING IN DIAGRAM OHMS OHMS E Sry EXHAUST 23 YE RD x SOLENOD 22 WIRE COLOR LEGEND 86 BEIGE TAN ENGINE GROUND v s 08 YE BK 1 BK BLACK i 8 Lent BLUE C CHASSIS GROUND BRAKE APPLIED WI 08 0 NC ACTIVE OPEN WHEN na CC CHASSIS a SWITCH NORMALLY NO INACTIVE SEE E BE Tee TRI Hop GN LIGHT GREEN CLOSED ree 987873 0G
3. wosnas 13 NOLLISOd Ng 23 3TLIOHHL 80 98 63 1 881 14 361 WsN 63502 Ol 300801 000 019 7 80 98 29 m 1 19 T Be ou 1 1 Os 1 e a GIONS OS 3ATVA 15 N J 21 j 4 4 11 14 2 102 80 98 63 Old 1 ES id zd z4 ng 23 ee 8 81 08 10 iaa PH NE 2 90 08 19 i W 1 LA 19 1 sss ES pere am Be 80 48 9 2H 90 7102 34 90 21 VW 4 08H90 1 51111 E 88 ef i 1 5 En
4. gt POLARIS WINNING 12 14 iagrams D iring W 2008 IQ CFI Chassis Harness 2 of 2 _6 GAUGE START SOLENOD LOCATED ON TOP OF BATTERY BOX OPTIONAL STARTER 771 6 GAUGE o l 1 72007701 I Z D 55 is _ i I 2 pg Ec 1 6 GAUGE LAT BW GROUND n E n iM m 5 RO 55 04 RD BK 2 ELECTRIC B9 s TT START P 01 RD WH 5 RELAY COIL T6 Q 888 uga 3 CHARGE RELAY e NC WIRE TERMINATION TABLE ELECTRIC START CCT COLOR GAUGE FROM CONNECTOR CAVITY TO CONNECTOR CAVITY FUNCTION 0 RED WHITE 16 ELECTRIC START A CHARGE RELAY 3 CHASSIS
5. PART NUMBER SIZE THICKNESS 1700080 0 700 1700086 0 800 0 004 1700092 0 900 1700081 0 700 1700087 0 800 1700093 0 900 1700121 1 000 0 006 1700129 1 100 1700134 1 250 1700139 1 300 1700094 0 900 1700122 1 000 1700130 1 100 0 008 1700135 1 250 1700140 1 300 1700082 0 700 duod 1700088 0 800 1700083 0 700 1700089 0 800 1700095 0 900 1700126 1 000 0 010 1700131 1 100 1700136 1 250 1700141 1 300 1700084 0 700 1700090 0 800 1700096 0 900 1700127 1 000 0 012 1700132 1 100 1700137 1 250 1700142 1 300 1700085 0 700 1700091 0 800 1700120 0 900 1700128 1 000 0 015 1700133 1 100 1700138 1 250 1700143 1 300 WINNING PERFORMANCE 9 3 POLARIS Shocks Fox Shock Valve Part Numbers PART NUMBER SIZE THICKNESS 1500055 0 700 1500054 0 800 1500053 0 900 1500048 1 000 0 006 1500049 1 100 1500050 1 250 1500052 1 300 1500029 0 700 1500028 0 800 1500033 0 900 1500032 1 000 0 008 1500031 1 100 1500051 1 250 1500030 1 300 1500044 0 700 1500047 0 800 1500046 0 900 1500045 1 000 0 010 1500027 1 100 1500026 1 250 1500062 1 300 1500056 0 700 1500057 0 800 1500058 0 900 1500059 1 000 0 012 1500060 1 100 1500078 1 250 1500079 1 300 1500081 0 700 1500082 0 800 1500083 0 900 1500084 1 000
6. PART NUMBER DESCRIPTION 2200421 Gas Shock Recharging Kit 2201639 Shock Shaft Seal Protector 50 Diameter 2201640 Shock Shaft Seal Protector 625 Diameter 2870623 Shock Absorber Spring Compression Tool 2870803 Shock Spring Pre Load Adjustment Tool PS 45259 Gas Fill Tool 9917736 VIDEO Rebuilding Mono Tube Shocks 9917737 VIDEO Rebuilding Remote Reservoir Shocks Ryde FX Shock Special Tools PART NUMBER DESCRIPTION PS 45259 Gas Fill Tool and Gauge Incl 5 needles PS 45259 1 Gas Fill Needles replacement pack PS 45259 2 Gas Fill Gauge replacement PS 45260 Lower Retainer Wrench PS 45261 IFP Positioning Extraction tool PS 45262 Cylinder Head Wrench PS 45263 Wear Band Tool PS 45629 Arvin Shock Body Holder PS 45280 Shock Collar Tool PS 45821 Shock Reservoir Holder FOX Shock Special Tools PART NUMBER DESCRIPTION 2871021 Shock Body Holding Tool 2871352 Shock Rod Holding Tool 50 Diameter Rod 2872429 Shock Rod Holding Tool 625 Diameter Rod 2871232 Fox Shock Spanner 2871351 Fox Shock IFP Depth Tool PS 44925 Fox Inner Tube Puller PS 2 INNING PERFORMANCE gt POLARIS Shocks VALVE SHIMS motion Refer to the appropriate parts manual for a complete listing of shock parts Shock shim stacks can be adjusted to control the amount of fluid that is forced by as the piston travels through its Ryde FX Shock Valve Part Numbers
7. General Front Suspension Width in cm 48 121 9 Suspension Type IQ 42 5 Length in cm 125 317 5 Fox HPG w IFP STD Height 48 121 9 Shocks Fox Compression Adj Remote cm Dry Weight 483 219 3 Resevoir HPG OPT Ib kg Rebuidable Fuel Gallons Liters 10 8 40 9 IFS Spring Rate 0055 Oil Quarts Liters 3 4 3 2 lbs in N mm Cooling System Capacity Spring Installed Length Quarts Liters Inches cm 10 55 26 8 Brake Fluid DOT 4 Front Vertical Travel 10 25 4 Drive Belt Inches cm Part Number 3211080 Ski Center Distance 42 5 108 Width inches cm 1 438 3 65 Inches cm Side Angle 28_ Camber Inches cm 2 25 0 31 57 7 9 Circumference inches cm 46 625 118 4 Center Distance inches cm 11 5 29 2 Toe Out Inches cm 0 0 12 0 0 31 Chaincase Rear Suspension Center Distance inches 8 373 Top Gear Stock 22 Suspension Type 10 144 Bottom Gear Stock 39 Fox HPG w IFP Chain Stock 76 Front Track Shock FTS Rebuildable Gear Lube Polaris Synthetic Capacity oz ml 11 3253 FTS Spring Rate 170 30 Reverse System Perc Ibs in N mm FTS Spring Installed Electrical Length Inches cm 229182 Alternator Output Fox Compression Adjustable Operating Voltage 13 5 14 5 Rear Track Shock RTS Remote Resevoir HPG Watts 13 5 Vdc Total 280 Ignition Timing
8. A NUB 21 SE 2 4 ES GOOH SISSWHO 391148 AN31IV8 02 1 Gnnoyg l2 2 31VIN 18918 dAV10V3H 1431 81 LHOTY 4 1331 81 t 414488 19 TIIM SHOLO3NNOO dil 4 16918 1331 81 000 5155 2 LB 91 L 177 310 330108 14131198 24 39119 02 301148 14 GOOH SISSWHO 24 39119 02 134208 1138 24 39119 02 dN3L WV 1 GOOH SISSVHO 2 390V9 0c 000 5155 2 24 39119 02 40 24 GOOH SISSWHO 24 39nvo 02 24 390v9 02 NUS 321145 W740 24 390v 02 YT dial uv 1 390vo 02 y18 24 000 5155 2 39nvo 02 80 889 11 24 000 15155 2 1 39nv9 02 87118 24 100 1 2 39nvo 02 18 80 QOOH SISSVHO 390vo 02 m 2 000 5155 2 1 390v9 02 24 000 5155 2 1 39nvo 02 Y18 N MINYOO 17 YOLOINNOD OL 300 9 0709 f 4 22V 16918 81 S9N1d LON GOLO3NNOO QOOH SISSVHO 133008 4138 81 18918 1320 AV138 02 000 5155 2 1331 91 000 5155 2 1397 91 QOOH SISSVHO 2 30 9 02 OIA Ges 000 5155 2 2 390v9 0
9. 8 11 HANDLEBAR CENTERING 8 11 TOE 8 11 DISASSEMBLY AND ASSEMBLY 8 12 SPINDLE REMOVA z u con RHET ati tee e eee pd ce esee en be g 8 12 SPINDLE ASSEMBLY 8 12 SPHERICAL BEARING REPLACEMENT 8 12 UPPER LOWER CONTROL ARM 8 12 UPPER LOWER CONTROL ARM 5 8 12 REAR SUSPENSION ASSEMBLY ILLUSTRATIONS 8 13 REAR SUSPENSION OPERATION 8 36 OPERATION Ih usen OM s EET RT ae Ska dus 8 36 WEIGHT IRANSEER rh e E IQ 8 36 eec 8 36 REAR SUSPENSION ADJUSTMENTS 8 37 ADJUSTMENT 5 8 37 REAR SUSPENSION RIDE 8 37 SCISSOR STOP ADJUSTMENT 8 37 LIMITER STRAP ADJUSTMENT 8 38 TORSION SPRING ADJUSTMENT 8 38 IQ 121 HEAVY TORSION SPRING 5 8 39 SUSPE
10. Ambient Temperature 2007 600 HO IQ gt gt 9 Model Number S07PP6FS B XE MEN 8 8 e 8 s Altitude a 52 918 ngine Meters fee 2 Z Z Bu 5282 Pel 85 9 9 95 Liberty Liquid Cooled q a r Engine Type Case Reed Induction i 5 u m E 5 1 a Model Number 3273 6044 PF6F 7 T i Displacement Cylinders 599cc 2 0 600 440 430 420 400 390 380 370 360 0 2000 3 3 2 2 2 2 2 1 Bore inches mm 3 04 77 25 600 1200 410 400 390 370 360 350 340 330 Stroke inches mm 2 52 64 2000 4000 3 43 2 2 2 2 1 Piston to Cylinder Clearance 004 006 105 159 1200 1800 370 360 350 340 330 320 310 300 inches mm 4000 6000 93 2 2 2 2 1 1 1 Installed Ring Gap 1800 2400 340 320 310 300 280 280 270 260 014 020 356 508 6000 8000 22 mis suis Operating RPM 200 8100 2400 3000 310 300 290 280 270 260 250 240 8000 10000 952 2 2 1 1 1 1 1 Idle RPM 1500 3000 3700 290 280 270 250 240 230 220 210 Engagement RPM 200 3800 10000 12000 2 2 1 1 1 41 1 Exhaust Valve Spring Pink When using non oxygenated fuel with a RON greater than 93 Carburetor Settings decr
11. WEIGHT GRAMS PART NUMBER WEIGHT GRAMS 80 PART NUMBER 23 1321849 S45H 45 1321850 TERN 18 22 S47H 47 1321851 iste 1322992 549H 49 1321730 xus 1322591 S51H 51 1321731 1322590 S53H 53 1321759 259 S55H 53 1322004 n 1322595 11 64 1322604 11 66 1322559 11 68 1322558 11 70 1322523 11 72 1322524 11 74 1322525 11 76 1322526 The Way Out PVT System PERC Team LWT Driven Helixes 24 Fin Team Ramp Angles PART NUMBER DESCRIPTION 5135401 64 42 36 5135402 64 38 25 5135403 56 42 36 5135503 54 38 25 5136255 542 5135504 536 5135772 66 44 46 Non PERC Team LWT Driven Helixes 24 Fin PART NUMBER DESCRIPTION Beginning angie steepest Measurement of transition 62 40 46 A pn rd 912549 64 40 55 64 38 65 The angles and length of the transition between the first and final 5135376 64 38 46 angle is stamped on the back of the helix The first number designates the starting angle of the ramp The second number 5135438 70144 46 designates the finish angle The last number is the 66 44 46 transition distance in inches between the starting and finish 64 38 65 angles 199359 64 38 46 62 40 46 5135486 64 40 55 A CAUTION 5135521 Do not install helix Perc equipped
12. 4 34 DROP IN FUEL PUMP 4 34 THROTTLE BODY 0000 ne 4 35 DIGITAL WRENCH DIAGNOSTIC SOFTWARE 4 36 OVERVIEW epu bb UR btn detent EI eiut et REESE 4 36 DIGITAL WRENCH 6 1 4 36 UPDATING DIGITAL 4 37 VERSION FILESET 1 4 38 ENGINE CONTROLLER REPROGRAMMING 4 38 WINNING PERFORMANCE 4 1 gt POLARIS Fuel Systems SERVICE WARNINGS AND PRECAUTIONS Service Warnings When servicing the fuel system it is important to heed the following warnings A WARNING PROPOSITION 65 WARNING Snowmobile engines discharge fuel and exhaust which contain chemicals known to the State of California to cause cancer and birth defects or other reproductive harm onto the snow on which they operate Keep this engine properly tuned and avoid unnecessary idling and spillage during fueling Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored or used Do not overfill the tank past the bottom of the filler neck If you get gasoline in your eyes or if you swallow gasoline see your doctor immediately Neve
13. Malfunction TROUBLE CODE P CODE DESCRIPTION Throttle Position Sensor Unrealistic TPS signal changes too rapidly to be correct Can be m P0120 Transition caused by faulty connections or a faulty TPS Throttle Position Sensor Voltage High P0123 1 TUS signal 3 ee faulty wire connection or faulty TPS Throttle Position Sensor Voltage Low P0122 u Bou Cu De caused Dye faulty wire connection or faulty TPS Engine Coolant Temperature Sensor Sensor signal is above 4 8 Vdc Can be caused by a 0118 Voltage High faulty wire connection or faulty temperature sensor 2 Engine Coolant Temperature Sensor P0117 Sensor signal is below 0 1 Vdc Can be caused by a Voltage Low faulty wire connection or faulty temperature sensor Intake Air Temperature Circuit Voltage Sensor signal is above 4 9 Vdc Can be caused by a 113 High 4 faulty wire connection or faulty Intake Air Temperature Circuit Voltage Low P0112 signal acd DEEP UC can faulty wire connection or faulty TBAP Barometric Pressure Sensor Voltage High P0108 Siena x eeu Can be caused Dye faulty wire connection or faulty TBAP 4 Barometric Pressure Sensor Voltage Low 0107 2 Sena b oD faulty wire connection of faulty TBAP ee Sensor signal is above 4 9 Vdc for at least 2 minutes Exhaust Temperature Sensor Circuit P0546 and the engine has
14. 04 REGULATOR STATOR CONNECTOR poa STATOR LEADS COOLANT TEMP SENSOR WIRES Q 39 BK LE Q YE TO NB 0 15 0 68 24 0 IGNITION 202195 2432 25 06 BK RD 15 100 2122 192 30 SWITCH Etele 283 GROUND DG TO GND OPEN RD BN ON REGULATED Dc BATT ELUDES TAB uem DG TO RD 15 DES ERE WH TO WH RD 185 BK WH RD 35 8 52 RD WH 32 BN WH 70 BN WH DC wR lt lt BN GROUND RESISTANCE 20 START 5 REGULATOR REGULATED M fiar PWR LOCATED IN SWITCHBACK ONLY SWITCH ACCESSORY OIL BOTTLE 2410868 02 N iagrams D iring W 2008 IQ Shift RMK 2 of 2 2909 9 _ 01140 X08 8311 78 30 401 NO 431 201 GIONSTOS 19 15 CIRCUIT BREAKER LOCATED ON TOP OF BATTERY BOX G OPTIONAL 10 90 HM 90 50 0 3
15. 5 12 EXHAUST VALVE ASSEMBLY 1 5 12 OPTIONAL EXHAUST VALVE SPRINGS 5 12 ENGINE MOUNTING SYSTEMS RON ER 5 13 2007 IQ CARBURETED ENGINE MOUNTING 5 13 2007 IQ 600 CFI ENGINE MOUNTING 5 14 2008 IQ CARBURETED ENGINE MOUNTING 5 15 2007 700 CFI 2008 IQ CFI ENGINE MOUNTING 5 16 ENGINE COMPONENT 5 5 517 600 CARBURETED CYLINDERS CYLINDER HEAD 5 17 600 CARBURETED RECOIL 5 18 600 HO CARBURETED PISTONS CRANKSHAFT 5 19 600 CARBURETED CRANKCASE 5 20 600 HO CARBURETED WATER OIL 5 21 2007 2008 600 700 CFI CYLINDER HEAD CYLINDERS PISTONS 5 22 2008 800 CFI CYLINDER HEAD CYLINDER PISTONS 5 24 2007 2008 600 700 800 CFI RECOIL STATOR ASSEMBLY 5 26 2007 2008 600 700 CFI CRANKCASE CRANKSHAFT ASSEMBLY 5 27 2008 800 CFI CRANKCASE 5 29 2007 2008 600 700 800 CFI WATER OIL PUMP ASSEMBLY 5 31 600
16. yOLISVdVS 193895 1 5 600 iJ 09995 55 HILIMS GOOH SISSVH3 OW 1331 AMINA 250 A A 170 HN 90 BFO Su3A3U o 48 9 801 80 8 290 49 160 8 08 190 n8 990 AOTHM 210 49 90 1L0 X8 SLO NGING 910 o H91H 109 190 135 YINYYM a gnnHl 990 300N 1077 8 08 210 80 38 590 80 98 290 18 38 8S0 1 800 SEO 40 110 1015 NB v90 8 38 650 Tig 90 1501 32185 MHOSN3S HAIN 011 1019 04 60 HOLIMS NI YOLVIIGNI 831 3 coi xg 280 4 180 aoras MOSN3S YOSNSS 4 ong io LSAVHXa 80 48 90 80 38 90 BI
17. Adjusting Belt Deflection Team Driven _ JAM SZ DEFLECTION STUD Loosen the Jam nut Using an 1 8 Allen head wrench turn the stud counter clockwise to decrease belt deflection and clockwise to increase belt deflection 3 When the proper belt deflection is achieved torque the lock nut to 90 110 in Ib 10 12 Nm NOTE When using a MBL drive belt the belt deflection should be set so that 9 to 10 of the outer cogs are outside of the driven sheaves 7 11 PVT System PVT SYSTEM ADJUSTMENTS Clutch Alignment Offset The engine is mounted in the bulkhead so the drive and driven clutches self align under high torque loads Offset is controlled by the number of washers installed on the jackshaft behind the driven clutch 1 Remove drive belt 2 Install the correct alignment tool depending on the type of driven clutch installed on the snowmobile TooL PART NUMBER APPLICATION PS 46998 Standard Team Driven PS 47477 Light Weight LW Team Driven NOTE A standard alignment tool will not work with a Team LW driven clutch Likewise a LW alignment tool will not work with a standard Team driven clutch A Team LW driven clutch can be identified as having 24 cooling fins 3 The optimum setup is when the front and rear of the tool touch the driven clutch No gap should be present in the front and the rear clearanc
18. Specifications Sensor Specifications BLK TO WHT Primary 0 30 22 F 4248 30 C Operating Temperature Range 120 C BLK or WHT TO OPENO SECONDARY LEAD Bosistaiea 2 4 2 6 68 F 20 C Measure in stirred water SECONDARY LEAD TO K LEAD Installation Torque 29 ft lbs 39 2Nm Lucca 299 Level Sender Exhaust Valve Solenoid To test the oil level sender position the sender as it would be in the oil tank Allow the float to drop in the direction it would if the oil tank were empty Continuity should be present when using a multimeter to test the sender with the float in the empty position No continuity should be present when the float is moved away from the empty position Specifications Coil Resistance WHT YEL to RED 150 15 68 F 20 C one 11 15 Battery and Electrical Systems 2007 600 HO Regulator Rectifier Circuit Specifications Thi lator rectifi f the following functions is regulator rectifier performs the following functions hrsg J RED REGULATED DC MFD POWER Regulates AC Voltage to 14 3 volts HARNESS RED REGULATED DC BATTERY POWER Provides regulated DC voltage to power the MFD HARNESS M gauge BROWN AC GROUND Provides regulated DC voltage to charge the battery if METAL TAB GROUND PLATE equipped Replace the regulator rectifier whenever the following occurs lluminates MFD brake
19. M8 Na zr 000 00 MBIA 77 am 29 77 24 E po 7 dq 77 77 77 77 90 Deer 25524 34 80 v1 1 pem 34 90 lt 1 T 1 BE 90 i H HK 4 I ie a ae a a SN E oa 80 04 10 i 90 28 0801 200 24 sls 0 0 07 Tan HM QU 13 Old AE ES WT ms 2 1 21 D 1 ES A 22 22 875 4 MEE v 22 a 22 E 22 22 2 1 1 1 1 H 1 1 1 1 ia m Q 80 18 EET T 1A 104 1 1 Bd 2 S wu OL SISSVHO OL Old Eie E ges at 1 E 9 TEES foes 580102 33VW1 NIYW 888 2825 NMOHS 80100 38 OML CNIN O 009 S801230NI 7008 HOTTA 3k i 1 10 2602109 sa C NIN 9 006 25901237841 001009 314804 131011 IA 2 1 10 95 0 SS3NUVH Tim au oa TEN 55 Luvdl Sam gt 985 mam a 30 HO193rNI 7804 13389 IH911 8 e
20. REGULATOR STARTER MOTOR V RED 8 AMP CIRCUIT BREAKER BATTERY 11 11 Battery and Electrical Systems System Schematic CFI 11 12 ECU CNA CONNECTOR GRN BLUE IGNITION SWITCH CLOSED WHEN KEY TURNED TO START CHARGE RELAY WHT RED START RELAY STARTER MOTOR Th BATTERY CHASSIS VOLTAGE BATTERY VOLTAGE BATTERY VOLTAGE CH ENG GROUND BATTERY GROUND WINNING PERFORMANCE POLARIS Battery and Electrical Systems Starter Motor Flex Drive Assembly FLEX DRIVE 11 13 Battery and Electrical Systems IQ Battery Box Assembly ga CIRCUIT BREAKER PX RIA pg BATTERY HOLD DOWN BRACKET GROUND eur at BATTERY BATTERY PAD 11 14 Battery and Electrical Systems CARBURETED ELECTRICAL Knock Sensor SYSTEMS ag 1 4 600 HO Stator Specifications em m KO NOTE Use a multimeter to test the stator circuits 4 870 000 OHMS Remember to test the circuits when the engine is TORQUE TO 2045 153 FT LBS cold and after the engine has been running for some time 600HO Coolant Temperature Sensor Specifications YEL TO BRN 0 150 BRN ENGINE 00 BLK RED TO GRN 150 RED TO GRN 150 BLK WHT TO ENGINE 00 WHT RED WHT 1850 Ignition Coil Packs
21. 050089 Aui3llv8 081089 AYILIVE wog 0032901 YILYVLS 8 030 051089 100201 3961 QION310S 19715 308 201 9319715 9 3L1HM N3349 HOLIMS 8318 15 W9SI QION310S 14715 108 8915 21912313 81 038 3L1HM 8311 8 3052 437348 1105815 10817 15 21812313 81 038 u3MOd 3081 1003201 31318 108 19918 21812313 91 M01134 010089 5155 1081 11004201 831815 10817 8915 21412313 9 NMOUB NOILONAS ALIAYJ 1 01 YOLISNNOD 40109 20 06 0 2 LYVd SS3NHVH 1 NOILVNINWYIL 20 06 01 2 3H38WnN SS3NHVH AINO 10 89801P2 SS3NUVHy x 32 81 0113 HLIM 038 34 08 31dWVX3 S80102 JOVUL NIVA NMOHS JYV 580102 3UIM 101131 3l1HM HM 114804 13101 Im 038 Qu Xd 39NVUO 90 3339 Waya 90 13389 1H911 N9 19 NOUS N8 3018 yava 80 3018 1H911 ng yov 18 NVI 39138 98 413931 80102 1818 WYYOVIC NI 9NI2VUI 13114815 0 53811 Q3HSVO YO 01105 AG 83183518438 JYV S3UIM 049 20 24 321145 0801089 20 9 3L IHM NMOUB 80 122 039 21145 N0089 uvg3T0NVH HOLIMS 4015 02 030 039 3Y 21145 1049
22. Engine pope Case Reed Induction Model Number 53206 6044 Displacement Cylinders 599cc 2 Bore inches mm 3 04 77 25 Stroke inches mm 2 52 64 Piston to Cylinder Clearance inches mm 004 006 105 159 Installed Ring Gap inches mm 014 020 356 508 Operating RPM 200 8250 Idle RPM 1700 Engagement RPM 200 3800 Exhaust Valve Spring Purple Fuel Delivery Recommended Fuel Octane R M 2 Type Cleanfire Direct Injection Throttle Body Marking 1203213 Throttle Body Bore 46mm TPS Voltage Idle 0 95 0 01 Fuel Pressure PSI bar 58 4 0 91 Non Oxygenated Clutch Settings General Width in cm 48 121 9 Length in cm 115 292 1 Height in cm 48 121 9 Estimated Dry Weight Ib kg 505 229 3 Fuel Gallons Liters 11 7 44 3 Oil Quarts Liters 3 4 3 2 Cooling System Capacity 63 6 Quarts Liters Brake Fluid DOT 4 Drive Belt Part Number 3211080 Width inches cm 1 438 3 65 Side Angle 28_ Circumference inches cm 46 625 118 4 Center Distance inches cm 11 5 29 2 Chaincase Center Distance inches 8 373 Top Gear Stock 22 Bottom Gear Stock 39 Chain Stock 76 Gear Lube Polaris Synthetic Capacity oz ml 11 325 3 Reverse System Perc Electrical Alternator Output Operating Voltage 13 5 14 5 Watts 13 5 Vdc Total 400 18 1700
23. H 1 3 3 1 1114 40 83138111 089 5155 2 189 UNIO 6 118 104 VIII 31049 ANION 814 1188 21 NUS 011080 048 CHING lH L OND W0SN3S H 106 918 01 24 Y 9 1331 14101140 189 02 ANIL 381983 1 2019 1 9121100 138 33104 d Y N 1 9 VN LS 351014 03345 QUA i NI 9NIOVUL AST TdNIS _ 01 S3NI1 Q3HSVQ 30 41105 UM 241 5 AG 43183538438 38853811 HOLIMS 3007 1 4 918 440 L PERFORMANCE gt POLARIS WINNING iring 2007 600 700 Hood Harness Pale HOLIMS 135 HOLIMS 12 6 iagrams D iring 2007 600 700 CFI Engine Harness ECU A WIRE ENTRY VIEW AON WIRES ARE REPRESENTED BY SOLID OR DASHED LINES SIMPLIFY TRACING IN DIAGRAM RECTIFIER amp REGULATOR MAGNETO STATOR WIRE COLOR LEGEND BEIGE TAN BLACK LIGHT BLUE DARK BLUE BROWN GRAY LIGHT GREEN DARK GREEN ORANGE PINK RED VIOLET PURPLE
24. 3 5 TORQUE STOP 3 6 ENGINE ISOLATOR LIMITER 3 6 ENGINE MAINTENANCE pL Thus ka tthe Dey PCI 3 7 EXHAUST VALVE 3 7 SURGE TANK Meld Sha ee VEU 3 7 RECOMMENDED 3 7 COOLING SYSTEM BLEEDING 3 7 OIL PUMP ADJUSTMENT CARBURETED 5 3 8 OIL PUMP ADJUSTMENT CFI MODELS 3 9 OIL PUMP BLEEDING 5g a Amir cag wee atk HERE Ein 3 11 FUEL INTAKE SYSTEM sa eee 3 11 WATER SEDIMENT 3 11 FUEL FILTER CARBURETED 5 3 11 FUEL FILTER MODELS 5 eau pee Lie 3 12 OIL FITER uu alee ue e beet part tmi te dett 3 12 FUEL TANK VENT SYSTEM 2252 22 22 3 13 AIR INTAKE BOX 3 13 GHASSIS EUBRIGATION ns sch lente eae UI Reno oe a 3 14 REAR 5 1 3 14 DRIVESHAF
25. WINMING PERFORMANCE gt POLARIS 1 7 Model Specifications 2007 600 HO IQ CFI Model Number SO7PP6HS A B Engine Engine Type suse eed slit Model Number 53206 6044 6 Displacement Cylinders 599cc 2 Bore inches mm 3 04 77 25 Stroke inches mm 2 52 64 Piston to Cylinder Clearance inches mm 004 006 105 159 Installed Ring Gap inches mm 014 020 356 508 Operating RPM 200 8250 Idle RPM 1700 Engagement RPM 200 3800 Exhaust Valve Spring Purple Fuel Delivery Recommended Fuel Octane R M 2 Type Cleanfire Direct Injection Throttle Body Marking 1203213 Throttle Body Bore 46mm TPS Voltage Idle 0 95 0 01 Fuel Pressure PSI bar 58 4 0 91 Non Oxygenated Clutch Settings General Width in cm 48 121 9 Length in cm 115 292 1 Height in cm 48 121 9 Estimated Dry Weight Ib kg 485 220 2 Fuel Gallons Liters 11 7 44 3 Oil Quarts Liters 3 4 3 2 Cooling System Capacity 63 6 Quarts Liters Brake Fluid DOT 4 Drive Belt Part Number 3211080 Width inches cm 1 438 3 65 Side Angle 28_ Circumference inches cm 46 625 118 4 Center Distance inches cm 11 5 29 2 Chaincase Center Distance inches 8 373 Top Gear Stock 23 Bottom Gear Stock 39 Chain Stock 76 Gear Lube Polaris Syn
26. 1 6 ALTITUDE DRIVE CLUTCH DRIVEN CLUTCH meters Shift Clutch Clutch Driven Gani feet Weight Spring Spring Helix 8 0 600 64 42 36 0 2000 10 62 ER 600 1200 2000 4000 10 60 1200 1800 m 4000 6000 x BLK GRN RED BLK 120 340 140 240 19 41 76 1800 2400 10 56 7042083 7043058 56 42 36 6000 8000 LW ER 2400 3000 3000 10000 1054 3000 3600 TS 10000 12000 Drive Clutch Bolt Torque 50 Ib ft 68Nm WINNING PERFORMANCE C POLARIS Model Specifications General Front Suspension Width in cm 46 5 118 1 Suspension Type IQ RMK Adjustable 144 2 125 318 Ryde FX Compression Adjustable Lene 155 130 3302 dide STD Height in cm 49 124 5 Walker Evans Air OPT Rebuidable Estimated Dry Weight 144 472 1 214 3 Ib kg 155 478 217 IFS Spring Rate 100 17 5 Ibs in N mm Fuel Gallons Liters 12 45 4 ring Installed Lengt Oil Quarts Liters 34 32 ER 5 10 35 26 3 Cooling System Capacity 6 3 6 WE Air Oil Volume 95 Quarts Liters WE Air Nitrogen Brake Fluid DOT 4 Charge 215 psi Drive Belt Stock 220 225 psi Part Number 3211115 Optional P Width inches cm 1 460 3 7 Front Vertical Travel Side Angle 26_ Inches cm 9 22 9 Circumference inches cm 46 77 118 8
27. Liberty Liquid Cooled Engine Type Case Reed Induction Model Number S3470 7044 PU7J Displacement Cylinders 700 2 Bore inches mm 3 19 81 Stroke inches mm 2 68 68 Piston to Cylinder Clearance 0044 0059 112 151 General Width in cm 48 121 9 Length in cm 115 292 1 Height in cm 48 5 123 2 Estimated Dry Weight Ib kg Base 476 216 1 Dragon 480 217 9 Fuel Gallons Liters 11 7 44 3 Oil qts l 3 2 8 Cooling System Capacity 85 8 Quarts Liters i Brake Fluid DOT 4 Drive Belt Part Number 3211115 Width inches cm 1 460 3 7 Side Angle 26 Circumference inches cm 46 77 118 8 Center Distance inches cm 11 5 29 2 Chaincase Center Distance inches 8 373 Top Gear Stock 25 Bottom Gear Stock 41 Chain Stock 76 Gear Lube Polaris Synthetic Capacity oz ml 11 325 3 Reverse System Perc Electrical Alternator Output Operating Voltage 13 5 14 5 Vdc Watts 13 5 Vdc Total 400 18 21700 RPM ining Coolant Temp 120 F 49 C Spark Plug Gap in mm 027 70 Spark Plug Champion RN57YCC Track Width Inches cm 15 38 Length Inches cm 121 307 3 1 2 54 Lug Height Inches cm 1 25 3 175 Dragon inches mm eee 017 026 44 6
28. 9 12 2008 SHOCK VALVE SHIM STACK CONFIGURATIONS 9 13 OPTIONAL SHOCK SETTINGS ee RET 9 15 WALKER EVANS AIR 9 15 RYDE FX AIR 2 0 9 15 SHOGKAVAINTENANG Evie oh s E BEL uda tt eut duci 9 16 RYDE FX AIR 2 0 SHOCK 5 8 9 16 RYDE FX AIR 2 0 SHOCK 9 18 WALKER EVANS AIR SHOCK DISASSEMBLY 9 20 WALKER EVANS AIR SHOCK ASSEMBLY 9 20 WALKER EVANS REMOTE RESERVOIR PIGGY BACK SHOCK DISASSEMBLY 9 21 WALKER EVANS REMOTE RESERVOIR PIGGY BACK SHOCK ASSEMBLY 9 22 RYDE FX REMOTE RESERVOIR SHOCK DISASSEMBLY 9 23 RYDE FX REMOTE RESERVOIR SHOCK ASSEMBLY 9 24 RYDE FX MONO TUBE SHOCK 9 26 RYDE FX MONO TUBE SHOCK 9 27 FOX PS 5 DISASSEMBLY de 9 27 FOX PS 5 ASSEMBLY uu the ah eed A es Reden 9 28 WINNING PERFORMANCE 9 1 gt POLARIS Shocks SPECIAL TOOLS Shock Rebuilding Tools Special Tools
29. 6 9 Drive System Terminology Backshifting 7 2 Clutch Weight 7 2 Drive Spring 7 2 Driven Spring 7 2 Engagement RPM 7 2 Final Gearing 7 3 Helix Ramp 7 3 Low High Ratio Lines 7 3 Neutral Speed 7 2 Shift Out Overrev 7 2 Driven Clutch Removal 7 18 Driven clutch installation 7 18 2 e e QE UT 6 7 Assembly View Electronic Speedometer Type 6 8 Assembly View Speedometer Cable Type 6 7 Electric Reverse PERC 11 18 Electric Start IQ 11 11 Electrical Specifications 11 2 Electrical System Maintenance 3 21 Headlight Bulb Replacement 3 21 Engine Component Assemblies 5 17 2007 2008 600 700 800 CFI Oil Hose Routing 5 32 2007 2008 600 700 800 CFI Recoil Stator Assembly 5 26 2007 2008 600 700 800 CFI Water Oil Pump Assembly 5 31 2007 2008 600 700 CFI Crankcase Crankshaft Assembly 5 27 2007 2008 600 700 CFI Cylinder Head Cylinders Pistons 5 22 2008 800 CFI Crankcase Crankshaft 5 29 2008 800 CFI Cylinder Head Cylinder Pistons 5 24 600 HO Carbureted Crankcase 5 20 600 HO Carbureted Cylinders Cylinder 5 17 600 HO Carbureted Pistons Crankshaft 5 19 600 HO Carbureted Recoil Magneto 5 18 600 HO Carbureted Water Oil Pump 5 21 Engine Data Formulas 2 5 Compression Ratio 2 5 Compression Ratio Example 2 6 Head cc Removal Exam
30. SQUEEZE CLAMPS NEC HOSE CYLINDER HEAD OUT TO FRONT COOLER FRONT TUNNEL COOLER GEAR CLAMP WINNING PERFORMANCE C POLARIS 5 45 Engine and Cooling Systems 2008 IQ Shift CFI 600 700 121 and Switchback Cooling System RH PERIMETER COOLER HOSE TUNNEL COOLERS OUT TO SURGE TAN HOSE FRT COOLER OUT TO SURGE TANK HOSE BYPASS TO FRT COOLER SURGE TANK CAP HOSE ENGINE OUT TO TUNNEL COOLER HOSE SURGE TANK OUT TO ENGINE IN THERMOSTAT OPEN W CROSS OVER HOSE 5 46 WINNING PERFORMANCE gt POLARIS Engine and Cooling Systems 2008 800 CFI RMK 155 Cooling System HOSE TUNNEL COOLER TO SURGE TANK lt HOSE ENGINE OUT TO TUNNEL COOLER SURGE TANK THERMOSTAT OPEN SQUEEZE CLAMPS HOSE THROTTLE BODY OUT SURGE TANK Q FRONT TUNNEL COOLER FOAM PAD D gt HOSE CYLINDER HEAD OUT FRONT COOLER HOSE SURGE TANK TO ENGINE IN 2 HOSE FRONT COOLER OUT SURGE TANK 2 GEARGEAMP 2008 800 CFI RMK 163 No Bypass Cooling System HOSE TUNNEL COOLER TO SURGE TANK SURGE TANK HOSE ENGINE OUT TO TUNNEL COOLER THERMOSTAT OPEN Q SQUEEZE CLAMPS HOSE THROTTLE BODY OUT TO SURGE TANK HOSE SURGE TANK TO ENGINE IN 2 GEAR CLAMP S PeLARIS Engine and Cooling Systems EXHAUST SYSTEMS Assembly View Typical 600
31. WOKE m 64mm STROKE 68mm STROKE 70mm STROKE Degrees BTDC MM Inches MM Inches MM Inches 1 0 0061 0 0002 0 0066 0 0003 0 0067 0 0003 2 0 0244 0 0010 0 0262 0 0010 0 0270 0 0011 3 0 0548 0 0022 0 0590 0 0023 0 0607 0 0024 4 0 0974 0 0038 0 1048 0 0041 0 1078 0 0042 5 0 1522 0 0060 0 1637 0 0064 0 1684 0 0066 6 0 2190 0 0086 0 2356 0 0093 0 2424 0 0095 7 0 2979 0 0117 0 3205 0 0126 0 3298 0 0130 8 0 3889 0 0153 0 4184 0 0165 0 4305 0 0169 9 0 4919 0 0194 0 5291 0 0208 0 5445 0 0214 10 0 6068 0 0239 0 6528 0 0257 0 6717 0 0264 11 0 7336 0 0289 0 7892 0 0311 0 8121 0 0320 12 0 8723 0 0343 0 9383 0 0369 0 9656 0 0380 13 1 0227 0 0403 1 1001 0 0433 1 1321 0 0446 14 1 1849 0 0466 1 2745 0 0502 1 3115 0 0516 15 1 3586 0 0535 1 4614 0 0575 1 5038 0 0592 16 1 5439 0 0608 1 6606 0 0654 1 7089 0 0673 17 1 7406 0 0685 1 8722 0 0737 1 9266 0 0758 18 1 9487 0 0767 2 0960 0 0825 2 1569 0 0849 19 2 1681 0 0854 2 3319 0 0918 2 3996 0 0945 20 2 3986 0 0944 2 5798 0 1016 2 6547 0 1045 21 2 6402 0 1039 2 8395 0 1118 2 9220 0 1150 22 2 8927 0 1139 3 1110 0 1225 3 2013 0 1260 23 3 1560 0 1243 3 3941 0 1336 3 4927 0 1375 24 3 4300 0 1350 3 6887 0 1452 3 7958 0 1494 25 3 7146 0 1462 3 9946 0 1573 4 1106 0 1618 26 4 0096 0 1579 4 3117 0 1698 4 4369 0 1747 27 4 3149 0 1699 4 6399 0 1827 4 7746 0 1880 28 4 6303 0 1823 4 9789 0 1960 5 1235 0 2017 29 4 9558 0 1951 5 3287 0 2098 5 4835 0 2159 30 5 2911 0 2083 5 6891 0 2240 5 8543 0 2305 31 5 6361 0 2219 6 0598 0 2
32. 3NI9N3 g 21 000 5155 2 31000W 102 8 034 119 S0 S lll0OF H3SWON luvd SS3NHVH 318Vl NOLLVNIWHSL 3HIM NOLLONNS YOLISNNOD OL ALIAVS YOLISNNOD 39nv9 30705 x 10 8980 92 3 0 62 01 luvd SSSNYVH 318 1 NOLLVNIWHSL PERFORMANCE POLARIS WINNING 12 12 iagrams D iring W 2008 IQ Shift RMK Hood Harness SET SWITCH C WH BK MODE SWITCH o2 um TACH P ACC TACH PUE LAMP SPEED PULSE POWER RELAY COIL 76 RD WH OPTIONAL RIDE 0G BK RIGHT HEADLAMP ENGINE TEMP aura SENSOR GND RI co 12 BN WH YE lee eee Se RE COLOR LEGEND BEIGE TAN BLACK LIGHT BLUE DARK BLUE NC NORMALLY CLOSED BROWN NO NORMALLY OPEN GRAY LIGAT GREEN HARNESS 2410906 02 DARK GREEN amp 2410697 ORANGE PINK RED VIOLET PURPLE WHITE 08 DB RD YELLOW r 12 BN WH EN E COLORS ARE SHOWN 25 WH WITH MAIN TRACE COLORS XAMPLE RD YE R ITH SELON TRACE idi HIGH BEAM 26 YE RD LED D WH RD WH all feet 2 L o 21 VT WH Wa 1 do 01 WH BK 1 2 3 4 5 6 07 06 8 1 8 9 21
33. RH ENGINE STRAP 4 7 j s lt 2 ENGINE MOUNT 2 2 2 s fa ENGINE MOUNT CLINCH PLATE A 28 Ft Lbs 38 Nm B 15 Ft Lbs 20 Nm C 30 Ft Lbs 41 Nm NOTE Use an engine mount socket PN 2871989 to remove the engine mounts from the bulkhead 5 16 WINNING ERFORMANCE gt POLARIS Engine and Cooling Systems ENGINE COMPONENT ASSEMBLIES 600 HO Carbureted Cylinders Cylinder Head BLEED AT f 9 WASHERS e THERMOSTAT CYLINDER HEAD O RINGS HOUSING J HEAD COVER THERMOSTAT 9 ee KNOCK SENSOR THERMO SENSOR D CYLINDER HEAD CYLINDER BASE GASKETS 8 Loosen all then remove the cylinder bolts Clean the bolt T threads to remove any thread locking residue 9 Carefully pull each cylinder upwards taking care not to 70 In Lbs 8 Nm drop the piston and rod abruptly against the crankcase B 9 Ft Lbs 12 Nm Apply Loctite 242 10 Remove the cylinder base gaskets Use a gasket scraper to C 25 Ft Lbs 34 Nm Apply Loctite 242 clean the gasket residue from the crankcase and cylinder D 18 Ft Lbs 24 Nm Apply Pipe Sealant bases E 168 In Lbs 19 Nm Clean and Dry 11 Inspect the cylinder walls Nicasil cylinders can only be F 97 Ft Lbs S0 Nm lightly honed Damage that cannot be removed with a light hone requires cylinder replacement or re lining 12
34. o 1 4 3 4 12 5 THROTTLE OPENING TYPICAL MIKUNI VM gt Throttle Valve Cut Away Jet Needle Needle Jet DECREASING WINNING PERFORMANCE 4 9 gt POLARIS Fuel Systems FUEL PUMP Fuel Pump Overview FUEL IN FROM TANK lt N IMPULSE HOSE FITTING ei 7 ALWAYS ON BACK OF PUMP The impulse powered fuel pump on carbureted engines works by using the positive and negative pressure pulses generated by the movement of the pistons inside the engine crankcase When the MAG piston is on the upward stroke negative vacuum pressure pulse is applied to the fuel pump This action draws fuel into the pump from the fuel tank When the MAG piston is on the downward stroke a positive pressure pulse is applied to the fuel pump This action forces fuel from the intake side of the pump to the supply side then to the carburetors A series of check valves prevents fuel from being drawn out of the carburetors on the vacuum stroke or forced back into the fuel tank during the pressure stroke 4 10 Maintenance The impulse operated powered fuel pump does not require any specific scheduled maintenance However the following procedures should be observed Operation The pump may be checked for operation by removing the fuel supply line from the carburetor and placing it into a container With the engin
35. 48 89 600 48 9 801 Ng 250 660 LYO 88 90 890 48 89 801 45395 80 98 290 49 1 0 ATHW3SSV HOLIMS 1331 3849 38 9 H9IH MM aurin sro 3 U 590 80 08 10 80 48 680 1 0 90 100 80 38 90 HOLIMS HOLIMS 131 38 CD Ng 80 38 090 MHOSN3S 80 38 660 S00 30 35 lSnVHX3 30 55 3unssaud dWwal o 38055344 NOSN3S 34055384 0028 0096 v 01 814 170028 0092 v OL 070002 2 52 3 1 311108 110 31 207 MHoSN3sS 00062521 2 02 1 99 130006 2 2 3 51 3 65 3ONVISIS3U dW3L 805835 XOGUIV Ohan cor 1 110 HA OY 660 I QU 910 SS3NUVH 01 O3HOVLLY SI
36. gt Inspect each cylinder for wear scratches or damage If no damage is evident measure the cylinder for taper and out of round with a telescoping gauge or dial bore gauge Crankshaft Runout Inspection Measure the bore 1 2 from the top of the cylinder in line with the piston pin and 90 to the pin to determine if the bore is out of round Repeat the measurements at the middle and bottom of the cylinder Use the chart below and record all measurements Cylinder Measurement Worksheet TOP Y SUPPORT SHAFT AT TWO ARROWS MIDDLE 1 Support the crankshaft in a set of V blocks as shown x Y 2 Useadial indicator to measure the runout at the following locations BOTTOM PTO end First taper after bearing flat MAG end 1 2 from bearing flat 3 Runout deflection cannot exceed 0025 07mm Out of Round Top X Top Y and Bottom Y Bottom X If the runout deflection exceeds the maximum Taper Top Y Bottom Y and Top X Bottom X specification crankshaft trueing may correct the deflection POLARIS Engine and Cooling Systems Piston Inspection Check piston for scoring or cracks in piston crown or pin area Excessive carbon buildup below the ring lands is an indication of piston ring or cylinder wear On Fuji engines measure piston outside diameter at a point that is 1 2 12 7mm up form the bottom of the skirt at a 90
37. 080 IM QN 660 QU 05 65 N A 501 IW QU 001 YOLIDVdVD 101 p M 0014 uorv nosu noa 9 08 210 80 110 39 08 010 48 9 600 IM QU 800 80 90 100 80 900 S00 12 00 90 08 00 VNo N33 HM 80 20 SLLSONSVIG k 5 120 50 90 920 X8 620 49 10 9S0 08 260 90 0 90 0 30 35 SISSVHO 2 GOOH SISSVHO 80 98 0 0 90 38 090 E NO 031201 uouv nos r uso 1901 9 190 13486 130 NO 031201 YOSN3S G33dS NG 2004 10 14 NONO 49 14 100 Ay Y NH NI 03004 90 150 20 SZO MO LIOVdVO 133456 0S0
38. 14 35 6 1 37 Model Specifications 2008 700 RMK 155 700 Dragon RMK 155 163 Model Number Base 155 SO8PM7JS Dragon 155 S08PG7JS SOSPG7JE Dragon 163 508 715 SOSPH7JE Engine Engine Type Ties eed s Model Number S3471 7044 PU7J Displacement Cylinders 599 2 Bore inches mm 3 19 81 Stroke inches mm 2 67 68 Piston to Cylinder Clearance inches mm 0044 0059 112 151 Installed Ring Gap inches mm 017 026 44 650 Operating RPM 0 300 8250 Idle RPM 1700 Engagement RPM 200 3800 Exhaust Valve Spring Pink Fuel Delivery Type Cleanfire Direct Injection Throttle Body Marking 1203213 Throttle Body Bore 46mm TPS Voltage Idle 0 95 0 01 Vdc Fuel Pressure PSI bar 58 4 0 Recommended Fuel Octane R M 2 91 Non Oxygenated Clutch Settings DRIVE CLUTCH DRIVEN CLUTCH Shift Clutch Clutch Driven ini Weight Spring Spring Helix earing 0 600 0 2000 10 66 600 1200 2000 4000 0 64 1200 1800 m 4000 6000 uy 220 20 41 76 1800 2400 n 7 1043063 LW ER 6000 8000 2400 3000 8000 10 000 0258 3000 3600 10 000 12 000 10 56 Drive Clutch Bolt Torque 80 Ib ft 108Nm 1 38 General Width in cm
39. 4 28 gt POLARIS Fuel Systems Fuel Rail Bleeding Pressure Testing All CFI engine fuel return hoses feature an inline Schrader valve that can be used to bleed the fuel system pressure and observe running system pressure using a fuel pressure gauge SCHRADER VALVE 312203 SCHRADER VALVE The model year and engine model will determine which fuel pressure tool adaptor is required to complete both tasks Pressure Bleed Testing Tools PRESSURE YEAR MODEL BLEED TooL ADAPTOR 2007 600 CFI Shallow Core None Deep Core PV 43506 A PS 48617 2007 700 CFI None 2008 ALL CFI PS 48762 1 Select the appropriate adaptor 2 Connect the adaptor to the fuel return hose Schrader valve 3 Connect the adaptor to the fuel pressure bleed tool gauge PV 43506 A 4 observe running fuel system pressure start the engine and compare reading to the specification In mm 600 700 800 CFI Fuel System Pressure 58 PSI 4 bar WINNING PERFORMANCE gt POLARIS 5 To bleed the fuel system pressure after the engine is stopped place the tool s bleed hose into an appropriate fuel handling container Open the valve to release the pressure and residual fuel 6 Close the valve then remove the gauge and adaptor from the fuel hose Schrader valve Replace the Schrader valve dust cap Disconnect Fittings The fue
40. WHITE YELLOW TWO WIRE COLORS ARE SHOWN WITH MAIN TRACE COLORS EXAMPLE RD YE RED WITH YELLOW TRACE ECU B WIRE ENTRY VIEW VC ENGINE GROUND W CHASSIS GROUND NC SWITCH NORMALLY CLOSED NO SWITCH NORMALLY OPEN HARNESS 4011605 02 WH YE H2 WH RD 44 WH DG 12 DG YE 15 DB YE 14 DB YE RESISTANCE 152 AT 20 C COLORS RESISTANCE OHMS YELLOW YELLOW 0 13 GREEN RED GREEN YELLOW 15 GREEN RED BROWN WHITE 30 BLUE YELLOW BLUE YELLOW 2 4 WHITE RED WHITE 190 WHITE GREEN GREEN 190 BROWN WHITE GROUND 0 BROWN GROUND 0 PRIMARY WITHOUT PLUG CAP SECONDARY PLUG CAP A2 YE RD WH A RD DB lt 2 YE WH lt RDIDB 82 06 BI RD DB DG WH 06 YE WH XE WH D2 DG WH DI RD DB 06 DB YE DB YE 06 BN BN BN 06 80 DG YE WH DG WH RD BK DB CHARGE COIL D E
41. www polarisdealers com 8 NOTE Only authorized Polaris dealers and distributors can access the dealer Internet website 1 Log on to www polarisdealers com Locate the SERVICE AND WARRANTY drop down menu 3 Click on DIGITAL WRENCH UPDATES The next screen is the Digital Wrench portal website WINNING PERFORMANCE POLARIS Home Digital Wrench Home Page Downloads Listing of current filesets and Digital Wrench downloadable updates Forums Member generated knowledge base Search Website search engine Topics Vehicle specific Digital Wrench information Locate the version of Digital Wrench currently running on the PC or laptop Locate and click on the fileset or service pack required to update the software Save the file s to the PC or laptop s desktop Locate the update file s on the desktop Double click and select RUN on the icon to install the update Delete the file after performing the update NOTE Delete the update file from the desktop when finished 4 37 Fuel Systems Version Fileset Identification Knowing what Digital Wrench or fileset versions are installed will help determine which updates are required NOTE Version and fileset versions are subject to change 1 Start the Digital Wrench software 2 Locate the version ID on the title screen Digital Wrench CH 600 H amp Status
42. 24 VT rz p SWITCH HIGH TEMP am Y EE RD 21 BK WH O lt gt MOSCOW CD 2205 05 SSIS SINR c osx 5732 5215555 gt S 12 13 PERFORMANCE gt POLARIS WINNING Harness 1 of 2 15 iagrams D iring 2008 IQ CFI Chass W 055322 Z 39NVHO 58155 300W 011089 839901 808838 VIVO 3008 B 88 5155 321785 18 101 93H r 001 NG 180 49 080 09 08 LEO HMI WG 92044 19 9 680469 391185 A HA QN 011452 R 5 lt 211 08 60 5 HW 08 601 Mo1v no3ad 200111 48 860 l 4 t Qu 48 560 011 HAI
43. BUSHING e ROD A PITMAN ARM ASSEMBLY e lt 2 5 B BUSHING ROD END IDLER ARM ASSEMBLY NOTE 2008 IQ steering linkage shown 2007 models Linkage Assembly Measurements feature adjustable steering links IQ 42 5 Tie Rod Length 15 06in 382 5mm IQ 42 5 Adjustable Steering CAUTION Brag tink Length 14 78in 375 4mm Never re use lock nuts Always re assemble using new 42 3 Fix d Steering Drag 15 31in 389mm Link Length lock nuts IQ 42 5 Steering Link Length 9 30in 236mm T IQ RMK Tie Rod Length 13 66in 345mm IQ RMK Fixed Steering Drag 29 Ft Lbs 40 Nm Link Length B 11 Ft Lbs 15 Nm Rod end jam nuts IQ RMK Steering Link Length 9 30in 236mm NOTE Orientate rod ends so they are parallel with NOTE Measurements rod end center to center mating component with rod ends perpendicular to tie rod 8 8 WINNING PER FORMANCE gt POLARIS Steering and Suspensions Handlebar Assemblies THROTTLE LEVER MIRRORS HANDWARMER GRIP 90 CLAMPS 16 Ft Lbs 21 Nm HEADLIGHT LOW HIGH SWITCH BLOCK MOUNTAIN BAR 0 ____ 16 Ft Lbs 21 Nm ADAPTER TIGHTEN FRONT SCREWS FIRST THROTTLE BLOCK d HANDWARMER SET SCREW 3 40 In Lbs 4 5 Nm p COVER HAND TIGHT HAND TIGHT RISER
44. WASTER PUMP COVER GASKET WASTER PUMP COVER A lt gt WASHER OIL PUMP 0 CROSS SHAFT 6 4 TEE FITTING 2 Remove the airbox exhaust pipe and resonator Remove S T the hose connected to the water pump cover 3 To access the impeller and mechanical seal remove the A 7 Ft Lbs 9 5 Nm water pump cover Discard the water pump cover gasket B 10 Ft Lbs 13 Nm 4 Remove the impeller nut impeller and washers from the C 9 Ft Lbs 12 Nm cross shaft 5 Carefully pry the mechanical seal and seal out of the Disassembly Assembly Process a IMPORTANT Use the mechanical seal installation Water putip assembly 15 the reverse ot disassembly tool to install the water pump seal PN 2872010 Always use new seals and gaskets during assembly To remove the oil pump remove the two fasteners then pull 1 Remove the coolant from the engine using a siphon wet the pump cover out of the crankcase bore Discard the dry vac or a drain pan 5 31 Engine and Cooling Systems gasket 10 Assembly is the reverse of disassembly Always use new 8 To remove the oil pump cover remove the two fasteners o rings seals and gaskets during assembly then pull the pump cover out of the crankcase bore 11 Install a new seal onto the shaft from the water pump side Discard the gasket 12 To install a new water pump seal use the se
45. 1 41 Model Specifications NOTES 1 42 gt POLARIS General Information CHAPTER 2 General Information SNOWMOBILE NUMBER 2 2 MODEL NUMBER DESIGNATION iiis ttr lace t t Etre a Rachid 2 2 VEHICLE IDENTIFICATION NUMBER 2 3 TUNNEL DECAL 2 3 VIN NUMBER 5 EE XAR ava 2 3 PUBLICATION PART NUMBERS sk eee Y 2 4 2008 PUBLICATIONS secre Er Geel Serre Ee de Pte hw eh OVES 2 4 20072 PUBLICATIONS GN 2 4 ENGINE DATA FORMULAS te daro as thecae robuste 2 5 COMPRESSION dite pontine eite 2 5 COMPRESSION RATIO EXAMPLE esed aces 2 6 HEAD REMOVAL EXAMPLE PAR I RR 2 6 PORT OPENING D RBATION 2 6 TORQUE CONVERSION I oou ek eod 2 7 US TOMETRIC Sa um r ui up 2 7 GENERAL REFERENCE hin Dore Kuwa det 2 8 STANDARD BOLT TORQUE 2 8 FUEL PREMIX RATIOS aeo o usce cx d RARE en 2 8 GASOLINE VOLATILITY uere inito Duces ge tte sede tege Tune
46. 8 42 Oil Pump Rear Suspension Ride Height 8 37 Bleeding 311 Rear Suspension Shock Rod Orientation 84 Optional Shock Settings 9 15 Rear Suspension Type by Model 8 3 Rear Suspension Weight Transfer 8 36 Walker Evans 9 15 Optional Shock Valve Shims Rear Track Shock Pivot Orientation 8 4 Recoil Assembly 5 11 gt POLARIS Reed Valve 5 6 V Reed Valve Disassembly 5 6 Variable Exhaust Systems VES 11 17 RMK FTA set up recommendations 8 38 Vehicle Identification Number 2 3 10 5 Tunnel Decal 2 3 VIN Designation 2 3 Scissor Stop Adjustments 8 37 VIN ee ee ee 2 3 Seat Cover Replacement 10 10 IQ 121 10 7 IQ Removable 10 7 IQ Touring 10 8 10 9 Service Precautions 2 11 Shock Maintenance 9 16 Air 2 0 Shock Assembly 9 18 Air 2 0 Shock Disassembly 9 16 Ryde FX Remote Reservoir Assembly 9 24 Ryde FX Remote Reservoir Disassembly 9 23 Walker Evans Air Shock Assembly 9 20 Walker Evans Air Shock Disassembly 9 20 Walker Evans Remote Reservoir Assembly 9 22 Walker Evans Remote Reservoir Disassembly 9 21 Shock Piston Orientatio
47. E eS 125 34 WH 1 PIN C lt 42 BN WH 14 BN Lm dd SPEED SENSOR GROUND SPEED LOCATED ON pog rn 2550 jL SES DRIVE SHAFT 11 06 BK 353 382 30 i ppp 2 1 1 aS 10 YE E8 08 80 48 E ay 437 i 5 YE er GY 1 ELECTRIC START 7 46 80 1 a Se TIT t6 8 80 16 TE SLOP 22 IPAP PEP PSPS POS PAPI IM CDI MODULE PAGE 2 19 YE 17 RD CHASSIS REGULATOR E5 5 1121314151611 818101112131 41516111 CONNECTOR 4 4 _ 1 _ _ _ u LLL s CONNECTOR 25 25 CUTS STDE gt i ae E26 DB YE 26 45 BN p 2 1 01 4 20 421 2 193 48 ON L_ I EN com SEE E23 WH YE 1 ds GROUND BN aS as Rim 4 E E24 DB WH Be 53 12 BN e m 1 al BK R lt 1 553 BIRD DC pc i BI Bo m HIZ GROUND GROUND El Be C 2 RD 3 see ep E 5
48. Ee Tq 5469 14 mm 5512 Metric Drill Sizes 2 916 5625 5781 15 mm 5906 i iH Si Decimal Nearest 19 393 5938 Tap Size Drill Size Equivalent Fraction TNR e ede 6094 3x 50 39 0 0995 932 s 5 8 62 60 16mm 6299 3x 60 3 32 0 0937 3 32 41 64 ee 2 m 21 32 j mm 4x 70 30 0 1285 1 8 6719 4x 75 1 8 0 125 Wee 1116 2225 s sala 6875 5 80 19 0 166 11 64 45 64 7031 18 mm 7087 D gus 23 abite ue 5 90 20 0 161 5 32 47 64 S E 7344 19 mm 7480 6 1 00 9 0 196 13 64 3 4 75 7x1 00 16 64 0 234 15 64 49 64 7656 25 32 7813 20 mm 7874 8x1 00 J 0 277 9 32 302 I pos 8x1 25 17 64 0 265 164 eee 222623 8125 21 mm 8268 9x1 00 5 16 0 3125 5 16 8281 9 1 25 5 16 0 3125 5 16 20 BU Der ge 2 10 1 25 11 32 0 3437 11 32 10x1 50 R 0 339 11 32 8906 23 mm 9055 11 1 50 3 8 0 375 3 8 P EAE Dee Sa Se SSE Ss 12x1 50 13 32 0 406 139 ears FR ME assum uc Cen 12x1 75 13 32 0 406 13 32 61 64 s ipee E em 9531 31 32 9688 25 mm 9843 aM e 9844
49. 17 To install the bearing press on the bearing outer race from the inside of the cover until fully seated Install the snap ring making sure it is seated in the groove Lightly coat the outer edge of each new seal with oil then install with the seal lips facing each bearing from the backside of the case WINNING PERFORMANCE POLARIS 18 Inspect the jackshaft seal sleeve for abnormal wear and tear Replace the o ring with a new part Chaincase Assembly 1 2 Install the jackshaft seal sleeve and new ring on the jackshaft Install the jackshaft installation tool PN 2871296 on to the end of the jackshaft or wrap electrical tape over the jackshaft splines Carefully re install the chaincase Install the chaincase fasteners and nuts Hand tighten the nuts so that the chaincase can still be moved Install the driveshaft back into the chaincase Remove the jackshaft installation tool from the jackshaft then install the jackshaft alignment tool PN 2871535 on to the jackshaft Torque all of the chaincase fasteners to specification using a criss cross pattern e Chaincase Mounting Fasteners 28 Ft Lbs 38 Nm DO NOT OVER TORQUE FASTENERS Remove the jackshaft alignment tool Install the brake caliper and torque fasteners to specification ey Brake Caliper Mounting Fasteners 19 21 Ft Lbs 26 28 Nm 8 Torque speedometer driveshaft flange nuts
50. 347 Square 77 Softest PN 7043240 067 PN 7043241 067 359 Square 12 58 Stock PN 7043079 067 PN 7043080 067 Rear Travel Inches cm 14 35 5 WINNING PERFORMANCE gt POLARIS 1 27 Model Specifications 2008 600 IQ LX Model Number SOSPD6HS Engine Engine Type phe Model Number 53468 6044 6 Displacement Cylinders 599 2 Bore inches mm 3 04 77 25 Stroke inches mm 2 52 64 Piston to Cylinder Clearance Gnches mm 004 006 105 159 Installed Ring Gap inches mm 014 020 356 508 General Width in cm 48 121 9 Length in cm 115 292 1 Height in cm 48 5 129 5 Estimated Dry Weight Ib kg 475 218 2 Fuel Gallons Liters 117 443 Oil qts l 3 2 8 Cooling System Capacity 85 8 Quarts Liters Brake Fluid DOT 4 Drive Belt Part Number 3211122 Width inches cm 1 460 3 7 Side Angle 26_ Circumference inches cm 46 77 118 8 Center Distance inches cm 11 5 29 2 Chaincase Center Distance inches 8 373 Top Gear Stock 23 Bottom Gear Stock 39 Chain Stock 76 Gear Lube Polaris Synthetic Capacity oz ml 11 3325 3 Reverse System Perc Electrical Alternator Output Operating Voltage 13 5 14 5 Vdc Watts 13 5 Vdc Total 400 18 1700 RPM Ignition Timing Coolant Temp 1
51. 7038 011089 OV 19915 21812313 011089 91 NMOUE GNNOYD 24 1 321145 080089 20 830835 13A31 1303 04 311 NMOUB 398 19311 8 19915 21812313 321145 443119 91 038 OV 1H9I TII VI 011089 81 TWNOIS 9 OV 1891111 1 HOLIMS 3949 8 JONVYO 43MOd 1891111 1 321145 41804 OV 8 M01134 GNNOYD 20 28 321145 ONNOY9 20 0112 4 2 81 311 NMOUB 40089 20 305135 03385 80112 4 2 81 31 IHM NMOUB 33804 805835 03345 305135 03385 80112 4 2 02 311 39NYHO 4015 QuvH HOLIMS NOILINOI HOLIMS 4015 81 30718 398 Au311V8 HOLIMS NOILINOI 321145 443119 81 038 1081802 01083105 131 HOLIMS NOILINOI 18 15 21812313 02 118 311 411089 5155 2 HOLIMS NOIIIN9 1810849 81 NMOUG TWNOIS 130 305115 130 010089 SISSVHD HOLIMS NOILINOI 83H131 8 4015 QuvH HOLIMS NOILINOI 83 131 81 X2v18 834835 1313 2 000 5155 2 830835 13437 1303 02 31 IHM 131014 180089 20 3 31 110 18055322 81 3LIHM NMOUG 019 541 405115 541 12V 18 010089 20 21 321145 4800849 20 33804 1081802 H1 8 31 1HM NMOJB 1 915 541 305115 541 101134 43MOd 321145 u3MOd OV 33804 1081802 H1 91
52. Clutch Spacer 130 3 3mm 4 Install spider washer s and spider aligning the X with the moveable sheave s X Notice as the spider seat location is changed the sheave marks made before disassembly no longer align C There are two ways to bring the sheave marks into alignment Gb Vary the amount and thickness of spacer washers washer thickness may vary slightly Re index marked spider leg to another tower This can be done because spider has little effect on overall clutch balance Re indexing the spider 1 3 turn clockwise or 1 leg will allow the realignment of the moveable and stationary sheaves as previously marked D For EXAMPLE 0 020 or 0 032 0 5 0 8mm washer removed re index spider clockwise 1 3 turn NOTE Alignment marks on the sheaves should be with in 1 25 4mm after final assembly and torquing 7 17 PVT System Drive Clutch Installation NOTE Always clean the clutch taper before re installing clutch on engine 1 Place a clutch taper reamer PN 2870576 in a vise and lubricate the cutting edges with cutting oil Clean the clutch taper by manually rotating the clutch clockwise on the reamer one or two revolutions Only use the weight of the clutch and do not push down on the clutch while turning 2 Check crankshaft taper for galling or scoring If necessary clean the taper evenly with 200 grit emery cloth 3 The clutch taper and the crankshaft taper s
53. YUMACRON TYPE 100 CHARGED 1 265v 1 275v 75 CHARGED 1 210v 1 225v 50 CHARGED 1 160v 1 175v 25 CHARGED 1 120v 1 135v 0 CHARGED 1 100v lt 1 115v Off Season Storage To prevent battery damage during extended periods of non use the following maintenance items must be performed 1 Remove battery from machine and wash the case and battery tray with a mild solution of baking soda and water Rinse with of fresh water after cleaning CAUTION DO NOT ALLOW ANY OF THE BAKING SODA SOLUTION TO ENTER THE BATTERY OR THE ACID WILL BE NEUTRALIZED 2 Using a wire brush or knife remove any corrosion from the cables and terminals 3 Charge at a rate no greater than 1 10 of the battery s amp hr capacity 4 Store the battery in a cool dry place NOTE Stored batteries lose their charge at the rate of 196 per day They should be fully recharged every 30 to 60 days during a non use period If stored during winter months the electrolyte will freeze at higher temperatures as the battery discharges Specific Gravity Freezing Point Specific Gravity of Electrolyte Freezing Point 1 265 59 C 1 225 F 37_C 1 200 17 27 1 150 5 15 1 100 18 F 8 C 1 050 27 3 C WINNING PERFORMANCE POLARIS Battery and Electrical Systems IGNITION TIMING Timing Procedure Carbureted Engines NOTE Always verify timing
54. cael ave Sako ata ORENSE 7 15 ROLLER 1 7 15 CLUTCH ASSEMBLEY lt c 7 16 SPIDER INDEXING eere rope ee be tu at ee 7 17 DRIVE CLUTCH 1 7 18 DRIVEN CLUTCH sn aka eee nati ie d adea 7 18 DRIVEN CLUTCH REMOVAL 1 7 18 DRIVEN CLUTCH 7 18 TEAM LWT 7 19 7 1 GP POLARIS The Way Out PVT System PVT SYSTEM Overview AX CAUTION Because of the critical nature and precision balance in corporated into the PVT system itis absolutely essen tial that no attempt at clutch disassembly and or repair be made without factory authorized special tools and service procedures Polaris recommends that only au thorized service technicians that have attended a Po laris sponsored service training seminar and understand the proper procedures perform adjust ments or repairs The Polaris drive system is a centrifugally actuated variable speed belt drive unit The drive clutch driven clutch and belt make up the torque converter system Each clutch comes from the factory with the proper internal components installed for its
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56. 180M STARTER LOCKOUT 180F AC POWER RED 18 ELECTRIC START 180M CIRCUIT BREAKER 250F BATTERY WHITE RED 18 ELECTRIC START 180M START SOLENOID 156M STARTER SWITCH GREEN WHITE 18 STARTER LOCKOUT 180F START SOLENOID 156F LOCKOUT GROUND BROWN 18 STARTER LOCKOUT 180M BATTERY GROUND 1 4R BATTERY GROUND L 05 BREAKER CIVNOILdO 08 AU311V8 30 401 NO 431 201 uva START SOLENOID LOCATED ON TOP OF _ _ OPTIONAL 6 GAUGE BATTERY BOX BATTERY OPTIONAL STARTER OPTIONAL 12 9 gt POLARIS ft Hood Harness iagrams D iring 2008 IQ Sh dNV10V3H LHOIN dAV1OV3H 1331 NMOUS dAV1OV3H 1 913 dAV1QViH 1331 3349 XQ dAV1OV3H 1 918 dNV1OV3H 1331 038 401134 NV I0VIH anv 1GV3H 0387801131 121145 3104 57 M01131 48 1 22V AAV 10V3H 1 918 13169 01 NO AYOSSIDV 121145 8304 OV DoW 1 Y dNVT 10 158138 M01131 yy 009 NO QUVONVIS AAV IOV IH 22V 43131003345 038 801134 22 dV 10H 3S83A3H 331 31003345 AAV 22V 3313800334S NMOUS 93139003345 93130003345 M01134 321145 93WO0d_ 3138003345 M01134 22 1 9 1 10H 3S83JA38 0
57. 2 1 1 1 Idle RPM 1500 2400 3000 310 300 290 280 270 260 250 240 Engagement RPM 200 3800 8000 10000 2 2 2 1 41 1 1 Exhaust Valve Spring Pink 3000 3700 290 280 270 250 240 230 220 210 10000 12000 2 2 1 1 1 1 1 1 Carburetor Settings When using non oxygenated fuel with a RON greater than 93 T decrease the main jet number in the above chart by 10 and raise the Mikuni TM38 E clip one position If the chart recommends clip 1 install washer Main Jet 420 on top when using RON 93 22 Clutch Settings Jet Needle Clip position 9DGN6 57 2 ALTITUDE DRIVE CLUTCH DRIVEN CLUTCH Necole det p m Shift Clutch Clutch Driven Gearing Throttle Gap Under Cutaway in mm 0 08 2 1 eet Weight Spring Spring Helix 0 600 64 42 36 Cutaway 1 5 Notch 0 2000 10 62 39 7 Valve Seat 1 5 600 1200 2000 4000 Starter Jet 145 10 58 BLK GRN RED BLK 22 40 76 Pilot Air Jet 6 120 340 140 240 1800 24 56 42 Fuel screw Turns Out 1 25 6000 8000 10 56 91 2400 3000 1 Recommended Fuel Octane R M 2 Non Oxygenated 3000 10000 10 54 20 41 76 3000 3600 10000 12000 0 AL Drive Clutch Bolt Torque 50 Ib ft 68Nm WINNING C POLARIS PERFORMANCE 1 4 Model Specifications
58. 32V18 311HM 031 130 1 19 3 5155 2 01131 118 HOLIMS 3007 2 GOOH SISSVHD 33104 1081802 H1 02 038 311HM 031 3543 34 3NI9N3 SISSVH2 NNOYD OV 321145 N0089 8 8310 011089 8 031 10H 3N19N3 SI1SSVH2 311 7118 54 1 0 3 MOT OOH SISSWHO 83804 1041802 H1 91 13389 019 01083105 Aj JNI9N3 SISSVH M0113A 311HM 13831 110 00H SISSYH2 13431 110 8 13101 3313N0H2V1 3NI9N3 SISSVH2 118 01131 SdAV 10V3H H9IH OOH SISSVH 83 04 1081 02 H1 91 138 801131 1102 8351 fld HOSN3S 039 20 00H S1SSVH2 1 321145 GNNOYD 20 9 311 NMOU8 GNNOYD 801 1 5 305115 318 13345 080089 00H SI1SSVH2 305535 03345 8 034 N3349 11 831N32 1102 83 11313 1102 83112 3 9 33104 20 1 Q00H SISSVH 321145 8304 20 8 311 038 059 1102 1102 NOILIN9I y18 33804 321145 83004 18915 21812313 91 M01134A GND 405835 130 305135 130 9 039 3Y aNnoud 8017 11938 91 039 398VH2 831178 01 101938 321145 18311 8 91 038 33804 20 321145 43804 20 YOLVINDIY 8 3L1HM 03U 33804 OV 21 GOOH SISSVHD 301v 11938 9 M01134 NNOY9 OV 400 5155 8017 11938 9
59. 4 Ifreplacingalowerinjector remove the two bottom screws bolts from the lower fuel rail 5 Remove the failed injector s NOTE Make sure that the green rubber washer comes out with the failed injector s 6 Measure from the end of the injector as shown below 3 76 2mm and cut the injector off 3 76 2mm 7 Strip the harness end injector wire covering 25 375 6 35 9 525mm WINNING PERFORMANCE POLARIS 8 Crimp the ends of the new injector firmly on to the wire harness 10 Apply 2 stroke oil to the fuel injector o rings seal and mating surfaces fuel rail amp case sides 11 Remove the fuel injector cap 12 Insert the fuel rail with injectors into the engine 13 Apply a light amount of 262 Loctite to the fuel rail fasteners and torque to specification ey Fuel Rail Hex Screw Torque 9 ft lb 12N m 14 Replace the harness to the original routing and apply panduit straps back to the original locations making sure they are not applied over any mesh part of the fuel rail NOTE Refer to Step 2 for proper routing and strap location 15 Install the engine if it was removed 16 If different color injectors were installed you will need to re flash the ECU to accept the new colors 4 31 Fuel Systems 2007 700 CFI Fuel System RETURN FUEL HOSE SUPPLY FUEL HOSE BRACKET FUEL RAIL FUEL INJECTORS FUEL PUMP ASSEMBLY THROTTL
60. Center Distance inches cm 11 5 292 Ski Center Distance 39 99 1 40 101 6 41 104 1 Inches cm Chaincase Center Distance inches 8 373 Camber Inches cm 2 17 0 31 55 7 9 Top Gear Stock 19 Toe Out Inches cm 0 0 12 0 0 31 Bottom Gear Stock 41 Chain Stock 76 Rear Suspension Gear Lube Polaris Synthetic Capacity oz ml 11 325 3 Suspension Type IQ 144 155 Reverse System Perc Ryde FX STD Front Track Shock FTS Walker Evans Air OPT Electrical FTS Spring Rate Ibs in N 190 33 Alternator Output s in N mm Operating Voltage 13 5 14 5 Vdc FTS Spring Installed 7 4 18 8 Watts 13 5 Vdc Total 280 Length Inches cm Ienition Timin 26 3500 RPM Ryde FX STD TPS Un plugged Rear Track Shock RTS Walker Evans Air OPT Spark Plug Gap in mm 027 70 Rebuildable Spark Plug Champion RN57YCC WE Air Oil Volume 70 CDI Marking 4011033 WE Air Nitrogen Charge Stock 215 psi Flywheel Marking 4010677 Optional 210 220 psi Track 359 Square 77 Stock 347 77_ Soft Width Inches cm 15 38 PN 7041627 067 144 325 Torsion Springs PN 7041628 067 5 155 393 7 375 77 Firm Lug Height Inches cm 2 0 5 or 2 4 6 1 Track tension sag in cm with 10 155 4 54 placed 16 in 40cm ahead of rear idler shaft 3 8 1 2 1 1 3cm PN 7041942 067 PN 7041943 067 Rear Travel Inches cm 144 14 5 36 8 155 15 5 39 4
61. Center Retainer IMPORTANT The M 10 rear suspension has been designed to be very sensitive to rider weight Changes in rider weight of 25 165 or more may require appropriate changes in FRA settings LIMITER STRAP REAR TRACK SHOCK RESERVOIR 2 FRONT TORQUE ARM PRELOAD SPACERS CENTER RETAINER LOCATED IN SPRING STACK CARRIER WHEEL REAR TORQUE ARM COUPLER BLOCK 84321 Q S E so c FRONT TRACK SHOCK SPRING FULL RANGE ADJUSTER FRA M 10 TERMINOLOGY Coupler Blocks Plastic blocks located at the rear of each rail Blocks facilitate the couple function Full Range Adjuster FRA FRA refers to the adjustable lower rear shock attachments Changing the FRA location has two effects on tuning First moving the shock forward increases shock speed resulting in firmer damping on compression and rebound Second it also increases the effect of the rear spring by displacing it further Sag Settings The difference in rear bumper height from the sleds fully extended position to its lower height with the rider seated on the sled M 10 ADJUSTMENTS The primary adjustment on the M 10 suspension is the Full Range Adjustment FRA Adjusting the FRA will have the MOST effect on rear suspension performance Polaris recommends that you allow between 25 to 200 miles for the suspension to break in before performing any adju
62. NOTE The engine temperature must be approximately 120 F 49 C to obtain accurate timing specification Use the MFD digital temperature display to view engine temperature 6 Point the timing light at the timing inspection hole 7 With your head positioned so there is a straight line between your eye the stationary pointer and the crankshaft center line note the relative position between the marked flywheel line and the pointer If the stationary pointer is aligned with the mark made in Step 3 or within the acceptable variance ignition timing is correct NOTE The stator plate two tooth and five tooth crankshaft position sensor locations are not adjustable 8 Ifthe pointer is outside the variance either the flywheel key has sheared allowing the flywheel to move on the crankshaft the crankshaft is out of index a problem with the engine electrical harness exists or one of the crankshaft position sensors has moved 11 5 Battery and Electrical Systems Ignition Timing Chart NOTE Always disconnect the TPS on carbureted engines prior to checking ignition timing Convert the ignition timing specification from degrees BTDC to either inches or millimeters then use a dial indicator to verify timing marks 600 CARBURETED 700 CFI 800 CFI 128mm ROD 128mm ROD 132mm ROD
63. Spindles and bushings Skis and skags Pitman arms Idler arms A arms and bushings Shock absorbers shock mounts springs All related fasteners check torque Refer to steering exploded views at the beginning of this section Grease all fittings Always follow rod end engagement guidelines Maximum setup width must be checked whenever front suspension components are adjusted or replaced Camber Toe Specifications Maximum width and camber measurements are to be taken with the front end elevated and shocks at full extension Toe alignment is measured at ride height This means that the machine is on the ground and resting at normal ride height not full rebound Measure at a point 10 2 54cm forward of the ski mount bolt and 10 2 54cm behind the ski mount bolt preferably on the center line of the carbide skags Width is measured from the center of the spindles 8 2 Camber measurement is taken from the top of the alignment bar to the top of the ski mount hole in the spindle with the bushing removed Camber amp Toe Specifications MAXIMUM SET TOE OUT suspension UP WIDTHIn CAMBER At ride height 25in 6cm IQ 425 425 108 2284331 57 7 9 aus 0 3 05 2 17 31 IQ RMK 38 67 98 2 55 79 Springs When the front suspension encounters a bump the force of the bump compresses the spring If the bump force is 450 pounds a 100 in spring will co
64. WINNING PERFORMANCE gt POLARIS Model Specifications Front Suspension Suspension Type 10 42 5 Shocks Ryde FX MPV IFS Spring Rate Ibs in N mm eae Spring Installed Length Inches 9 95 25 3 Front Vertical Travel Inches cm 10 254 Ski Center Distance Inches cm 42 5 108 Setup Width 41 16 104 5 Camber Inches cm 2 25 0 31 57 7 9 Toe Out Inches cm 0 0 12 0 0 31 Rear Suspension Suspension Type IQ 136 Comfort Front Track Shock FTS Ryde FX MPV FTS Spring Rate Ibs in N mm 219 48 FTS Spring Installed Length inches cm Rear Track Shock RTS Ryde FX MPV Torsion Springs 405 16 Stock PN 7043347 067 PN 7043346 067 421 188 Firm PN 7043369 067 PN 7043368 067 Rear Travel Inches cm 14 35 6 WINNING PERFORMANCE gt POLARIS 1 31 Model Specifications 2008 600 RMK 155 Model Number SO8PM6HS SOSPM6HE Engine Engine Type Model Number 53468 6044 6 Displacement Cylinders 599 2 Bore inches mm 3 04 77 25 Stroke inches mm 2 52 64 Piston to Cylinder Clearance inches mm 004 006 105 159 Installed Ring Gap inches mm 014 020 356 508 Fuel Delivery Operating RPM 200 8250 Idle RPM 1700 Engagement RPM 200 3800 Exhau
65. 1 54 o A ma Rear Travel Inches cm 14 35 6 WINNING PERFORMANCE gt POLARIS 1 15 Model Specifications 2007 700 HO IQ Dragon Model Number SO7PC7JS SO7PC7JE Engine Liberty Liquid Cooled Engine pope Case Reed Induction Model Number 53305 7044 7 Displacement Cylinders 700 2 Bore inches mm 3 19 81 Stroke inches mm 2 68 68 Piston to Cylinder Clearance inches mm 0044 0059 112 151 Installed Ring Gap inches mm 017 026 44 650 Operating RPM 200 8250 Idle RPM 1700 Engagement RPM 200 3800 VES Spring Color Purple Fuel Delivery Recommended Fuel Octane R M 2 Type Cleanfire Direct Injection Throttle Body Marking 1203213 Throttle Body Bore 46mm TPS Voltage Idle 0 95 0 01 Fuel Pressure PSI bar 58 4 0 91 Non Oxygenated Clutch Settings General Width in cm 48 121 9 Length in cm 115 292 1 Height in cm 47 119 4 Estimated Dry Weight Ib kg 476 216 1 Fuel Gallons Liters 10 8 40 9 Oil Quarts Liters 3 4 3 2 Cooling System Capacity 63 6 Quarts Liters Brake Fluid DOT 4 Drive Belt Part Number 3211115 Width inches cm 1 460 3 7 Side Angle 26_ Circumference inches cm 46 77 118 8 Center Distance inches cm 11 5 29 2 Chaincase Center Distance inches 8
66. 2 8 SAE TAP DRILE SIZES S irt site sito esie EAR CREE mia h 2 9 METRIC TAP DRILL SIZES pen i eee 2 9 DECIMAL EQUIVALENTS vr oes rey e e este DER oe 2 9 MEASUREMENT CONVERSION CHART xir ier op ege ee 2 10 PISTON WASH SPARK PLUG 2 10 SERVICE PRECAUTIONS ek dal ret rye te Cases Bee es daa reete tes Eee asa 2 11 GENERAL o urere qr eee ei RE eg 241 WINNING PERFORMANCE 2 1 gt POLARIS General Information SNOWMOBILE NUMBER DESIGNATIONS Model Number Designation Example S08sMX6FS MODEL OPTION GROUP YEAR MopEL LINE MopEL TYPE ENGINE MODIFIER VIN IDENTIFIER 1st digit 2 3rd digit 4th digit 5th digit 6th digit 7th digit 8th digit 9th digit 5 08 x 6 F 5 B Basic D LX G 155 4121 F C OHV 4 Cycle Fuji H 163 RMK 3A 340 F C Piston Port 08 2008 136 RMK 4B 488 L C Piston Port 09 2009 K 144 RMK M Race IQ 5B 544 F C Cylinder Reed E Europe 10 2010 155 STD 11 2011 N Edge N 163 STD 6F 600 EV L C Case Reed M Military S Snow P IQ 4 6H 600 EV L C Case Reed CFI R Rolling Option 12 2012 S Gen II 6J 600 EV Case Reed Race Chassis 13 2013 n R Switchback We Mini Indy 7E 750 Four Stroke S Standard 14 2014 S Switchback 15 2015 Prem 7F 750 Four Stroke Turbo i T Tourin
67. 3 Click on the SPECIAL TESTS icon toolbox Click on ENGINE CONTROLLER REPROGRAMMING 5 Locate the fileset version number Engine Controller Reprogramming Select the Proper ECU Program from the List Below MATCH THE ENGINE SIZE AND INJECTOR COLOR AS INSTALLED CHOOSING THE WRONG COMBINATION WILL RESULT IN POOR ENGINE PERFORMANCE AND POSSIBLE DAMAGE File Set Version v1 0 2007 600 CFI Blue injectors 2007 600 CFI Red injectors Pr 4011812 2007 600 CFI Yellow injectors Pr 4011814 B Select File 4 Prepare Vehic 5 Reprogram 6 Verify Success Status 4 38 Engine Controller Reprogramming Reflash NOTE New service replacement programmed as no start and require a reflash in able to work 1 Verify the most current service packs updates and filesets are downloaded and loaded into Digital Wrench See Version Fileset Identification on page 4 38 2 Connect the communication cables to the snowmobile connectors See Digital Wrench Connections on page 4 36 3 Start Digital Wrench Select the model year and machine using the CHANGE VEHICLE TYPE button Click on the SPECIAL TESTS icon 5 Click on ENGINE REPROGRAMMING 6 Select the engine model and color of the injectors installed on the engine Record the 7 digit injector part number Click CONTINUE 7 NOTE four fuel injectors must share the same c
68. 311004 102 9 038 NOILIN9I 1102 NOILIN9I 11008 102 8 915 1583 38 TWNOIS 1081802 H1 3101004 102 81 LLLP NOLLONn3 MO123NNO9 01 YOLOSNNOD 39nv9 0705 4811 3NI9N3 9 28 GOOH SISSYH Y 310004 102 81 038 018 SO SZIMOb YSEWAN luvd SS3NHVH 3 8Vl NOLLVNIWH3L NOILONAS ALIAVS YOLISNNOD OL MO193NNO9 39nv9 407109 x 10 89802 3 0 62 01 LYVd SSANYVH 3 8Vl PERFORMANCE gt POLARIS WINNING 12 2 iagrams D iring 2007 600 HO Carbureted Hood Harness SWITCH SET SWITCH mel 1 07800 MODE SWITCH 159 2 wn TACH PULSE Y BLK SPEED PULSE s LT GRN R RELAY COIL 76 0 any OPTIONAL RIDE LEFT HEADLAMP RIGHT ENGINE TEMP 20 SENSOR GND GROUND ENGINE GROUND I ORN BLK BLU R GAUGE 1 E 9 M GAUGE 2 27 Qu RECTIFIER p 05 LT GRN R 22 ORN 03 Y BLK 02 WIR WO COLOR WIRES ARE SHOWN WITH CHECK ENGINE 93 yg AIN TRACE COLORS EXAMPLE 2 0 3 5 f Y RED WITH YELLOW TRACE
69. 4 Nm Assembly Notes Never re use parts Nylock nuts Always replace with new All pivots must rotate freely after tightening fasteners Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table 8 16 WINNING PER FORMANCE gt POLARIS Steering and Suspensions IQ 121 Shift Front Rear Torque Arms FRONT TORQUE ARM x SHOCK ASSEMBLY UPPER SHAFT NY REAR PIVOT SCISSOR LIMITER STRAPS REAR TORQUE ARM REAR TRACK SHOCK b y y SHOCK R D lt CARRIER WHEEL TORSION SPRING MOUNTING ARM Apply Polaris Premium All Season Grease to all grease zerks as outlined the periodic maintenance table A 12 Ft Lb 16 Nm B 35 Ft Lb 47 Nm C 45 Ft Lb 61 Nm D 60 Ft Lb 81 Nm CAUTION The fasteners securing the rear suspension to the tunnel are pre coated with a locking agent when new Assembly Notes Never re use these fasteners when removed Always use new pre coated fasteners when mounting the suspension to the tunnel Never re use Nylock nuts Always replace with new parts All pivots must rotate freely after tightening fasteners WINNING PERFORMANCE gt POLARIS 8 17 Steering and Suspensions M 10 128 Pivots Rear Idler BOGIE WHEEL EA WASHERS 4 gt FTA SHAFT CENTERING SLEEVE S27
70. 68 Brake Fluid DOT 4 Piston to Cylinder Clearance Drive Belt inches mm Ade alo Part Number 3211115 Width inches cm 1 460 3 7 Installed Ring Gap 017 026 44 650 Side Angle 26_ Circumference inches cm 46 77 118 8 Operating RPM 0 300 8250 Center Distance inches cm 11 5 29 2 Idle RPM 1700 Chaincase Engagement RPM 200 3800 Center Distance inches 8 373 Exhaust Valve Spring Pink Top Gear Stock 22 Bottom Gear Stock 40 Fuel Delivery Chain Stock 76 Gear Lube Polaris Synthetic Type Cleanfire Direct Injection Capacity oz ml 11 325 3 Throttle Body Marking 1203213 Pere Throttle Body Bore 46mm Electrical TPS Voltage Idle 0 95 0 01 Alternator Output Fuel Pressure PSI bar 58 4 0 Operating Voltage 13 5 14 5 Recommended Fuel Octane Watts 13 5 Vdc Total 400 91 Non Oxygenated ee Ignition Timin Coolant Temp 120 F 49 Clutch Settings Spark Plug Gap in mm 027 70 ALTITUDE DRIVE CLUTCH DRIVEN CLUTCH Spark Plug Champion RN57YCC meters Shift Clutch Clutch Driven Gua feet Weight Spring Spring Helix k rac 0 600 HE Width Inches cm 15 38 idth Inches cm 2000 4000 106 ues Length Inches cm 136 345 4 10 62 BLK GRN RED BLK 42 Straight Lug Height Inches cm 1 25 3 175 120 340 140 240 5136955 1800 2400 1060 7042083 7043058 lt Track tension sag in cm with
71. Crankshaft Position Sensors CPS The 5 tooth crank position sensor picks up all 5 flywheel teeth The 2 tooth crank position sensor picks up 2 flywheel teeth Both crank position sensors will have a gap to the flywheel pick up of 0 031 0 8mm These sensors must be in the correct position or the engine will not run as expected A sheared flywheel key will cause the engine to not start or kill if running The 2 tooth pick up detects the crank angle and obtains minimal information of the crank angle when control enters into limp home mode 5 tooth pickup is to obtain the following information in combination with the 2 tooth pickup Judge direction of rotation forward and backward Ignition advance angle control Injector drive angle control Excess advance ignition control at reverse MAG PTO cylinder detection 4 25 Fuel Systems Stator Assembly CRANK POSITION SENSORS Stator Specifications RESISTANCE ITEM COLOR SYSTEM FUNCTION 4 15 068 20 C CHASSIS BATTERY YEL TO YEL 0130 CHARGE LIGHTING COIL YELLOW NOONE EO GEOUND Crank Position Sensor 5 D CRANK POSITION SENSOR CRN to WHI GRN Tooth Ignition timing CPS Crank Position Sensor 2 _ WHT to WHT RED h Locates TDC and WHT to WHT RED 1900 GRN RED re GRN RED to GRN YEL 150 COILS GRN YEL Ketter towers eT GRN RED to BRN WHT
72. Either Digital Wrench or the TPS Test Tool can be used to see the TPS return signal voltage set the TPS baseline and set the idle gap on CFI models To use Digital Wrench follow these steps A TPS Fasteners B TPS Harness Connector 5 Remove the throttle cable barrel from the throttle flipper Status 11 8 gt POLARIS Battery and Electrical Systems 6 Loosen the idle speed screw until the screw no longer touches the tab and the throttle plates are completely closed Idle Speed Screw 10 Carefully tighten the screws to 31 In Lbs 3 5 Nm when the voltage is 0 70 0 01 Vdc B Lock Nut 11 Open and close the throttle plate 2 3 times and verify the voltage is still within specification e Throttle Stop 7 Open and close the throttle plates 2 to 3 times to ensure plates are completely closed 8 Using the TPS test tool verify the TPS is set to 0 70 0 01 Vde 9 Toadjust TPS base line slightly loosen the screws then slowly turn the TPS clockwise or counter clockwise to adjust the voltage enn 11 9 Battery and Electrical Systems TPS Idle Speed Adjustment CFI Models 1 Verify the TPS voltage is 0 70 0 01 Vdc with the throttle plates closed 2 Slowly turn the idle speed adjustment screw A clockwise until the voltage displayed on the multi meter reads 0 95 0 1 Vdc 93 0 1 for 800 CFI engines 3 Carefully tighten the loc
73. Engine 515151513213 8 8 8 E 9 Libertv Liauid Cooled Altitude Engine Type iberty Liqui Coo ed M 2 3 5 2 5 z 5 Case Reed Induction eters feet a m n 2 Model Number S3466 6044 PUGF Displacement Cylinders 599cc 2 A Bore inches mm 3 04 77 25 0 600 440 430 420 400 390 380 370 360 Stroke inches mm 2 52 64 0 2000 3 3 3 3 3 2 2 1 Piston to Cylinder Clearance 600 1200 410 400 390 370 360 350 340 330 inches mm 2000 4000 3 3 3 3 2 2 1 1 Installed Ring Gap 1200 1800 370 360 350 340 330 320 310 300 inches mm 014 020 0356 508 4000 6000 83 2 2 2 2 ala 981 Operating RPM 200 8100 1800 2400 340 320 310 300 280 280 270 260 ___ _______________________________ 6000 8000 3 2 2 2 2 1 1 1 Idle RPM 1700 2400 3000 310 300 290 280 270 260 250 240 Engagement RPM 200 3800 8000 10 000 2 2 2 41 1 41 1 1 Exhaust Valve Spring Pink 3000 3700 290 280 270 250 240 230 220 210 10 000 12 000 2 2 1 1 1 1 1 1 Carburetor Settings When using non oxygenated fuel with a RON greater than 93 decrease the main jet number in the above chart by 10 and raise the Typ
74. 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 5 Remove the 2 left hand console mounting screws and electrical center cover piece 6 Remove the rear 2 lower clutch guard mounting screws and 3 forward mounting nuts and plate 7 Remove the 3 screws securing the lower clutch guard to the upper plate leaving the electrical center components in place 8 Loosen and remove the throttle body assembly and set aside 9 Using a mirror or a bore scope and a light visually inspect the current oil pump setting CAUTION The oil pump lever and pump boss marks must be 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 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 11 12 13 14 WRENCHES When adjusting the lever make adjustments in small incre
75. Fuel Systems The main system is designed to deliver fuel between low speed and high speed operation This system is made up of the jet needle needle jet and main jet The main system begins to take effect as soon as there is enough air flow into the carburetor venturi to draw fuel up through the main jet and needle jet assembly This system works in conjunction with the needle jet system During low speed driving there is very little clearance between the jet needle and the needle jet therefore very little fuel from the main jet can pass between the jet needle and the needle jet As the throttle valve opening is increased the tapered jet needle is raised farther out of the needle jet allowing greater fuel flow Under full throttle opening the cross sectioned area of clearance between the jet needle and the needle jet becomes greater than the cross sectioned area of the main jet Thus the main jet is now controlling the amount of fuel flow Pilot Jet From idling to low speeds the fuel supply is metered by the pilot jet There are several air bleed openings in the sides of the pilot jet which reduce the fuel to mist The number stamped on the jet is an indication of the amount of fuel in cc s which passes through the jet during a one minute interval under a given set of conditions Fuel Screw The fuel screw controls the fuel mixture from idle to low speeds The tapered tip of the fuel screw projects into the passage leading
76. IGNITION KILL 6 4 23 VEHICLE SPEED SENSOR olde Ado ohh Rem sas gd RR ee 4 24 EXHAUST TEMPERATURE 4 25 TEMPERATURE AIR PRESSURE SENSOR 4 25 CRANKSHAFT POSITION SENSORS 5 4 25 STATOR ASSEMBLY ze zen Gee E users 4 26 EXHAUST VALVE SOLENOID 4 27 GFIIGNITION orem Pei Eee e EIS 4 27 REGULATOR RECTIFIER 2 4 nan hada Sea ee Reine ue bee Neg Es 4 27 CHASSIS POWER 4 27 ENGINE COOLANT TEMPERATURE 4 28 KNOCK SENSOR beta ea di ER ee ee edd de i in 4 28 FUELSINJECTORS decane Pays ern ale Tuy eset sie ae ede gis 4 28 FUEL RAIL BLEEDING PRESSURE 4 29 DISCONNECT FITTINGS ae ae eee ee ee aaa 4 29 FUEL TANK PRESSURE 5 4 30 CFI FUEL RAIL INJECTOR S REMOVAL INSTALLATION 4 30 2007 700 CFI FUEL SYSTEM 4 32 2007 700 CFI FUEL PUMP 4 32 CFI DROP IN PUMP FUEL SUPPLY TYPICAL 4 34 DROP IN FUEL PUMP
77. Inches cm 42 5 108 41 16 104 5 Camber Inches cm 2 25 0 31 57 7 9 Toe Out Inches cm 0 0 12 0 0 31 Rear Suspension Length Inches cm Suspension Type Fast M 10 128 Front Track Shock FTS Ryde FX MPV FTS Spring Rate Ibs in N mm FTS Spring Installed 8 20 3 Rear Track Shock RTS Fox Zero Pro Lower Outer Spring Rate Ibs in N mm 715 125 Lower Inner Spring Rate Ibs in N mm 425 74 4 Upper Spring Rate Ibs in N mm 273 48 Rear Travel Inches cm 13 33 WINMING PERFORMANCE gt POLARIS 1 29 Model Specifications 2008 600 IQ Touring General Model Number SO8PT6HS SO8PT6HE Width in cm 48 121 9 Length in cm 129 327 7 Engine Height in cm 53 134 6 Liberty Liquid Cooled Esti timated Dry Weight Engine pope Case Reed Induction d ies 574 260 6 Model Number 3468 6044 PU6H Fuel Gallons Liters 11 7 443 Displacement Cylinders 599 2 Oil 18 1 3 2 8 Bore inches mm 3 04 77 25 Cooling System Capacity Stroke inches mm 2 52 64 Quarts Liters TE Piston to Cylinder Clearance 004 006 105 159 Brake Fluid DOT 4 inches mm Drive Belt Installed Ring Gap Part Number 3211122 014 0
78. Install the new U cup seal into bearing U cup should be installed so the cupped end is facing the DU bushing inside of bearing Check to make sure seal is properly seated If a tool is required to aid in proper seating of U cup seal use the non writing end of a pen or a similar soft blunt object to push it in Install FIST bearing into housing Check for proper orientation of the FIST bearing The stepped side of the FIST bearing should be visible Using a small pair of snap ring pliers install the snap ring into the bearing housing Check for proper orientation of the snap ring The flat side of the snap ring should be visible Check to make sure the snap ring is properly seated 10 Install the new well greased o ring onto the IFP 11 Install the new well greased o ring on the IFP bleed screw WINNING PERFORMANCE gt POLARIS Chassis CHAPTER 10 Chassis IQ CHASSIS 5 ERU ex E RR E xe 10 2 STEERING HOOP ASSEMBLY 2 2 10 2 HOOD ASSEMBLY seine wis i ht ee VII 10 3 HOOD PLASTIC REPAIR te eel xu rem dewalt Hee ROS 10 3 FRONT BUMPER ASSEMBLY TYPICAL 10 4 IQ CONSOLE ASSEMBLY TYPICAL 10 4 RMK TUNNE wu ete RIP cere e a ec eed eed ea ae ale 10 5 FENDERS AND SIDE 5 1
79. OFF position Position a container or shop towels under the work area to help catch some of the contaminated gasoline Ne 3 Slide the clamp A away from the drain plug B and POLARIS The Way Out 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 Fuel Filter Carbureted Models A CAUTION The in tank fuel filter and fuel lines should be inspected regularly Special attention should be given to 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 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 11 Maintenance Fuel Filter 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
80. Shocks RYDE FX MONO TUBE SHOCK DISASSEMBLY Procedures for the proper disassembly and assembly of Ryde FX gas charged IFP and emulsion mono tube shock absorbers CAUTION BEFORE SERVICING A GAS SHOCK IT IS IMPORTANT THAT ALL THE GAS PRESSURE BE DISCHARGED FROM THE UNIT REFER TO THE INSTRUCTIONS LISTED BELOW FOR THE PROPER PROCEDURE OF DISCHARGING THE GAS PRES SURE FROM A SHOCK PROTECTIVE EYE WEAR SHOULD BE WORN TO AVOID RISK OF INJURY WHILE SERVICING RY DEF X GAS CHARGED MONO TUBE SHOCKS Remove the shock s from the vehicle Before unscrewing pre load springs measure the compressed length of the installed spring and mark position for reinstallation 3 If the shock incorporates a spring remove the spring and all collateral retainers CAUTION WHEN REMOVING THE SPRING FROM A SHOCK THAT UTILIZ ES A FIXED LOWER RETAINER THE USE OF A PROPER SPRING COMPRESSOR SHOULD BE USED TO AVOID RISK OF BODILY INJURY 4 Wash the shock body in parts cleaner then dry with compressed air to remove sand and dirt A WARNING WHEN USING COMPRESSED AIR TO DRY COMPONENTS PROTECTIVE EYE WEAR SHOULD BE WORN TO AVOID RISK OF INJURY 5 Remove bearing sleeve and or bushings from lower shock mount eyelet Secure the lower mount of the shock ina vise The use of soft jaws is recommend to prevent damage or marks to the shock CAUTION IT IS IMPORTANT THAT THE GAS SHOCK
81. Vent Path Closed 11 17 Battery and Electrical Systems DIAGNOSTIC PLUGS AY Secr IQ Chassis Power Plug IQ models CFI and carbureted feature a chassis power diagnostic plug Connect the plug to the M 10 ACE ECU Chassis Power Up cable PN PA 46355 and a fully charged 12 volt battery The plug consists of two wires BRN and RED WHT Once powered all of the RED WHT chassis power circuits will be powered with battery voltage The circuits include e Head Tail Brake Lamps MFD Multi Function Display Accessory Power Plugs Hand Thumb Warmers IQ CFI Fuel Pump Prime Plug IQ CFI models feature a fuel pump prime plug Use the fuel pump prime plug to power up the fuel pump when purging the fuel system of air or when testing fuel pump pressure The fuel pump prime plug consists of two wires BRN and RED 11 18 ELECTRONIC REVERSE PERC Overview Some models are equipped with Polaris electric reverse control PERC The operation of the electronic reverse system is achieved by automatically reversing the engine rotation with a push of a button When in reverse you will have an indicator light that will flash notifying you that the machine is in the reverse mode The design of the clutches are matched to the specifications that will allow the backwards rotation of the engine to move the sled in reverse To get back to forward is as easy as pushing the butt
82. e 19 Ft Lb 26 Nm B 35 Ft Lb 47 Nm C 3 6 Ft Lb 4 8 Nm D 35 In Lb 4 Nm Assembly Notes Never re use Nylock nuts Always replace with new parts All pivots must rotate freely after tightening fasteners Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table 8 28 WINNING PER FORMANCE gt POLARIS Steering and Suspensions IQ 136 Comfort Front Rear Torque Arms FRONT TORQUE ARM BUSHING To BUSHING s 0 Aa 9 2 9 O RING B c INNER SHAFT C o LIMITER STRAPS BUSHING WO Ex REAR TORQUE ARM E REAR SCISSOR BUSHING nA SHOCK ROD 2 S SPRING ADJUSTER BUSHING 7 BUSHING S WHEEL 24 EZ SLEEVE ie gt BUSHING 6 Z Z Sup TORSION SPRING B Apply Polaris Premium All Season Grease to all grease T zerks as outlined in the periodic maintenance table 12 Ft Lb 16 Nm B 40 Ft Lb 54 Nm CAUTION C 35 Ft Lb 47 Nm The fasteners securing the rear suspension to the Assembly Notes tunnel are pre coated with a locking agent when new Never re use these fasteners when removed Always Never re use Nylock nuts Always replace with new use new pre coated fasteners when mounting the parts suspension to the tunnel All pivots must rotate freely after tightening fa
83. e Never re use Nylock nuts Always replace with new parts All pivots must rotate freely after tightening fasteners Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table 8 22 WINNING PER FORMANCE gt POLARIS Steering and Suspensions M 10 136 Front Rear Torque Arms N FRONT TORQUE ARM SHOCK ASSEMBLY Fastener 35 Ft Lb 47 Nm REAR TORQUE ARM LOWER SHAFT MID TRACK SHOCK UPPER SHAFT M 10 ACE ONLY Be lt SPACER Apply Polaris Premium All Season Grease to all grease T zerks as outlined in the periodic maintenance table A 12 Ft Lb 16 Nm 35 Ft Lb 47 Nm A CAUTION 70 Ft Lb 94 Nm The fasteners securing the rear suspension to the Assembly Notes tunnel are pre coated with a locking agent when new Never re use these fasteners when removed Always Never re use Nylock nuts Always replace with new use new pre coated fasteners when mounting the parts suspension to the tunnel All pivots must rotate freely after tightening fasteners 8 23 Steering and Suspensions IQ Switchback 144 Pivots Rear Idler INNER SHAFT FRONT TORQUE ARM SHAFT 35 Ft Lb 47 Nm Assembly Notes Never re use Nylock nuts Always replace with new parts All pivots must rotate freely after tightening fasteners App
84. gt N3dO ATIVWYON H2LIMS ON TE i Neg m 435012 HOLIMS ON m i 9 000 9 dV 9014 mii 1 3018 16911 18 wo a dV 9014 1 mm annoys sisswo N x AYVONODIS 8 LI aniona ZA 43931 30103 3818 5770 og 0 NNOD NNONG 0 410089 111 HM NMOUS 81 08 lY Na ER RR A AV89V10 NI ONIOVHL AJITdNIS 0401 Tn UN 34 80 gt H1331S YOSNIS NOILISOd NVED 01 S3NI7 0385 0 80 01108 WOLO3PNI End 34780 vie MOVIIA INIG MOTIFA INIG XQ 18 03103539939 38 SIYIM OVW o 3LIRA MIONS 038 N3385 30 813312 YOSNIS 0111504 1 L d8 90 SI 101133 13380 038 3380 30 8 1103 01937 311203 1 1 15 013 CSWHO 3ONVISIS3U 580102 2 02 61 3ONVISIS3N 1102 PERFORMANCE gt POLARIS WINNING 12 16
85. gt POLARIS Shocks 2008 Shock Valve Shim Stack Configurations NOTE All measurements are in inches 2008 Front Track Shocks NOTE Valve shim stacks listed as they would appear on the shaft when shock rod is locked in a table vise eyelet down threaded end up WINNING PERFORMANCE gt POLARIS 2008 IFS Shocks SHOCK 7043244 7043365 SHOCK 7043245 7043315 7043364 22 625 065 8 015 700 x 010 700 x 012 a 9 015 00 008 800 012 800x222 10015 5 900 x 008 900 x 012 1 0005 010 1 1 015 1 00 x 012 m AT 1 2 x 015 4 000 x 008 1 100 010 1 100 x 008 1105015 aia 1 2 x 015 tc 1 250 008 1 20 x 015 1 25 015 i 1 25 x 010 1 25 x 015 1 25 x 015 1 25 x 015 Piston Piston Orifice 070 052 060 052 Orifice TBA 1 3 x 010 1 30 x 015 1 1 x 010 1900 x 008 120 015 gt 1 300 008 9x 012 1 100 x 006 666 OU 1 20 x 010 1 100 006 7 x 012 o 50200 1 10 x 015 1900 x 008 1 3 x 012 0 1 10 x 010 1 250 x 008 1 2 x 012 1 100 x 008 tc 1 000 x 006 1 00 x 015 1 100 008 1 1 x 012 900 x 006 900 x 015 1 000 010 1 0 x 012 800 015 900 010 9x 012 o 800 x 006 O 700 x 015 700 x 015 o 800 x 008 8 x 012 1875 x 090 7x 012 625 x 065 NOTE Valve shim stacks listed as they would appear on the shaft when shock
86. 1 000 x 006 7000 008 1 000 008 006 1 000 006 1 100 x 010 900 x 006 900 010 110 015 900 x 006 300 008 900x008 800x 006 900x 006 1 000 x 012 800 x 006 800 x 010 an 5 800x 006 700 012 3003 000 700 006 800 006 900 012 700 x 006 20050101 700 015 700 ME 625 065 700x 015 800x 012 625 x 065 625 065 900x 1 125 x 093 1 125 x 093 700 x 010 875 x 090 875 x 090 130 150 EE DA Rebound 1700 x 008 700 x 010 700 x 010 700 x 010 cc 700 x 010 Ww 700 x 010 700 010 1 100 025 1 10x 025 0 600 010 1 000 025 1 00 025 N A N A 600 010 625x 065 625 065 a 600 x 010 lt 500 x 006 500 x 006 500 x 006 500 x 006 Back Up 400 x 020 NOTE Valve shim stacks listed as they would appear on the shaft when shock rod is locked in a table vise eyelet down threaded end up WINNING PERFORMANCE gt POLARIS 9 9 Shocks 2007 Front Track Shocks SHOCK 7041975 7043142 7043244 7043267 7043204 7043234 620 x 093 620 x 093 625 x 065 20052018 s 700 x 015 625 x 065 a ae 800 x 015 800 x 015 700 x 012 900 x 012 800 x 012 800 x 015 900 x 012 800 x 015 800 x 012 5 1 00 x 010 900 x 010 900 x 015 Dien 900 x 012 900 x 012 22 m x tooo x010 10005 1 000 x 010 1 000 x 012 Do 010 1
87. 15 SPL HYVO CM 3221098 22 3 4W 15 SPL HYVO PM 3221099 23T 3 4W 15 SPL HYVO PM 3221101 24T 3 4W 15 SPL HYVO PM 3221102 25T 3 4W 15 SPL HYVO PM 2900009 25T 3 4W 15 SPL HYVO CM 3222127 26T 3 4W 15 SPL HYVO PM 3222126 36T 3 4W 15 SPL HYVO PM 2900010 37T 3 4W 15 SPL HYVO CM 3222125 37T 3 4W 15 SPL HYVO PM 2900144 37T 3 4W 15 SPL HYVO Light Weight 3222129 38T 3 4W 15 SPL HYVO PM 2900143 38T 3 4W 15 SPL HYVO Light Weight 3222108 39T 3 4W 15 SPL HYVO PM 2900012 39T 3 4W 15 SPL HYVO 2900142 39T 3 4W 15 SPL HYVO Light Weight 3222099 407 3 4W 15 SPL HYVO 2900141 40T 3 4W 15 SPL HYVO Light Weight 3222101 411 3 4W 15 SPL HYVO 2900140 411 3 4W 15 SPL HYVO Light Weight 2900139 42T 3 4W 15 SPL HYVO Light Weight 2900016 43T 3 4W 15 SPL HYVO CM 3221188 43T 3 4W 15 SPL HYVO PM 2900138 43T 3 4W 15 SPL HYVO Light Weight 3222126 457 3 4W 15 SPL HYVO Light Weight CM Cut Metal Sprocket PM Powder Metal Sprocket WINNING PERFORMANCE POLARIS Drive Chains NUMBER DESCRIPTION 3221114 64P 3 AW HYVO CHAIN 3221113 66 3 AW HYVO CHAIN 3221112 68P 3 4W HYVO CHAIN 3221115 70P 3 AW HYVO CHAIN 3221110 72P 3 AW HYVO CHAIN 3221109 74P 3 4W HYVO CHAIN 3221108 76P 3 4W HYVO CHAIN 3222110 78P 3 4W HYVO CHAIN 6 3 Final Drive and Brakes 8 373 CHAINCASE Assembl
88. 2 11 3 SPECIFICATIONS Ne ae ls eds ERU come sia 11 3 REFILLING A CONVENTIONAL 11 3 FRESH BATTERY ete rex ys wees eva tu 11 3 BATTERY 2 11 3 SPECIFICATIONS L E Hr de Os 11 3 BATTERY TESTING ume Le toc eg eed e 11 4 TESTING PROCEDURES 11 4 OPEN CIRCUIT VOLTAGE TEST 11 4 LOAD TEST E ae ede ee 11 4 SPECIFIC GRAVITY TEST CONVENTIONAL 11 4 OFF SEASON STORAGE 11 4 IGNITION TIMINGS zuo p IIR E Ru ERE EM RI eae a DA puas 11 5 TIMING PROCEDURE CARBURETED ENGINES 11 5 TIMING PROCEDURE CFI ENGINES 11 5 IGNITION TIMING 11 6 THROTTLE POSITION SENSOR 8 11 7 TOOL SETUP sie copilot kee Seen Ca TER ioe de ded 11 7 USING THE TEST TOOL ose REG back vee Ren etur 11 7 TPS ADJUSTMENT CARBURETED 5 11 8 TPS ADJUSTMENT CFI MODELS USING DIGIT
89. 26_ 3500 RPM TPS Un plugged Torsion Springs 359 Square 77 Stock 347 77_ Soft PN 7041627 067 PN 7041628 067 375 77_1 Firm PN 7041942 067 PN 7041943 067 Rear Travel Inches cm 13 9 35 3 Spark Plug Gap in mm 027 70 Spark Plug Champion RN57YCC CDI Marking 4011033 Flywheel Marking 4010677 Track Width Inches cm 15 38 Length Inches cm 144 366 Lug Height Inches cm 1 25 3 175 STD 1 50 3 8 OPT Track tension sag in cm with 10 155 4 54 placed 16 in 40cm ahead of rear idler shaft 3 8 1 2 1 1 3cm WINNING PERFORMANCE gt POLARIS 1 5 Model Specifications 2007 600 HO RMK Model Number 144 07 6 SO7PK6FE 155 S07PMGFS A Carburetor Jetting Ambient Temperature oo 9 i n F 8 8 8 E E 8 p Altitude p o p Ex p p 5 T 5 Meters feet E E gt lt 8 2 tf F M 2 8 M 8 2 8 A E p E e Wi 0 600 440 430 420 400 390 380 370 360 0 2000 3 43 2 2 42 2 42 1 Engine Engine Type Gis Red Model Number 53273 6044 6 Displacement Cylinders 599 2 Bore inches mm 3 04 77 25 Stroke inches mm 2 52 64 Piston to Cylinder C
90. 7 To remove the oil pump cover remove the two fasteners then pull the pump cover out of the crankcase bore Discard the gasket 8 cross shaft can be extracted from the water pump side of the crankcase 9 Assembly is the reverse of disassembly Always use new o rings seals and gaskets during assembly 10 Install a new seal onto the shaft from the water pump side 11 To install a new water pump seal use the seal installation tool PN 2872010 Verify the seal lips are facing the cross shaft gear 5 21 Engine and Cooling Systems 2007 2008 600 700 CFI Cylinder Head Cylinders Pistons BLEED SCREW E HEAD COVER THERMOSTAT O RINGS e GASKET KNOCK SENSOR een E CYLINDERS TEMP SENSOR vie c8 we gt gt CYLINDER HEAD PISTON ES PISTON Se BEARING PISTON un C CLIP lt Piston Matrix 1 2203312 53322 7044 7 EK 2486a A 70 In Lbs 8 Nm Subs to 2203512 B 9 Ft Lbs 12 Nm Apply Loctite 242 53470 7044 7 2203707 3050 00 25 Ft Lbs 34 Apply Loctite 242 2203606 D 18 Ft Lbs 24 Nm Apply Pipe Sealant S3471 7044 PU7J Single Ring 2975 01 E 168 In Lbs 19 Nm Clean and Dry F 2 37 Ft Lbs 50 Nm Disassembly Assembly Process 1 Remove the coolant from the engine using a siphon wet dry vac or drain pan Engine Model Piston PN Piston
91. 74 48 46 ME snowmobile where the engine changes directions 5135522 74 44 46 74 40 46 70 50 46 91939225 70 48 46 70 44 46 91959562 70 40 46 66 50 46 5182225 66 48 46 66 44 46 518558 66 40 46 5135537 64 38 65 7 7 POLARIS The Way Out PVT System Team Driven Springs TEAM Driven Springs PART NUMBER COLOR LOAD 2 2 Ibs LOAD 1 1 Ibs Rate Lbs per inch 7042181 Black Yellow 145 208 56 7043058 Red Black 140 240 90 7043059 Red Green 120 220 90 7042066 Green Black 135 198 56 7043061 Red Silver 125 175 45 7043062 Red Yellow 100 150 45 7043057 Red Blue 140 200 54 7043064 Blue Black 123 203 73 7043060 Red White 100 200 91 7043069 Red Pink 140 260 110 7043363 Black Purple 160 240 72 7043063 Black 155 222 155 222 65 7043252 Black 160 280 160 280 109 7043253 Black 180 280 180 280 91 7043254 Black 140 300 140 300 146 7043255 Black 160 300 160 300 127 7043256 Black 180 300 180 300 109 NOTE Team driven springs listed with a color will have the beginning and ending spring rates painting on the spring coils Tag the spring with the part number when not in use The Way Out PVT System Drive Belts Part Belt Width Side Center to Outer N Projected Angle Center Circumference Notes umber in mm Ove
92. 87 89 81 91 85 83 75 8750 136 122 131 127 117 115 107 110 107 111 103 106 103 96 99 96 90 92 84 94 87 85 78 9000 140 126 134 131 121 118 110 113 110 114 106 109 106 99 101 99 92 94 86 97 90 87 80 9250 143 129 138 134 124 121 113 116 114 117 109 112 109 102 104 102 95 97 88 99 92 90 82 9500 147 133 142 138 128 124 116 119 117 120 112 115 112 104 107 105 97 100 91 102 95 92 84 9750 151 136 145 141 131 128 119 123 120 123 115 118 115 107 110 107 100 102 93 105 97 95 86 10 000 155 140 149 145 134 131 122 126 123 127 118 121 118 110 113 110 103 105 95 107 100 97 89 6 2 WINNING PERFORMANCE POLARIS Final Drive and Brakes DRIVE GEARS AND CHAINS Drive Gears PART NUMBER DESCRIPTION 3221107 16T 3 4W 15 SPL HYVO PM 3221093 17T 3 4W 15 SPL HYVO PM 3221094 18T 3 4W 15 SPL HYVO PM 3221095 19T 3 4W 15 SPL HYVO PM 2900003 19T 3 4W 15 SPL HYVO CM 3221096 20T 3 4W 15 SPL HYVO PM 2900004 20T 3 4W 15 SPL HYVO CM 3221097 21T 3 4W 15 SPL HYVO PM 2900005 21T 3 4W
93. Au0SS322V 81 311HM NMOUG 039 OV 21145 080089 uv NYH HOLIMS dOLS 02 049 039 2V 21145 080089 UV YINYYMANNHL 04 049 9 OV 321145 080089 MH u3AUVMONYH 1H91U 0c NMOYE MH 321145 MH 03 1 918 02 039 3018 MOTI MH 21145 MH MO LHOIY 02 3018 N0089 DV HOLIMS 3 vug 81 039 IV 321145 010089 HOLIMS 04 9 OV 321145 081089 1331 02 H91H MH 21148 MH 03 1331 04 1387 3018 MOTI MH 1 1 M N 1 21145 1049 8 831 M M N 1 21145 MH MO 1331 04 1118 N0089 IV 21145 080089 8 831 1 915 1041802 H1 02 049 MH 121145 MH 03 915 1081802 H1 02 038 3078 MOT MH 21145 MH MOT 915 1081N02 H1 02 1118 UIWYVAGWNHL HDIH 3 1 915 1031402 H1 02 0 311 MOT 1 915 1081N02 H1 02 AV89 39NVUO 011089 20 28 321145 0 089 24 1 121145 080089 20 8 311 NMOSB 8 311HM 038 3 09 20 321145 43804 20 18055322 31104 20 010 310 i 321145 83004 20 81 311
94. CHASSIS POWER BROWN CHASSIS GROUND ACCESSORY POWER CHASSIS GROUND WHITE RED ELECTRIC START START SOLENOID 156 STARTER SWITCH BLACK IGNITION SWITCH TETHER STARTER SOLENOID GROUND ORANGE GREEN ELECTRIC START CHARGE RELAY 2 CHARGE RELAY CONTROL BLACK BLUE IGNITION SWITCH TETHER CHASSIS GROUND WHITE RED IGNITION SWITCH ELECTRIC START HARD STOP RED BLACK ELECTRIC START CHARGE RELAY 5 RED FUEL PUMP REGULATOR POWER SPLICE REGULATOR POWER RED WHITE CHARGE RELAY CHARGE RELAY 3 CHASSIS POWER BROWN FUEL PUMP CHASSIS GROUND CHASSIS GROUND BROWN FUEL PUMP SPEED CAPACITOR CHASSIS GROUND RED BLACK CHARGE RELAY CIRCUIT BREAKER BATTERY BROWN FUEL PUMP ECU GROUND SPLICE ECU GROUND RED BLACK CIRCUIT BREAKER START SOLENOID BATTERY BROWN CHASSIS GROUND ELECTRIC START CHASSIS GROUND BROWN CHASSIS GROUND TAILLIGHT CHASSIS GROUND BROWN ELECTRIC START BATTERY GROUND BATTERY GROUND BROWN CHASSIS GROUND CHASSIS GROUND SPLICE CHASSIS GROUND BROWN BRAKE SWITCH HANDLEBAR GROUND SPLICE CHASSIS GROUND RED WHITE ELECTRIC START CHASSIS POWER SPLICE CHASSIS POWER RED REGULATOR CHASSIS RELAY REGULATOR POWER RED REGULATOR REGULATOR POWER SP
95. Carefully remove the tension from the compression tool 7 Remove the cover and inspect the cover bushing Replace if damaged or worn NOTE Replace the cover bushing if the inside diameter is over 1 40 28 95mm 8 Remove the spring 9 Mount the drive clutch securely in a drive clutch holding WASHER SPACERS WEIGHT WEIGHT PIN BEARING SLEEVE MOVEABLE INSERT MOVEABLE SHEAVE STATIONARY SHEAVE fixture PN 2871358 10 Remove the jam nut in a counterclockwise direction standard thread using the drive clutch spider nut socket PN 2871358 11 Install the spider removal tool PN 2870341 and remove the spider in a counterclockwise direction standard thread 12 Measure the total thickness of the spacer washers that are installed on top of the clutch spacer Record the thickness of these spacer washers 13 Inspect both sheave surfaces for wear or damage 14 Inspect the moveable sheave bushing for wear or damage 15 Remove all three drive clutch weights 16 Inspect each weight The surface should be smooth with no waves or galling Place bolt inside weight to check flyweight bushing and pin surface for wear by rocking the weight back and forth 17 Inspect all the rollers bushings and roller pins by pulling a flat metal rod across the roller 18 Roller can also be inspected by rolling with a finger to feel for flat spots roughness or loose bushing NOTE The flyweight bushing is not replaceabl
96. HINGE NOTE TORQUE FASTENERS HAND TIGHT Hood Plastic Repair Hoods are made of Thermoplastic Olefin 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 Drill hole d rans bd Chassis Front Bumper Assembly Typical FOIL FABRIC NOTE TORQUE FASTENERS HAND TIGHT FIXED STEERING COVER a RIDER SELECT STEERING COVERS STORAGE DOOR NOTE TORQUE FASTENERS HAND TIGHT 10 4 ena Chassis RMK Tunnel BULKHEAD TUNNEL ASSEMBLY 1 PIECE CONTROL ARM SUPPORT REAR BUMPER CLOSE OFF SNOW FLAP WINNING PERFORMANCE POLARIS 10 5 Chassis Fenders and Side Panels RH SIDE PANEL RH FENDER PUSH RIVETS HEAT SHIELD t RIVETS 10 6 WINNING PERFORMANCE POLARIS Chassis SEAT ASSEMBLIES IQ Removable Seat Assembly IQ Fixed Seat Assembly LATCH SEAT SEAT BASE T ey T 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 2008 VERSION 10 7 WINNING PERFORMANCE POLARIS Chassis 2007 IQ Touring Seat Assembly 5 5 Ft
97. Place the spider on a vise Install pin centering tool PN 2870401 Drive the roller pin through the second land of the spider 00 sd QN Repeat process for the other two rollers G POLARIS Way Out 10 Measure the width of the spider leg with the buttons installed 9 and record the measurement Specification is 1 496 37 99mm 11 Measure the width of the moveable sheave towers Specification is 1 50 38 1mm 12 Subtract the spider measurement form the tower measurement The clearance between the spider buttons and the moveable sheave towers is 002 004 05 10mm 7 15 PVT System Clutch Assembly 9 Install the spider jam nut onto the shaft and torque to specification 1 Assemble the rollers bushings and roller pins if they were removed T 2 Install the head of the weight pin so that it is on the leading side of rotation This will orientate the nut on the trailing side of rotation Spider Jam Nut Torque All Except 800 CFI 225 250 Ft Lbs 305 339 Nm 3 T ight pin t ification ee Apply Loctite 620 to Threads T 800 CFI 290 310 Ft Lbs 393 420 Nm Apply Loctite 242 to Threads Weight Pin Torque 20 30 In Lbs 2 2 3 4 Nm 10 Place the drive spring on the shaft 11 Place the cover onto the clutch and torque the cover Place the moveable sheave onto the stationary sheave fasteners to spec
98. Se 10 25 30 In Lbs 2 9 3 4 N 16 Ft Lbs 21 Lbs 2 9 3 4 16 Ft Lbs 21 Nm POLARIS 8 9 Steering and Suspensions ADJUSTMENT PROCEDURES SETUP AND ADJUSTMENTS Spring preload is the amount of pressure at which the spring is held The longer the installed length of the spring the less the amount of preload the shorter the installed length of the spring the more the amount of preload An increase in IFS shock spring preload will result in an increase in ski pressure To adjust front spring preload on threaded adjust models grasp the spring and turn in a clockwise direction as viewed from the top of the shock to increase the preload Turn in a counterclockwise direction to decrease preload Always set the preload equally between the right and left side shocks For the best ride the spring preload should be as low as possible Set the preload to use the full travel of the ski shock with occasional light bottoming CAUTION If the plastic nut is unscrewed from the threaded body the nut will break Always leave one thread showing above the plastic nut or the spring coils will stack resulting in damage To determine if the suspension is using full travel place the shock s jounce bumper against the shock body then test ride the machine The bumper will move on the rod in relation to the amount of travel For example if the shock travel is full the bumper
99. The Way Out 6 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 the parking brake or have an assistant hold the brake lever Loosen the adjuster bolt jam nut 1 Finger tighten the adjuster bolt 2 until it con no longer be adjusted by hand then back 1 4 turn Tighten the jam nut while holding the adjuster bolt torque to 21 ft Ibs 28 Nm Release the brake lever lock 3 15 Maintenance BRAKE SYSTEM MAINTENANCE Brake Lever Travel 1 2 iin 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
100. angle to the direction of the piston pin 90 to pin DOMESTIC ENGINES Measure 3 8 10 0mm up from bottom of skirt FUJI ENGINES Measure 1 2 12 7mm up from bottom of skirt Subtract this measurement from the minimum cylinder measurement 90 to the pin If clearance exceeds the service limit the cylinder should be re bored replaced if Nicasil lined and new pistons and rings installed Piston Ring Installed Gap 1 2 1 3cm Position the ring 1 2 1 3 cm from the top of the cylinder using the piston to push it squarely into place Measure installed gap with a feeler gauge at both the top and bottom of the cylinder NOTE A difference in end gap indicates cylinder taper The cylinder should be measured for excessive taper and out of round Replace rings if the installed end gap exceeds the service limit Always check piston ring installed gap after re boring a cylinder or when installing new rings us Straight Edge Keystone Piston Ring Cutaway 5 6 Piston rings are installed with marking or beveled side up Reed Valve Inspection 1 Loosen he hose clamps Remove the carburetor or the throttle body from the intake boots 3 Remove the intake boot fasteners and hose holders if applicable 4 Remove the intake assembly 5 Separate the intake boot s from the reed cage 6 Separate the reed stuffer s from the reed cage and inspect the reeds before they are removed
101. assembly from the rod in the sequence of disassembly Shock Absorber Part 7043315 a af 6 Using interlocking channel pliers loosen and remove the cylinder head assembly 10 Remove the rod head assembly and spring from the rod shaft 11 Again using compressed air invert the rod shaft over a clean shop towel Pressurize the cylinder to 90 psi to remove the IFP from the cylinder Account for the floating piston and o ring 12 With the shock disassembled inspect the following items 36mm piston rod for straightness nicks or burrs Cylinder head assembly bearing Inside of shock body for scratches burs or excessive 7 Pour the oil out of the cylinder Discard oil into an approved wear container and dispose appropriately Never reuse shock oil 8 Using compressed air invert the large diameter cylinder Teflon piston and IFP wear band for cuts chipped or over a clean shop towel Pressurize the cylinder to 90 psi nicked edges or excessive wear to remove the IFP from the cylinder Account for the floating piston wear band and o ring wey 7j 7 O rings for nicks cuts or cracks Valve discs for kinks or waves d EE 9 17 Shocks Ryde FX Air 2 0 Shock Assembly 7 Apply a light film of grease to the 36mm rod assembly pressure valve port counter bore where the pressure valve 1 Place the 36mm piston rod upper mount in a soft jawed assembly o ring meets bench vise Lubri
102. gt POLARIS General Information Measurement Conversion Chart UNIT OF MEASURE MULTIPLIED BY CONVERTS TO ft lb 12 in lb 0833 ft lb ft Ib x 1 356 N m in lb x 0115 kg m N m x 7376 ft lb kg m x 7 233 ft lb kg m x 86 796 in Ib kg m x 10 N m in x 25 4 mm mm x 03937 in in x 2 54 cm mile x 1 6 km km x 6214 mile Ounces 07 x 28 35 grams g grams g x 035 Ounces oz 03381 Fluid Ounces 02 Ibs x 454 kg kg x 2 2046 lbs Cubic Inches x 16 387 Cubic Centimeters x 061 Cubic Inches Imperial pints x 568 liters 1 liters 1 x 1 76 Imperial pints Imperial quarts x 1 137 liters 1 liters 1 x 88 Imperial quarts Imperial quarts x 1 201 US quarts US quarts x 833 Imperial quarts US quarts x 946 liters liters x 1 057 US quarts US gallon 3 785 liter x 264 US gallon 6 895 Kilo pascals kPa Kilo pascals kPa x 145 Pound force pef 2 10 square inch psi Piston Wash Spark Plug Reading Changing temperature barometer altitude and fuel supply are just a few of the factors that can affect the day to day performance of your engine That is why using Exhaust Gas Temperatures EGT are important for maintaining optimum performance There are two methods for helping you determine what the EGTs are for your machine Piston wash and th
103. of brake lines These fittings can be purged of air by following a standard bleeding procedure at these fittings instead of the bleed screw on caliper if necessary to speed the bleeding process This is usually only needed if system was completely drained of fluid Bleed each line connection starting with the fitting closest to the master cylinder working toward the caliper and ending with the bleed screw An unsafe condition exists when air is trapped in the hydraulic brake system Air in the brake hydraulic system acts like a soft spring and absorbs a large percentage of the pressure developed by the master cylinder Without this pressure the braking system cannot develop full braking force to allow for safe controlled stops It is extremely important to bleed the brakes properly after any brake system work has been performed or when inspection reveals spongy brakes A soft spongy feeling in the brake lever and or brake pedal could indicate a hazardous condition in the brake system Do not operate the vehicle until the failure in the brake system is corrected Always torque banjo bolts and other brake system fittings to specified torque Change fluid every 2 years or when fluid is dark or contamination is suspected Keep brake fluid tightly sealed and out of reach of children Brake fluid can accumulate moisture Brake Fluid Replacement amp Bleeding reducing it s effectiveness This procedure should be used to chan
104. to the chaincase 5 Remove the caliper from the chaincase WINNING PERFORMANCE gt POLARIS Final Drive and Brakes Caliper Assembly 1 Replace caliper bolts 1 and torque them to 18 20 ft lb 24 27 N m e Caliper Bolts 18 20 ft lb 24 27 N m On a liquid cooled caliper hook up the coolant lines 3 Place the brake line on the caliper in the same orientation as it was before it was removed 4 Clean the threads of the banjo bolt and the threads in the caliper 5 Follow Brake Line Replacement See Brake Line Replacement on page 6 13 6 Install banjo bolt into the caliper and torque it to 168 216 in Ib 19 24 N m 7 Bleed the brakes See Brake Fluid Replacement amp Bleeding on page 6 11 8 Onaliquid cooled caliper you will need to bleed the cooling system of any trapped air Brake Pad Replacement Brake Pad Brake pads need to be replaced if the total thickness of the pads and backing are less than 250 6 35mm Remove brake pad retaining pin 3 Remove the brake pads 4 Inspect the brake disc 5 for any wear Boop dr Replace brake pads in reverse order of removal 250 6 35mm Brake Disc Replacement The brake disc should be replaced if the thickness of the disc is below 193 49cm Remove the chaincase Slide the brake disc from the jackshaft Check the jackshaft for any damage Replace the o ring on the jackshaft Replace the brake disk
105. 10 Access www polarisdealers com Locate REFLASH AUTHORIZATION under the SERVICE AND WARRANTY drop down menu 11 Locate and click on the product requiring the reflash Click on the model year 15 The reflash process will begin Verify all connections are properly made Do not touch anything during the process 16 Verify the reflash was a success by comparing the software ID number listed under the CUSTOMER AND VEHICLE C ERE IDENTIFICATION button with the number recorded in step 6 Sort Naber ECU Part Number 5201 Software Part 1011367 12 Enterthe request code generated by Digital Wrench Select the fuel injector color and model year engine from the drop down menu Type in the Request Code EXACTLY as it appears in the Digital Wrench Then choose the same Reflash File as was chosen in the Digital Wrench Seen the drop down box below before diding the Authorw button Pons Fuel Systems NOTES 4 39 gt POLARIS Engine and Cooling Systems CHAPTER 5 Engine and Cooling Systems ENGINE SPECIFICATIONS Os as ccs ae XXe Rex ee Rte due ex x ed e See 5 2 FASTENER TORQUE GUIDE 5 2 ENGINE 5 2 5 3 ENGINE SERVICE SPECIFICATIONS ALL ENGINES 5 3 COMPONENT TORQUE 5 4 ENGINE INSPEC TIONS c nens Ess
106. 17 ft lb 21 24 Nm The Way Out Maintenance ENGINE MAINTENANCE Exhaust Valve Cleaning The exhaust valve guillotines must be cleaned to ensure maximum engine performance and throttle response 2 FASTENERS EV ASSEMBLY L 9 GASKET 9 Remove the vent hose from the EV base fitting Remove the two fasteners that secure the valve assembly to the cylinder but not the two screws that secure the cover to the EV base 3 Carefully extract the guillotine out of the cylinder Discard the gasket Ne 4 Using aclean rag or shop towel remove the oil residue from the cylinder guillotine and EV base 5 Inspect the guillotine for signs of damage Replace guillotine if damage is found and inspect the cylinder and piston for damage 6 Clean the guillotine with brake cleaner and a piece of fine steel wool Clean only to remove hardened carbon deposits 7 Once clean rinse blade with mild detergent and water Dry completely 8 Install a new gasket then reinstall the EV assembly Apply Loctite 242 to the fastener threads then torque to specification 9 Reconnect the vent hose NOTE obtain maximum exhaust valve performance Polaris recommends using Polaris VES Gold Synthetic Two Stroke engine oil Never mix different brands of engine oil ey T Exhaust Valve Housing Fasteners 12 Ft Lbs 16 Nm Apply Loctite 242 POLARIS The Way Out Surge
107. 18TXL CHASSIS HOOD 9 GROUND SPEED SENSOR SPLICE GROUND SPEED 109 ORANGE 18 BRAKE SWITCH 180F BRAKE SWITCH SPLICE BRAKE LIGHT RED WHITE L6TXL CHASSIS POWER l CHASSIS POWER SPLICE CHASSIS POWER BROWN 16131 CHASSIS POWER 3 CHASSIS GROUND SPLICE CHASSIS GROUND BLACK BLUE 20 SENSOR GROUND 156M BLACK BLUE SPLICE SENSOR GROUND BLACK BLUE 18 SENSOR GROUND SPLICE 1 BLACK BLUE SPLICE SENSOR GROUND RED WHITE 18 INTAKE AIR PRESSURE 3 5V POWER SPLICE 5V POWER RED 16 ELECTRIC START F REGULATOR POWER SPLICE REGULATOR POWER 12 15 PERFORMANCE WINNING gt POLARIS iagrams D iring W 2008 IQ CFI Engine Harness 9
108. 2 i p 222 06 sss es ___ ____ nem vni BRAKE L L SIGNAL REGULATOR STATOR ae E 211 IFUEL LEVEL i 8 i eee I 38 80 STATOR LEADS ON memi COOLANT TEMP SENSOR DC BRAKE 2 z CRANK POSITION PES 1 gt YET zi 20 C 68 F 24324 250 o o of blo 14 COILS E TO NB 0 15 5 55 IGNTION 1002C 212 F 192830 7 DG TO BK RD 15 lt m SWITCH P GROUND DG TO DG OPEN 725 REGULATED INCLUDES 1 81 5 555 i DC BATT wama DG TO RD 15 8 wwe l ee im ee Low wH RD 185 REGULATED 1 DC PWR BN GROUND BK WH RD 5 FULL 840 RESISTANCE 20 START OFF HALF 40230 REGULATED REGULATOR m OL E S COOLANT me ED LI SENSOR SWITCH ACCESSORY LOCATED IN SWITCHBACK ONLY 122 2410868 02 ____ 2007 600 Carbureted 1 of 2 12 1 PERFORMANCE gt POLARIS WINNING iagrams D iring 2007 600 HO Carbureted 2 of 2 1140 8311 8 30 3onvo 9 401 NO 031 201 GIONS10S 1915 Y CIRCUIT BREAKER LOCATED ON TOP OF BATTERY
109. 2 95cm exhaust port height is 29 5mm Effective Displacement 3 1416 PI x 42 25 bore squared x 2 95 exhaust port height cm 4 97 89cc Effective Displacement 97 89cc Effective Compression Ratio 17 1 cc 97 89 Effective Displacement cc 17 1 HV 6 725 Effective Compression Ratio 6 725 In order to increase the Full Stroke Compression Ratio to 13 6 how much material do you need to remove from the cylinder head You know that R IHV Displacement IHV and you want to find out Displacement 199 098cc and we want to 13 6 so then desired Displacement 199 098cc R 13 6 1 2 12 6 IHV desired 15 801cc desired IHV to have 13 6 1 Full Compression Ratio 2 6 Head cc Removal Example The total number of cc s to remove from the head Old IHV 17 1 Desired IHV 15 801 1 299cc s Removed cc s 1 299cc s I Stroke 6 0cm Displacement 199 098 x 2 54 I 0 01186 inches To find out how much to machine off multiply the number of cc s you need to remove by the number of inches to remove per cc Thickness to remove I 0 01186 x 1 299cc 0 015 Port Opening Duration Port open 81 5 This indicates the degrees after TDC that the exhaust port opens and also the degrees before TDC that the port closes Duration closed 2 x 81 5 port open Duration closed 163 Total Duration 360 Duration Open Total Duration 360 Durat
110. 30 28 4 Front Vertical Travel Inches cm 10 55 26 8 Ski Center Distance 42 5 108 Camber Inches cm 2 25 0 31 57 7 9 Toe Out Inches cm 0 0 12 0 0 31 Rear Suspension Suspension Type IQ 121 Walker Evans w IFP Front Track Shock FTS Reno Reson Compression Adjustable Rebuildable FTS Spring Rate Ibs in N mm 130 270 23 47 FTS Spring Installed Length Inches cm 7 97 20 2 Walker Evans w IFP Remote Resevoir Beate Sheek RIS Compression Adjustable Rebuildable Torsion Spring 347 Tail Angle 80_ Rear Travel Inches cm 13 33 WINMING PERFORMANCE gt POLARIS 1 17 Model Specifications 2007 700 HO RMK Dragon Model Number SO7PL7JS SO7PL7JE Engine Engine Type Model Number 53322 7044 7 Displacement Cylinders 700 2 Bore inches mm 3 19 81 Stroke inches mm 2 68 68 Piston to Cylinder Clearance inches mm 0042 006 109 163 Installed Ring Gap inches mm Upper 010 018 25 45 Lower 014 020 35 50 Operating RPM 200 8250 Idle RPM 1700 Engagement RPM 200 3800 VES Spring Color Purple Fuel Delivery Type Cleanfire Direct Injection Throttle Body Marking 1203213 Throttle Body Bore 46mm TPS Voltage Idle 0 95 0 01 Fuel
111. 3v8310NVH YINYYMANNHL 02 039 2v 321145 QN0089 MH 1918 02 049 H9IH QIW MH 321145 MH YINYYMONYH LHOIY 02 039 3018 MO1 MH 321145 MH LHOIY 02 3n18 049 OV 21145 0 0089 uvg310NVH HOLIMS 3339 8 NOUS 039 321145 QN0089 MH HOLIMS 3 88 02 039 321145 GNNOYD MH 3 1331 02 039 MH 321145 MH IN 1331 02 030 3018 MO1 MH 321145 MH 1331 02 3n18 N0089 3Y 21145 049 TWNOIS 1041402 H1 02 H9IH OIN MH 331145 MH Q3N 915 1081NO2 H1 02 1187 3018 MH 321145 MH JVN91S 1081502 H1 02 3118 YINYYMANNHL H9IH YINYYMANNHL TVN9IS 1081NO2 H1 02 AV89 3L1HM u3NHVMBNQHI MOT 1 915 1041402 H1 02 Av89 39NYUO 039 20 24 321145 GNNOYD 20 1 321145 GNNOYD 20 8 311HM NMOUS 33804 20 321145 43804 20 80 122 8 3L1HM Q3U 43MOd 20 01083105 321145 83004 20 8 3L1HM Q3U 039 3Y Luvis 21812313 039 91 039 039 20 1 121145 GNNOYD 20 830835 13431 1303 02 311 HM NMOUB 398 2 AU311V8 18915 218123
112. 425 WH BLACK TO WHITE 3 Q 41 BN WH PLUG LEAD TO PLUG LEAD 5KO 1 CHASSIS ENGINE 40 i xpi RESISTANCE 20 BD PONER IN PIN A xh EL v out Pi HAL sal Fa B Pin 42 PM a SPEED SENSOR GROUND SPEED LOCATED ON CAPACITOR DRIVE SHAFT 5 E8 DB RD E7 GY i 37 WH R2 4 a 1 ELECTRIC START 46 RD 1 t6 BK RD 215267 168 PAGE 2 19 YE i 5 BK 7718 BICHASSIS REGULATOR 2 45 CLIP SIDE GROUND 26 DB YE E22 YE RD 1211 53 E24 DB WH E12 BN Ell BK GROUND GROUND SPLICE SPLICE 2 32 BN WH F24 VT 233 VT WH E4 WH RD l xe BN WH
113. 45 65 Engine Service Specifications All Engines Cylinder Head Warp Limit 006 015mm Cylinder Taper Limit 002 051mm Cylinder Out of Round Limit 002 051mm Main Bearing Interference Fit Carbureted 001 002 026 051mm CFI 0014 0024 036 061mm Connecting Rod Side Clearance 0114 0295 289 749mm Crankshaft Runout Deflection Limit 0025 07mm gt POLARIS Engine and Cooling Systems Component Torque Sequences Cylinder Head Torque Pattern All 5 0 G lt 4 lt lt 2 e MAG PTO CFI Crankcase Torque Pattern o 90 0 59 e 8 o0 F 2 c MAG PTO Carbureted Crankcase Torque Pattern 00 9 Cylinder Torque Pattern Except Monoblock W 2 MAG CO 8 Cylinder Torque Pattern Monoblock C 1 QU 2922220 CFI Recoil Cover 5 4 WINNING PERFORMANCE gt POLARIS Engine and Cooling Systems ENGINE INSPECTIONS Cylinder Head Inspection Middle Using a flat bar and a feeler gauge inspect each cylinder head for warping Replace head if warping exceeds 003 08mm In mm Cylinder Head Warp Limit 006 015mm In mm Cylinder Measurement Taper Limit 002 051mm Out of Round Limit 002 051mm Bottom
114. 46 5 118 1 Length in cm 129 327 7 Height in cm 48 121 9 Estimated Dry Weight Ib kg Base 155 489 221 8 Dragon 155 484 219 5 Dragon 163 489 221 8 Fuel Gallons Liters 11 5 43 5 Oil Quarts Liters 3 2 8 Cooling System Capacity 155 6 5 6 1 Quarts Liters 163 6 625 6 3 Brake Fluid DOT 4 Drive Belt Part Number 3211115 Width inches cm 1 460 3 7 Side Angle 26_ Circumference inches cm 46 77 118 8 Center Distance inches cm 11 5 29 2 Chaincase Center Distance inches 8 373 Top Gear Stock 20 Bottom Gear Stock 41 Chain Stock 76 Gear Lube Polaris Synthetic Capacity oz ml 11 325 3 Reverse System Perc Electrical Alternator Output Operating Voltage 13 5 14 5 Vdc Watts 13 5 Vdc Total 400 Ignition Timin pO Coolant Temp 120_F 49_C Spark Plug Gap in mm 027 70 Spark Plug Champion RN57YCC Track Width Inches cm 15 38 155 393 7 Length Inches cm 163 414 Lug Height Inches cm 2 4 6 1 Track tension sag in cm with 10 Ibs 4 54kg placed 16 in 3 8 1 2 1 1 3cm 40cm ahead of rear idler shaft WINNING PERFORMANCE C POLARIS Model Specifications Front Suspension Inches cm Suspension Type IQ Shocks Base Ryde FX Dragon Walker Evans Air IFS Spring Rate Ibs in N mm BOO CERA Spring Installed Length Inches em 10 35 26 3 WE Air Oil Volume 95 WE Air Nitrogen Charge 220 psi Front
115. 5 0H009 80 ONS 10 GOOH YY LSIHS 0 009 8002 PERFORMANCE gt POLARIS WINNING 12 10 iagrams D iring W 2008 IQ Shift RMK 1 of 2 12 11 LOCATED AT WIRES ARE REPRESENTED BY BRAKE LEVER SOLID OR DASHED LINES TO SIMPLIFY TRACING IN DIAGRAM r ET 23 YE RD RE COLOR LEGEND lt VALVE oo 22 BN WH 2 010 LOR LEGEN 86 BEIGE ENGINE GROUND 5 20 RD WH 08 BK BLACK 80 N CHASSIS GROUND DB DARK BLUE BRAKE APPLIED 14 BN BN BROWN NC ACTIVE OPEN WHEN GRAY NC SWITCH NORMALLY INACTIVE FLIPPER 24 GN LIGHT GREEN CLOSED PUSHED 09 WH OG 06 DARK GREEN 06 ORANGE SWITCH NORMALLY PK PINK OPEN RD RED VT VIOLET PURPLE WH WHITE YE YELLOW 06 BK WH 05 WH MEDIUM BRAKE LIGHT HW SWITCH THROTTLE SAFETY SWITCHES SWITCH IS CLOSED IN NORMAL OPERATION SPLICE T2 o gt 65 08 80 15 YE 0 DBIRD 33 VT WH p n 2 STOP AUXILIAR
116. 6000 8000 2400 3000 A Wer Fa e Lat iV 208 1 1 8 2 2 29cm 8000 10 000 10 58 Ocm ahead of rear idler 3000 3600 2 959 shaft 10 000 12 000 19 56 Drive Clutch Bolt Torque 80 Ib ft 108Nm 1 36 WINNING PERFORMANCE gt POLARIS Model Specifications Front Suspension Suspension Type 10 42 5 Shocks Base Ryde FX PRO HPG w IFP Dragon Ryde FX Air 2 0 IFS Spring Rate Ibs in N mm Spring Installed Length Inches em 10 55 26 8 Air 2 0 Nitrogen Pressure 36mm Cylinder 145 psi 47mm Cylinder 60 psi Front Vertical Travel Inches cm 10 254 Ski Center Distance Inches cm 42 5 108 Setup Width 41 16 104 5 Camber Inches cm 2 25 0 31 57 7 9 Toe Out Inches cm 0 0 12 0 0 31 Rear Suspension Suspension Type IQ 136 Coupled Front Track Shock FTS Ryde FX HPG w IFP FTS Spring Rate Ibs in N mm 130 270 23 47 FTS Spring Installed Length inches cm 20 Rear Track Shock RTS Base Fox PS5 Dragon Ryde FX Compression Adj w Remote Res Torsion Springs 347 Square 80_ Soft Dragon Stock IQ PN 7043070 067 PN 7043071 067 347 Square 77_ Softest Dragon Soft IQ PN 7043240 067 PN 7043241 067 359 Square 12 5 Stock Dragon PN 7043079 067 PN 7043080 067 Rear Travel Inches cm WINNING PERFORMANCE gt POLARIS
117. 7 L Lower Spherical Bearing Replacement 8 12 M M 10 Adjustments 8 40 M 10 FRA Adjustment Indicator 8 41 M 10 FRA Adjustments 8 40 M 10 FRA Set 8 41 M 10 Overview 8 40 M 10 Ski Pressure 8 41 M 10 Spring Preload 8 41 M 10 Terminology 8 40 Maintenance Products 3 4 Master Cylinder Service 6 12 Mikuni Carburetor Components Float System 4 6 Fuel Delivery 4 6 Fuel Metering 4 6 Function 4 6 Jet Needle 4 8 Main Jet 4 7 Needle Jet 4 8 Pilot Air Screw 4 7 Pilot Jet 4 7 Piston Valve or Throttle Valve 4 8 Mikuni Piston or Throttle Valve Part Numbers 4 4 Mikuni TM Carburetor 4 6 Mikuni TM38 Flat Slide Service Assembly 4 13 Disassembly 4 11 Fox 9 4 Ryde FX 9 3 Walker Evans 9 5 Walker Evans 7 16 9 6 Periodic Maintenance 3 2 Schedule 3 2 Piston Inspection 5 6 Piston Ring Installed Gap 5 6 Piston Wash Reading 2 10 Publication Part Numbers 24 2007 Publications 2 4 2008 Publications 2 4 PVT System Adjusting Belt Deflection 7 11 Drive Belts 7 9 Drive Clutch Springs 7 5 Non ER LW Driven Helix
118. 700 800 CFI OIL HOSE 5 32 ENGINE REMOVAL 2 2 5 33 ENGINE 5 36 COOLING SYSTEMS tinte d teda ande dc 5 41 EXHAUSTS YSTEMS netbeans pukuq Nerd 5 48 ASSEMBLY VIEW TYPICAL 2 5 48 WINNING PERFORMANCE 5 1 gt POLARIS Engine and Cooling Systems ENGINE SPECIFICATIONS Fastener Torque Guide COMPONENT 600 700 CFI 800 NOTE Spark Plug 18 Ft Los 24 Nm Apply Nyogel Head Cover 25 Ft Lbs 34 Nm Loctite 242 Cylinder Head Bypass Fitting 7 Ft Lbs 9 5 Nm N A Bleed Screw 70 In Lbs 8 Nm Knock Sensor 168 In Lbs 19 Nm Clean and Dry Temp Sensor 18 Ft Lbs 24 Nm EV Housing Base Cover 12 Ft Lbs 16 Nm Loctite 242 EV Bellows Nut 16 Ft Lbs 22 Nm Apply Loctite 2760 to the first 3 guillotine threads Cylinder Base Nuts 37 Ft Lbs 50 Nm N A 37 Ft Lbs 50 Nm Cylinder Bolts N A 42 Ft Lbs 57 Nm N A PTO Crank Seal Guard N A 12 Ft Lbs 16 Nm N A Intake Boots 9 Ft Lbs 12 Nm Exhaust Manifold 22 Ft Lbs 30 Nm Water Pump Impeller 10 Ft Lbs 13 Nm Oil Pump 7 Ft Lbs 9 5 Nm Water Pump Cover 9 Ft Lbs 12 N
119. 700 x 010 875 x 090 700 x 010 700 010 700 x 010 700 010 700 x 010 700 010 700 x 010 700 x 010 700 x 008 Rebound Check Valve NOTE Valve shim stacks listed as they would appear on the shaft when shock rod is locked in a table vise eyelet down threaded end up WINNING PERFORMANCE 9 11 gt POLARIS Shocks 2008 Shock Specifications 2008 Front Suspesion Shocks EXTENDED COLLAPSED SHOCK STROKE IFP DEPTH OIL SHOCK PN LENGTH LENGTH iN Rop VoLUME PSI IN IN IN 7043245 Ryde FX 17 98 11 77 6 21 49 6 92 Full 200 36mm Rod Cylinder 145 PSI 7043315 Ryde FX 18 00 11 80 6 20 N A 5 75 Full 47mm Body Cylinder 60 PSI 7043364 Walker 1702 11 27 5 75 1 124 N A 95 220 Evans 2008 Front Track Shocks EXTENDED COLLAPSED SHOCK SHOCK PN MODEL LENGTH LENGTH di M OiL VOLUME PSI IN IN IN 7043244 Ryde FX 12 12 8 61 3 52 50 4 68 Full 200 7043365 Walker Evans 12 49 8 92 3 57 1 124 N A 60cc 217 5 2008 Rear Track Shocks EXTENDED COLLAPSED SHOCK SHOCK PN MODEL LENGTH LENGTH rus m OiL VOLUME PSI IN IN IN 7043177 Fox 15 60 10 56 5 04 50 1 22 Full 200 7043216 Fox 14 12 9 29 4 83 50 2 40 Full 300 7043316 Ryde FX 15 60 10 60 5 00 50 1 60 Full 200 7043366 Walker Evans 16 71 10 96 5 75 50 6 75 Full 200 9 12 WINNING PERFORMANCE
120. 7J 700 EV L C Case Reed CFI E voie 8E 795 EV L C Case Reed CFI U Utility X Race Y Touring LTD digits that would transfer to 17 digit VIN and are used in digits 4 8 respectively 9th digit will be used on color featured versions of models not including the base First 3 digits and 9th digit are sued in model number only They are not used with the 17 digit VIN gt POLARIS General Information VEHICLE IDENTIFICATION NUMBER VIN Tunnel Decal The Tunnel Decal has the Model Number 1 V I N Number 2 and the Manufactured Date 3 These numbers should be MODEL NO MADE IN U S A V I N NO THIS VEHICLE CONFORMS TO ALL APPLICAELE U S FEDERAL AND STATE REQUIREMENTS AND CANADA MOTOR VEHICLE SAFETY STANDARD IN EFFECT ON THE DATE OF MANUFACTURE MFD DATE VIN Number Designation referred to in any correspondence regarding warranty service or replacement parts The machine model and V I N number identification decal is located on the right front side of the tunnel The V I N 2 number is permanently stamped into the tunnel The model number is embossed on the decal PELARIS PATENT NOTICE Mid by Polaris Industries Inc in Roseau MN under one or more of the following patents U S Patents 3 605 511 3 580 647 3 483 766 3 533 662 3 545 821 3 605 510 3 525 412 3 613 810 3 867 991 4 793 950 5 038 881 5 172 675 5 090 386 5 050 564 5 050 559 5 048 503 5 056 482 5 099 813
121. 9 Belt Installation TEAM driven clutch 7 1 Belt Removal Team Driven Clutch 7 1 Brake Caliper Assembly 6 15 Brake Caliper Removal 6 14 Brake Caliper Replacement 6 14 Brake Disc Replacement 6 15 Brake Fluid Indicator 3 16 Brake Fluid Type 3 16 Brake Light Switch Replacement 6 14 Brake Line Replacement 6 13 Brake Pad Replacement 6 15 Brake System 6 10 Bleeding 6 11 Compensating Port 6 10 Fluid Change 6 11 Overview 6 10 Brake System Maintenance 3 16 Brake Fluid 3 16 Brake Lever Travel 3 16 C Carbureted Electrical Systems 11 15 Carburetor Fuel Systems 4 3 Mikuni Long Pilot Air Jets 4 4 Mikuni Short Pilot Air Jets 4 4 Mikuni Jet Needles 4 4 Mikuni Main Jets 4 3 Mikuni Notched Piston Valves 4 4 Mikuni Pilot Jets 4 3 Mikuni Starter Jets 4 3 Typical Fuel System 4 5 Carburetor Synchronization 4 14 Chaincase Chains 6 3 Gears 6 3 Chaincase Assembly 6 5 Chaincase Assembly View 6 4 Chaincase Disassembly 6 5 Chassis Lubrication 3 14 Chaincase Oil Level Check 3 15 Chaincas
122. ACE ECU Chassis Power Up Cable part number PA 46355 12 volt battery Connect to Vehicle Diagnostic Connector Vehicle Interface Digital Wrench 9 7 Serial Interface Cable to PC Connect to Digital Wrench PC Smartlink Module 4 36 Digital Wrench Connections The access point for the ECU power up and Digital Wrench connectors is located in the front left side of the nosepan ua t ia Follow these steps to connect the diagnostic and power up cables to the snowmobile 1 Assemble the Smart Link cables and module as shown in the illustration 2 Open the hood and locate the connectors Remove the protective cap from the diagnostic connector 3 Connect the vehicle interface cable to the diagnostic connector 4 Using the power up cable part number PA 46355 and a fully charged 12 volt battery connect the power up cable to the ECU connector NOTE To verify the 12 volt battery and power up cable are working connect the cable to the chassis power up connector If working correctly the headlights should illuminate WINNING PERFORMANCE POLARIS Fuel Systems Updating Digital Wrench The following selections can be made on the update website Fileset updates and service packs are released for Digital Wrench via the Internet The Digital Wrench update website can be found by accessing the dealer Internet site
123. Assemble the chaincase ON 260 o Ta WINNING PERFORMANCE 6 15 POLARIS Final Drive and Brakes NOTES WINNING PERFORMANCE 6 16 POLARIS PVT System CHAPTER 7 PVT System PVT SYSTEM Rx eaa qne bathe pa d bras 7 2 OVERVIEWS Sarda eh oe oe ati lee eae gu 7 2 DRIVE SPRING sai ieee fyi id e i ere NA D 7 2 CLUTCH WEIGHT nas en Rui 7 2 NEUTRAL SPEED Rh b uec MARRE eas eee et ds 7 2 ENGAGEMENT RPM RU eiit oer as we Seg RU REN RANA 7 2 SHIFVOUT OVERREV ber CERE M Eure eee 7 2 SHIFT OUT RPM cui Seance sue RR 7 2 DRIVEN SPRING emer eM cro pie desta 7 2 BACK SHIFTING alesse 7 2 FINAL GEARING paskay UL eh ted UO RIPE CENT 7 3 TAL SHIET RATIO rre etum A a RU be ATO UE 7 8 LOW 7 HIGH RATIO tiit itte anak are Mave a te ess S poh cy e ete 7 3 DRIVEN HELIX 7 RAMP u Sac Ree teer es Gee Te eye anes 7 3 GENERAL INFORMATION 04 23 ea od ded ek yaad be 7 4 SPECIAL TOOLS uua ec euh BE abe tue du bees eho Ted 7 4 DRIVE CLUTCH SPRINGS 7 5 SPRING FREE LENGT
124. BOX OPTIONAL HD HM 90 G0 Gu HM 10 gt N8 90 N8 HM 90 0 ouo Ego co QN0089 Auillvg GNNOYD 11 8 108 1003201 YILYVIS 81 NMOUG 411089 1003201 3951 01083105 1391 30817 100201 318915 9 311HM N33HD HOLIMS 1 1 WN9S1 1083105 131 108 1 1491 21812313 9 Q38 311HM 1831178 3052 u3xv3ug 1102815 luviS 2181231131 81 038 u3MOd 3081 1 201 YALYVLS 10817 LYVLS 21412313 91 M01134 QN0089 SISSVHD 1081 1009201 31 1 3081 18 1 2181234134 81 NMOUG NOLLONAS ALIAVO YOLISNNOD 01 192 0 39NV9 20 06 0172 YSEWAN lHVd SS3NHVH 418 1 NOLLVNINH31 20 06 01 92 H3HAnN SS3NHVH NINO 10 898017 SSINYVH 22 81 M01134 038 34 08 31dWVX3 580102 JJVYL NIVW HLIM NMOHS 38 580102 JYIM 101131 11 HM 319809 131014 038 Qu Ad 39NvuO 90 13389 8 0 90 N3349 1H911 N9 19 NMOUS N8 3018 wav 80 3078 1H911 ng yv 18 X8 NY1 39138 98 013931 40109 3318 WYYOVIG NI 9NIOVUL AAI TdWIS 01 S3NI 1 4385 0 40 41105 8 63183538438 35 53811 011089 20 3121145 0 0089 24
125. EYES OR CLOTHING ANTIDOTE EXTERNAL FLUSH WITH WATER INTERNAL DRINK LARGE QUANTITIES OF WATER OR MILK FOLLOW WITH MILK OF MAGNESIA BEATEN EGG OR VEGE TABLE OIL CALL PHYSICIAN IMMEDIATELY Spark Plugs EYES FLUSH WITH WATER FOR 15 MINUTES AND GET Model Spark Plug Gap Inches mm PROMPT MEDICAL ATTENTION ALL MODELS BATTERIES PRODUCE EXPLOSIVE GASES KEEP SPARKS Standard Champion uM em FLAME CIGARETTES ETC AWAY VENTILATE WHEN CHARG Optional i ING OR USING IN CLOSED SPACE ALWAYS SHIELD EYES WHEN WORKING NEAR BATTERIES Charging System KEEP OUT OF REACH OF CHILDREN Model Stator Output of Pulses ALL 600 CARBURETED 290 P ALL 600 700 800 CFI 400W N A Ignition Timing Model Specification 26 3500 RPM Disconnect TPS 18 Idle 1700 RPM ALL 600 700 800 CFI 0 95 TPS and 120 Engine Coolant Temperature ALL 600 CARBURETED WINNING PERFORMANCE POLARIS 11 2 Battery and Electrical Systems CONVENTIONAL BATTERY NOTE Do not service the battery unless it will be put into regular service within 30 days Battery Preparation 1 Fill battery with electrolyte to the upper level marks on the case 2 Set battery aside and allow it to cool and stabilize for at least 30 minutes 3 Add electrolyte to bring the level back to the upper level mark on the case NOTE This is the last time e
126. ID 2 Remove the air box exhaust pipe and resonator from the engine compartment 3 Remove the high tension wires and spark plugs from the Piston Matrix 53206 6044 6 S3468 6044 PU6H 2203319 EK 22202c cylinder head S3469 6044 PU6H S3305 7044 PF7J 2203512 2922 06 gt POLARIS Engine and Cooling Systems 10 11 12 13 14 15 16 Remove the thermostat housing outlet cooling hose from the housing Loosen all then remove all head cover fasteners Clean the fastener threads to remove any thread locking residue Discard the head cover and cylinder head o rings Always use new o rings during assembly Inspect the cylinder head combustion domes for any damage Measure cylinder head flatness Replace cylinder head if required If only the cylinders are going to be removed remove the fuel rail from the upper fuel injectors See CFI Fuel Rail Injector s Removal Installation on page 4 30 Loosen all then remove the cylinder bolts Clean the bolt threads to remove any thread locking residue Carefully pull each cylinder upwards taking care not to drop the piston and rod abruptly against the crankcase Remove the cylinder base gaskets Use a gasket scraper to clean the gasket residue from the crankcase and cylinder bases Inspect the cylinder walls Nicasil cylinders can only be lightly honed Damage that cannot be removed with a light hone requires cyli
127. Inches cm 15 38 144 365 7 Length Inches cm 155 393 7 2 0 5 08 144 Lug Height Inches cm 2 4 6 155 Track tension sag in cm with 10 155 4 54 placed 16 in 40cm ahead of rear idler shaft 3 8 1 2 1 1 3cm WINNING PERFORMANCE gt POLARIS 1 23 Model Specifications 2008 600 Dragon IQ General Model Number Width in cm 48 121 9 SORTEOS SOGEROHE Length in cm 115 292 1 Engine Height in cm 48 5 123 2 Liberty Liquid Cooled Estimated Dry Weight 476 216 1 Case Reed Induction Ib kg Model Number S3468 6044 PU6H Fuel Gallons Liters 117 443 Displacement Cylinders 599 2 Oil qts l 3 2 8 Bore inches mm 3 04 77 25 Cooling System Capacity 8 5 8 Quarts Liters Stroke inches mm 2 52 64 B Brake Fluid DOT 4 iston to Cylinder Clearance 004 006 105 159 Drive Belt Part Number 3211122 Installed Ring Gap 014 020 356 508 Width inches cm 1 460 3 7 inches mm Side Angle 26_ Operating RPM 200 8250 Circumference inches cm 46 77 118 8 Idle RPM 1700 Center Distance inches cm 11 5 29 2 Engagement RPM 200 3800 Chaincase Center Distance inches 8 373 Exhaust Valve Spring Purple Top Gear Stock 23 Bottom Gear Stock 39 Fuel Delivery Chain Stock 76 Cleanfire Direc
128. LED indicator by grounding the MFD circuit whenever the module receives an Vac AC voltage is over 14 8 volts when the engine is brake light signal operator pulls brake lever running No DC voltage found on the RED WHT or RED circuits when the engine is running ES The brake lights illuminate when the brake lever is SIRI pulled but the LED indicator does not 2008 RMK Shift 155 Regulator Rectifier The RMK Shift regulator rectifier performs the same functions as the 2007 600 HO regulator rectifier Circuit Specifications PLUG PIN COLOR FUNCTION 1 YEL BLK AC POWER INPUT 2 YEL BLK AC POWER INPUT Circuit Specifications 4 RED VDC BATTERY CHARGE PLUG PIN COLOR FUNCTION 5 RED WHT VDC REGULATED FOR MED STATOR 2 BROWN GROUND 6 ORANGE AC BRAKE SIGNAL 3 7 YELLOW REGUALTED VAC 8 YELLOW REGULATED VAC STATOR 4 BROWN GROUND TUUM STATOR 6 ELLO AC POWER INPUT 10 BROWN GROUND VICTIME 13 BRN WHT DC GROUND YELLOW 14 ORG BLK DC BRAKE LAMP GROUND MFD HARNESS TORG Saa ANE GROUND 15 BROWN GROUND 16BROWN AC GROUND HARNESS C ORANGE AC BRAKE SIGNAL INPUT HARNESS D BRN ae DC GROUND HARNESS F COW AC GROUND HARNESS G EON REGULATED AC POWER 11 16 WINNING PERFORMANCE POLARIS Battery and Electrical Systems 2008 I
129. Lower Control Arm Removal 8 12 IX 4 WINNING PERFORMANCE gt POLARIS iagrams D iring W
130. Model TYPE MODEL IQ 121 2007 2008 IQ 121 Models 2007 IQ Switchback Models 2007 2008 IQ RMK Models 2007 2008 IQ LX Models 2007 600 HO IQ Touring All 2008 IQ Switchbacks 2008 600 IQ Touring IQ 144 155 163 10 128 10 136 IQ 136 Coupled IQ 136 Comfort Suspension Mounting Fastener Torque Torque component Specification Front Suspension Upper Lower Control Arm to Bulkhead Mount Fasteners IQ 121 FTA RTA to Tunnel Fasteners IQ 144 155 163 RTA to Tunnel Fasteners M 10 128 136 FTA RTA to Tunnel Fasteners IQ 136 Coupled FTA RTA to Tunnel Fasteners IQ 136 Comfort FTA RTA to Tunnel Fasteners 40 Ft Lbs 54 60 Ft Lbs 81Nm 45 Ft Lbs 61Nm 70 Ft Lbs 95Nm 60 Ft Lbs 81Nm 60 Ft Lbs 81Nm NOTE FTA Front Torque Arm RTA Rear Torque Arm CAUTION Torque arm fasteners are pre coated with thread locking agent Always replace with new fasteners Never re use Nylock nuts Always replace components with new nuts 8 3 Steering and Suspensions IQ Rear Suspension Shock Rod Orientate the shock rod with the reinforcement plate facing down REINFORCEMENT PLATE IQ Rear Track Shock Pivot Orientation The rear track shock pivot must be properly located on all IQ rear suspensions when installing the rear skid into the tunnel Failure to properly locate t
131. POWER 02 WHITE RED 20 ELECTRIC START B START SOLENOID 156M STARTER SWITCH 03 ORANGE GREEN 20 ELECTRIC START C CHARGE RELAY 2 CHARGE RELAY CONTROL 04 RED BLACK 20 ELECTRIC START E CHARGE RELAY 5 BATTERY 05 RED WHITE 20 CHARGE RELAY CHARGE RELAY 3 CHASSIS POWER 06 RED BLACK 16 CHARGE RELAY 5 CIRCUIT BREAKER 250F BATTERY 07 RED BLACK 20 CIRCUIT BREAKER 250 START SOLENOID 156F BATTERY 08 BROWN 16 ELECTRIC START D BATTERY GROUND 1 48 BATIERY GROUND WIRE TERMINATION TABLE COLOR GAUGE FROM CONNECTOR CAVITY TO CONNECTOR CAVITY FUNCTION 02 WHITE BROWN 20 ECU CNA 2 MODE CHANGE 1 156F BOOT MODE 03 RED LT BLUE 20 ECU CNA 3 RED BLUE SPLICE K LINE POWER 04 ORANGE 20TXL ECU CNA 4 ECU POWER EXTERNAL POWER 05 WHITE BLACK 20TXL ECU CNA 5 EXHAUST TEMP 156F EXHAUST TEMP SIGNAL 06 LT BLUE 20 ECU CNA 6 INTAKE AIR PRESSURE 2 AIR TEMP SIGNAL 07 GREEN LT BLUE 20 ECU CNA 1 IGNITION SWITCH STARTER LOCKOUT 08 RED WHITE 20 ECU 8 5V POWER SPLICE 5 5V_POWER 09 LT GREEN RED 20 ECU 9 GROUND SPEED SENSOR SPLICE lt GROUND SPEED 10 RED BLACK 20 ECU 10 ELECTRIC START BATTERY WHITE LT BLUE 20TXL ECU CNA CHASSIS RELAY 2 CHASSIS RELAY COIL 12 BLACK RED 20 ECU CNA 12 STOP SWITCH SOFT STOP 13 BROWN 20 ECU CNA 13 ECU GROUND SPLICE 1 ECU GROUND 14 LT BLUE RED 20TXL ECU CNA 14 5515 000 20 WATER TEMP
132. PU 45419 Remove the flywheel nut and washer 5 26 RETURN SPRING WIRE RETAINER FLYWHEEL NUT FLYWHEEL FRICTION PLATE FRICTION SPRING 5 Using the flywheel puller tool PN 2871043 insert the puller s three screws into the flywheel NOTE Do not thread the puller screws into the magneto stator located behind the flywheel 6 Turn the puller center bolt in until the flywheel pops off of the crankshaft 7 Mark the location of the magneto stator plate in several places using a scribe Remove the magneto stator from the crankcase Assembly is reverse of disassembly Reference the fastener torque specifications at the beginning of the chapter 10 Do not use an impact wrench to install the flywheel nut WINNING PERFORMANCE gt POLARIS Engine and Cooling Systems 2007 2008 600 700 CFI Crankcase Crankshaft Assembly GEAR CLAMPS gt 2 a AS CYLINDER STUDS amp 1 am KN INTAKE BOOTS LH U REED STUFFERS ALIGNMENT DOWELS PTO SEAL NEEDLEBEARINGS jj 5 1 3 WU PTO BEARINGS FLYWHEEL KEY MAG BEARING Q MAG SEAL 1 Remove the engine from the engine compartment 5 g p l N 2 Follow the process for removing the cylinder head In 5 y In mm cylinders pistons flywheel recoil housing and th
133. Polaris Premium All Season Grease to all grease zerks as outlined periodic maintenance table A 12 Ft Lb 16 Nm B 19 Ft Lb 26 Nm A CAUTION C 45 Ft Lb 61 Nm D 35 Ft Lb 47 Nm The fasteners securing the rear suspension to the E 25 Ft Lb 34 Nm tunnel are pre coated with a locking agent when new Never re use these fasteners when removed Always use new pre coated fasteners when mounting the suspension to the tunnel WINNING PER FORMANCE gt POLARIS Steering and Suspensions IQ 136 Comfort Pivots Rear Idler BUSHING 1 IDLER WHEEL 560 SPACER INNER SHAFT l SPACER H BRACKET 7 IDLER WHEEL B 3 Su T A 45 Ft Lb 61 Nm B 35 Ft Lb 47 Nm Assembly Notes Never re use Nylock nuts Always replace with new parts All pivots must rotate freely after tightening fasteners Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table 8 27 Steering and Suspensions IQ 136 Comfort Rail Assembly FRSS WHEEL MOUNT 25622 amp 5 AS 22 B 5 2d IDLER WHEEL ADJUSTER BUMPER RAIL TIP 0 SPRING ROLLER 0 Ses 3 Places WHEEL MOUNT 22 ae RAIL SLIDER 116 2 WISS WHEEL MOUNT a BOGIE WHEEL
134. Pressure PSI bar 58 4 0 Recommended Fuel Octane 91 Non Oxygenated Ignition Timing Coolant Temp 120_F 49_C General Width in cm 46 5 118 1 Length in cm 130 330 2 Height in cm 49 124 5 Estimated Dry Weight Ib kg 478 217 Fuel Gallons Liters 12 45 4 Oil Quarts Liters 3 4 3 2 Cooling System Capacity 63 6 Quarts Liters Brake Fluid DOT 4 Drive Belt Part Number 3211115 Width inches cm 1 460 3 7 Side Angle 26_ Circumference inches cm 46 77 118 8 Center Distance inches cm 11 5 29 2 Chaincase Center Distance inches 8 373 Top Gear Stock 20 Bottom Gear Stock 41 Chain Stock 76 Gear Lube Polaris Synthetic Capacity oz ml 11 325 3 Reverse System Perc Electrical Alternator Output Operating Voltage 13 5 14 5 Watts 13 5 Vdc Total 400 18 1700 RPM R M 2 Clutch Settings ATP UDE DRIVE CLUTCH DRIVEN CLUTCH meters gt Shift Clutch Driven feet Weight Clutch Spring Spring Helix Gearing 0 600 0 2000 10 59 600 1200 2000 4000 1064 1200 1800 4000 6000 aa o EE 428 1800 2400 10 60 7042083 6000 8000 2400 3000 8000 10000 19 58 3000 3600 10000 12000 10 56 Spark Plug Gap in mm 027 70 Spark Plug Champion RN57YCC Track Width Inches cm 15 38 Length Inches cm 155 393 7 Lug Height Inches cm 2 4 6 1 T
135. REEL sA V Va Aa 5 5 KS N 4 ADS y gt SA 12 A MAGNETO STATOR A i yY 620 J ROPE GUIDE ji 2 Z lt FLYWHEEL 57 FLYWHEEL NUT RECOIL HOUSING ey T 9 Ft Lbs 12 Nm B 5 Ft Lbs 7 Nm Apply Loctite 242 Stator C 90 Ft Lbs 122 Nm Apply Loctite 242 Disassembly Assembly Process 1 Remove the exhaust pipe and resonator If the recoil assembly does not require attention the recoil rope can remained attached to the handle If recoil component work is desired reference the Recoil Assembly section See Recoil Assembly on page 5 11 3 Remove the recoil magneto housing cover The recoil assembly is located inside the housing 4 Remover the recoil hub from the flywheel Secure the flywheel with a strap wrench PN PU 45419 Remove the flywheel nut and washer 5 Using the flywheel puller tool PN 2871043 insert the puller s three screws into the flywheel NOTE Do not thread the puller screws into the magneto stator located behind the flywheel 6 Turn the puller center bolt in until the flywheel pops off of the crankshaft 5 18 10 11 Mark the location of the magneto stator plate in several places using a scribe Remove the magneto stator from the crankcase Clean the crankshaft and flywheel tapers with a solvent such
136. STATOR EXCITER COIL EXCITER COIL 17 WHITE GREEN CRANK POSITION SENSOR 5 TOOTH COIL GROUND 18 WHITE RED CRANK POSITION SENSOR 2 TOOTH COIL GROUND 19 BLACK BLUE DETONATION SENSOR GROUND 20 PURPLE DETONATION SENSOR SENSOR SIGNAL 21 RED BLUE PTO FULL LOAD INJECTOR INJECTOR POWER SUPPLY 22 RED BLUE MAG PTO PART LOAD INJECTOR INJECTOR POWER SUPPLY 23 AQUA TPS SENSOR SIGNAL RETURN 24 BLACK BLUE COOLANT TEMP SENSOR TPS SENSOR GROUND 25 YELLOW COOLANT TEMP SENSOR SENSOR SIGNAL RETURN 26 RED EV SOLENOID REGULATED VOLTAGE WINNING PERFORMANCE gt POLARIS 4 21 Fuel Systems Chassis Relay ECU CNA CONNECTOR WHT BLUE RED WHT CAPACITOR REGULATOR RECTIFIER REDAVHT CHASSIS VOLTAGE REGULATED DC VOLTAGE CH ENG GROUND UNREGULATED AC YELLOW VOLTAGE FROM STATOR 422 Tv Fuel Systems Throttle Ignition Kill System ECU CNA CONNECTOR IGNITION SWITCH CLOSED WHEN KEY TURNED TO OFF RED BLK TETHER SWITCH OPTIONAL THROTTLE FLIPPER SWITCH CLOSED THROTTLE SAFETY SLAP SWITCH CLOSED CIRCUIT PUSHED DOWN CLOSED CIRCUIT BLK BLU SENSOR GROUND BRN HASSIS GROUND BLK BATTERY GROUND System Overview The second system is the hardware stop system The hardware stop system is a direct ignition kill system That is whenever the There are two methods for cutting the ignition on CFI systems operator turns the key t
137. Stock Optional 625 065 700 010 620 093 620 093 085 625 x 065 700 x 010 800 x 010 700 008 700 012 700x 015 700x 008 800x 010 700 x 010 800 x 010 900 x 010 z 800 x 008 800 012 800x 015 00x 800x 008 800x 100x 800 x UE 5 800 x 010 900 x 010 800 x 010 900 010 1 000x 010 900 x 008 900 012 900x 012 900 x 008 900 x 010 1 00 010 1 100x 010 000 000 x 1 00 010 1000 1 100 x 010 1 00 x 010 110 012 1100 015 4 100 x 008 1 100 x 010 1 100 x 010 1 100 x 008 1 10 x 008 1 250 x 006 1 10 x 008 140x 010 1 200x 015 t 1 250 008 700x 008 700x 008 1 250 x 008 0 1 20 x 008 120x012 1250 015 250 x 250 x 1 20 010 1250 015 Piston 052 Orifice 060 078 078 052 081 093 Gah eee 052 052 1 300 x 015 1 30 x 006 1 30 x 006 1 30 x 015 z 1 300 x 008 1 300 006 1900 x 008 1 00x 012 1 300 008 1 300 x 008 1 00 x 012 1203 015 2222 o 1 100 x 006 1 00 008 1280 pos 1 20x 006 1 100 006 1 250 x 008 1 20 x 006 120 010 800 x 008 300 008 1280x009 900 012 800x 008 900 x 006 900 x 012 1 10x 015 4598 12 o 1 250 x 006 1 250 008 900 010 140 006 1 250x 006 1 300 x 010 1 10 x 006 1405010 1100 008 1100 08 1 100 008 1 00 006 1 100 008 1 250 x 008 1 00 x 006 1 00x 015 213085 016
138. TUBE SHOCK ASSEMBLY 1 Place the piston rod upper mount into the vise Reassemble damper rod assembly in the reverse order of disassembly Special attention should be paid the order of the Rebound and Compression disc shim stacks ensuring that they are in the same order prior to disassembly Tighten the lock nut to 15 20 ft lb of torque DO NOT OVER TORQUE If excessive torque is applied damage to the piston and valves will occur 2 Secure the shock body by its lower mount in vise The use of soft jaws is recommend to prevent damage or marks to the shock It is important that the gas shock be retained in the vice by the lower mount Any other method of securing the shock body during these procedures may deform the shock body cylinder NOTE The next points on IFP are not applicable for emulsion shocks Proceed to assembly of the pressure valve 3 Thread the positioning head onto the I F P locator tool and adjust the top of the value indicator to the appropriate measurement Depending on which shock absorber is being worked on adjust the piston location tool to the specified depth indicated in the shock specification chart 4 Apply a thin film of oil onto the floating wear band and O ring and install the floating piston into the top of the shock body positioning it below the counterbore 5 Using the tool as a handle push the floating piston down into the shock body being careful not to damage I F P wear band and O ring unt
139. Ta ee Ms 3 21 HEADLIGHT BULB 3 21 OFFSEASON STORAGE vicc id uu Bere RR 3 21 CHASSIS AND 3 21 CLUTCH AND DRIVE 5 3 21 CONTROLS AND 3 21 ELECTRICAL CONNECTIONS 1 3 21 CARBURETOR THROTTLE 3 21 3 1 GE POLRRIS The Way Out Maintenance PERIODIC MAINTENANCE Periodic Maintenance Schedule Periodic Maintenance Table Item 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 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 Syste
140. The assembly process is the reverse of disassembly 1 Remove the coolant from the engine using a siphon wet 13 Always use new gaskets and o rings during assembly dry vac or drain pan Liberally coat the inside of each cylinder and the outside 2 Remove the air box exhaust pipe and resonator from the of each piston with Polaris two stroke engine oil engine compartment 14 When installing a piston into a cylinder verify each piston 3 Remove the high tension wires and spark plugs from the ring opening is located at each piston ring locating pin cylinder head Squeeze the top ring then carefully slide the cylinder over 4 Remove the thermostat housing outlet cooling hose from the compressed ring Do the same with the bottom ring the housing 15 Follow the torque specifications and torque sequences 5 Loosen all then remove all head cover fasteners Clean the located at beginning of chapter when tightening fasteners fastener threads to remove any thread locking residue 6 Discard the head cover and cylinder head o rings Always use new o rings during assembly 7 Inspect the cylinder head combustion domes for any damage Measure cylinder head flatness Replace cylinder head if required oS 5 17 Engine and Cooling Systems 600 HO Carbureted Recoil Magneto FRICTION PLATE FRICTION SPRING E RECOIL HANDLE RETURN SPRING RECOIL HUB n ea amp S lt y lt ROPE
141. Un screw the chain tensioner bolt 4 Remove the cotter pin from the upper gear castle nut and discard Lock the parking brake then remove the castle nut 5 Remove the lower gear fastener and washer Note that beveled side of the washer faces out 6 Remove the chain and upper lower gears from the chaincase 7 Remove the brake caliper from the chaincase Secure the caliper up and away from the chaincase Ay CAUTION Do not kink or bend the brake hose 8 Remove the drive belt from the clutches Remove the driven clutch 9 Raise the rear of the vehicle on a track stand Loosen the rear idler wheels and track tension adjusters Slide the rear idler shaft completely forward 10 Remove the speedometer flange housing from the bulkhead 11 Slide the driveshaft out of the chaincase towards the clutch side of the vehicle NOTE On some models it may be necessary to remove the left side console storage bucket 12 13 14 15 Remove the nuts securing the chaincase to the frame Carefully pull the chaincase away from the jackshaft then out of the engine compartment To replace the seals and bearings carefully pry out the seals from the backside of the chaincase and discard Remove the two snap rings securing the bearings inside the case Press on the outer race of each bearing from the backside of the case to remove each bearing CAUTION Always press on the outer race of the bearings 16
142. and the piston is outward As the temperature within the hydraulic system changes this port compensates for fluid expansion caused by heat or contraction caused by cooling During system service be sure this port is open Due to the high temperatures created within the system during heavy braking it is very 6 10 important that the master cylinder reservoir have adequate space to allow for the brake fluid to expand Master cylinder reservoirs should be filled to the top of the fluid level mark on the inside of the reservoir 1 4 5 16 6 8 cm below lip of reservoir opening This system also incorporates a diaphragm E as part of the cover gasket and a vent port on cover located between the gasket and the cover The combination diaphragm and vent allow for the air above the fluid to equalize pressure as the fluid expands or contracts Be sure the vent is open and allowed to function If the reservoir is overfilled or the diaphragm vent is plugged the expanding fluid may build pressure in the brake system and lead to brake failure WINNING PERFORMANCE gt POLARIS Final Drive and Brakes General Guidelines pressure will cause a surge of fluid through the small orifices of the brake system when the bleeder screw is opened and introduce air into the system by means of A WARNING cavitation Small amounts of air can become trapped in the banjo bolt fittings at the master cylinder s and junction points
143. and body when charging CAUTION or discharging any shock 10 11 Insert the Fox Safety Needle squarely into center of gas valve Using a blunt object depress the air valve core to release pressure When the shock is FULLY DISCHARGED pull reservoir away from the Fox Safety Needle in a straight smooth motion Clamp the body end eyelet of the shock securely in vice with shaft side up Using the 1 3 8 wrench loosen and unscrew the bearing assembly from the shock body If the body cap unscrews instead of the bearing that is OK You will need to remove both for this rebuild procedure 9 27 Shocks 12 13 14 15 16 17 18 19 20 21 22 Clamp the shock in the vice using the body clamp blocks If the bearing is still in the body use the 1 3 8 end wrench to loosen and un thread the bearing If the body cap is what needs removal use the large crescent wrench to loosen and unthread the body cap Remove the shaft assembly from the body tube and place on a clean lint free paper towel Remove the shock from the vice and pour shock oil from body tube into a proper disposal container Do not re use old shock oil Using the handle of the mallet push the IFP out of the shock body on to a folded shop towel Remove the bleed screw from the IFP using the 1 8 T Handle Clean the IFP with solvent Dry with compressed air in a well ventilated area If compressed air is not
144. as clutch cleaner Assembly is reverse of disassembly Reference the fastener torque specifications at the beginning of the chapter Do not use an impact wrench to install the flywheel nut WINNING PERFORMANCE gt POLARIS Engine and Cooling Systems 600 HO Carbureted Pistons Crankshaft PISTON RINGS PISTON PIN 4 C CLIP MAG CRANKCASE SEAL Piston Matrix 6 When installing a new piston insert one c clip into the piston making sure the open end is 180 opposite of the Engine Model Piston PN Piston ID groove opening S3273 6044 PF6F 7 Apply a liberal amount of Polaris two stroke engine oil to 2202258 EK 2202b 3274 6044 PF6F Subs to 2203319 the needle bearings piston pin and piston assembly 8 Push the pin in to the piston then through the needle S3466 6044 PU6F 2203319 EK 2202c bearing Install the remaining c clip with the open end is S3467 6044 PU6F 180 opposite of the groove opening NOTE Always use new cylinder base gaskets Disassembly Assembly Process 9 Apply a liberal amount of Polaris two stroke oil to the 1 the pistons follow the process for removing the cylinder wall Align the piston ring gaps around the piston cylinder head and cylinders from the engine locating pins Compress the upper ring then carefully slide 2 To remove the crankshaft follow the process for the cylinder down over the ring dis
145. available dry parts using clean lint free paper towels and let sit in a well ventilated area to allow the solvents to evaporate Set body assembly aside on a clean lint free towel Clamp the shaft eyelet securely in vice with the piston end up Using a 9 16 wrench remove the piston lock nut from the end of the shaft Hold the tip of the Phillips Head Screwdriver against the end of shaft Hold the piston assembly under the top out plate and lift upwards Slide the piston assembly onto the shaft of the screwdriver Pull the Screwdriver away from shock shaft while supporting the piston assembly Set this on a clean lint free towel There are many pieces to the piston assembly and the assembly order of these pieces is critical to the proper performance of your shock This step ensures that the proper order is kept Slide bearing assembly off of shaft Use extreme caution not to scratch inside of the bearing assembly when passing it over the threads at end of shaft and set it on a clean lint free towel Remove the bleed screw from the IFP and set them both on a clean lint free towel FOX PS 5 ASSEMBLY 1 9 28 Using a small pair of snap ring pliers remove the snap ring from the bearing housing Using your fingers remove the FIST scraper from the housing Use a scribe or a dental pick to remove the o ring from the inside of the FIST scraper by spearing the seal with the point of the scribe and pulling it out Use extreme caut
146. been running at or above 3000 Voltage High RPM 5 arae Sensor signal is below 0 06 Vdc for at least 2 minutes Exhaust Temperature Sensor Circuit 545 and the engine has been running at or above 3000 Voltage Low RPM 5 Engine speed is above 6000 RPM and the sensor Peranan gn Sensor signal is above 4 3 Vdc for at least 2 seconds 6 Engine speed is above 6000 RPM and the sensor Detonation Sensor voltage Tow cid signal is below 1 23 Vdc for at least 2 seconds Exhaust Valve Solenoid Circuit P1477 8 Solenoid control circuit is OPEN Can be caused by faulty wiring solenoid or ECU 4 16 WINNING PERFORMANCE gt POLARIS Fuel Systems CFI Diagnostic Trouble Codes TROUBLE CODE P CODE MED BLINK DESCRIPTION CODE MAG Part Load Injector Circuit Open P0261 MAG Full Load Injector Circuit Open P1261 OPEN circuit or short to ground Can be caused by PTO Part Load Injector Circuit Open P0264 faulty wiring injector stator or ECU PTO Full Load Injector Circuit Open P1264 7 Engine is running but the injector voltage is above Fuel Injector Voltage Too High P2148 the acceptable limit Can be caused by faulty wiring ECU or stator Engine is running but the injector voltage is below Fuel Injector Voltage Too Low P2147 the acceptable limit Can be caused by faulty wiring ECU or stator MAG Ignition Coil Circuit Malfu
147. blended it is given a Reid Vapor Pressure RVP number which reflects its ability to vaporize or mix with air at a given temperature range Gasoline vapor pressure is measured by putting a sample of fuel inside a closed container and applying a specified amount of heat to the container for a certain amount of time RVP will vary from about 7 0 PSI during the summer to approximately 13 5 PSI during the colder months Service stations selling a large volume of fuel will normally have the correct blend to work well at all times throughout the year in their local area When the weather is very cold gasoline must be able to vaporize very quickly in order for an engine to start and warm up properly If summer blend fuel is being used in the winter little or no vaporization will occur Droplets will form causing flooding and very hard starting If winter blend fuel is being used during the summer months it may cause vapor lock boiling fuel inside the fuel lines fuel pump or carburetor This will cause warm engine drive ability problems and hard starting when warm WINMING PERFORMANCE gt POLARIS General Information SAE Tap Drill Sizes Decimal Equivalents Thread Size Drill Size Thread Size Drill Size URS npa ME eee See 0156 0 80 3764 172 3 27 64 361 27 30394 1 64 53 1 2 20 29 60 007707 mee eea 0625 1 72 53 9 16 12 31 64 ee ee
148. 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 Use 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 16 THROTTLE AND CHOKE CABLE ADJUSTMENTS Throttle Lever Free Play Non CFI REC CU anam hw i Throttle Lever Free Play 0 010 0 030 25 mm CAUTION When adjusting throttle lever free play always verify the engine RPM doesnotrise 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 A 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 Shut off engine 3 Locate the throttle cable that is attach
149. e T PFA Nut Torque 21 Ft Lbs 28 Nm 17 Fuel tank installation is the reverse of removal Always test the PFA gasket seal before tank installation by performing a pressure check Throttle Body Removal Remove the box Remove the throttle body air box adapter Pinch off the coolant lines with the hose pincher tool PN PU 45149 Remove the coolant lines from the throttle body Loosen the intake boot clamps and pull the throttle body upward enough to gain access to the throttle cable and TPS connector Loosen the throttle cable lock nut and remove the cable from the throttle body Disconnect the TPS from the throttle body Remove throttle body 4 35 Fuel Systems DIGITAL WRENCH DIAGNOSTIC SOFTWARE Overview The Digital Wrench diagnostic software allows the technician to perform the following tests and observations View clear trouble codes Analyze real time engine data Reflash ECU calibration files Guided diagnostics Create customer service account records The following components are required to use the Digital Wrench software PC or laptop with Microsoft Windows operating system Digital Wrench software part number PU 47063 Smart Link Module part number PU 47468 Interface Cable part number PU 47469 PC Interface Cable part number PU 47470 Smart Link Module Kit Includes PU 47468 PU 47469 and PU 47470 in one kit part number PU 47471 M 10
150. fastener Remove the fasteners securing the LCA to the bulkhead Remove the snap ring then using a press press the spherical bearing out of the LCA Press in a new bearing then install the snap ring Assemble the LCA into the spindle and shock into LCA Reference front suspension assembly illustration for fastener torque values Upper Lower Control Arm Removal 1 3 Remove the fastener securing the control arm being removed from the spindle Remove the lower shock fastener Remove the fasteners securing the control arm to the bulkhead Remove the control arm pivot bushings and pivot shafts Upper Lower Control Arm Installation 1 2 Replace the upper or lower control arm bushings in the control arm s Replace the upper or lower control arm s into the bulkhead Reference the front suspension illustration for the appropriate fastener torque NOTE There is a washer located on the rearward lower control arm mounting at the bolt head WINNING PER gt POLARIS FORMANCE Steering and Suspensions REAR SUSPENSION ASSEMBLY ILLUSTRATIONS IQ 121 Pivots Rear Idler SHOCK PIVOT WASHER IDLER WHEEL A 45 Ft Lb 61 Nm B 35 Ft Lb 47 Nm Assembly Notes Never re use Nylock nuts Always replace with new parts All pivots must rotate freely after tightening fasteners Apply Polaris Premium All Season Grease to all grease zerks as outlined
151. in the measurement range for the appropriate vehicle see chart o this page 6 Ifadjustment is needed loosen up the lock nuts B on each side Loosen up the idler shaft bolts F Turn each adjuster bolt C clockwise to tighten track Turn the adjuster bolt counterclockwise to loosen track tension 9 Torque the lock nuts B and idler shaft bolts on each side to 35 ft Ib 48 N m SUSPENSION MEASUREDENT 7 8 1 1 8 136 Comfort 2 2 2 9cm 2 em 12250 IQ RMK Switchback v ta 3 19 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 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
152. into reverse 4000 RPM Max RPM for operating in reverse 6000 RPM Engine must first reach 900 RPM at start up before the reverse system can be used The system works between 900 and 4000 RPM If the button is pushed above 4000 RPM the system is bypassed and nothing will happen Flashing light on the instrument panel indicates that the system is in reverse On carbureted units a slow flash indicates that the system is set for low elevation and a WINNING PERFORMANCE POLARIS fast flash indicates the system is set up for high elevation Push and hold the reverse button for longer than 5 seconds to toggle back and forth from high and low elevation settings On Cleanfire units this is automatically done through the engine controller unit ECU Elevation above 6000 ft 1829m requires a different timing curve to eliminate a kick back effect f engine is shut off or dies in forward or reverse gear the engine when started will automatically be in forward gear When servicing clutches ensure that the vehicle is in the forward gear 11 19 Battery and Electrical Systems NOTES 1 1 20 WINNING PERFORMANCE POLARIS A Adjustments Choke 3 17 Arvin Monotube Assembly 9 27 Arvin Monotube Disassembly 9 26 B Battery Testing 11 4 Belt Burning Diagnosis 7 10 Belt Inspection e eme pe ERI Bu 7
153. involving de pressurizing the fuel system and disconnecting fuel hoses See Cleanfire Fuel Injection on page 4 15 FUEL FILTER SUPPLY lie FUEL FILTER BRACKET s 1 a aem 29 By 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 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 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 S212 PEL ARIS The Way Out 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 VA
154. less than 12 8 Vdc Charge battery if voltage is lower than 12 8 Vdc Load Test A battery may pass the OCV test but still not have the storage capacity necessary to properly function 1 Connect multimeter to the battery as if performing the test 2 Turn the engine over using the electric starter 3 Replace battery if Vdc drops below 9 5Vdc NOTE Battery load test tools can be purchased commercially Follow the manufactures instructions for use Specific Gravity Test Conventional Battery NOTE Do not attempt to open the vent cover on a fresh pack battery A battery hydrometer PN 2870836 can be used to measure electrolyte strength or specific gravity As the battery goes through the charge discharge cycle the electrolyte goes from a heavy more acidic state at full charge to a light more water state when discharged The hydrometer can measure state of charge and differences between cells in a multi cell battery Readings of 1 270 or greater should be observed in a fully charged battery Differences of more than 0 025 between the lowest and highest cell readings indicate a need to replace the battery Battery Voltage STATE OF CHARGE ACD YUMACRON TYPE 100 CHARGED 12 60v 12 70v 75 CHARGED 12 40v 12 50v 50 CHARGED 12 10v 12 20v 25 CHARGED 11 90v 12 00v 0 CHARGED lt 11 80v 11 90v 11 4 Battery Voltage Per Cell STATE OF CHARGE
155. push and pull the barbs pins through the holes in the flange 21 After installing the fuel pump assembly the fuel tank must be tested for leaks by pressurizing the tank See Fuel Tank Pressure Test on page 4 30 Fuel Systems CFI Drop In Pump Fuel Supply Typical NOTE 2008 fuel 2007 models similar System shown FUEL RETURN HOSE FUEL SUPPLY HOSE N FILTER BRACKET cd YY FueL FILTER H e FUEL RAIL FUEL INJECTORS HARNESS NOT SHOWN THROTTLE BODY FUEL PUMP NUT GASKET Drop In Fuel Pump Service 3 Some models feature drop in fuel pump and fuel level sender 4 assemblies Reference the fuel level sender resistance table for models that display the fuel level on the MFD gauge NOTE The fuel pump be mounted on the right 6 side or left side of the fuel tank depending on model Drop In Fuel Pump Replacement 1 Siphon the fuel out of the fuel tank into a suitable container 2 Remove the console and the seat assembly 4 34 PINS COLOR FUNCTION 7 Full lt 8 1 1 Red Pump PWR 1 2 40 3 2 WHT BLU Fuel Level Sender Empty 85 4 3 Black Pump Ground 4 Pink Black Sender Ground CAP FUEL LEVEL GAUGE ON SOME MODELS 10 FT LBS 14 Nm 4 6 1 FUELTANK 55 8Nm Disconnect the positive battery cable from the battery if applicable Remove the fasteners securing the fuel tank to the tunn
156. rod is locked in a table vise eyelet down threaded end up 9 13 Shocks 2008 Rear Track Shocks SHOCK 7043177 7043216 7043316 7043366 625 x 065 620 x 093 700 x 015 a 800 x 012 800 x 015 900 x 012 900 x 015 1 000 x 012 11100 x 010 1 00 x 015 T 1 100 x 012 1250 x 012 1 10 x 015 cc 1 250 x 010 i 1 20 x 015 1 250 x 010 1 25 x 015 1 25 x 015 Piston Orifice 093 055 065 1 30 x 015 1 20 x 012 1 300 x 008 1 00 x 012 gt 1 300 x 008 1 300 x 008 1 300 x 006 TBA 800 x 012 1 000 x 006 1 30 x 012 0 800 x 010 0 1 100 x 008 1 300 x 010 1 25 x 012 1 100 x 010 1 20 x 012 tc 1 300 x 008 1 100 x 012 1 300 x 008 1 10 x 012 1 000 x 010 900 x 008 1 00 x 015 900 010 pend 900 x 015 1 125 x 093 800 015 700 x 012 625 x 065 0 5 lt NOTE Valve shim stacks listed as they would appear on the shaft when shock rod is locked in a table vise eyelet down threaded end up 9 14 WINNING PERFORMANCE gt POLARIS Shocks OPTIONAL SHOCK SETTINGS Walker Evans Air Shock NOTE Always adjust both IFS shocks to the same pressure setting Discharge the shock gas pressure completely before refilling the shock with nitrogen Raise the shock nitrogen gas pressure within each shock in 2 5 psi increments and keep the fill tool needle installed in the charge port for
157. rope handle protection when working with recoil housing 9 Slide the pulley down the center shaft and into the housing components making sure the recoil spring re engages the pulley tab 1 With the recoil housing removed from the engine un tie 10 Install the ratchet spring and ratchet into the pulley face The ratchet spring leg fits in the notch on the ratchet any knots handle in the recoil rope and allow the pulley to slowly unwind holds the ratchet in retracted 2 Remove the nut friction plate friction spring ratchet and 11 Install friction spring with one leg inserted in the bottom ratchet spring from the pulley hole on the ratchet 3 Lift the pulley straight out of the housing making sure the 12 Install nut and torque to 5 ft Ibs 7 Nm spring is no longer connected to the backside of the pulley 13 Pull rope out to its full extension and align pulley notch with NOTE If all of the recoil spring tension was rope hole in housing removed the spring should stay inside the housing 14 Using a needle nose pliers or hooked wire pull a loop of when the pulley is removed rope through the notch in the pulley 15 Prevent the rope from being retracted by tieing a knot in the 4 Inspect all components for signs of abnormal wear and tear rope on the outside of the housing at the rope guide hole Replace components as required If replacing n 16 Wind the recoil pulley counterclockwise until the spring a s
158. so the track runs slowly at least five complete revolutions Stop the engine and 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 Loosen up the rear idler shaft F 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 3 20 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
159. the ECU determines there is a current problem with one or more of the sensors Use Digital Wrench to troubleshoot fix and clear the codes When a blink code is displayed the CHECK ENGINE light will illuminate for 1 2 second and 1 2 second with a 1 second off interval between close except for exhaust temperature sensor codes where the engine has to run over 3000 RPM for 60 to 90 seconds depending on model to trigger a blink code DTC Troubleshooting Always use the Digital Wrench diagnostic software program to troubleshoot DTCs MFD blink codes and overall performance problems Digital Wrench can be used to display trouble codes and offers guided diagnostics Guided diagnostics allows the technician to perform diagnostic checks in an attempt to isolate the root problem 1 access trouble codes click on the codes are listed select a code to proceed button If any Status 2 To access guided diagnostics click on the SPECIAL TESTS toolbox button Then click DIAGNOSTIC PROCEDURES 3 Select acode or system in the SYSTEM CHARTS menu A description of the DTC or system will be displayed 4 18 Trouble Code Information Detonation Sensor Circuit Voltage Low This Trouble Code sets if the Engine Speed is above 6000 RPM and the Detonation Sensor Signal is below 1 23 Volts for more than 2 seconds Can be caused by Damaged Wiring a faulty Detonation Se
160. the engine cooling system Engine coolant can be under pressure and hot Escap ing steam and or coolant may cause severe burns to ex posed skin Thermostat Orientation The thermostat must be installed in the cylinder head has shown in the illustrations Center Thermostat Location BRIDGE ALIGNED WITH HOLES 800 CFI Thermostats There are two different thermostats used depending on the engine model number Engine Model Thermostat PN Bleed Hole ID 53489 8044 7052433 2 3471 8044 PU8E 7052452 3 5 Remove the housing cover by removing the cover bolts Check the gasket condition and replace if damaged Qe 3 Replace the thermostat Make sure that the spring side is facing downward or toward the engine 4 Replace cover Torque the cover fasteners to specification ey T Cover Fasteners 9 Ft Lbs 12 Nm 5 Verify the bleed screw and washer are installed WINNING PERFORMANCE gt POLARIS The larger bleed hole thermostat is designed for cooling systems that do not feature a bypass circuit in the cooling system 5 41 Engine and Cooling Systems 2007 700 Dragon IQ Cooling System HOSE THROTTLE BODY OUT TO SURGE TANK CFI ONLY REAR TUNNEL COOLER SURGE BOTTLE LH PERIMETER COOLER HOSE FRT COOLER TO SURGE BOTTLE e HOSE SURGE BOTTLE OUT TO ENGINE IN uM rcf HOSE BYPASS OUT TO TU
161. trying 5 Bleed or replace the fluid by attaching a clear hose from the to purge Watch the reservoir closely and add fluid caliper bleeder fitting to a clean container sure the hose when necessary to prevent air from entering the system fits tightly on the bleeder fitting Apply only light to moderate pressure to the lever or 6 Pump the brake lever a few times and hold pedal when bleeding the brake system Extreme 7 Slowly open the bleeder fitting and let the old fluid or air Tp 6 11 Final Drive and Brakes 10 escape You will feel the lever release as you let the fluid or air escape Pump the brake lever a few times and hold it again Repeat steps 7 and 8 until you see new brake fluid coming from the caliper bleeder fitting or if you are bleeding the air repeat this step until you see only fluid coming out This may take several intervals Torque the bleeder screw to 8 11 ft lb 11 15 N m ey T Bleeder Screw 8 11 ft lb 11 15 N m 11 12 13 When adding fluid add DOT 4 brake fluid to 1 4 5 16 6 8 cm from the reservoir top Install cover and diaphragm assembly Tighten the cover screws to 16 20 in Ib 1 8 2 3 N m ey Cover Screws 16 20 in Ib 1 8 2 3 N m 14 15 16 6 12 Field test machine before putting into service Check for proper braking action and lever reserve Lever reserve is when the lever is firmly applied the l
162. 0 Engagement RPM 200 3800 Exhaust Valve Spring Pink Fuel Delivery Type Cleanfire Direct Injection Throttle Body Marking 1203505 Throttle Body Bore 48 mm TPS Voltage Idle 93 0 01 Fuel Pressure PSI bar 58 4 0 Recommended Fuel Octane R M 2 91 Non Oxygenated Clutch Settings General Width in cm 46 5 118 1 Length in cm 129 327 7 Height in cm 49 5 125 7 Estimated Dry Weight Ib kg 155 487 220 9 163 487 220 9 Fuel Gallons Liters 11 5 43 5 Oil Quarts Liters 3 2 8 Cooling System Capacity 155 6 5 6 1 Quarts Liters 163 6 625 6 3 Brake Fluid DOT 4 Drive Belt Part Number 3211115 Width inches cm 1 460 3 7 Side Angle 26_ Circumference inches cm 46 77 118 8 Center Distance inches cm 11 5 29 2 Chaincase Center Distance inches 8 373 Top Gear Stock 20 Bottom Gear Stock 41 Chain Stock 76 Gear Lube Polaris Synthetic Capacity oz ml 11 325 3 Reverse System Perc Electrical Alternator Output Operating Voltage 13 5 14 5 Vdc Watts 13 5 Vdc Total 400 18 1700 RPM Ignition Timing Coolant Temp 120_F 49_C Spark Plug Gap in mm 027 70 Spark Plug Champion RN57YCC Track Width Inches cm 15 38 155 393 7 Length Inches cm 163 414 Lug Height Inches cm 2 4 6 1 ALTITUDE DRIVE CLUTCH DRIVEN CLUTCH meters S
163. 0 F Polaris calibrates all shocks at 30 F ride temperature Any IFS shock service that requires gas recharging needs to be performed on both IFS shocks to maintain the same spring rate between both shocks When charging any shock let the nitrogen gas stabilize within the shock for at least 30 seconds before removing the shock charge needle from the charge port If the rider is requesting stiffer shock settings for more bottoming resistance increase the shock rod nitrogen pressure in 5 PSI increments until the desired performance level is achieved CAUTION Do not exceed 200 psi shock rod chamber pressure Always reset the shock body chamber pressure to the factory specification charge If the rider is requesting softer shock settings for less bottoming resistance decrease the shock rod nitrogen 9 15 Shocks pressure in 5 PSI increments until the desired performance level is achieved Again always reset the shock body chamber pressure to the factory specification charge If one shock appears to be too soft place the vehicle on flat level ground Stand on the sled and rock the skis back and forth to verify issue Determine if the shock is leaking or has leaked an oil then determine why Look for shaft damage and replace the shaft and seal if damage is found If no oil leaks are found verify there are no gas leaks at the charge ports Replace the charge ports as required After inspe
164. 0 015 1500085 1 100 1500086 1 250 1500087 1 300 9 4 WINNING PERFORMANCE gt POLARIS Shocks Walker Evans Shock Valve Part Numbers PART NUMBER SIZE THICKNESS 1800051 700 1800075 800 1800076 900 1800077 1 000 006 1800078 1 100 1800079 1 200 1800080 1 300 1800081 700 1800082 800 1800083 900 1800084 1 000 1800085 1 100 1800086 1 200 1800087 1 250 1800088 1 300 1800052 700 1800053 800 1800054 900 1800055 1 000 010 1800056 1 100 1800057 1 200 1800058 1 300 1800059 700 1800060 800 1800061 900 1800062 1 000 n 1800063 1 100 1800064 1 200 1800089 1 250 1800072 1 300 1800066 700 1800067 800 1800068 900 1800069 1 000 1015 1800070 1 100 1800071 1 250 1800072 1 300 1800090 1 000 1800091 1 100 1800092 1 200 is 1800093 1 300 1800050 625 065 1800204 875 090 WINNING PERFORMANCE gt POLARIS 9 5 Shocks Walker Evans Shock Valve Part Numbers 7 16 1 0 PART NUMBER SIZE THICKNESS 1800244 900 1800245 1 000 1800246 1 100 1800247 1 200 1800248 1 300 oo 1800249 1 450 1800250 1 500 1800251 1 550 1800252 900 1800253 1 000 1800254 1 100 1800255 1 200 1800256 1 300 1800257 1 450 1800258 1 500 1800259 1
165. 0 11 Chassis 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 YOU ENCOUNTER AIR BUBBLES DO NOT ATTEMPT USE ASTRAIGHT PIN TO POKE THE BUBBLE AND LET THE AIR OUT A HOLE POKED INA CHROME DECAL WILL BE VERY NOTICEABLE 5 When finished installing the decal carefully remove the decal mask at a 180_ angle 6 Peel the backing off and install the urocals in the appropriate places These also have 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 10 12 Battery and Electrical Systems CHAPTER 11 Battery and Electrical Systems SPECIFICATIONS wen o ls eU u ba 11 2 ENGINE MODELS 25 ERR ERE aye i eet ote 11 2 SPARK PLUGS uere Denke mie eine oho 11 2 CHARGING SYSTEM Sehr nes Seed ea a T 11 2 IGNITION TIMING 11 2 CONVENTIONAL BATTERY cork suena Ae pa ne EM 11 3 BATTERY
166. 0 11 8 6 2 50 1 42 Full 200 7043268 Fox 18 00 11 8 6 2 49 2 55 Full 200 7043269 RH 7043095 Walker Evans 18 00 11 738 6 27 625 2 25 Full 200 7043090 Ryde FX 17 00 11 20 5 80 49 6 54 Full 200 7043082 Ryde FX 16 25 12 76 5 25 49 6 27 Full 280 7043206 Walker Evans 18 00 10 13 6 26 625 2 25 Full 200 7043233 Walker Evans 17 02 11 27 5 75 1 124 N A 95cc 220 25 Front Track Shocks SHOCK PN MODEL pies ocius e ons OIL VOLUME PSI IN IN IN 7041975 Ryde FX 12 10 8 60 3 5 50 4 61 Full 200 7043142 Fox 12 51 8 92 3 59 50 840 Full 200 7043244 Ryde FX 12 12 8 61 3 52 50 4 68 Full 200 7043267 Fox 12 07 8 63 3 44 50 1 8 Full 200 7043204 Walker Evans 12 10 8 60 3 50 625 2 25 Full 200 7043234 Walker Evans 12 49 8 92 3 57 1 124 N A 70 210 2 Rear Track Shocks SHOCK PN MODEL 1 read STE ne ee OIL VOLUME PSI IN IN IN 7043177 Fox 15 60 10 56 5 04 50 1 22 Full 200 7043246 Fox 16 60 10 91 5 96 50 2 23 Full 200 7043266 Fox 15 65 10 56 5 09 50 1 63 Full 200 7043205 Walker Evans 15 60 10 56 5 04 625 2 25 Full 200 7043216 Fox 14 12 9 29 4 83 50 2 40 Full 300 7043235 Walker Evans 16 71 10 96 5 75 50 7 25 Full 200 9 8 gt POLARIS Shocks 2007 Shock Valve Shim Stack Configurations NOTE All measurements are in inches 2007 IFS Shocks 7043268 7043233 7043233 SHOCK 7042258 7043141 7043095 7043090 7043082 7043206 7043269
167. 0 31 57 7 9 Toe Out Inches cm 0 0 12 0 0 31 Rear Suspension Suspension Type IQ 121 Front Track Shock FTS Ryde FX HPG w IFP FTS Spring Rate Ibs in N mm 130 270 23 47 FTS Spring Installed Length inches cm 20 Rear Track Shock RTS Base Fox PS5 Dragon Ryde FX Compression Adj w Remote Res Torsion Springs 347 Square 80_ Soft Dragon Stock IQ PN 7043070 067 PN 7043071 067 347 Square 77_ Softest Dragon Soft IQ PN 7043240 067 PN 7043241 067 359 Square 12 58 Stock Dragon PN 7043079 067 PN 7043080 067 Rear Travel Inches cm WINNING PERFORMANCE gt POLARIS 13 9 35 3 1 35 Model Specifications 2008 700 Switchback General 700 Dragon Switchback Width in cm 48 121 9 Model Number Base SOSPR7IS SOSPR7JE Pee Dragon SO8PS7JS SO8PS7JE Height in cm 48 5 123 2 Engine Estimated Dry Weight Ib kg Base 494 224 3 Liberty Liquid Cooled Dragon 498 226 1 Type Induction Fuel Gallons Liters 11 7 44 3 Displacement Cylinders 700cc 2 Cooling System Capacity F Bore inches mm 3 19 81 Quarts Liters Stroke inches mm 2 67
168. 0 6 SEAT ASSEMBLIES 2 55 Res eR og eb rtc dea y aca bs eae ea 10 7 IQ FIXED SEAT 5 10 7 IQ RAW SEAT 5 10 7 IQ REMOVABLE SEAT 5 10 7 2007 IQ TOURING SEAT 10 8 2008 IQ TOURING SEAT 10 9 SEAT COVER 10 10 DECALS ub e e Sad d datis s uel Mec chef a 10 10 DECAL REMOVAL node pepe a hee UA eR Rd apu Se Ie 10 10 DECAL 10 11 WINNING PERFORMANCE 10 1 POLARIS Chassis IQ CHASSIS COMPONENTS Steering Hoop Assembly Typical RH UPPER BRACE 2 A LH UPPER BRACE 9i ES W 5 62 2 lt CROSS MEMBER SS _ It ey 9 2 BRACKET T A 18 Ft Lb 24 Nm B 21 Ft Lbs 28 Nm 10 2 WINNING PERFORMANCE gt POLARIS Chassis Hood Assembly FLARE HEADLIGHT SEALS ATTACH TO INSIDE OF HOOD AROUND HEADLIGHT OPENING AND WHERE POD MEETS WINDSHIELD __ FILTER X fy INSTRUMENT POD BRAKE DUCT NOT ALL MODELS HOOD CONSOLE SEAL FRONT GRILLE
169. 0 x 012 900 x 008 800 x 010 900 x 008 900 x 010 1 125 x 093 1 000 x 012 1 100 x 015 900 x 010 1 000 x 010 1 00 x 010 1 100 x 010 m 1 100 x 012 1 100 x 015 1 00 x 010 1 100 x 010 1 10 x 010 1 250 x 012 cc 1 250 x 010 700 x 006 1 10 x 010 1250x 010 1 250x 008 700 008 900 27008 1 25 x 012 i 1 250 x 008 1 25 x 012 Piston Orifice 093 070 076 082 055 040 1 30 x 010 1 300 x 006 1 300 x 008 1 25 x 010 gt 1 300x 008 2 250 1250x 008 2785 x 010 1 130x 010 1 300 008 900 x 010 1 25 010 800 x 008 1 10 x 008 1 300 x 006 1 000 x 006 1 250 x 010 1 10 x 008 0 1 250 x 012 900 x 008 800 x 010 o 1 100 x 008 1 100 x 008 1 10 x 008 ul 1 100 x 012 1 10 x 008 1 300 x 010 1 100 x 010 1 000 x 008 1 00 x 010 tc 1 000 x 010 1 00 x 010 1 300 x 008 1 100 x 012 900 x 010 900 x 010 700 x 015 900 x 010 1 300 x 008 z 1 000 x 010 700 x 015 800 x 008 900 x 010 700 x 015 700 x 015 800 x 008 900 x 008 700 x 010 1 125 x 093 700 x 015 700 x 015 700 x 008 1 125 x 093 875 x 090 1 125 x 093 1 125 x 092 625 x 065 875 x 090 400 x 020 400 x 020 80055006 500 x 006 500 x 006 500 x 006 500 x 006 500 x 006 500 x 006 500 x 006 600 x 010 oc 600 x 010 600 x 010 1 10 x 025 E 00 O10 600 x 010 1 00 x 015 005010 700 x 010 1 10 x 015 2 700 x 010 700 x 010 700 x 010 lt
170. 00 5155 3L 1HM Y2V 18 32V 9 dV 10H 3S83A3U QO0H SISSVH 321145 33404 Q00H SISSYH M01131 83118003145 000 5155 2 131014 8113 00334 QOOH SISSVHD JONVYO dAVIQV3H 1131 QO0H SISSYH NMOUB AAV IOV IH 1131 GOOH SISSVHD 11189 X0 y dAVIQV3H 1131 Q00H SISSYH 038 01131 30123NNO 01 30123NNO2 WOY 4 80102 31881 NOIIVNIMUJI 3818 88 009 NO 3810039 LON 13189 OI NO QUVONVIS Blan 96 2060172 ON 18 4 JSN YILINOHIVL 3J191HJA 31 1660172 ON 18 4 150 4313800334 SVH 3121H3A 31 I JA 60r JA 90 frees JA SI 08731 10 5 NO QJYINOJY LON TY 48 009 NO QUVONVIS MORS JAV 480102 3318 ONL 20601 Z WOTTIA JLTHM 314804 131013 20 460 SSSNUVH E 3389 wavd 3349 18911 ITE 011089 SISSVH NNOUB 3018 Wave 18911 GNNOYD 3NI9N3 90 02 90 20 NVI 39138 081931 8010 3818 Ng 0 8 NI ONIOVUL AAT TAN IS 01 S3NIT1 Q3HSVO YO 01105 A8 03143538934 387 S3UIM Q00H YY 131
171. 010677 Rear Travel Inches cm 13 9 35 3 Track Width Inches cm 15 38 Length Inches cm 121 307 1 0 2 5 Lug Height Inches cm 1 25 3 175 Option Track tension sag in cm with 10 155 4 54 placed 16 in 40cm ahead of rear idler shaft 7 8 1 1 8 2 2 2 9cm WINMING PERFORMANCE gt POLARIS 1 3 Model Specifications 2007 600 HO Switchback Carburetor Jetting Model Number SO7PS6FS A Ambient Temperature 9191 191815 Engine 8 8 e 8 s Liberty Liquid Cooled Altitude E E Engine Type Case Reed induction Meters fee gt rz zz Z ES 32 Model Number 3273 6044 PF6F n 5 5 Displacement Cylinders 599 2 gt 2 E 9 7 gt e Bore inches mm 3 04 77 25 0 600 440 430 420 400 390 380 370 360 Stroke inches mm 2 52 64 0 2000 3 3 2 2 2 2 2 1 Piston to Cylinder Clearance 600 1200 410 400 390 370 360 350 340 330 inches mm 2000 4000 43 43 42 2 2 2 1 1 Installed Ring Gap 1200 1800 370 360 350 340 330 320 310 300 inches min 014 020 356 508 4000 6000 83 2 2 2 2 192 381 Operating RPM 200 8100 1800 2400 340 320 310 300 280 280 270 260 6000 8000 3 2 2 2
172. 1 019 dN31 305115 1NV1002 QN0089 20 1 321145 N0089 20 801 10934 8 3L IHM NMOUG 915 dW3l 83 308115 1 1002 1 915 HOLIMS 3 98 8017 11938 8 JONVYO 1 915 3 20 QOOH SISSVHO 8017 11938 02 12v 18 39NVuO 33104 DV 45 u3MOd OV 301v 1093U 9 801134 4131 381983 5155 2 1000N 8 033 019 031 NOI LVNOI30 00H SISSVH2 311004 102 8 39NY30 311HM 915 3S33A38 381983 5155 2 1000N 8 199 YALINOHIVL OOH SISSVH 31000W 102 8 2 18 801131 4015 140 3N19N3 SISSVH2 INON 8 038 18 10811023 01083105 083105 3 31000W 102 8 M01134 311HM 4015 3NI9N3 SISSVH2 1000N 8 318 031 10H OOH SISSWHO 311004 103 8 3LIHM Y2V 18 1102 8351 fld 305135 1040 8 1387311 031 3Su3A3U 00 5155 2 311004 102 9 4015 QuvH 3 131 31000N 102 8 309718 1102 83112 3 1102 83112 3 1000N 102 8 038 4015 1305 HILIMS 4015 31000W 102 8 038 2V 18 NOI1IN9I 1102 NOILINOI INOW 102 8 915 3583 38 3 TWNOIS 1041402 H1 311004 102 8 9 NOLLONn3 MO193NNOO 01 YOLISNNOD 39nv5 40109
173. 1 50 3 8 OPT Drive Clutch Bolt Torque 80 Ib ft 108Nm 1 10 Track tension sag in cm with 10 155 4 54 placed 16 40cm ahead of rear idler shaft 3 8 1 2 1 1 3cm WINNING PERFORMANCE C POLARIS Model Specifications Front Suspension Inches cm Suspension Type 10 42 5 Fox HPG w IFP STD Rebuidlable Shocks Fox Compression Adj Remote Resevoir HPG OPT Rebuidable IFS Spring Rate Ibs in N mm Spring Installed Length Inches em 10 55 26 8 Front Vertical Travel Inches cm 10 254 Ski Center Distance 42 5 108 Camber Inches cm 2 25 0 31 57 7 9 Toe Out Inches 0 0 12 0 0 31 Rear Suspension Length Inches cm Suspension Type IQ 144 Fox HPG w IFP Front Track Shock FTS Rebuildable FTS Spring Rate Ibs in N mm 170 Q9 75 FTS Spring Installed 725 184 Rear Track Shock RTS Fox Compression Adjustable Remote Resevoir HPG Rebuildable Torsion Springs 359 Square 77 Stock 347 177 _ 1 Soft 7041627 067 7041628 067 375 177 _ Firm 7041942 067 7041943 067 Rear Travel Inches cm 13 9 35 3 WINMING PERFORMANCE gt POLARIS 1 11 Model Specifications 2007 600 HO IQ LX CFI Model Number SO7PD6HS SO7PD6HE Engine Liberty Liquid Cooled
174. 100 17 5 Height 48 121 9 Ibs in N mm Estimated Dry Weight 472 214 3 144 Spring Installed Length 10 35 26 2 Ib kg 478 216 8 155 Inches cm Fuel Gallons Liters 11 5 43 5 Front Vertical Travel 9 22 9 Oil Quarts Liters 3 28 Inches cm Cooling System Capacity 144 6 25 6 PET center Distance Setup Width 38 67 98 2 Brake Fluid DOT 4 Camber Inches cm 2 17 0 31 55 7 9 Drive Belt Part Number 3211115 Toe Out Inches cm 0 0 12 0 0 31 Width inches cm 1 460 3 7 Side Angle 26_ Rear Suspension Circumference inches cm 46 77 118 8 Suspension Type IQ RMK 144 155 Center Distance inches cm 11 5 29 2 Front Track Shock FTS Ryde FX Chaincase Center Distance inches 8 373 FTS Spring Rate 190 33 Top Gear Stock 19 lbs in N mm Bottom Gear Stock 41 Ryde AFX Chain Stock 76 Ret Bese Is Compression Adjustable Gear Lube Polaris Synthetic 359 Square 77_ Stock Reverse System Perc PN 7041627 067 Torsion Springs PN 7041628 067 Electrical 375171 1 Firm Alternator Output PN 7041942 067 Operating Voltage 13 5 14 5 Vdc PN 7041943 067 Watts 13 5 Vdc Total 280 14 5 36 8 144 Ignition Timing 26 93500RPM TPS Un plugged Rear Travel Inches cm 15 5 39 4 155 Spark Plug Gap in mm 027 70 Spark Plug Champion RN57YCC CDI Marking 4011033 Flywheel Marking 4010677 Track Width
175. 100 x 010 1 10 x 015 E E oo O10 esae p 010 1 100 x 012 800 x 008 PRU 800 x 006 1 200 x 012 22 1 250 x 008 1 250 x 008 Piston Orifice 070 078 070 070 082 052 1 30 x 015 1 30 x 015 gt 1 300 006 1300 008 1 300 010 1 30 x 012 1 300 008 1 250 x 008 1 20 x 015 1 100 006 1 250 x 008 1 20 x 012 2 1 000 006 900 x 008 1 10 015 D 900 x 008 1 100 x 008 1 10 x 012 P 1 300 008 1 250x 008 1 00 x 015 o 250 x 008 900 x 008 1 00 x 012 1 100 010 1 100 x 008 900 x 015 1 100 x 008 800 x 008 900 x 012 1 000 008 900 x 008 800 x 015 1 000 x 010 700 x 008 800 x 012 900x 008 700 012 700 x 015 5 900 x 010 700 x 012 700 x 012 0 800 008 700x 002 900 010 2 2 1 30 x 025 1 125 093 8003 SEDE 825 1 30 x 025 875 x 090 1 30 x 025 1 100x 012 ui 1 000x 012 1 000 012 700 010 875x 090 NOTE Valve shim stacks listed as they would appear on the shaft when shock rod is locked in a table vise eyelet down threaded end up WINNING PERFORMANCE 919 POLARIS Shocks 2007 Rear Track Shocks SHOCK 7043177 7043246 7043266 7043205 7043216 7043235 620 x 093 950 x 050 890 090 825 X065 625 x 065 950 x 050 700 x 010 a 800 x 012 950 x 050 700 x 010 gt 800 x 008 800 x 010 620 093 90
176. 101133 33804 805835 03395 2 000 5155 2 80112 4 2 02 311 39NYUO AS Sdl 305135 541 HOLIMS 135 2 GOOH SISSVHD u3MOd 1ONINOD H1 02 2 18 311 031 130 3N19N3 SI1SSVH2 MN01134 018 HOLIMS 300N 2 GOOH SISSVHO 33804 1081302 H1 0c 038 3L1HM 031 3583 38 3NI9N3 SISSVH2 GNNOYD OV 321145 N0089 8 8310 GNnoud 81 049 131 10H 3NI19N3 SISSVH 311 1118 SdWV10V3H_ M01 1 GOOH SISSVHD 43MOd 1081802 H1 91 349 13431 110 1 000 5155 2 13411 110 81 13101A GND 01083105 3 3N19N3 SISSVH2 N01134 311HM 3131 3 1 311983 5185 2 033 801134 SdNV10V3H 1 Q00H SISSVH2 33 04 1ONINOD H1 91 033 801134 102 835104 0 3 YNYUD GNNOYD 20 1 400 5155 2 1 321145 080089 20 8 31 1HM NMOJB QN0089 801 15 305135 318 03345 081089 1 000 5155 2 305135 03345 81 039 13389 11 83004 20 1 000 5155 2 321145 u3MOd 20 8 3L 1HM Q3U 331435 1102 83112 3 1102 83112 3 9 83004 OV 321145 83 04 OV 1491 21812313 91 QN9 1102 1 1102 NOILIN9I 118 805835 130 305115 130 9 011089 OW 011089 801 10938 9 NM013g 398 2 Au311V8 8017 10
177. 110 290 137 NOTE Springs listed as color will have the spring coil Tag each spring with the part number last four digits of the part number painted on the spring force when not in use 7 5 POLARIS The Way Out PVT System Spring Free Length 10 Series Weights Measure the drive and driven spring free length with the spring WEIGHT GRAMS 1g PART NUMBER resting on a flat surface Replace spring if out of specification 10 8 21 1321530 10M W 46 1321527 10M B 47 5 1321529 10 5 48 8 1321528 10M 49 5 1321531 10A L 51 1321531 10 51 5 1321526 10 53 1321589 10 54 54 1321685 10 56 56 1321684 10 58 58 1321588 10 60 60 1321587 In addition to proper free length the spring coils should be 2 i 180 parallel to one another when placed a flat surface Distortion 10 62M 61 5 1321614 of the spring indicates stress fatigue Replacement is required 10 64 64 1321585 10 64M 63 5 1321615 AX CAUTION 10 66 66 1321584 10 68 68 1322427 Never shim a drive clutch spring to increase its compression 10 70 70 1322414 rate This may result in complete stacking of the coils and 10 72 72 1322428 subsequent clutch cover failure 10 74 74 1322429 10 76 76 1322585 Drive Clutch Weights TET Full Tail Weigh ull Tail Weights 11 Series Weights
178. 13 321145 AU311V8 9 038 039 1H91 TII VL 039 8 040 71 91 1H91 TII VL HOLIMS 3XVu8 8 39NvuO uiMOd OV 1H9I TII VL 121145 8304 OV 8 M01134 NNOY9 20 28 321145 080089 20 30112Vd4V2 8 311 NMOUB 039 20 305135 03345 40112 4 2 9 3L IHM NMOUB 31104 805135 03345 805835 03345 80112 4 2 02 311HM 39NV8O 4015 QuvH H21IMS NOILINOI HOLIMS 4015 8 2 18 398 2 8311 8 HOLIMS NOIIIN9I 321145 AU311V8 8 038 1081N02 QION310S 18 15 HOLIMS NOILIND 18915 21812313 02 138 311 011089 SISSVHD HOLIMS NOILIN9I 039 8 049 1 915 130 105835 130 451089 5155 2 HOLIMS NOIIIN9I 3 131 8 4015 QuvH HOLIMS NOILINO 3 131 8 309718 830835 1313 21 Q00H SISSVH 830N3S 13131 1303 02 31IHM 13101A 039 20 13431 110 4805 122 8 311 HM NMOUS GND 541 308135 541 yov18 039 20 321145 080089 20 83804 10NI1NOD H1 8 311 NMOUB 915 541 805835 541 101131 3304 OV 121145 83 04 OV 33104 1041802 H1 9 M01134 AS 541 305135 541 33804 805835 03345 21 000 5155 2 80112 4 2 02 311 39NY30 HOLIMS 135 24 000 5155 2 83004 1041802 H1 02
179. 131258 1 2 3131259 1 3 3131260 1 4 3131261 1 5 3131262 1 6 3131263 1 7 3131264 1 8 3131265 1 9 3131266 2 0 3131267 Mikuni TM Piston Valves PISTON VALVE PART NUMBER 1 5 3130940 2 0 3131252 2 5 3130790 3 0 3130791 3 5 3130792 4 0 3130793 Mikuni TM Notched Piston Valves PISTON VALVE PART NUMBER 1 5 3131216 2 0 3131206 2 5 3131217 3 0 3131218 3 5 3131219 4 0 3131220 AIR JET PART NUMBER 0 5 3130773 0 6 3130774 0 7 3130775 0 8 3130776 0 9 3130777 1 0 3130778 1 1 3130799 1 2 3130780 1 3 3130781 1 4 3130782 1 5 3130783 1 6 3130784 1 7 3130785 1 8 3130786 1 9 3130787 2 0 3130788 Mikuni Long Pilot Air Jets AIR JET PART NUMBER 0 5 3131255 0 6 3131249 0 7 3131256 0 8 3131254 0 9 3131203 4 4 WINNING PERFORMANCE gt POLARIS Fuel Systems Carbureted Fuel System Typical VENT FITTING SEAT BRACKET FUEL GAUGE 10 FtLbs 4 4 6 FtLbs Wu com FUEL ON OFF VALVE L FUEL PUMP FOAM PADS HAND TORQUE FASTENERS 9 FUEL FILTER gt POLARIS Fuel Systems MIKUNI TM CARBURETOR Function The function of a carburetor is to produce a combustible air fuel mixture by breaking fuel into tiny particles in the form of vapor to mix the fuel with air in a proper ratio and to deliver the mixture to the engine A proper ratio means an i
180. 190 3130121 340 3130137 510N 3131400 115 3130106 195 3130122 350 3130138 520 N 3131401 120 3130107 200 3130123 360 3130139 530 3131402 125 3130108 210 3130124 370 3130290 540 3131408 130 3130109 220 3130125 380 3130140 550 N 3131409 135 3130110 230 3130126 390 3130480 560 3131410 140 3130111 240 3130127 400 3130141 145 3130112 250 3130637 410 3130599 150 3130113 260 3130129 420 3130142 155 3130114 270 3130130 430 3130143 160 3130115 280 3130131 440 3130144 165 3130116 290 3130132 450 3130145 170 3130117 300 3130133 460 3130146 Mikuni Pilot Jets Mikuni Starter Jets WINNING PERFORMANCE gt POLARIS PILOT JET NUMBER PART NUMBER STARTER JET PART NUMBER 25 3130064 130 3130805 30 3130065 135 3130767 35 3130066 140 3130768 40 3130067 145 3130769 45 3130068 150 3130770 50 3130629 155 3130771 55 3130070 160 3130772 60 3130071 4 3 Fuel Systems Mikuni Jet Needles JET NEEDLE PART NUMBER J8 9FH04 57 3130794 18 9 01 57 3130795 J8 9DH01 54 3130796 J8 8BEYOI 3131250 18 9 06 57 3131253 18 9 01 60 3131207 18 9 07 60 3131268 J8 9DFH10 57 3131313 J8 9DGI01 60 3131377 J8 9DGJ02 57 3131378 J8 9EFY02 61 3131202 J8 9DGN6 57 3131438 Mikuni Short Pilot Air Jets AIR JET PART NUMBER 1 0 3131257 1 1 3
181. 2 M 321148 A8311V8 39nvo 02 321145 W NUG 1 390v9 02 133008 1 138 39079 02 Tn GOOH SISSWHO 39nvo 02 W NUO 11 M NUO 61 SENI NOLVNINESL M NUO F 121149 QOOH SISSVHO 11 J 1 148 Ob M NIB 6 121148 17120 M NU8 12 7118 90 99 I M 52 Le 19 NYO 22 OIA a 824 3301 H9IH NYG 06 Uh 0 2 47189 11 60 TL MINYA SE 4 92 H9IH 66 m LED 1 148333 GOOH SISSVHO M N18 12 90 9599 SS3NHVH 340 ATIVNYON HOLIMS ON NOE LISO 035012 ATIVAYON ON 110 N01 M NYO 61 OIA 211 4 10 822 81 MOTTSA 038 J Taa oa TVNOLLdO 10 4 20182 SS3NHYH NER NS VM k T ak 8 M ande WO I Sus 11 9 M M OIA I2
182. 20 356 508 inches mm Width inches cm 1 460 3 7 Operating RPM 200 8250 Side Angle 26_ 17 Circumference inches cm 46 77 118 8 Idle RPM 00 Center Distance inches cm 11 5 29 2 Engagement RPM 200 3800 Chaincase Exhaust Valve Spring Purple Center Distance inches 8 373 Top Gear Stock 23 Fuel Delivery Bottom Gear Stock 37 Chain Stock 76 Cleanfire Direct Injection Gear Lube Polaris Synthetic Throttle Body Marking 1203213 Capacity oz ml 11 325 3 Throttle Body Bore 46mm Reverse System Perc TPS Voltage Idle 0 95 0 01 Vdc Electrical Fuel Pressure PSI bar 58 4 0 Fuel Alternator Output Mel Octane 91 Non Oxygenated Operating Voltage 13 5 14 5 Vde R M 2 Watts 13 5 Vdc Total 400 Coolant Temp 120_ 49_C ALTITUDE DRIVE CLUTCH DENS Spark Plug Gap in mm 027 70 meters Shift Clutch Clutch Driven Gearing feet Weight Spring Spring Helix Spark Plug Champion RN57YCC 0 600 0 2000 Track 6001200 0 62 22 43 78 2000 1000 Width Inches cm 15 38 0 60 BLK GRN RED BLK Length Inches cm 136 345 4 1800 2400 222111 176 Lug Height Inches cm 1 2 54 6000 8000 0 58 4 8 2400 3000 Track tension sag in cm with 8000 10000 10 56 MERETUR 10 Ibs 4 54kg placed 16in 4 11 8 2 2 29cm 3000 3600 40cm ahead of rear idler 10000 12000 7 shaft Drive Clutch Bolt Torque 80 Ib ft 108Nm 1 30
183. 2007 2008 10 SNOWMOBILE SERVICE MANUAL FOREWORD This service manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly equipped shop and should be kept available for reference All references to left and right side of the vehicle are from the operator s perspective when seated in a normal riding position Some procedures outlined in this manual require a sound knowledge of mechanical tool use and shop procedures in order to perform the work safely and correctly Technicians should read the text and be familiar with service PER before starting the work Certain procedures require the use of special tools Use only the proper tools as specified Comments or suggestions about this manual may be directed to Service Publications Dept Polaris Sales Inc 2100 Hwy 55 Medina Minnesota 55340 2007 2008 IQ Snowmobile Service Manual PN 9921044 Copyright 2007 Polaris Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures c
184. 20_F 49_C Spark Plug Gap in mm 027 70 Spark Plug Champion RN57YCC Track Width Inches cm 15 38 Length Inches cm 128 325 Lug Height Inches cm 1 2 54 Operating RPM 200 8250 Idle RPM 1700 Engagement RPM 200 3800 Exhaust Valve Spring Purple Fuel Delivery Type Cleanfire Direct Injection Throttle Body Marking 1203213 Throttle Body Bore 46mm TPS Voltage Idle 0 95 0 01 Vdc Fuel Pressure PSI bar 58 4 0 Recommended Fuel Octane 91 Non Oxygenated R M 2 Clutch Settings ALTITUDE DRIVE CLUTCH DRIVEN CLUTCH meters Shift Clutch Clutch Driven Gus feet Weight Spring Spring Helix earning 0 600 0 2000 600 1200 2000 4000 0 52 1200 1800 on 4000 6000 BLK GRN RED BLK 56 42 36 120 340 140 240 wer 22 40 76 1800 2400 0 58 7042083 7043058 6000 8000 2400 3000 8000 10000 056 3000 3600 10000 12000 10 54 Drive Clutch Bolt Torque 80 Ib ft 108Nm 1 28 Track tension sag in cm with 10 Ibs 4 54kg placed 16 in 40cm ahead of rear idler shaft 7 8 1 18 2 2 2 9cm WINNING PERFORMANCE C POLARIS Model Specifications Front Suspension Setup Width Suspension Type 10 42 5 Shocks Ryde FX MPV IFS Spring Rate Ibs in N mm Spring Installed Length Inches 9 95 25 3 Front Vertical Travel Inches cm 10 254 Ski Center Distance
185. 3 1 77 1 82 1 95 1 90 1 95 2 10 2 05 2 25 2 00 2 16 2 21 2 42 Jackshaft MPH at 1 1 Clutch Rati RPM at Clutch Ratio 6000 93 84 89 87 81 79 73 75 74 76 71 73 71 66 68 66 62 63 57 64 60 58 53 6250 97 87 93 91 84 82 76 79 77 79 74 76 74 69 70 69 64 65 60 67 62 61 55 6500 101 91 97 94 87 85 79 82 80 82 76 79 77 71 73 72 67 68 62 70 65 63 58 6750 105 94 101 98 91 88 82 85 83 85 79 82 80 74 76 74 69 71 64 72 67 66 60 7000 109 98 104 102 94 92 85 88 86 89 82 85 83 77 79 77 72 73 67 75 70 68 62 7250 112 101 108 105 97 95 88 91 89 92 85 88 86 80 82 80 74 76 69 78 72 70 64 7500 116 105 112 109 101 98 92 94 92 95 88 91 89 82 85 83 77 79 72 81 75 73 67 7750 120 108 116 112 104 101 95 97 95 98 91 94 92 85 87 85 79 1 81 74 83 77 75 69 8000 124 112 119 116 107 105 98 101 98 101 94 97 95 88 90 88 82 84 76 86 80 78 71 8250 128 115 123 120 111 108 101 104 101 104 97 100 97 91 93 91 85 86 79 89 82 80 73 8500 132 119 127 123 114 111 104 107 104 108 100 103 100 93 96 94
186. 300 Ignition Coils ECU BRN WHT BRN WHT to Ground 0Q INJECTOR POWER COIL BLU YEL BLU YEL BLU YEL to BLU YEL 2 40 ENGINE GROUND BROWN ENGINE GROUND 00 4 26 WINNING PERFORMANCE C POLARIS Fuel Systems Exhaust Valve Solenoid Specifications Coil Resistance WHT YEL to RED 150 1596 68 F 20 C CFI Ignition Coils Specifications Primary Coil Resistance Black to White 0 450 15 68 F 20 C Secondary Coil Resistance Without Plug Cap Black to High Tension Lead 18 0000 15 68 F 20 C Plug Cap Resistance 4 000Q 6 0009 WINNING PERFORMANCE gt POLARIS Regulator Rectifier I t Regulator Rectifier Connections WIRE CONNECTOR COLORS ITEM STATOR YELLOW _ Vac from stator charge coils Vdc supplied to ECU to boost ECU ORANGE power to fuel injectors during engine start up BROWN i CHASSIS 14 5 chassis power RED supply Chassis Power Capacitor Capacitor Testing 1 Charge the capacitor for 10 seconds using a 12 volt battery by connecting the positive lead to the Red White wire and the negative lead to the brown wire Monitor the capacitor voltage with a multimeter The voltage should slowly drain down from the initial charge If the cap does not hold a charge or drains rapidly replace the c
187. 373 Top Gear Stock 23 Bottom Gear Stock 39 Chain Stock 76 Gear Lube Polaris Synthetic Capacity oz ml 11 325 3 Reverse System Perc Electrical Alternator Output Operating Voltage 13 5 14 5 Watts 13 5 Vdc Total 400 18 1700 RPM Ignition Timing Coolant Temp 120_F 49_C Drive Clutch Bolt Torque 80 Ib ft 108Nm 1 16 ALTITUDE DRIVE CLUTCH DRIVEN CLUTCH S park Plug in mm 027 70 meters Shift Clutch Spring Clutch Driven Gearing Ceot Weight Spring Helix Spark Plug Champion RN57YCC 0 600 10 64 0 2000 66 44 46 Track 600 1200 ID Tis 2000 4000 19 62 2960 06 Width Inches cm 15 38 1200 1800 m 4000 6000 196 RED BLK Length Inches cm 121 307 140 240 1800 2400 7043058 M Lug Height Inches 1 25 3 2 60008000 10 60 BLKsoRN 22 39 76 g Heig cm 3 2 SIGNE DIET Track tension sag in cm with 10 58 8000 10000 56 42 10 Ibs 4 54kg placed 16 in 36 20 41 76 7 8 1 1 8 2 2 2 9 3000 3600 10 55 LWER 40cm ahead of rear idler 10000 12000 shaft WINNING PERFORWANCE gt POLARIS Model Specifications Front Suspension Inches cm Suspension Type 10 42 5 Walker Evans w IFP Remote Resevoir ones Compression Adjustable Rebuildable IFS Spring Rate Ibs in N mm Spring Installed Length Inches em 10
188. 386 6 2358 0 2455 32 5 9907 0 2359 6 4408 0 2536 6 6278 0 2609 33 6 3546 0 2502 6 8318 0 2690 7 0302 0 2768 34 6 7278 0 2649 7 2326 0 2847 7 4427 0 2930 35 7 1099 0 2799 7 6431 0 3009 7 8652 0 3097 36 7 5010 0 2953 8 0632 0 3174 8 2974 0 3267 37 7 9007 0 3111 8 4925 0 3343 8 7392 0 3441 38 8 3089 0 3271 8 9308 0 3516 9 1903 0 3618 39 8 7254 0 3435 9 7381 0 3692 9 6506 0 3799 40 9 1501 0 3602 9 8340 0 3872 10 1198 0 3984 11 6 WINNING PERFORMANCE POLARIS THROTTLE POSITION SENSOR TPS The TPS is located on the carburetor rack carbureted engines or on the throttle body CFI engines The TPS is set at the time of manufacture and should only require adjustment when When the TPS is replaced When the carburetor rack or throttle body is replaced or adjusted The TPS is suspected of being set incorrectly as part of troubleshooting The TPS test tool PN 2201519 is used to accurately adjust the TPS return signal settings TPS Test Tool Setup The test tool must be always be used to inspect the TPS on carbureted engines On CFI models either the test tool or Digital Wrench can be used to test the TPS NOTE Signal readings can be affected if the 9 volt battery is weak Always verify the battery is in good condition 1 Set the multimeter to read Vdc Verify the 9 volt battery condition by inserting the black multimeter probe into the black wire terminal and the red multimeter probe into the pink wire te
189. 43 2007 700 Dragon IQ 5 42 2008 800 CFI RMK 155 5 47 2008 800 CFI RMK 163 5 47 2008 IQ CFI 121 and Switchback 5 46 800 CFI Thermostats 5 41 Thermostat Orientation 5 41 Crankcase Inspection Bearing fit 5 6 Crankshaft Runout Inspection 5 5 Truing 5 10 Crankshaft Indexing 5 8 Crankshaft Inspection Checking Crankshaft Indexing 5 8 Connecting Rod small end 5 7 Connecting rod bearing 5 7 Indexing 5 8 Main bearing 5 7 Cylinder Honing 5 9 Cylinder Measurements 5 5 D Decal Replacement 10 10 Detonation Control DET 11 17 Diagnostic Plugs 11 18 Digital Wrench Connections 4 36 Engine Controller Reprogramming 4 38 Overview 4 36 Updating 4 37 Version Fileset Identification 4 38 Digital Wrench Diagnostic Software 4 36 Drive Driven Clutches 3 5 IX 1 Belt Deflection Adjustment 3 5 Belt Deflection Inspection 3 5 Engine Isolator Limiter Setting 3 6 Torque Stop Adjustment 3 6 Drive Clutch Assembly 7 16 Disassembly 7 14 Identification 7 13 Removal 7 13 Roller Installation 7 15 Roller Removal 7 15 Spider Indexing 7 17 Drive Clutch Weights 7 6 Drive Gears and Chains 6 3 Drive Shaft Installation 6 9 Drive Shaft Removal
190. 5 074 271 5 191 531 3 613 811 Patented Canada 882 491 71 883 694 71 864 394 71 Canadian Rd 34 573 71 34 572 71 1 227 823 87 7072133 Vehicle Descriptors Vehicle Identifiers 5 5 az World Mfg ID 8 5 gt Individual Serial No o x S p Pp S 585 m ml u G gt 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 5 1 5 B 5 B 5 0 2 2 0 0 0 0 0 0 WINMING PERFORMANCE gt POLARIS 2 3 General Information PUBLICATION PART NUMBERS 2008 Publications PARTS BOOK MODEL OWNER S MANUAL SUPPLEMENT ONLINE PART MANUALS AVAILABLE ONLINE AT WWW POLARISINDUSTRIES COM IQ Shift 9921427 9921067 9921068 600 RMK 144 9921108 9921102 9921112 600 RMK Shift 155 9921545 600 Dragon IQ 9921069 9921075 600 Switchback 600 Dragon 9921076 9921081 Switchback 9921065 600 IQ LX 9921072 9921070 600 IQ Touring 9921082 9921083 600 RMK 155 9921102 9921109 9921549 700 IQ 9921071 9921070 700 Dragon IQ 700 Switchback 9921065 700 Dragon 9921078 9921081 Switchback 700 RMK 155 9921104 700 Dragon RMK 155 9921549 1163 9921102 9921104 9921106 1 BIS Ton 9921301 9921107 9921114 2007 Publications PARTS BOOK MODEL OWNER S MANUAL SUPPLEMENT ONLINE PART MANUALS AVAILABL
191. 5 rapes Le D EE RH Dee Nano ea ee 1 6 2007 eed a eee ERR emo de din td 1 8 2007 600 SWITCHBACK 1 10 2007 600 HO IQ EX es Bg 1 12 2007 600 HO IQ TOURING 1 14 2007 700 IQ 1 1 16 2007 700 1 18 2008 IQ SHIET Dec VUE EUER Ee eed 1 20 2008 600 144 600 SHIFT 155 1 22 2008 600 u urusan kh sone ne Pe Pek des ds 1 24 2008 600 SWITCHBACK 600 DRAGON 1 26 2008 600 IQ LX re RR CHER SV ERR 1 28 2008 600 IQ TOURING 2 1 30 2008 600 155 oin ese rh ek eco A ach ADI e Lees 1 32 2008 700 IQ 700 1 34 2008 700 SWITCHBACK 700 DRAGON 1 36 2008 700 155 700 DRAGON RMK 155 163 1 38 2008 800 DRAGON 155 163 1 40 WINMING PERFORMANCE 1 1 gt POLARIS Model Specifications SPECIFICATIONS Carburetor Jetting
192. 50 inches mm Operating RPM 0 300 8250 Idle RPM 1700 Engagement RPM 200 3800 Exhaust Valve Spring Pink Fuel Delivery Type Cleanfire Direct Injection Throttle Body Marking 1203213 Throttle Body Bore 46mm TPS Voltage Idle 0 95 0 01 Vdc Fuel Pressure PSI bar 58 4 0 Recommended Fuel Octane R M 2 91 Non Oxygenated Clutch Settings ALTITUDE DRIVE CLUTCH DRIVEN CLUTCH meters Shift Clutch Clutch Driven feet Weight Spring Spring Helix caring 0 600 0 2000 855 ANGE 25 41 76 2000 4000 Mi 1200 1800 m 4000 6000 7 BLK GRN RED BLK 42 Straight 120 340 140 240 5136255 23 39 76 1800 2400 060 7042083 7043058 6000 8000 2400 3000 8000 10 000 10 58 3000 3600 SUM 10 000 12 000 10 56 Drive Clutch Bolt Torque 80 Ib ft 108 Track tension sag in cm with 10 Ibs 4 54kg placed 16 in 40cm ahead of rear idler shaft 7 8 1 1 8 2 2 2 9cm 1 34 WINNING PERFORMANCE gt POLARIS Model Specifications Front Suspension Suspension Type 10 42 5 Shocks Base Ryde FX PRO HPG w IFP Dragon Ryde FX Air 2 0 IFS Spring Rate Ibs in N mm Spring Installed Length Inches em 10 55 26 8 Air 2 0 Nitrogen Pressure 36mm Cylinder 145 psi 47mm Cylinder 60 psi Front Vertical Travel Inches cm 10 254 Ski Center Distance Inches cm 42 5 108 Setup Width 41 16 104 5 Camber Inches cm 2 25
193. 550 1800260 900 1800261 1 000 1800262 1 100 1800263 1 200 1800264 1 300 1800265 1 450 1800266 1 500 1800267 1 550 1800268 1 000 1800269 1 100 090 WASHERS 1800270 1 250 1800271 1 300 025 9 6 gt POLARIS Shocks Valve Shim Arrangement NOTE The rebound and compression valve stacks will always be positioned as shown in the Shown below is an example of how valving stacks are illustration regardless of how the shock assembly is arranged installed on the snowmobile FULLY COMPRESSED lt SHOCK ROD we FULLY EXTENDED PISTON SHOCK ROD NY T UN 2 7 8 REBOUND VALVE STACK COMPRESSION VALVE STACK Piston Orientation NOTE On some Walker Evans shocks piston is color coded The face of the piston with the greater number of relief COMPRESSION SIDE ports will always face the rebound valve stack Red REBOUND SIDE Relief Port Faces Rebound Stack Faces Compression Stack WINNING PERFORMANCE 9 7 POLARIS Shocks SPECIFICATIONS 2007 Shock Specifications Front Suspension Shocks SHOCK PN MODEL 5 psu pod ore OIL VOLUME PSI IN IN IN 7042258 Ryde FX 18 00 11 8 6 2 49 6 92 Full 200 7043245 Ryde FX 18 00 11 8 6 2 49 6 92 Full 200 7043141 Fox 18 0
194. 700 SILENCER HEAT SHIELD ZINC PLATED YELLOW SPRINGS GASKETS 600 700 MANIFOLD SNOW DEFLECTOR EXHAUST PIPE STAINLESS STEEL GRAY SPRINGS A Sensor 32 Ft Lbs 44 Nm B Exhaust Manifold Fasteners 22 Ft Lbs 30 Nm NOTE Always use the stainless steel gray springs to connect the exhaust pipe to the exhaust manifold 5 48 coru Final Drive and Brakes CHAPTER 6 Final Drive and Brakes GEAR RATIO SPEED CHARTS coy x Ree xx Rae ee oes 6 2 8 373 CD CHAINCASE SPEED 5 6 2 DRIVE GEARS AND CHAINS 4 ik RR RR Pecans Pe pe bud ER ds es 6 3 DRIVE GEARS epider ee E aden 6 3 DRIVE aoa Be UY ita Q 6 3 S379 CHAINGASE Gem hi Ex eR Sal RO A e d 6 4 ASSEMBLY VIEW PRENDE see wende mecum 6 4 CHAINCASE 6 5 CHAINCASE 6 5 DRIVE TRAIN queda d co ted E cali b Ra dU QR eu 6 7 SPEEDOMETER CABLE TYPE DRIVE TRAIN 6 7 ELECTRONIC SPEEDOMETER DRIVE TRAIN ASSEMBLY 6 8 DRIVESHAFT REMOVAL INSTALLATION 6 9 BRAKE S Ye TEN un store A DU ion au NOR dir
195. 938 321145 443119 91 038 33 04 20 321145 43804 20 30111938 81 3L 1HM 033 3304 2 GOOH SISSVHD 30111934 91 M01134 GNNOYS OV 1 000 5155 2 401v 10938 91 4131 1 305135 1NY 1009 9 450089 24 1 321145 080089 20 801 10938 81 311 NMOUB 91 dW3l 931 805835 LNV 1002 318 TWNOIS 34vug OV HOLIMS 3 49 801 10938 8 39NYuO TWNOIS 3 20 1 400 5155 30111934 02 32v 18 JONVYO 43M0d OV 321145 83 04 OV 301111933 91 M01134 4131 331V 3NI9N3 SISSVHO 31000N 8 034 018 131 NOI1VNOL30 1 Q00H SISSVHO JINON 102 8 39NY40 311HM 3313A0H2V1 1 000 5155 2 310008 102 81 YOW18 MO11394 WNOIS 3593438 3NI9N3 SISSVH2 31000N 8 179 1081802 01081105 11083108 3 JINON 102 8 81011317 311 4015 1305 3 19 3 1 INOW 8 038 18 4015 3N19N3 SISSVH2 1000N 8 318 131 10H 1 GOOH SISSVHO JINON 102 8 311 HM X2V18 102 83S10d 305135 XNYUD 1100 8 138 311 031 158338 1 GOOH SISSVHD 310008 103 8 311 4015 QuvH 83131 JINON 102 81 X2v18 4015 1105 HOLIMS 4015 310408 102 81 0334 7219 1102 83112 3 1102 83112 3
196. AL WRENCH 11 8 TPS BASELINE ADJUSTMENT CFI MODELS 11 8 TPS IDLE SPEED ADJUSTMENT CFI MODELS 11 10 THROTTLE PLATE 11 10 ELECTRIC START GARBURETED 7 a batas wu bel Pa eal MEHR 11 11 SYSTEM SCHEMATIC 600 CARBURETED 11 11 SYSTEM SCHEMATIC 11 12 STARTER MOTOR FLEX DRIVE ASSEMBLY 11 13 IQ BATTERY BOX ASSEMBLY 11 14 CARBURETED ELECTRICAL SYSTEMS 1 11 15 600 HO STATOR 8 11 15 IGNITION COIL PACKS ren clem hm ek e ep Eel 11 15 EXHAUST VALVE 11 15 KNOGK SENSOH 3 5 eT eI e ip E Rey xd 11 15 600HO COOLANT TEMPERATURE SENSOR 11 15 OIL EEVEL SENDER ERE Gass E RE ERRARE RETE 11 15 2007 600 HO REGULATOR 11 16 2008 SHIFT 155 REGULATOR 11 16 2008 IQ SHIFT REGULATOR RECTIFIER 11 17 DETONATION CONTROL DET eu nme ce
197. B 0 RING 5 gt n SHOCK LIMITER STRAP SHAFT T WASHER FRA ADJUSTER T 45 Ft Lb 61 Nm B 35 Ft Lb 47 Nm C 19 Ft Lb 26 Nm Assembly Notes Never re use Nylock nuts Always replace with new parts All pivots must rotate freely after tightening fasteners Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table 8 18 WINNING PER FORMANCE gt POLARIS Steering and Suspensions M 10 128 Rail Assembly BUMPER FRA BLOCK COUPLER BLOCK RAIL TIP BOGIE WHEEL B 3 6 4 8 Nm 19 Ft Lb 26 Nm C 35 In Lb 4 Nm D 35 Ft Lb 47 Nm Assembly Notes Never re use Nylock nuts Always replace with new parts All pivots must rotate freely after tightening fasteners Apply Polaris Premium Season Grease to all grease zerks as outlined in the periodic maintenance table one 8 19 Steering and Suspensions M 10 128 Front Rear Torque Arms CARRIER WHEEL BRACKET REAR TORQUE ARM FRONT TORQUE ARM 0 SHAFT CARRIER WHEEL JN L N SHOCK ASSEMBLY V N N LP 4 SN lt a 2 LOWER SHAFT T 12 Ft Lb 16 Nm B 35 Ft Lb 47 Nm C 70 Ft Lb 94 Nm Apply Polaris Premium All Season Grease to all grease
198. BE RETAINED IN THE VISE BY THE LOWER MOUNT ANY OTHER METHOD OF SECURING THE CHOCK BODY DURING THESE PRO CEDURES MAY DEFORM THE SHOCK BODY CYLINDER 6 Remove the small button head screw from the pressure valve assembly 9 26 7 Depressurize the shock NITROGEN GAS IS UNDER EXTREME PRESSURE USE A WARNING CAUTION WHEN RELEASING NITROGEN GAS FROM SHOCK PROTECTIVE EYE WEAR SHOULD BE WORN TO AVOID RISK OF INJURY 10 11 12 13 14 15 16 17 Internal Floating Piston Shocks using slotted screwdriver loosen the pressure valve assembly counter clockwise two full revolutions allowing the gas pressure to fully escape past the pressure valve assembly O ring Emulsion Shocks With the shock inverted and the piston rod fully extended secure the lower mount of the shock in a vise Allow a couple of minutes for the gas pressure to separate from the oil and rise to the top Using a rag as a shield to prevent spraying gas and oil place rag over top the pressure valve assembly and slowly loosen the valve assembly with slotted screw driver three full revolutions allowing all the gas pressure to escape past the pressure valve assembly O ring Allow all the gas pressure to escape before proceeding with the removal of the pressure valve assembly Pressurized gas and shock oil could eject the valve assembly from the cylinder resulting in bodily injury Using a slotted screwdriver remov
199. BusHING UPPER CONTROL ARM LOCK NUT 4 JAM NUT Ye B LOCK NUT SWAY BAR BLOCK SPINDLE PIVOT BUSHING BUSHING Orientate rod ends so they are parallel with mating component 8 5 Steering and Suspensions IQ Fixed Steering Post Assembly UPPER POST BRACKET m STEERING POST LOWER POST BRACKET AX CAUTION lock nuts B Where Applicable BUSHINGS FASTENERS UPPER POST BRACKET BUSHINGS SUPPORT PLATE MOUNT SUPPORT BUSHING Never re use lock nuts Always re assemble using new T A 16 Ft Lbs 22 Nm B 13 Ft Lbs 17 Nm WINNING PERFORMANCE gt POLARIS Steering and Suspensions IQ Rider Select Steering Post Assembly ADJUSTING LEVER STEERING BLOCK ADJUSTER BLOCK NUTSERT STEERING POST FASTENER STEERING POST MID BRACKET BRACKET STEERING POST LOWER BRACKET BUSHINGS NOTE Assembly Notes CAUTION Torque steering post lower bracket fasteners first then Never re use lock nuts Always re assemble using new torque the steering post mid bracket fasteners lock nuts 6 7 Ft Lbs 10 Nm 11 Ft Lbs 15 Nm gt POLARIS 8 7 Steering and Suspensions IQ Steering Linkage Vu f ex sS FIXED LENGTH STEERING LINK BUSHING 5 BEARING TIE ROD JAM NUT BUSHING
200. CHASSIS ENGINE SOFT STOP BLACK WHITE 5515 000 HOT LAMP GRY 18 MODUL CHASSIS ENGINE REVERSE SIGNA CDI MODULE BLU RED 18 MODUL CHASSIS ENGINE WATER TEMP ORANGE 5515 000 BRAKE SWITCH AC BRAKE SIGNAL BLK COOLANT SENSOR WATER TEMP SIGN BROWN AC SHUNT REGULATOR STATOR OUTPUT DC GROUND BRN COOLANT SENSOR WATER TEMP GN STATOR OUTPUT 5515 000 AC_GROUND BROWN RED DK GREEN AC SHUNT REGULATOR EV SOLENOID BATTERY CHARGE BROWN AC SHUNT REGULATOR GROUND AC GROUND GRN DET SENSOR DET SENSOR GN YELLOW ELECTRIC START AC POWER SPLICE AC POWER BLK IGNITION COIL IGN COIL GND YELLOW AC POWER SPLICE STATOR OUTPUT GRN EXCITER COIL EXCITER COIL CENTER AC_POWER BLK CRANK SENSOR STATOR GROUND WHITE CRANK SENSOR PULSER COIL YELLOW RED LH CONTROL POWER 5515 000 HIGH HEADLAMPS YELLOW RED CHASSIS ENGINE TACHOMETER VIOLET OIL LEVEL CHASSIS HOOD OIL LEVEL WHITE YELLOW CHASSIS ENGINE EV SOLENOID GND DK GREEN LH CONTROL POWER CHASSIS HOOD LOW HEADLAMPS BLU WHITE CHASSIS ENGINE HOT LED BROWN GROUND HANDLEBAR GROUND SPLICE AC GROUND WHITE CHASSIS ENGINE REVERSE LED BLU YELLOW C
201. CK ECU CNA ELECTRIC START BATTERY WHITE BLUE ECU CHASSIS RELAY CHASSIS RELAY COIL BLACK RED ECU CNA STOP SWITCH SOFT STOP BROWN ECU CNA ECU GROUND SPLICE ECU GROUND BLUE RED ECU CNA xlelm lse e e w CHASSIS HOOD 32 WATER TEMP GAUGE YELLOW RED ECU CNA CHASSIS HOOD 1 TACHOMETER ORANGE ECU CNA ECU REGULATOR VOLTAGE BOOST PINK ECU CNA DIAGNOSTIC K LINE GRAY ECU CNA GRAY SPLICE MODE WHITE ECU CNA CHASSIS HOOD 1 REVERSE LED GREEN ECU CNA INTAKE AIR PRESSURE PRESSURE SENSOR SIGNAL BLUE WHITE ECU CNA CHASSIS HOOD 1 HOT DET LED ORANGE GREEN ECU CNA ELECTRIC START BATTERY RELAY COIL BLACK WHITE ECU CNA DIAGNOSTIC SPLICE DIAGNOSTICS BLACK ECU CNA TETHER HARD STOP BLACK BLUE ECU CNA SENSOR GROUND SPLICE 1 SENSOR GROUND GRAY ECU CNA LH CONTROL SIGNAL REVERSE SIGNAL RED ECU CNA REGULATOR POWER SPLICE REGULATOR POWER ORANGE ECU CNA ECU REGULATOR VOLTAGE BOOST ORANGE ECU CNA ECU REGULATOR VOLTAGE BOOST BLACK WHITE DIAGNOSTIC SPLICE ECU POWER DIAGNOSTICS RED BLUE RED BLUE SPLICE MODE CHANGE 2 K LINE POWER RED BLUE RED BLUE SPLICE DIAGNOSTIC K LINE POWER BLACK BLUE SENSOR GROUND SPLICE 1 ECU POWER SENSOR GRO
202. Compresses drive clutch without removing clutch from engine 2871173 The Way Out PVT System Drive Clutch Springs PART NUMBER COLOR DIAMETER Piero ped RATE inches Ibs inch 7041021 Clear 157 4 14 70 130 44 7041022 Black 140 4 25 44 77 25 7041063 Purple 168 4 37 75 135 53 7041062 Silver 207 3 12 75 243 151 7041065 Pink 177 4 69 112 200 64 7041060 196 3 37 70 199 98 7041083 Red 192 3 77 120 245 94 7041102 Yellow 192 2 92 44 185 105 7041061 Brown 200 3 14 69 212 109 7041132 White 177 2 92 34 141 81 7041168 Green 177 3 05 42 142 76 7041148 Gold 207 3 25 100 275 133 7041150 Red White 192 3 59 100 220 91 7041286 Silver Gold 218 3 05 77 240 163 7041080 Blue 207 3 55 120 300 137 7041781 Dark Blue White 225 3 42 120 310 145 7041945 Almond 218 3 65 140 330 145 7041645 Almond Gold 207 4 00 150 290 107 7041818 Black White 218 3 52 140 320 137 7041816 Almond Black 200 3 75 165 310 111 7041922 Almond Blue 218 3 75 150 310 122 7041988 Almond Red 207 4 27 165 310 110 7042083 Black Green 218 3 38 120 340 168 7043342 Black 3342 218 3 46 140 330 145 7043076 Black 3076 225 2 67 40 340 229 7043120 Black 3120 225 2 78 60 340 213 7043077 Black 3077 255 2 90 80 340 198 7043121 Black 3121 255 3 05 100 340 183 7042287 Black 2287 207 3 40
203. D SPLICE LH CONTROL SIGNAL SENSOR GROUND BLACK BLUE SENSOR GROUND SPLICE IGNITION SWITCH SENSOR GROUND BROWN FUEL PUMP OIL SENSOR CHASSIS GROUND BLUE LEFT HANDWARMER BLUE SPLICE HANDWARMER LOW BLUE LH CONTROL SIGNAL BLUE SPLICE HANDWARMER LOW BLUE RED LH CONTROL SIGNAL BLUE RED SPLICE HANDWARMER HI BLUE RED LEFT HANDWARMER BLUE RED SPLICE HANDWARMER HI BROWN RIGHT HANDWARMER HANDLEBAR GROUND SPLICE CHASSIS GROUND BROWN LEFT HANDWARMER HANDLEBAR GROUND SPLICE CHASSIS GROUND ORANGE GRAY LH CONTROL SIGNAL THUMBWARMER THUMBWARMER LOW WHITE GRAY LH CONTROL SIGNAL THUMBWARMER THUMBWARMER HI BROWN HANDLEBAR GROUND SPLICE THUMBWARMER CHASSIS GROUND BLACK BLUE STOP SWITCH SENSOR GROUND SPLICE 2 SENSOR GROUND BLACK STOP SWITCH IGNITION SWITCH HARD STOP RED WHITE CHASSIS RELAY LH CONTROL POWER CHASSIS POWER WIRE TERMINATION TABLE ELECTRIC START BROWN HANDLEBAR GROUND SPLICE LH CONTROL POWER CHASSIS GROUND ORANGE BRAKE SWITCH SPLICE TAILLIGHT BRAKE LIGHT COLOR FROM CONNECTOR CAVITY TO CONNECTOR CAVITY FUNCTION BROWN CHASSIS GROUND SPLICE HANDLEBAR GROUND SPLICE CHASSIS GROUND RED WHITE ELECTRIC START CHARGE RELAY 3 CHASSIS POWER RED WHITE CHASSIS POWER SPLICE ACCESSORY POWER
204. DARK GREEN K WH 06 ORANGE NO z SWITCH NORMALLY HW MEDIUM LOW BRAKE LIGHT ds PK PINK OPEN GROUND HW SWITCH THROTTLE SAFETY SWITCHES 5 RD RED lo SPLICE r3 SWITCH I CLOSED 2 i VT VIOLET PURPLE E IN NORMAL OPERATION ita ba mu CBA 2 1 i 15 SITE HARNESS 2410756 03 2 55 TET TWO WIRE COLORS ARE SHOWN 401175 05 a gt l ba 33 VT WH WITH MAIN TRACE COLORS O 24079002 528 8 582 SHUT OFF s WR YELLOW TRACE 2410868 01 151 83 S85 POWER lt cHASSIS SPLICE 3 HOOD 2 HEATER d 5 5 HEAD e INDICATOR i o i LAMPS CAMP wd E eI e e dt EE 8 108 i goog 2885 668 101 5 I fA 23 YE RD E uses r4 x 2 17 zem 777 E 4 811 d Ibi tli t 20 m 2 m 5 22 de I 1 T o 1 I MODE L D miim L nt 72 THUMB 1 i WARMER SET o gt w Bk l n ee ee Ee 8 3 22 RE 9 mM 1 i S
205. E BODY 2007 700 CFI Fuel Pump Service The fuel pump flange assembly PFA can be removed and replaced without replacing the entire fuel tank assembly Note that the 2007 700 CFI fuel pump does not feature a fuel level sender FUEL FILTER VENT FITTING VENT HOSE PIN COLOR ITEM 1 Red Pump Power 2 N A N A 3 Black Pump Ground 4 Brown Chassis Ground 1 4 32 Remove the fuel from the fuel tank Store the fuel is an FUEL CAP GAUGE 10 FT LBS 14 FUELTANE 4 6 FT LBS 5 5 8 FOAM PADS appropriate fuel holding container Remove the following components Seat Assembly Console Loosen fasteners then lift console away from tank and set to the side Air box If electric start is installed disconnect the negative cable the positive cable from the battery Relieve the fuel pressure See Fuel Rail Bleeding Pressure Testing on page 4 29 Unplug the fuel pump electrical connector Remove the fuel hoses from the fuel pump See Disconnect Fittings on page 4 29 Remove the fasteners securing the fuel tank to the tunnel WINNING PERFORMANCE POLARIS Fuel Systems 8 Remove the fuel tank from the chassis 15 Carefully slide the pump assembly into the fuel tank until 9 Place the fuel tank is a well ventilated area the gasket rests on the tank 10 Remove and discard the six fuel pump flange screws 16 U
206. E ONLINE AT WWW POLARISINDUSTRIES COM 600 HO IQ 9920460 9920461 9920459 600 HO Switchback 9920597 9920598 600 HO RMK 9920476 9920477 9920483 9920478 600 HO IQ CFI 9920487 9920466 eel FIO Switchback 9920495 9920496 9920464 600 HO IQ LX CFI 9920465 9920466 50019 e Touring 9920501 9920502 CFI 700 HO IQ Dragon 9920648 9920910 9921200 700 HO RMK Dragon 9920476 9920484 9920912 2 4 WINNING PERFORMANCE gt POLARIS General Information ENGINE DATA FORMULAS Compression Ratio 17 g DANGER ZONE UNNECESSARY OCTANE FULL STROKE COMPRESSION RATIO REGULAR PREMIUM RACE FUEL 84 86 88 90 92 100 105 110 115 120 PUMP OCTANE NUMBER R IHV DISP IHV IHV INSTALLED HEAD VOLUME DISP CYLINDER DISPLACEMENT cc R COMPRESSION RATIO 5 S FULL ENGINE STROKE DISP x 25 4 I INCHES PER cc OF IHV B CYLINDER BORE cm Pl 3 1416 DISP PI x x S 4 WINNING PERFORMANCE 2 gt POLARIS 2 General Information Compression Ratio Example Bore 6 5cm Stroke 6 0 cm IHV 17 1cc Displacement 3 1416 PI x 42 25 Bore squared x 6 0 stroke 4 199 098cc Displacement 199 098 R 17 1 199 098 17 1 12 643 Full Stroke Compression Ratio To calculate the Effective Compression Ratio substitute the exhaust port height for the stroke in the formulas above Exhaust
207. FERENCE Standard Bolt Torque Specification Grade 2 Grade 5 Grade 8 oF oF uz uz uz E lt m lt m lt m 3 m S 1 4 20 5 7 8 11 12 16 1 4 28 6 8 10 14 14 19 5 16 18 11 15 17 23 25 35 5 16 24 12 16 19 26 29 40 3 8 16 20 27 30 40 45 62 3 8 24 23 32 35 48 50 69 7 16 14 30 40 50 69 70 97 716 20 35 48 55 76 80 110 1 2 13 50 69 75 104 110 152 1 2 20 55 76 90 124 120 166 FT LB X 1 356 X 7376 FT LB Fuel Oil Premix Ratios FUEL 20 1 RATIO 32 1 RATIO GALLONS OUNCES OF OIL OUNCES OF OIL 1 6 4 4 5 32 20 10 64 40 Formula 1 Gallon 128 Ounces 128 Desired Ratio Ounces of oil for every 1 gallon of fuel 128 20 lee Ratio 6 4 ounces of oil for every 1 gallon of fuel Always mix ratio in 5 gallon increments 2 8 Gasoline Volatility AMBIENT AIR TEMP MAXIMUM REID VAPOR RANGE CLASS PRESSURE LOW HIGH 60 F 110 F A 7 0 psi 0 5 bar 16 C 43 50 F 110 F B 9 0 psi 0 6 bar 1090 4390 40 2 5 10 5psi 0 7 bar 4 C 97 F 36 C 30 F 5 5 12 0psi 0 8 bar 1 C 85 F 29 C 20 F 2 2 13 5 1 0 9 7 69 21 Add 2 45 F for each 1000 ft 305m above sea level When gasoline is
208. G 080 180 NB 680 66054 960 Ng 610 8 10 0S0 65 HW 08 001 48 61 Qu Z 49 220 48 580 r 20 HMI LA GHO HM NB 250 9 201 M8 201 NB III X8 HM 61 0 90 rtt 90 110 NB 960 NB 60 _ ante 26 coo p Na s0t 48 19 600 08 800 18 89 L00 90 900 500 r 90 HILNII NO 031201 uo uv 109 mos roo 48 660 gt zd 00 221 1no 2d VN2 noa 3180 NO 0310201 3217595 610 YOSNAS 08395 V J 2 N02 HAND 120 HANG 550 tp 11015 a QU I 8 Nid 100 321145 0 98 180 Hazna 620 Su NB 20049 rans 2l 920 Y Nid NI 8304 pp PAI 08 38 11
209. GAUGE 15 PINK 20 ECU 19 DATA LOGGER DATA LOGGER 16 YELLOW RED 20TXL ECU 16 5515 000 1 TACHOMETER 11 ORANGE 20 ECU 7 ECU REGULATOR B VOLTAGE BOOST 19 WHITE BLACK 20 ECU CNA 19 DEVELOPMENT 1 RXD 20 YELLOW WHITE 20 ECU CNA 20 DEVELOPMENT TXD 21 PINK 20TXL ECU CNA 2 DIGITAL WRENCH C K LINE 22 GRAY 20 ECU 22 GRAY SPLICE 1 MODE 23 WHITE 20TXL ECU CNA 23 5515 000 6 REVERSE LED 24 LT GREEN 20 ECU CNA 24 INTAKE AIR PRESSURE 4 PRESSURE SENSOR SIGNAL 25 LT BLUE WHITE 20TXL ECU 25 5515 000 15 HOT DET LED 26 ORANGE LT GREEN 20 ECU CNA 26 ELECTRIC START C BATTERY RELAY COIL 21 BLACK WHITE 20 ECU CNA 27 DIAGNOSTIC SPLICE DIAGNOSTICS 29 BLACK 20 ECU CNA 29 TETHER HARD STOP 30 BLACK LT BLUE 20 ECU 30 SENSOR GROUND SPLICE 1 SENSOR GROUND 3l GRAY 20 ECU CNA 3 LH CONTROL SIGNAL E REVERSE SIGNAL 3 RED 20 ECU CNA 32 REGULATOR POWER SPLICE REGULATOR POWER 33 ORANGE 20 ECU 33 ECU REGULATOR 5 VOLTAGE BOOST 34 ORANGE 20 ECU 34 ECU REGULATOR 1 VOLTAGE BOOST 35 RED WHITE 18 DEVELOPMENT 5V POWER SPLICE 5V POWER 36 BLACK WHITE 18TXL DIAGNOSTIC SPLICE ECU POWER DIAGNOSTICS 31 RED LT BLUE 18TXL RED BLUE SPLICE B MODE CHANGE 2 K LINE POWER 38 RED LT BLUE 18TXL RED BLUE SPLICE DIGITAL WRENCH K LINE POWER 39 BLACK LT BLUE 18TXL SENSOR GROUND SPLICE 1 ECU POWER 3 SENSOR GROUND 40 BLACK LT BLUE 18 1 SENSOR GROUND SPLICE 1 DIGITAL WRENCH D SENSOR GROUND 41 ORANGE WHITE 2 G
210. Grease 30z Grease Gun Kit 2871312 140z 2871423 Starter Grease 2871460 Carbon Clean Plus 2871326 Isopropyl 2870505 Fuel Stabilizer Quart 2870652 2 5 Gallon 2872280 Cross Shaft Assembly Lubricant 807 2872435 2 5 Gallon 2872436 Three Bond Sealant 5oz 2871557 Loctite 242 2871950 DESCRIPTION PART NUMBER Premium 2 Cycle Oil Quart 2875035 Gallon 2875036 2 5 Gallon 2874037 16 Gallon 2875038 55 Gallon 2875039 330 Gallon 2875040 VES Gold 2 Cycle Oil Quart 2874438 Gallon 2874439 2 5 Gallon 2874443 16 Gallon 2874440 55 Gallon 2874441 330 Gallon 2874442 Racing 2 Cycle Oil Quart 2873025 Gallon 2873023 16 Gallon 2873919 PS 4 4 Cycle 0W 50 Oil Quart 2874865 55 Gallon 2874867 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 Fox Quart 2870995 Gallon 2872279 Shock Oil Ryde FX Arvin 2873716 Brake Fluid DOT 4 2872189 Fogging Oil Aerosol 2870791 Quart 2871517 3 4 E POLARIS Way Out Maintenance 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
211. H ore cce et RT e d vec ele t uris erbe t 7 6 DRIVE CLUTCH WEIGHTS cio Lec eei e e WERE I us 7 6 PERC TEAM LWT DRIVEN HELIXES 24 7 7 NON PERC TEAM LWT DRIVEN HELIXES 24 7 7 TEAM RAMP 7 7 TEAM DRIVEN SPRINGS 2 7 8 DRIVE BELTS ar okie tere eene Peces 7 9 BELT INSPECTION y eme Rev Rec Rp peri Re ete QUE RA 7 9 DRIVE CLUTCH BOLT 7 9 BELT WEAR BURN DIAGNOSTICS 7 10 DRIVE BELT REMOVAL TEAM DRIVEN 7 11 DRIVE BELT INSTALLATION TEAM DRIVEN 7 11 ADJUSTING BELT DEFLECTION TEAM DRIVEN CLUTCH 7 11 PVT SYSTEM ADJUSTMENTS ke RR x E qu 7 12 CLUTCH ALIGNMENT OFFSET 7 12 OFFSET 7 12 DBIVE GEUTOH o oi hal cub rw por deae dux s yuq I tog dod 7 13 IDENTIFICATION u nien Bin Remote epa pendet idet 7 13 DRIVE CLUTCH m 7 13 DRIVE CLUTCH 5 1 7 14
212. HASSIS ENGINE DET LED PINK TPS SENSOR TPS 5V YELLOW YELLOW TPS SENSOR TPS SIGNAL LH CONTROL POWER AC_POWER SPLICE AC POWER BLACK TPS SENSOR TPS GND YELLOW AC POWER SPLICE OIL LEVEL AC POWER BLACK TETHER IGNITION SWITCH HARD STOP BROWN TETHER IGNITION SWITCH CHASSIS GROUND DET SENSOR DET SIGNAL BROWN GROUND IGNITION SWITCH CHASSIS GROUND WHITE RED ELECTRIC START IGNITION SWITCH START SOLENOID CONTROL BLACK STOP SWITCH IGNITION SWITCH HARD STOP YELLOW AC POWER SPLICE TAILLIGHT AC POWER ORANGE BRAKE SWITCH TAILLIGHT AC BRAKE SIGNAL BROWN GROUND TAILLIGHT AC GROUND RED IGNITION SWITCH ELECTRIC START BATTERY CHARGE AC GROUND BROWN GROUND ELECTRIC START YELLOW 5515 000 AC_SHUNT REGULATOR YELLOW STATOR OUTPUT AC SHUNT REGULATOR RED ACCESSORY IGNITION SWITCH DC POWER ORANGE GRAY LH CONTROL SIGNAL THUMBWARMER LOW THUMBWARMER WHITE GRAY LH CONTROL SIGNAL THUMBWARMER HIGH THUMBWARMER DK BLUE LH CONTROL SIGNAL LOW HW SPLICE HW LOW DK BLUE RED LH CONTROL SIGNAL MED HW SPLICE HW MED HIGH ROWN LH CONTROL SIGNAL HANDLEBAR GROUND SPLICE AC GROUN DK BLUE LEF
213. I models remove the Schrader valve cover located under the steering hoop and depressurize the fuel rail See Fuel Rail Bleeding on page 4 20 26 Using the fuel line disconnection tool PN PS 47152 20 separate the fuel filter and the fuel return line 24 Remove the four engine mounting fasteners located on the engine straps 27 Secure the loose fuel lines out of the way for engine removal NOTE A helper will be needed for the following steps 28 Lift engine out of chassis and carefully place engine on shock tower brace 29 While holding the engine remove the throttle bodies by loosening up the intake boot clamps and separating the throttle bodies from the intake boots 30 Remove the cable located in the center of the throttle bodies 31 Remove the oil cable lock nut from the threads on the cable housing 32 Remove the throttle cable from the oil pump bracket rowan nd Engine and Cooling Systems 33 Remove the oil cable from the oil pump lever by holding the pump open and rotating the cable and keeper to the slot in the pump arm 34 Remove the cable from the oil pump bracket 35 Remove the engine from the chassis 36 Inspect the motor mounts and replace if needed 5 36 Engine Installation Typical Make sure that you have the engine assembled in the state that it was when it was removed This includes all the coolant hoses oil lines and electrical wires Fill oil lin
214. IS HOOD 1 R 20 GAUGE 2 BATTERY HOLDER Y R 16 LEFT HEADLAMP CHASSIS HOOD 1 BRN 16 LEFT HEADLAMP CHASSIS HOOD 1 GRN 16 LEFT HEADLAMP CHASSIS HOOD 1 Y R 18 LEFT HEADLAMP RIGHT HEADLAMP BRN 18 LEFT HEADLAMP RIGHT HEADLAMP GRN 18 LEFT HEADLAMP RIGHT HEADLAMP BRN W 20 BATTERY SPLICE CHASSIS HOOD 1 Y R 20 ACC_HEADLAMP RIGHT HEADLAMP BRN 18 RIGHT HEADLAMP ACC LAMP YELLOW 18 ACC HEADLAMP CHASSIS HOOD 2 12 3 PERFORMANCE gt POLARIS WINNING iring Harness 1 of 2 IS 2007 600 700 Chass z 8000 49 80 08 1604 IEN 80 38 60 9 32185 lo 1 49 220 2 SPO NG 180 980 du se N 90 110 321185 3018 E 00 39795 48 34 910 ______ 8 TNNG 990 7 l 4915 915378 HA OY 60 AMOSS399V SISSVHO 8 HM QU 080 88 011425 5165 la Hau 01 32145 SISSVHO
215. LICE REGULATOR POWER BROWN REGULATOR CHASSIS GROUND SPLICE CHASSIS GROUND RED CHASSIS RELAY CHASSIS RELAY CHASSIS POWER RED CHASSIS RELAY REGULATOR POWER SPLICE REGULATOR POWER RED WHITE CHASSIS RELAY CHASSIS POWER SPLICE CHASSIS POWER RED WHITE CAPACITOR CHASSIS POWER SPLICE CHASSIS POWER BROWN CAPACITOR CHASSIS GROUND SPLICE CHASSIS GROUND BROWN CHASSIS GROUND SPLICE ECU GROUND SPLICE ECU GROUND RED WHITE CHASSIS POWER SPLICE TAILLIGHT CHASSIS POWER RED PUMP PRIME REGULATOR POWER SPLICE REGULATOR POWER BROWN PUMP PRIME CHASSIS GROUND CHASSIS GROUND BLUE RIGHT HANDWARMER BLUE SPLICE HANDWARMER LOW BLUE RED RIGHT HANDWARMER BLUE RED SPLICE HANDWARMER HI LT GREEN RED CHASSIS HOOD 1 GROUND SPEED SENSOR SPLICE GROUND SPEED ORANGE BRAKE SWITCH BRAKE SWITCH SPLICE BRAKE LIGHT RED WHITE CHASSIS POWER CHASSIS POWER SPLICE CHASSIS POWER BROWN CHASSIS POWER CHASSIS GROUND SPLICE CHASSIS GROUND 12 5 PERFORMANCE gt POLARIS w iagrams D 31010 193118 321145 AN311V8 02 321145 0 33138111 02 321145 0 2 QOOH SISSWHD 02 8313W111V 321145 M NU8 02
216. LVE ARROW POINTS AWAY FROM TANK me eas VACUUM CHECK VALVE lt 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 VALVE The rollover check valve is not serviceable When inspecting the system verify the hose is not kinked D eon 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 13 Maintenance CHASSIS LUBRICATION M 10 136 Chassis suspension and mechanical grease points should be lubricated Polaris Premium All Season Grease G Polaris Premium All Season Grease Part N
217. Lbs 7 5 Nm 7 2 PASSENGER SEAT ASSEMBLY LUMBAR ADJUSTER SEAT LATCH i X LATCH BRACKETS SEAT ASSEMBLY Qu 1150 7 LY HAND GUARD v 10 8 WINNING gt POLARIS PERFORMANCE Chassis 2008 IQ Touring Seat Assembly D z lt HAND GUARD 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 WINNING PERFORMANCE POLARIS 10 9 Chassis Seat Cover Replacement 1 Remove seat Remove the old covering by removing the staples that hold it on the base 3 Drape the new cover over the seat foam Turn the assembly over and begin upholstering by lining up the seat cover vinyl side flaps with the indented square location indicators located on the plastic seat base A 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 Usinga 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
218. ND 100 A NG LO 3 NIYN 01 Q3H0VLLY SISSVHO 430 10S KAYI TIXNY 80 900 AHM 210 lt 9 110 4 NB 260 ng 901 02 08 16 101 lt 18 90 lousna 890 690 010 HOLIMS HOLIMS 31108 110 NI 031 201 NOILVY3dO TVNYON NI 5 1 035012 SI HOLIMS 3 2113 1133 5 31108HL lt 3OYEL NOTTE NAOHS 880103 OAL 801131 04102 I0 0vOlpZ SS3NHVH ai 038804 11 3 30 r M qau an1a N3dO ATTVMYON HOLIMS MH 035012 ATTWHYON HOLIMS QU HM A 1 1431 ira ue 05835 9151102 4Y134 sissvHo 38155184 3N19N3 13631 0103 TATA au 120028 00 v 01 Nid Q0028 00r2 OL L ga 070052 22 3 02 1 9 19 0313538838 83818 070006 Z 2 61 3 66 33111 8 3 181538 dil 0317201 HOLUS 305115 0881 a 08 190 lt Qu n8 101 8 440 18115 38155184
219. NNEL COOLING SYSTEM THERMOSTAT CLOSED OPEN 5 42 Engine and Cooling Systems 2007 600 IQ Switchback LX 2008 CFI LX Cooling System SURGE BOTTLE S 5 HOSE THROTTLE BODY 2 RH PERIMETER COOLER OUT TO SURGE TANK 9 e CFI ONLY 4 REAR COOLER REVERSED ON S B VOSE SURGE pose ENGINE OUT TO TUNNEL COOLING SYSTEM THERMOSTAT OPEN HOSE BYPASS TO FRONT COOLER LH PERIMETER COOLER HOSE RADIATOR TO SURGE BOTTLE RADIATOR pee Engine and Cooling Systems 2007 2008 CFI Touring Cooling System SURGE TANK RH FOOTBOARD COOLER HOSE THROTTLE BODY OUT TO SURGE TANK M ae TANK Bs TO ENGINE IN 2220 y E HOSE RADIATOR TO 5 SURGE TANK a gt RADIATOR CFI ONLY e SR 0 22 HOSE ENGINE OUT TO TUNNEL COOLING SYSTEM THERMOSTAT OPEN HOSE BYPASS By pass LH FOOTBOARD COOLER TO RADIATOR FRONT COOLER o REAR COOLER lt 5 44 WINNING PERFORMANCE gt POLARIS Engine and Cooling Systems 2007 2008 600 700 RMK Cooling System HOSE TUNNEL COOLER TO SURGE TANK SURGE TANK CAP HOSE THROTTLE BODY OUT TO SURGE TANK CFI ONLY HOSE FRONT COOLER OUT TO SURGE TANK HOSE ENGINE OUT TO TUNNEL COOLER gt THERMOSTAT OPEN HOSE SURGE TANK ENGINE
220. NSION ta cused 8 40 BAILGPIBERS cis te ached Ca a eq ean ee 8 42 WEAR eed Se Seat oe oes eet 8 42 REMOVAL 1 5 deer ben rera a oT 8 42 BREAKSIN ccs see 8 42 REAR SUSPENSION REMOVAL AND INSTALLATION 8 42 Dass Eel cer tha es as eed 8 42 INSTALLATION RE IS rtr re ner t RYE eR Ela SS aos C ua 8 42 WINNING PERFORMANCE 8 1 gt POLARIS Steering and Suspensions OVERVIEW SPECIFICATIONS Inspection When inspecting steering and suspension components for wear or damage always replace parts as necessary Refer to the assembly exploded views in this chapter for identification of components and torque values of fasteners Make notes of the direction a bolt goes through a part what type of nut is used in an application etc Some of the fasteners used in the IFS are special and cannot be purchased at a hardware store Always use genuine Polaris parts and hardware when replacing front end components Review steering adjustment guidelines before making adjustments The following components must be inspected at this time Tie rods and tie rod ends Torsion bar and bushings linkage where applicable Handlebars and steering post assembly
221. NSOR GROUND SPLICE 2 IGNITION SWITCH SENSOR GROUND 64 BROWN 20 FUEL PUMP 3 OIL SENSOR 180F CHASSIS GROUND 65 LT BLUE 20 LEFT HANDWARMER A BLUE SPLICE E HANDWARMER LOW 66 LT BLUE 20 LH CONTROL SIGNAL BLUE SPLICE 1 HANDWARMER LOW 67 LT BLUE RED 20 LH CONTROL SIGNAL D BLUE RED SPLICE HANDWARMER HI 68 LT BLUE RED 20 LEFT HANDWARMER B BLUE RED SPLICE HANDWARMER HI 69 BROWN 18 RIGHT HANDWARMER HANDLEBAR GROUND SPLICE 1 CHASSIS GROUND 70 BROWN 18 LEFT HANDWARMER HANDLEBAR GROUND SPLICE CHASSIS GROUND 71 ORANGE GRAY 20 LH CONTROL SIGNAL A THUMBWARMER A THUMBWARMER LOW 12 WHITE GRAY 20 LH CONTROL SIGNAL B THUMBWARMER B THUMBWARMER HI 13 BROWN 18 HANDLEBAR GROUND SPLICE THUMBWARMER C CHASSIS GROUND 74 BLACK LT BLUE 18 STOP SWITCH y SENSOR GROUND SPLICE 2 SENSOR GROUND 15 BLACK 20 STOP SWITCH 2 IGNITION SWITCH 5 HARD STOP 16 RED WHITE 16TXL CHASSIS RELAY 5 LH CONTROL POWER C CHASSIS POWER 11 BROWN 20 HANDLEBAR GROUND SPLICE LH CONTROL POWER CHASSIS GROUND 18 ORANGE 18 BRAKE SWITCH SPLICE TAILLIGHT B BRAKE LIGHT 19 BROWN 18 CHASSIS GROUND SPLICE gt HANDLEBAR GROUND SPLICE 2 CHASSIS GROUND 80 RED WHITE 16 CHASSIS POWER SPLICE 5 ACCESSORY POWER CHASSIS POWER 8 BROWN 16 CHASSIS GROUND 1 4R ACCESSORY POWER 180M CHASSIS GROUND 82 BLACK 20 IGNITION SWITCH 5 1 STARTER SOLENOID GROUND 83 BLACK LT BLUE 18 IGNITION SWITCH TETHER CHASSIS GROUND 84 WHITE RED 20 IGNITION SWITCH ELECTRIC START HARD STOP 85 RED 18 FUEL PUM
222. ONS 8 2 SPRINGS reco aa kuma oni 8 2 ADJU STABEESHOGKS Z cole Vus Q eee reete Godino ae 8 3 FRONT SUSPENSION BY MODEL 8 3 REAR SUSPENSION BY 8 3 SUSPENSION MOUNTING FASTENER 8 3 IQ REAR SUSPENSION SHOCK ROD 8 4 IQ REAR TRACK SHOCK PIVOT 8 4 FRONT SUSPENSION ASSEMBLY ILLUSTRATIONS 8 5 IQ FRONT SUSPENSION 8 5 IQ FIXED STEERING POST ASSEMBLY 8 6 IQ RIDER SELECT STEERING POST ASSEMBLY 8 7 IQ STEERING LINKAGE 8 8 HANDLEBAR ASSEMBLIES 8 9 ADJUSTMENT PROCEDURES 8 10 SETUP AND ADJUSTMENTS 8 10 ALIGNMENT BAR 5 8 10 deem ee pe 8 10 R D ENDS S d at cee todd aoe ia ah ren eft EN alee Anaad aed ten S utaq ata kaypu 8 11 ROD END 8 11 CAMBER
223. P 1 REGULATOR POWER SPLICE REGULATOR POWER 86 BROWN 18 FUEL PUMP 3 CHASSIS GROUND 1 4R CHASSIS GROUND 87 BROWN 20 FUEL PUMP 4 CAPACITOR 180M CHASSIS GROUND 88 BROWN 20 FUEL PUMP 4 ECU GROUND SPLICE E ECU GROUND 89 BROWN 16 CHASSIS GROUND 1 4R ELECTRIC START D CHASSIS GROUND 90 BROWN 18 CHASSIS GROUND 1 4R TAILLIGHT C CHASSIS GROUND 91 BROWN 16 CHASSIS GROUND 1 4R CHASSIS GROUND SPLICE 1 CHASSIS GROUND 92 BROWN 18 BRAKE SWITCH 1802 HANDLEBAR GROUND SPLICE CHASSIS GROUND 93 RED WHITE 16 ELECTRIC START A CHASSIS POWER SPLICE E CHASSIS POWER 94 RED 16TXL DC OUT CHASSIS RELAY 3 REGULATOR POWER 95 RED 16 DC OUT REGULATOR POWER SPLICE REGULATOR POWER 96 BROWN 16 DC OUT CHASSIS GROUND SPLICE E CHASSIS GROUND 97 RED 20TXL CHASSIS RELAY l CHASSIS RELAY 3 CHASSIS POWER 98 RED 16131 CHASSIS RELAY 3 REGULATOR POWER SPLICE REGULATOR POWER 99 RED WHITE 16TXL CHASSIS RELAY 5 CHASSIS POWER SPLICE CHASSIS POWER 100 RED WHITE 16 CAPACITOR 156F CHASSIS POWER SPLICE E CHASSIS POWER BROWN 16 CAPACITOR 156M CHASSIS GROUND SPLICE CHASSIS GROUND 102 BROWN 18 CHASSIS GROUND SPLICE 5 ECU GROUND SPLICE ECU GROUND 103 RED WHITE 18 CHASSIS POWER SPLICE TAILLIGHT A CHASSIS POWER 104 RED 18TXL PUMP PRIME 1 REGULATOR POWER SPLICE REGULATOR POWER 105 BROWN 18TXL PUMP PRIME 2 CHASSIS GROUND 1 4R CHASSIS GROUND 106 LT BLUE 20 RIGHT HANDWARMER A BLUE SPLICE HANDWARMER LOW 107 LT BLUE RED 20 RIGHT HANDWARMER B BLUE RED SPLICE 1 HANDWARMER HI 108 LT GREEN RED
224. PERFORMANCE gt POLARIS 1 13 Model Specifications 2007 600 HO IQ Touring CFI General Model Number SO7PT6HS SO7PT6HE Width in cm 48 121 9 Length in cm 129 327 7 Engine Height in cm 53 134 6 Liberty Liquid Cooled Esti timated Dry Weight Type Case Reed Induction 574 260 6 Model Number 83206 6044 PF6H Fuel Gallons Liters 11 7 443 Displacement Cylinders 599cc 2 Oil Quarts Liters 34 32 Bore inches mm 3 04 77 25 Cooling System Capacity Stroke inches mm 2 52 64 Quarts Liters 6 3 6 Piston to Cylinder Clearance 004 006 105 159 Brake Fluid DOT4 inches mm Drive Belt Installed Ring Gap Part Number 3211080 014 020 356 508 inches mm Width inches cm 1 438 3 65 Operating RPM 200 8250 Side Angle 28_ 17 Circumference inches cm 46 625 118 4 Idle RPM 00 Center Distance inches cm 11 5 29 2 Engagement RPM 200 3800 Chaincase Exhaust Valve Spring Purple Center Distance inches 8 373 Top Gear Stock 22 Fuel Delivery Bottom Gear Stock 43 Chain Stock 78 Type Cleanfire Direct Injection Gear Lube Polaris Synthetic Throttle Body Marking 1203213 Capacity oz ml 11 325 3 Throttle Body Bore 46mm Reverse System Perc TPS Voltage Idle 0 95 0 01
225. PERFORMANCE gt POLARIS 1 21 Model Specifications 2008 600 RMK 144 600 RMK Shift 155 Carburetor Jetting Model Number Ambient Temperature 600 144 SO8PK6FS 508 6 5 _ o 600 Shift 155 SOSPM6FS B m om SR S n UTE Ey Engine oe He su lee fie S Meters y 5 9e 2 in 3 E Liberty Liquid Cooled feet P OSP MEE E Case Reed Induction V E 5 E B Model Number S3467 6044 PU6F 5 T Displacement Cylinders 599 2 440 430 420 400 390 380 370 360 Bore inches mm 3 04 77 25 0 2000 3 3 2 2 2 2 2 1 Stroke inches mm 2 52 64 600 1200 410 400 390 370 360 350 340 330 2000 4000 3 3 2 2 2 2 2 1 Piston to Cylinder Clearance inches mm 004 006 105 159 1200 1800 370 360 350 340 330 320 310 4000 6000 83 2 2 42 2 2 1 41 t a 2 Fi 014 020 0356 508 1800 2400 340 320 310 300 280 280 270 260 6000 8000 43 42 2 2 42 41 1 1 Operating RPM 200 8100 310 300 290 280 270 260 250 240 Idle RPM 1500 8000 1000 55 55 55Pj 55 55 55 55 Engagement RPM 200 3800 Mu soc Exhaust Valve Spri
226. Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table A 12 Ft Lb 16 Nm 35 Ft Lb 47 Nm CAUTION C 45 Ft Lb 61 Nm D 60 Ft Lb 81 Nm The fasteners securing the rear suspension to the tunnel are pre coated with a locking agent when new Assembly Notes Never re use these fasteners when removed Always use new pre coated fasteners when mounting the Never re use Nylock nuts Always replace with new suspension to the tunnel parts All pivots must rotate freely after tightening fasteners 8 32 oa Steering and Suspensions IQ RMK 144 155 163 Pivots Rear Idler SPACER BLOCK IDLER WHEEL SPACER INNER SHAFT 155 163 ONLY A 35 Ft Lb 47 Nm Assembly Notes Never re use Nylock nuts Always replace with new parts All pivots must rotate freely after tightening fasteners Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table 8 33 WENNING PERFORMANCE C POLARIS Steering and Suspensions IQ RMK 144 155 163 Rail Assembly BUMPER RAIL SLIDER 6 A 3 6FtLb 4 8 Nm B 19 Ft Lb 26 Nm C 35 Ft Lb 47 Nm D 35 In Lb 4 Assembly Notes Never re use Nylock nuts Always replace with new parts All pivots must rotate freely after tightening fastener
227. Q Shift Regulator Rectifier The regulator rectifier on a 2008 IQ Shift limits AC Voltage to 14 3 volts The module also supplies 12 Vdc to power the exhaust valve solenoid Replace the regulator rectifier if the AC Voltage is above 14 8 or when there is no 12 supply on the RED GREEN circuit Circuit Specifications PLUG PIN COLOR FUNCTION YELLOW REGULATED 14 3 Vac POWER EXHAUST VALVE SOLENOID RED GREEN POWER Vdc BROWN GROUND DETONATION CONTROL DET Overview Detonation control is achieved by using a knock sensor mounted to the cylinder head and an ECU CFI engines or the CDI 600HO engines The knock sensor listens for combustion knock by converting internal engine noise in to an electrical signal The ECU or CDI uses the signal to determine the level of knock within the combustion chambers after each combustion event When the ECU or CDI determines detonation has occurred the CHECK ENGINE DET LED lamp will blink on and off at 0 5 second intervals On CFI models the ECU will retard timing and provide additional fuel to eliminate the detonation On carbureted engines the CDI will retard timing until the detonation stops If the detonation continues past a pre determined level the ECU or CDI will initiate an engine mis fire mode To prevent detonation follow these steps Always use premium fuel 91 92 or 93 octane On carbureted engines follow the carbur
228. R 07 ORN BLK t7 8 2 C SWITCH NORMALLY CLOSED dod qne O SWITCH NORMALLY OPEN T 25 00 HARNESS 2410819 02 amp 2410697 i 5 LED CHASSIS GROUND f 5 X HIGH BEAM 26 Y R T SWITCH HIGH TEMP LED CLOCK BATTERY ry 28 0 24 V 1 22 ORN 23 W OR 21 BLK W 25 31 GRN 39 Y 08 BLU R 2 VIO W 02 W R 21 BLK CHASSIS HOOD 2 07 ORN BLK 01 W BLK 19 OR W WIRE TERMINATION TABLE COLOR __ GAUGE FROM CONNECTOR TO CONNECTOR W BLK 20 GAUGE 1 CHASSIS HOOD 2 W R 20 GAUGE 1 CHASSIS HOOD 2 Y BLK 20 GAUGE 1 CHASSIS HOOD 1 LT GRN R 20 GAUGE 1 CHASSIS HOOD 1 R W 20 GAUGE 1 CHASSIS HOOD 1 OR BLK 20 GAUGE 1 CHASSIS HOOD 2 BLU R 20 GAUGE 1 CHASSIS HOOD 2 BRN W 20 GAUGE 1 BATTERY SPLICE OR W 20 GAUGE 2 CHASSIS HOOD 2 VIO W 20 GAUGE 2 CHASSIS HOOD 2 OR 20 GAUGE 2 CHASSIS HOOD 1 W OR 20 GAUGE 2 CHASSIS HOOD 1 VIO 20 GAUGE 2 CHASSIS HOOD 1 20 GAUGE 2 CHASSIS HOOD 1 Y R 20 GAUGE 2 ACC_HEADLAMP BLK W 20 GAUGE 2 CHASS
229. ROUND SPEED SENSOR A CAPACITOR SPEED SENSOR POWER 42 BROWN GROUND SPEED SENSOR CAPACITOR CHASSIS GROUND 43 GRAY 18TXL GRAY SPLICE MODE CHANGE 2 MODE 44 GRAY 18TXL GRAY SPLICE DIGITAL WRENCH MODE 45 VIOLET WHITE 20TXL CHASSIS HOOD 19 FUEL PUMP 2 FUEL LEVEL 46 WHITE RED 20TXL CHASSIS HOOD 16 LH CONTROL POWER D MODE SWITCH 41 WHITE BLACK 20TXL CHASSIS HOOD 3 LH CONTROL POWER F SET SWITCH 48 ORANGE WHITE 20TXL CHASSIS HOOD 4 CAPACITOR SPEED SENSOR POWER 49 BROWN 16TXL CHASSIS HOOD 10 DC OUT CHASSIS GROUND 50 RED WHITE 18TXL CHASSIS HOOD 8 CHASSIS POWER SPLICE 3 CHASSIS POWER 51 LT GREEN RED 18 GROUND SPEED SENSOR SPLICE GROUND SPEED SENSOR GROUND SPEED 52 BROWN WHITE 18TXL CHASSIS HOOD 2 ECU GROUND SPLICE 1 ECU GROUND 53 YELLOW 16131 CHASSIS HOOD LH CONTROL POWER A HIGH BEAM 54 VIOLET 20TXL CHASSIS HOOD 12 OIL SENSOR 180M LOW OIL LED 55 ORANGE 20TXL CHASSIS HOOD 13 BRAKE SWITCH SPLICE d BRAKE LIGHT 56 BLACK WHITE 18TXL CHASSIS HOOD 14 DIAGNOSTIC SPLICE E DIAGNOSTICS 51 LT GREEN 16131 CHASSIS HOOD LH CONTROL POWER B LOW BEAM 58 BLACK LT BLUE 18 SENSOR GROUND SPLICE 2 SENSOR GROUND SPLICE 1 SENSOR GROUND 59 BLACK LT BLUE 18TXL SENSOR GROUND SPLICE 1 EXHAUST TEMP 156M SENSOR GROUND 60 BLACK LT BLUE 18 SENSOR GROUND SPLICE 1 INTAKE AIR PRESSURE l SENSOR GROUND 61 BLACK BLUE 18 DEVELOPMENT BLACK BLUE SPLICE 1 SENSOR GROUND 62 BLACK LT BLUE 20 SENSOR GROUND SPLICE 2 LH CONTROL SIGNAL F SENSOR GROUND 63 BLACK LT BLUE 18 SE
230. RPM Ignition Timing Coolant Temp 120_F 49_C ALTITUDE DRIVE CLUTCH DRIVEN CLUTCH meters Shift Clutch Clutch Driven cm feet Weight Spring Spring Helix 0 600 64 42 36 0 2000 LWER 22 39 76 600 1200 2000 4000 10 60 1200 1800 a 4000 6000 BLK GRN RED BLK 120 340 140 240 22 40 76 1800 2400 10 56 7042083 7043058 56 42 36 6000 8000 LW ER 2400 3000 3000 10000 10 54 20 41 76 3000 3600 10000 12000 0 Spark Plug Gap in mm 027 70 Spark Plug Champion RN57YCC Track Width Inches cm 15 38 Length Inches cm 128 325 Lug Height Inches cm 1 2 5 Drive Clutch Bolt Torque 80 Ib ft 108Nm 1 12 Track tension sag in cm with 10 Ibs 4 54kg placed 16 in 40cm ahead of rear idler shaft 7 8 1 18 2 2 2 9cm WINNING PERFORMANCE C POLARIS Model Specifications Front Suspension Inches cm Suspension Type 10 42 5 dis ME isin Nim 120 21 2 9 95 25 3 2 9 92 25 2 Ski Center Distance 42 5 108 Camber Inches cm 2 25 0 31 57 7 9 Toe Out Inches cm 0 0 12 0 0 31 Rear Suspension Suspension Type Fast M 10 128 Front Track Shock FTS Ryde FX Gas Bag EE sas Rear Track Shock RTS 1 54 mas Rear Travel Inches cm 13 33 WINNING
231. Rapid Reaction Driven Clutch Registered Trademark of Team Industries Inc VM and TM Carburetors Registered Trademarks of Mikuni American Corporation Fox and Fox PS 5 Trademark of Fox Racing Shox Inc Ryde FX and Air 2 0 Registered Trademark of Arvin Meritor Inc alker Evans Air Shock Registered Trademark of Walker Evans Racing Inc WINNING PERFORMANCE z P LARIS 2007 2008 IQ Snowmobile Service Manual Chapters Model 1 General Information 2 3 Fuel 4 Engine 5 5 Final Drive and Brake Systems 6 7 Suspension and Steering 8 21005 9 Chassis eee 10 Electrical Systems 11 Wiring Schematics 12 Model Specifications CHAPTER 1 Model Specifications SPECIFICATIONS 2 2 4 0 owes ed werk E E Yee XU ROO RO RR ER n 1 2 2007 600 ee eret ae ded a 1 2 2007 600 1 4 2007 600 8 25265
232. SSVHO QN ON 91 1103 Av138 ayga 90 0 48 290 10 38 860 SS 80 38 910 8 08 210 330 1198 48 84 L90 gq 990 330 210 1 avidi xov 011 8340 NI 135012 1 HOLIMS 3H211MS 4134 31110881 oe oe 43 504 8344114 N3HM 330 ts 33131 33VU8 1Y 931501 Hous 1 49 90 ILO 190 4 Ng LL0 P 135 1 ma 48 990 4 0 8 910 9 300W 90 190 660 4 NG 10 9 ZLO a m 419 90 110 690 90 90 0 09 80 101 880 OL 010 1 Lr 80 19 4 90 101 ONVH 1481 019 pn HOLIMS NI 54 1 01 21081 Qv3H 01 01 2 0 0 404 2 SS3NHVH 3349 IH911 N3dO ATIVNYON HOLIMS ON 035012 A
233. T DET LED 26 ORANGE GREEN ELECTRIC START CHARGE RELAY COIL GROUND 27 BLACK WHITE DIAGNOSTIC SPLICE CHASSIS HOOD 1 DIAGNOSTICS CHECK ENGINE LED 29 BLACK aired PEN SN er HARDWARE STOP IGNITION KILL SIGNAL 30 BLACK BLUE SENSOR GROUND SPLICE 1 SENSOR GROUND 31 GRAY LH CONTROL PERC SIGNAL 32 RED REGULATOR POWER SPLICE REGULATED POWER 33 ORANGE REGULATOR RECTIFIER VOLTAGE BOOST POWER 34 ORANGE REGULATOR RECTIFIER VOLTAGE BOOST POWER 4 20 Jrr WINNING PERFORMANCE C POLARIS Fuel Systems 26 Pin CNB ECU Connector NOTE Wire Entry View PIN COLOR GOES To CONNECTOR FUNCTION 1 ORANGE PTO IGNITION COIL COIL POWER 2 BLUE YELLOW STATOR FUEL INJECTOR COIL FUEL INJECTOR POWER COIL 3 BLUE YELLOW STATOR FUEL INJECTOR COIL FUEL INJECTOR POWER COIL 4 GREEN STATOR CRANK POSITION SENSOR 5 TOOTH COIL SIGNAL 5 WHITE STATOR CRANK POSITION SENSOR 2 TOOTH COIL SIGNAL 6 YELLOW MAG FULL LOAD INJECTOR INJECTOR CONTROL GROUND 7 YELLOW WHITE MAG PART LOAD INJECTOR INJECTOR CONTROL GROUND 8 GREEN PTO FULL LOAD INJECTOR INJECTOR CONTROL GROUND 9 GREEN WHITE PTO PART LOAD INJECTOR INJECTOR CONTROL GROUND 10 RED WHITE TPS 5 VDC POWER SUPPLY 13 WHITE YELLOW EV SOLENOID SOLENOID CONTROL GROUND 14 BROWN MAG IGNITION COIL STATOR STATOR GROUND 15 GREEN RED STATOR EXCITER COIL EXCITER COIL 16 GREEN YELLOW
234. T BEARING be else 3 14 THROTTLE CABLE ee EEG ret dave de 3 15 CHOKE AND CHOKE 3 15 CHAINCASE OIL LEVEL CHECK 3 15 CHAINCASE OIL REPLACEMENT 3 15 DRIVE CHAIN TENSION 3 15 BRAKE SYSTEM 3 16 BRAKE LEVER TRAVEL usus When Ru RD RU Y ete 3 16 BRAKE FLUID oa ea SS RU esee 3 16 THROTTLE AND CHOKE CABLE ADJUSTMENTS 3 16 THROTTLE LEVER FREE 3 16 THROTTLE LEVER FREE PLAY CFI 5 3 17 CHOKE ADJUSTMENT 3 17 STEERING SUSPENSION MAINTENANCE 3 18 HANDELEEBARS Wid b asua tbat 3 18 RIDER SELECT STEERING 3 18 SKI SKI SKAG FASTENERS 3 19 TRACK TENSIONS cee te tears gay ak eae tet E MIELE 3 19 TRACK 3 20 ELEGTRICAE SYSTENMS he ia
235. T HANDWARMER LOW HW SPLICE HW LOW DK BLUE RED LEFT HANDWARMER MED HW SPLICE HW MED HIGH ROWN LEFT HANDWARMER HW GROUND SPLICE AC GROUN ROWN HANDLEBAR GROUND SPLICE HW GROUND SPLICE AC GROUN YELLOW BRAKE SWITCH AC POWER SPLICE AC POWER DK BLUE RIGHT HANDWARMER LOW HW SPLICE HW LOW DK BLUE RED RIGHT HANDWARMER MED HW SPLICE HW MED HIGH ROWN RIGHT HANDWARMER HW GROUND SPLICE AC GROUN ROWN THUMBWARMER HANDLEBAR GROUND SPLICE AC GROUN ROWN STOP SWITCH HANDLEBAR GROUND SPLICE AC GROUN ROWN ACCESSORY ELECTRIC START DC GROUN WIRES ARE REPRESENTED BY SOLID OR DASHED LINES TO SIMPLIFY TRACING WIRE COLOR LEGEND BG BEIGE TAN BK BLACK BU LIGHT BLUE DB DARK BLUE BN BROWN GY GRAY GN LIGHT GREEN DG DARK GREEN 0G ORANGE PK PINK RD RED VIOLET PURPLE WH WHITE YE YELLOW TWO WIRE COLORS ARE SHOWN WITH MAIN TRACE COLORS EXAMPLE RD YE RED WITH YELLOW TRACE IN DIAGRAM HARNESS NUMBER 2410790 02 WIRE TERMINATION TABLE HARNESS PART NUMBER 2410790 02 COLOR GAUGE FROM CONNECTOR CAVITY TO CONNECTOR CAVITY FUNCTION BROWN 18 ELECTRIC START 180F STARTER LOCKOUT 180M CHASSIS GROUND YELLOW 16 ELECTRIC START
236. TIVMYON HOLIMS annoys sissvHo 2 0 089 3MI9N3 3 WVYOVIG NI ONIOVUL 13114815 OL 83811 03 01105 AG 03143534938 388 53818 PERFORMANCE gt POLARIS WINNING 12 4 iagrams D iring Harness 2 of 2 15 2007 600 700 Chass 6 GAUGE START SOLENOD LOCATED ON TOP OF BATTERY BOX OPTIONAL 04 RED BLK Ge 6 GAUGE ERE LOCATED ON TOP OF BATTERY BOX OPTIONAL B 02 WHT RED 07 RED BLK 06 RED BLK 07 RED BLK ELECTRIC 08 BRM START 03 ORN GRM 02 WHT RED 01 RED WHT RELAY COIL 76 Q 05 RED WHT 03 ORN GRM 04 RED BLK 06 RED BLK CHARGE RELAY WIRE T RMINATION TABLE COLOR FROM CONNECTOR CAVITY TO CONNECTOR CAVITY FUNCTION RED BLUE ECU CNA RED BLUE SPLICE K LINE POWER ORANGE ECU CNA ECU POWER EXTERNAL POWER WHITE BLACK ECU CNA EXHAUST TEMP EXHAUST TEMP SIGNAL BLUE ECU CNA INTAKE AIR PRESSURE AIR TEMP SIGNAL GREEN BLUE ECU CNA IGNITION SWITCH STARTER LOCKOUT RED WHITE ECU CNA INTAKE AIR PRESSURE 5V POWER LT GREEN RED ECU CNA GROUND SPEED SENSOR SPLICE GROUND SPEED RED BLA
237. TMENTS Adjustment Procedures NOTE Break in the suspension for at least 150 miles 240 km before making adjustments All settings will vary from rider to rider and are dependant on rider weight vehicle speed riding style and trail conditions Always start with the factory settings Make individual adjustments to suit rider preference The machine should be methodically tested under the same conditions after each adjustment trail and snow conditions vehicle speed riding position etc until a satisfactory ride is achieved Adjustments should be made to one area at a time in order to properly evaluate the change Rear Suspension Ride Height 1 To set up the rear suspension torsion spring preload measure the distance between the ground and rear bumper with out the rider on the seat and the suspension at full extension This can be achieved by lifting the rear of the machine so that the suspension is off the ground and carefully setting the machine down Write this down as measurement X 2 Have the rider in full gear drop down on the seat work the suspension slightly by bouncing up and down and sit in the seated riding position With the rider in the seated position measure from the ground to the bumper in the same spot as you did for measurement X and write it down as measurement Y 3 Todetermine the correct ride height subtract measurement X from measurement Y X Y ride height 4 The ideal ride
238. Tank 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 Never remove the surge tank pressure cap when the cooling system is warm Severe burns to skin may occur from escaping coolant or steam Recommended Coolant Use Polaris Premium 60 40 pre mix antifreeze This premium antifreeze is rated for temperatures down to 62 F 52 Cooling System Bleeding 1 Allow the cooling system to cool completely Verify the coolant level in the surge tank is at the COLD mark Fill the surge tank if required Loosely install 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 Elevate the front of the machine slightly Apply the parking brake and start the engine Allow the engine idle time to stabilize IDWS 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 10 T
239. UND BLACK BLUE SENSOR GROUND SPLICE 1 DIAGNOSTIC SENSOR GROUND ORANGE WH I TE SPEED SENSOR SPEED CAPACITOR SPEED SENSOR POWER BROWN SPEED SENSOR SPEED CAPACITOR CHASSIS GROUND GRAY GRAY SPLICE MODE CHANGE 2 MODE GRAY GRAY SPLICE DIAGNOSTIC MODE VIOLET WHITE CHASSIS HOOD 2 FUEL PUMP FUEL LEVEL WHITE RED CHASSIS HOOD 2 LH CONTROL POWER MODE SWITCH WHITE BLACK CHASSIS HOOD 2 LH CONTROL POWER SET SWITCH ORANGE WHITE CHASSIS HOOD 2 SPEED CAPACITOR SPEED SENSOR POWER BROWN CHASSIS HOOD 1 REGULATOR CHASSIS GROUND RED WHITE CHASSIS HOOD 1 CHASSIS POWER SPLICE CHASSIS POWER LT GREEN RED GROUND SPEED SENSOR SPLICE SPEED SENSOR GROUND SPEED BROWN CHASSIS HOOD 1 ECU GROUND SPLICE ECU GROUND YELLOW CHASSIS HOOD 1 LH CONTROL POWER HIGH BEAM VIOLET CHASSIS HOOD 1 OIL SENSOR LOW OIL LED ORANGE CHASSIS HOOD 1 BRAKE SWITCH SPLICE BRAKE LIGHT BLACK WHITE CHASSIS HOOD 1 DIAGNOSTIC SPLICE DIAGNOSTICS GREEN CHASSIS HOOD 1 LH CONTROL POWER LOW BEAM BLACK BLUE SENSOR GROUND SPLICE SENSOR GROUND SPLICE 1 SENSOR GROUND BLACK BLUE SENSOR GROUND SPLICE EXHAUST TEMP SENSOR GROUND BLACK BLUE SENSOR GROUND SPLICE INTAKE AIR PRESSURE SENSOR GROUND BLACK BLUE SENSOR GROUN
240. UNT ISOLATOR CLINCH PLATE ey A 28 Ft Lbs 38 Nm B 15 Ft Lbs 20 Nm C 45 Ft Lbs 61 Nm NOTE Use an engine mount socket PN 2871989 to remove the engine mounts from the bulkhead WINNING PERFORMANCE POLARIS 5 13 Engine and Cooling Systems 2007 IQ 600 CFI Engine Mounting TORQUE STOP RH ENGINE STRAP ENGINE MOUNT TA Fey 1a ae j gt 09 c34 I ENGINE MOUNT BRACKET C EA aT A a lt lt 9 a RO CLINCH PLATE Re Pie te T A 28 Ft Lbs 38 Nm B 15 Ft Lbs 20 Nm C 30 Ft Lbs 41 Nm NOTE Use an engine mount socket PN 2871989 to remove the engine mounts from the bulkhead 5 14 WINNING PERFORMANCE C POLARIS Engine and Cooling Systems 2008 IQ Carbureted Engine Mounting TORQUE STOP B S P o A eu ENGINE MOUNT T ENGINE MOUNT BRACKET LH ENGINE STRAP CLINCH PLATE ey T A 28 Ft Lbs 38 Nm B 15 Ft Lbs 20 Nm C 45 Ft Lbs 61 Nm NOTE Use an engine mount socket PN 2871989 to remove the engine mounts from the bulkhead eros 5 15 Engine and Cooling Systems 2007 700 CFI 2008 IQ CFI Engine Mounting aec 2727 25952 2 2 7 2 552522 A UZNA lt i 72202 2 2 A Dh ix ES Or WHET TORQUE STOP
241. Vdc Electrical Fuel Pressure PSI bar 58 4 0 Fuel Alternator Output Mel Octane 91 Non Oxygenated Operating Voltage 13 5 14 5 Vde R M 2 Watts 13 5 Vdc Total 400 Coolant Temp 120 F 49 C ALTITUDE DRIVE CLUTCH DRIVEN Spark Plug Gap in mm 027 70 Shift Clutch Clutch Driven Gearing Weight Spring Spring Helix Spark Plug Champion RN57YCC 0 600 e 64 42 36 0 2000 LW ER Track 600 1200 10 60 22 43 78 2000 4009 Width Inches cm 15 38 10 58 BLK GRN RED BLK Length Inches cm 136 345 1800 2400 ee 56 42 36 Lug Height Inches cm 1 2 5 6000 8000 10 56 2400300 144 inus Track tension sag in cm with 8000 10000 10 Ibs 4 54kg placed 16 in 3 4 1 0 1 9 2 5cm 3000 3600 40cm ahead of rear idler I 10000 12000 E shaft Drive Clutch Bolt Torque 80 Ib ft 108Nm 1 14 WINNING PERFORMANCE C POLARIS Model Specifications Front Suspension Inches cm Suspension Type 10 42 5 dis ME Ibn Nimm 120 Qn 2 9 95 25 3 10 25 4 Ski Center Distance 42 5 108 Camber Inches cm 2 25 0 31 57 7 9 Toe Out Inches cm 0 0 12 0 0 31 Rear Suspension Suspension Type Fast M 10 136 Front Track Shock FTS Ryde FX Gas Bag E bles 220 38 5 sas Rear Track Shock RTS
242. Vertical Travel 9 22 9 Ski Center Distance Inches cm Setup Width 39 99 1 40 101 6 41 104 1 38 67 98 2 Camber Inches cm 2 17 0 31 55 7 9 Toe Out Inches cm 0 0 12 0 0 31 Rear Suspension Suspension Type IQ RMK 155 163 Front Track Shock FTS Base Ryde FX Dragon Walker Evans Air FTS Spring Rate Ibs in N mm WE Air Oil Volume 60cc WE Air Nitrogen Charge 217 5 psi Rear Track Shock RTS Base Ryde AFX Dragon Walker Evans w IFP Maximum Nitrogen Charge 200 psi Torsion Springs 359 Square 77 Stock 347 77_ Soft PN 7041627 067 PN 7041628 067 375 77_ Firm PN 7041942 067 PN 7041943 067 Rear Travel Inches cm 15 5 39 4 155 16 5 41 9 163 WINMING PERFORMANCE gt POLARIS 1 39 Model Specifications 2008 800 Dragon RMK 155 163 Model Number Dragon 155 S08PGSES SO8PG8EE Dragon 163 SO8PH8ES Engine Liberty Liquid Cooled type Case Reed Induction 53489 8044 8 155 S3741 8044 PUSE 163 Displacement Cylinders 794 2 Bore inches mm 3 34 85 Stroke inches mm 2 75 170 Piston to Cylinder Clearance inches mm 0037 0053 095 135 Installed Ring Gap inches mm 017 025 45 65 Operating RPM 0 300 8250 Idle RPM 170
243. WINNING PERFORMANCE gt POLARIS Engine and Cooling Systems Disassembly Assembly Process 2008 800 CFI Cylinder Head Cylinder Pistons 1 Remove the coolant from the engine using a siphon wet dry vac or drain pan 2 Remove the air box exhaust pipe and resonator from the engine compartment 3 Remove the high tension wires and spark plugs from the cylinder head 4 Remove the thermostat housing outlet cooling hose from the housing 5 Loosen all then remove all head cover fasteners Clean the fastener threads to remove any thread locking residue 6 Discard the head cover and cylinder head o rings Always use new o rings during assembly 7 Inspect the cylinder head combustion domes for any damage Measure cylinder head flatness Replace cylinder head if required 8 Ifonly the cylinder is going to be removed remove the fuel rail from the upper fuel injectors See CFI Fuel Rail Injector s Removal Installation on page 4 30 9 Loosen all then remove the cylinder bolts Clean the bolt threads to remove any thread locking residue 10 Carefully pull the cylinder upwards taking care not to drop the pistons and rods abruptly against the crankcase 11 Remove the cylinder base gasket Use a gasket scraper to clean the gasket residue from the crankcase and cylinder base 12 Inspect the cylinder walls Nicasil cylinders can only be lightly honed Damage that cannot be removed with a light hone
244. XCITER COIL 0 INJECTOR COIL 1 CRANK POSITION SENSOR 2TEETH 1 CRANK POSITION SENSOR STEETH BLK F2 M 5 FF YE IGNITION COIL PTO IGNITION COIL L2 WH YE Lec LI RD 11 01 VT 62 BK DB E3 BK DB E BU 4 810 000 OHMS TORQUE TO 2045 NsM 1543 FT LBS EI RD WH 12 7 gt POLARIS PERFORMANCE WINNING ft 1 of 2 iagrams D iring 2008 IQ Sh W
245. Y SWITCH SHUT OFF THO WIRE COLORS ant suo ARNESS 2475603 WITH MAIN TRACE COLORS 24079002 EXAMPLE RD YE RED WITH YELLOW TRACE 2410907 04 61 BN 60 08 80 09 59 DB 66 BN 07 WH YET N 49 RD WHE 51 DB RD r64 08 gt 1 4 o m 2 HEATER EAD INDICATOR LAMPS LAMP IN SWITCH HIGHS 9 LOW 1 MODE 5 4 9 OFF 9 5 8 52 RD WH 49 RD WH 23 25 A 8 C 30 D 16 RD WH 20 RD WH 39 BK 03 BK RD 68 BN 1 31 28 T55 WH GY o OFF 56 08 2 LOW 57 DBIR n 58 BN m L DETONATION MED HANDWARMER UE TO 205 N M 153 FT LBS 06 67 8 D t F HIGH H 22 THROTTLE REVERS L p POSITION 5 POTENTIOMETER j BN E8 DB RD GY HI BN m 6 BK RD E5 BK LEFT HANDLEBAR SWITCH ASSEMBLY IGNITION COIL BK 1 j
246. YON NI E 13114814 131011 222235012 SI HOLIMS 0 os i S3HOL IMS AL34VS 311108H1 jn gone ONS TN N3349 8 0 118012 N3349 1 911 aausnd Tama ATIYWYON HOLIMS ON noo COOH SISSYHO NAHM N3dO 3019 Wave z 3018 1H911 l annouo 152 N E NVI 39138 OS _ 013931 10102 1818 BAVA sna 3ALLOVNI ON SWHO JA119V ON 12 WWHOVIG NI 2 AJI TdNIS 031144 01 S3NI1 Q3HSVQ 80 01105 43411 39 v88 1Y 0317201 SWHO AG 03183638438 JYV 5331 HOLIMS 1 Divya MNHVMONVH iagrams D iring W 2008 IQ Shift 2 of 2 WIRE TERMINATION TABLE WIRE TERMINATION TABLE HARNESS PART NUMBER 401175 05 COLOR FROM CONNECTOR CAVITY TO CONNECTOR CAVITY FUNCTION COLOR GAUGE FROM CONNECTOR TO CONNECTOR FUNCTION GRAY CDI MODULE LH CONTROL SIGNAL F REVERSE SIGNAL WHITE 18 CDI MODUL IGNITION COIL IGNITION BLACK RED CDI MODULE STOP SWITCH SOFT STOP RED 18 CDI MODUL EXCITER COIL EXCITER COIL BLACK CDI MODULE TETHER HARD STOP WHITE CDI MODULE CHASSIS HOOD REVERSE LED WHITE RED 18 MODUL CRANK SENSOR PULSER COIL BLK 18 MODUL CHASSIS ENGINE HARD STOP WHITE YELLOW CDI MODULE EV SOLENOID SOLENOID CONTROL BLK RED 18 MODUL
247. a low pressure pump bicycle tire pump is recommended Schrader Valve Added 1 To fuel tank vent fitting 4 Once the tank is pressurized saturate the area around the PFA gasket with a mixture of water and mild detergent 5 Ifany bubbles form re check the PFA nut torque If bubble formation continues the PFA gasket will have to be replaced or tank replacement is required NOTE There may be bubbles present from the initial application of leak detector Slightly blow on the bubbles to pop them Watch for new bubble formation New bubble formation may very small so look closely Apply additional water detergent solution if required 4 30 CFI Fuel Rail Injector s Removal Installation NOTE Keep the red protective cap on the end of the injector to prevent damage when installed Follow the steps and remove when instructed to do so 600 700 CFI INJECTOR KITS INJECTOR KITS COLOR 2203325 053 Yellow 2203325 027 Blue 2203325 015 Red 800 CFI INJECTOR KITS INJECTOR KITS COLOR 2203575 053 Yellow 2203575 027 Blue 2203575 015 Red 1 Depressurize the fuel rail See Fuel Rail Bleeding Pressure Testing on page 4 29 2 Remove the panduit straps as shown compartment to access the lower two fuel injectors WINNING PERFORMANCE POLARIS Fuel Systems 3 Remove the hex screws securing the fuel rail it to the cylinders o9
248. a Mity Vac or similar vacuum tool Bleed the system of brake fluid Note the orientation of the brake line The brake line will need to be replaced in the same orientation Remove the brake line from the caliper Cap or cover the end to catch any brake fluid that may still be in the line Loosen the brake line from the master cylinder 1 4 to 1 2 turn Remove the 4 screws that hold the master cylinder to the handlebar This will separate the master cylinder from the switch pack 168 216in Ib 18 9 24 4 N m Unplug the brake light switch harness from the master cylinder Remove the brake line from the master cylinder Install new brake line on caliper and orientate it as noted in step 4 WINNING PERFORMANCE POLARIS 11 Torque the caliper banjo bolt to 168 216 in Ib 19 24 N m Caliper Banjo Bolt 168 216 18 24 e 12 Insert the new brake line and install into the master cylinder Torque the brake line to 144 192 in Ib 16 21 N m Brake Line 144 192 16 22 N m 13 14 15 Tighten the brake line into the master cylinder in an orientation so that the line does not have any sharp bends when it is installed on the handlebar Route the brake light switch in the harness correctly Place the switch pack with the master cylinder onto the handle bar Two smaller screws should be placed on the top and the longest screw is placed on th
249. al installation 9 The cross shaft can be extracted from the water pump side tool PN 2872010 Verify the seal lips are facing the cross of the crankcase shaft gear 600 700 800 CFI Oil Hose Routing NC Ta FR 4 QUIET 2 OD 27 KE Ars i TEE FITTING a Sholas Engine Removal Typical NOTE Inspect all parts for wear or damage during disassembly Replace all seals o rings and gaskets with Genuine Pure Polaris parts during assembly NOTE The following removal and installation process involves a CFI engine Carbureted engines do not use throttle bodies or the electrical components housed in the drive clutch cover electrical center 1 Open the hood and remove the side panels Disconnect the battery ground cable from the battery if equipped 3 If equipped unplug exhaust temperature sensor and remove the exhaust system 4 Remove the spark plug leads from the spark plugs 5 If equipped remove the belt cover electrical center cover 6 7 On CFI models remove the return fuel line P holder located on the MAG side of the airbox WINNING PERFORMANCE POLARIS 10 Engine and Cooling Systems On CFI models separate the fuel filter from the filter clip that is on the MAG side of the airbox Remove the airbox by removing the gear clamps then pulling the airbox assembly o
250. and torque to specification T Speedometer Driveshaft Nuts 17 Ft Lbs 23 Nm 9 Torque speedometer housing nuts to specification 10 Lock the parking brake e Speedometer Housing Nuts 17 Ft Lbs 23 Nm 6 5 Final Drive and Brakes 11 Reinstall the chain and upper lower gears Install the lower gear washer with the beveled side facing out Torque castle nut and lower gear fastener to specifications 6 Upper Gear Castle Nut 50 Ft Lbs 68 Nm Back nut off only to align cotter pin holes with nut Lower Gear Fastener 19 Ft Lbs 26 Nm 12 Turn the chain tensioner bolt in until there is 0 25 in 6 35mm deflection between the backside of the chain and the chaincase N In mm Drive Chain Deflection 0 25in 6 35 13 Turn the tensioner bolt seal down into the chaincase Torque the tensioner bolt jam nut to specification ey T Tensioner Jam Nut 21 Ft lbs 28 Nm 14 Verify the cover seal is in good condition Install the cover and bracket Torque fasteners to specification using a criss cross pattern Chaincase Cover Fasteners 10 Ft Lbs 13 Nm 15 Fill the chaincase with new chaincase oil until the level is at the mid point of the sight glass 16 Reinstall the exhaust silencer and door panel 17 Reference the PVT System and Front and Rear Suspensions chapters for idler sha
251. ar FORWARD OPERATION 1 If unit was operated in reverse ensure that the path ahead is clear and push an hold the reverse button for 1 second and then release the button The engine will now automatically change direction form reverse to forward and the reverse light on the instrument panel will stop flashing NOTE When servicing clutches ensure that the vehicle is in forward gear If not damage to the driven clutch may occur when removing the belt Altitude Setting If your engine is carbureted you can adjust the elevation setting of the Polaris electric reverse control PERC If your engine is a Cleanfire system this is automatically done through the engine controller unit ECU and you do not need to do any setting At higher elevations over 6000 ft 1829m the engine requires a different ignition RPM setting to improve the operation of the reverse system To set the altitude settings 1 With the engine running push and hold the reverse button for 5 6 seconds and then release the button The reverse light will flash rapidly on the instrument panel 3 Youhave now set the PERC system to the higher elevation setting 4 To go back to the low elevation setting repeat step 1 The reverse light will flash slowly indicating that the system is now in the lower elevation setting NOTE The elevation setting will be set in the memory engine running or not until it is changed Important Notes Max RPM for shifting
252. ard off the slide rail 4 With the rail slider at room temperature install a new rail slider by reversing steps 3 NOTE Lightly coat rail slider track clip area with a lubricant such as LPS2 or WD 40 to ease installation 8 42 Break In After installing new rail sliders they must be broke in for longer life and better wear patterns When performing the breaking in procedure ride the sled on a surface that has adequate snow conditions with deeper snow nearby Run the sled on the adequate snow surface and dip into the deeper snow every so often REAR SUSPENSION REMOVAL AND INSTALLATION Removal 1 Support the rear of the machine so that the track is off the floor 2 Loosen the rear idler bolts then push the rear idler shaft toward the front of the machine 3 Carefully release the torsion spring pressure if equipped Remove the support from the tunnel letting the suspension carry the weight of the machine 5 Remove the fasteners securing the skid to the tunnel 6 Placea protective mat on the floor and tip the unit over on the left side supporting the sled on the end ofthe handlebar 7 Collapse the torque arms and remove the suspension from the tunnel Installation Ay CAUTION Always use new fasteners when securing the torque arms to the tunnel 1 With the unit on its left side place the suspension in the tunnel 2 Align the front and rear torque arms with the tunnel mounting hol
253. assembling the crankcase assembly 10 Compress the lower ring then slide the cylinder down over 3 With the piston out of the cylinder remove one of the c the ring clips and discard Never re use piston c clips 4 Push the piston pin out of the piston and upper rod bearings Inspect the pin for galling and abnormal wear Inspect the needle bearing by feel and replace as required 5 New pistons are supplied with new rings and a piston pin It is recommended that new needle bearings be installed as well 5 19 Engine and Cooling Systems 600 HO Carbureted Crankcase Wey a WATERPUMP BUSHING SCREW i gt B C CYLINDER STUDS OIL INJECTION CHECK VALVES 6 9 Ft Lbs 12 Nm 22 Ft Lbs 80 Nm Apply Loctite 242 9 Ft Lbs 12 Nm Apply Loctite 242 Long Studs Height Exhaust side 3 66 93mm Small Stud Height Intake side 2 16 55mm Disassembly Assembly Process 1 Remove the engine from the engine compartment 2 Follow the process for removing the cylinder head 5 20 cylinders pistons flywheel recoil housing and the water oil pump Remove the intake boots and reed assemblies Discard any seals or gaskets Remove the crankcase fasteners then carefully pry apart the crankcase halves Discard the PTO and MAG crankshaft seals Clean the two crankcase mating surfaces with carburetor cleaner and a gasket remover Flush out th
254. astener 17 Ft Lbs 23 Nm B Jackshaft Flange Nuts 17 Ft Lbs 23 Nm C Speedometer Housing Nuts 17 Ft Lbs 23 Nm D Driveshaft Housing Nuts 17 Ft Lbs 23 Nm E Chaincase Mounting Nuts 28 Ft Lbs 88 Nm F Speedometer Sensor Screw 5 Ft Lbs 7 Nm G Speedometer Gear Screw 15 Ft Lbs 11 Nm CAUTION Do not over torque the chaincase mounting nuts 6 8 JACKSHAFT SEAL SLEEVE SNAP RING NOTE Set driven clutch offset following procedure in the PVT System Chapter Lubricate components as outlined in the Periodic Maintenance Table Tighten chaincase mounting nuts using a criss cross pattern Install jackshaft seal sleeve with beveled edge towards brake disc then install o ring inside sleeve WINNING PERFORMANCE gt POLARIS Final Drive and Brakes Driveshaft Removal Installation Remove the side panels Remove the intake plenum Remove the drain plug and drain the chaincase fluid gt Replace the chaincase drain plug and torque it to 8 ft lb 11 N m ey T Drain Plug 8 ft lb 11 5 Remove the chaincase cover 6 Loosen the tensioner 7 Remove the lower sprocket bolt and washer 8 Shut off the fuel valve if so equipped 9 Remove the exhaust system 10 Remove the speedo drive pickup 11 Remove the speedo drive housing 12 Remove the rear skid 13 With the sled over on its
255. at least 30 seconds to allow the gas pressure to stabilize Perform work on shocks when shocks and nitrogen gas supply tank are at room temperature 70F 21C The Walker Evans IFS Air shocks can be configured using the stock and optional 2007 settings or the stock 2008 settings In 2007 an optional valve stack setting was specified to accommodate riders wanting a stiffer shock setting There is not an optional valve stack configuration specified for 2008 Walker Evans IFS Air shocks The stock nitrogen gas pressure setting for a 2007 Walker Evans FTS Air shock can be adjusted to increase its stiffness Currently there is not an optional nitrogen gas pressure setting for the 2008 Walker Evans FST Air Shock Ryde FX Air 2 0 Shock The shock rod pressure setting can be adjusted to accommodate different rider weights and riding styles Before making any shock pressure adjustments the rider should ride the snowmobile for at least 250 500 miles in all types of riding conditions NOTE Do not adjust the shock body chamber pressure setting Always charge the shock body chamber to specification WINNING PERFORMANCE gt POLARIS SHOCK ROD GAS FILL PORT SHOCK BODY GAS FILL Air 2 0 Shock Notes All shock work must be performed when the shock assembly and nitrogen supply tank are at least 70 F 21 C Nitrogen pressure changes by approximately 2 for every 10 F from 7
256. at the shock rod is facing downward 4 Pressurize the shock to specification Hold the fill tool needle in the port for thirty seconds to allow the nitrogen gas to stabilize IMPORTANT Never re insert the fill tool needle back into the shock to check pressure after initial charging The amount of gas required to fill the tool will give a false pressure reading Always completely discharge the shock and refill to obtain an accurate pressure reading 5 Check for any leaks 6 Reinstall the protective boot and carefully reinstall shock WINNING PERFORMANCE gt POLARIS Shocks Walker Evans Remote Reservoir Piggy Back Shock Disassembly NOTE Remote reservoir shock shown IMPORTANT To prevent damage or marks to the shock the use of soft jaws on a vise is recommended 1 Clean and carefully remove shock from the suspension 2 Remove button head screw 1 from reservoir cap if applicable 6 Place the shock lower eyelet in a vise 7 Loosen and remove the bearing cap from the shock 8 Remove the used oil from the shock body NOTE Insert the IFP tool PN PS 45908 and cycle the internal floating piston IFP a few times to purge the shock oil from the reservoir 9 Remove the IFP from the reservoir with the IFP tool PN PS 45908 10 Clean and inspect ALL parts and replace worn out parts if needed IMPORTANT Seal kits are available and should be installed at this time if seals or o rin
257. ather As the weather turns colder it will be necessary to re jet upward to prevent engine damage When selecting the proper main jet always use the lowest elevation and temperature that is likely to be encountered CAUTION A Main Jet that is too small will cause a lean operation condition and may cause serious engine damage Jet the carburetors carefully for elevation and temperature according to the jetting charts in the Specifications Chapter of this manual or the models Owner s Manual Supplements 4 7 Fuel Systems Piston Valve Or Throttle Valve THROTTLE VALVE NEEDLE 3 L NEEDLE JET intake side The throttle valve controls the rate of engine air intake by moving up and down inside the main bore At small throttle openings air flow control is performed chiefly by the cutaway By controlling air flow the negative pressure over the needle valve is regulated in turn varying the fuel flow The throttle valves are numbered 1 0 1 5 2 0 etc according to the size of the cutaway in millimeters The higher the number the leaner the gasoline air mixture Jet Needle The jet needle tapers off at one end and the clearance between the jet needle and the needle jet increases as the throttle valve opening gets wider The air fuel mixture ratio is controlled by the height of the E ring inserted into one of the five slots provided in the head of the jet needl
258. atteries require filling with electrolyte and a full charge prior to service 1 battery with electrolyte to the upper level marks on the case 2 Setbattery aside and allow it to cool and stabilize for at least 30 minutes 3 Add electrolyte to bring the level back to the upper level mark on the case NOTE This is the last time that electrolyte should be added 4 Charge battery at 1 10 of its amp hour rating Example 1 10 of 9 amp battery 9 amps 1 10 of 14 amp battery 1 4 amps 1 10 of 18 amp battery 1 8 amps recommended charging rates 5 Check specific gravity of each cell with a hydrometer to ensure each has a reading of 1 270 or higher 6 Install vent cover NOTE Once the vent cover is installed the battery is sealed Do not remove the cover Specifications Battery PN 4011092 4010905 Battery Type YTX14AH BS Fresh Pack Nominal Capacity 12Vdc 12AH Electrolyte Volume 22 30z Specific Gravity 1 320 CCA OF 18C 210 AMPS Charging Current 1 2 AMPS 11 3 Battery and Electrical Systems BATTERY TESTING Testing Procedures Batteries should be kept at or as near full charge as possible If the battery is stored or used in a partially charged condition hard crystal sulfication will form on the plates reducing their efficiency and possibly ruining the battery Open Circuit Voltage Test OCV Check static battery voltage with multimeter Voltage should be no
259. bile 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 5 Maintenance Torque Stop Adjustment GAP gt si Set torque stop bumper gap to specification after aligning drive and driven clutches 7 NL In mm Torque Stop Bumper to Engine Gap 010 030 25 75mm After setting gap torque jam nut to specification e Torque Stop Jam Nut 15 17 ft lb 21 24 Nm NOTE Where applicable when installing a new torque stop position bumper so the tip is just touching crankcase 3 6 Engine Isolator Limiter Setting Some models use an engine mount strap isolator The isolator is located on left front corner of the bulkhead The isolator should not make contact with the engine strap If the 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 6 Jam Nut 15
260. ble sheave Glo POLARIS Way Out 7 3 PVT System GENERAL INFORMATION Special Tools Team 12 Cooling Fin Driven Clutch Offset Alignment Tool PS 46998 Team 24 Cooling Fin Driven Clutch Offset Alignment Tool PS 47477 Drive Clutch Puller 3 4 16 x 7 16 All Fuji Fan Liquid Cooled Engines 2872084 Drive Clutch Puller 3 4 16 x 14mm Domestic 500 600 700 800 FS FST Engines 2872085 Drive Clutch Puller 14mm 2871855 Replacement Handle for ALL Clutch Pullers 5020326 Drive Clutch Holding Wrench 9314177 A Strap Wrench PU 45419 Replacement Strap 305085 Drive Clutch Spider Nut Socket 2870338 Drive Clutch Spider Removal and Spider Installation 2870341 A Pin Centering Tool 2870401 Clutch Pin Installation Tool 2870402 Clutch Pin Punch 2870507 Tapered Reamer 29mm Short Drive Fuji Snow Engines Only 2870576 Tapered Reamer 29mm Long Drive Non 2007 600 700 CFI Domestic Snow Engines Only PS 48584 Tapered Reamer 31mm 2007 600 700 CFI Domestic Snow Engines Only PS 48587 Roller Pin Tool 2870910 A Drive Clutch Button Removal Tool 2870985 Clutch Bushing Replacement Tool Kit 2871025 Clutch Holding Fixture 2871358 Clutch Compression Tool 8700220 Spider Assembly Tool 8700221 Clutch Compression Tool Extensions for TEAM driven PS 45909 Clutch Pilot Tool used with the 2871358 to compress the clutch PU 45779 Drive Clutch Compression Tool
261. cate the internal IFP and o ring with shock oil 2 Install the internal flat side o ring side first into the piston rod 3 Install the rod head assembly Torque to specification ey T 4 Install the compression and rebound valve shim stacks back on to the piston valve assembly in the order they were removed 5 Apply a small amount of Loctite 290 to the bolt threads Thread piston assembly into piston rod by hand Pressure Valve Assembly Torque lt 100 110 In Lbs 9 Pressurize the 36mm piston rod through the pressure valve with nitrogen gas to the specified pressure NOTE The internal IFP will be forced to the top of the piston rod after cylinder is pressurized 10 Secure the shock body lower mount in a soft Jawed bench vise 11 Thread the head onto the IFP locator tool and adjust the top of the value indicator to the specified IFP measurement LN gt Piston Valve Bolt Torque 28 32 Ft Lbs CAUTION DO NOT OVER TORQUE PISTON VALVE BOLT 9 18 snn Shocks 12 Apply a thin layer of oil to the IFP wearband and o ring Insert the IFP o ring side first into the shock body i 13 using the locator tool slowly push the IFP down into the cylinder The IFP is set to the correct position when the indicator knob makes contact with the shock body 14 Install the pressure valve assembly into the valve port a
262. consists of a lighting charge coil ignition exciter coil fuel injector charge coil and two independent external crank position two and five pulse coils Flywheel The CFI flywheel houses the magnets for energizing the stator windings as well as two independent encoder ribs The set of two encoder ribs are spaced 180 degrees apart from each other and provide RPM information required at engine start up A set of five encoder ribs is responsible for crank angle detection speed and direction information Regulator Rectifier Responsible for converting to Vdc for the chassis and battery electric start circuits Regulates voltage to 14 5 Vdc Also supplies fuel injector boost power when engine RPM is 700 RPM or less Capacitor The capacitor suppresses voltage spikes and ensures consistent voltage throughout the chassis RED WHT circuit Chassis Relay The chassis relay is activated by the ECU at approximately 950 RPM Below 950 RPM all power supplied by the regulator rectifier RED circuit is used to power the ECU and fuel pump Ignition Coils Provide ignition energy to each spark plug Both coils are fired at the same time Fuel Injectors CFI uses one set of full load injectors located in the crankcase and one set of part load injectors located in each cylinder s transfer port The full load injectors are used at idle and high RPM speeds while the part load injectors are used at low to mid engine spee
263. corners of the seat base 7 Pull the vinyl tight and tack the seat cover to the plastic seat base in each corner Use two or three staples per 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 the staple sequence above 10 Turn the seat cushion assembly over and inspect for wrinkles or imperfections If imperfections are visible remove the staples in the affected area and staple correctly 11 Trim excess vinyl from the bottom around the back of the seat area only after a satisfactory fit is obtained 10 10 DECALS Decal Removal Before beginning read these instructions and check to be sure all parts and tools are accounted for Use the following items Squeegee Cheese Cloth or a non abrasive cloth Paper Shop Towels Hair Drier or Heat Gun Wallpaper seam roller or similar roller 3Mt citrus based clear 3Mt PN 62 4615 430 5 available at most auto parts stores Cleaning solution 99 water 1 mild dish washing detergent ScotchR 233 Performance masking tape Perform the decal removal procedures carefully If care is not taken
264. ct the belt for loose cords missing cogs cracks abrasions thin spots or excessive wear spots Replace if necessary 3 Inspect the belt for hour glassing extreme circular wear in at least one spot an on both sides of the belt Hour glassing POLARIS The Way Out occurs when the drive train does not move and the drive clutch engages the belt Example would be taking off while the track is frozen to the ground Remember to always warm up the track and free it from the ground Drive Clutch Bolt Torque Follow the torque table below when installing the drive clutch ey All 600 Carbureted Engines 50 Ft Lbs 68 All 600 700 800 CFI Engines 80 Ft Lbs 108 Nm Re torque clutch bolt after running engine 7 9 PVT System Belt Wear Burn Diagnostics Table 7 1 Belt Wear Burn Diagnostics POSSIBLE CAUSE SOLUTION Driving at or about engagement RPM for extended periods of time in any type of snow condition Drive at higher RPM if possible Gear the machine down Make sure belt deflection is at 1 1 4 to achieve optimum starting ratio Cold weather startups Be patient Warm up engine at least 5 minutes or until it readily responds to throttle input For the quickest most efficient drive away in extreme cold weather take drive belt off machine and bring it in to a warm environment Break skis and track loose from the snow Engage throttle aggressively for shor
265. cting both shocks recharge both shocks to the desired pressure settings and specifications SHOCK MAINTENANCE Ryde FX Air 2 0 Shock Disassembly A WARNING Before servicing a gas shock it is important that all the gas pressure be discharged from the shock Nitrogen gas is under extreme pressure Protective eyewear must be worn at all times to avoid risk of injury while servicing shocks or using compressed air CAUTION Always clamp the lower mount of the shock in a vise Any other method of securing the shock body may deform the shock body cylinder 1 Remove the shock from the snowmobile Wash the entire shock assembly in parts cleaner then dry with compressed air or a clean shop towel 2 Remove lower shock body mount eyelet components 9 16 Secure shock in a soft jawed table vise 3 Remove both small bottom head screws form each pressure valve assemblies located at both ends of the shock 4 Using a flat blade screwdriver carefully loosen both pressure valve assemblies counter clockwise two full rotations Allow all of the nitrogen gas to fully escape past each pressure valve assembly o ring WINNING PERFORMANCE gt POLARIS Shocks 5 After all of the nitrogen gas has been allowed to escape 9 Place the 36mm piston shock rod upper mount in a soft from the shock remove both pressure valve assemblies jawed bench vise Remove the piston valve and valve shim igh y
266. d bo eee ee ipe Ded 11 17 rss posses sets oig cete oN Mees e Ere us re d ane 11 17 VARIABLE EXHAUST SYSTEM VES 11 17 OVERVIEW c tie ib RES NU SO noH C eU aer ets 11 17 DIAGNOSTIC PLUGS Ree a P IE DE De oe a 11 18 IQ CHASSIS 2 11 18 IQ CFI FUEL PUMP PRIME PLUG 2 11 18 ELECTRONIG REVERSE PERG acai Sava bie eee scale bale ea HU 11 18 WINNING PERFORMANCE 11 1 POLARIS Battery and Electrical Systems SPECIFICATIONS Engine Models Model Number Engine 53273 6044 3274 6044 53466 6044 6 53467 6044 6 Liberty 600 Carbureted 53206 6044 6 53468 6044 6 53469 6044 6 Liberty 600 CFI 53305 7044 7 53322 7044 7 53470 7044 7 53471 7044 7 Liberty 700cc CFI 53489 8044 53471 8044 Liberty 800cc CFI A WARNING PROPOSITION 65 WARNING BATTERY POSTS TERMINALS AND RELATED ACCESSORIES CONTAIN LEAD AND LEAD COMPOUNDS CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER AND RE PRODUCTIVE HARM WASH HANDS AFTER HANDLING BATTERY ELECTROLYTE IS POISONOUS IT CONTAINS ACID SERIOUS BURNS CAN RESULT FROM CONTACT WITH THE SKIN
267. d IFP locating position for the shock 7 Apply a thin layer of shock oil to the IFP o ring and wear band 8 Carefully install the IFP back into the reservoir Set the IFP to the specified depth Take care not to damage the IFP wear band while setting the IFP depth 9 When the IFP is set to the depth specification reinstall the bleed screw 10 Fill the shock body with new Ryde FX shock oil to the bottom of the shock body threads 11 Carefully and slowly install the shock rod bearing assembly back into the shock body Use a slight up and down movement to dispose of any air trapped below the piston assembly WINNING PERFORMANCE POLARIS 12 Using an adjustable wrench secure the bearing cap assembly to the shock body 13 Pour all of the remaining oil out of the reservoir body into a suitable container 14 Apply a light film of Lithium grease to the pressure valve counter bore on the reservoir cap 15 Apply a thin layer of shock oil to the cap o ring then carefully reinstall the cap back into the reservoir Push cap just below the c clip groove 16 Use a pliers to pull the cap up against the c clip 17 Charge the reservoir with nitrogen to the specified pressure Once pressurized the shock rod should fully extend 18 With pressure working against the reservoir cap secure the pressure valve into the cap then remove the shock fill tool from the valve Reinstall the button head screw 9 25
268. d Assembly Process 1 Remove the screws from the helix then carefully pry the helix out of the moveable sheave 2 Install the clutch in the clutch compressor fixture PN 8700220 Install the extensions PN PS 45909 3 Wearing eye protection carefully compress the roller assembly to gain access to the snap ring Remove the snap ring 4 Slowly release the fixture arm to remove the roller assembly and spring Disassembly the clutch sheaves 5 Inspect the sheaves for abnormal wear Clean sheave faces with a Scotch Brite pad and a solution of warm soapy water 6 Inspect spring spring cup spacer and rollers for wear and replace as required 7 To assemble the clutch slide the components back on to the stationary sheave shaft 8 Align the notch in the roller assembly with row of double splines on the shaft Slowly compress the spring and roller assembly down on to the shaft Install the snap ring making sure it is fully seated in the groove 9 Install the helix by aligning the rollers with the ramps Push the helix down into the sheave while keeping the screws holes aligned 7 19 G POLARIS Way Out PVT System NOTES 7 20 n n PCLARIS Steering and Suspensions CHAPTER 8 Steering and Suspensions OVERVIEW 8 2 INSPECTION KA atau ku ets 8 2 CAMBER TOE SPECIFICATI
269. d the level of performance the operator hopes to achieve Gearing a snowmobile too low for extended high speed runs may cause damage to the drive belt and drive system while gearing a snowmobile too high for deep snow mountain use may cause premature belt and clutch wear Typically it is recommended to gear the snowmobile with a slightly higher ratio than the actual top speed the snowmobile will ever achieve 1 1 Shift Ratio A 1 1 shift ratio occurs when the drive clutch and the driven clutch are rotating at the same RPM The mathematical vehicle speed for a given gear ratio at a 1 1 shift ratio is represented in the chaincase gearing charts located in the Final Drive Chapter Low High Ratio Low ratio is the mechanical position when the drive belt is all the way down into the drive clutch and all the way out on the driven clutch High ratio represents when the drive belt is all the way out on the drive clutch and all the way in on the driven clutch Driven Helix Ramp The helix cam is the primary torque feedback component within the driven clutch regardless of driven clutch type The beginning angle of the helix must transmit enough torque feedback to the moveable sheave in order to pinch the drive belt while minimizing belt slip The flatter or lower the helix angle the more side force will be exerted on the moveable sheave while the steeper or higher the helix angle the less side force will be exerted on the movea
270. deal air fuel mixture which can burn without leaving an excess of fuel or air Whether the proper mixture ratio is maintained or not is the key to efficient engine operation The engine of a vehicle is operated under a wide range of conditions from idling with the throttle valve remaining almost closed to full load or maximum output with the throttle valve fully opened In order to meet the requirements for the proper mixture ratio under these varying conditions a low speed fuel system or pilot system and a main fuel system are provided in Mikuni type carburetors The Mikuni carburetor has varying operations depending upon varying driving conditions It is constructed of a float system pilot system main system and starter system or initial starting device Float System The float system is designed to maintain a constant height of gasoline during operation When the fuel flowing from the fuel pump into the float chamber through the needle valve reaches the constant fuel level the floats rise When the buoyancy of the float and the fuel pressure of the fuel pump balance the needle valve sticks fast to the needle seat preventing further delivery of gasoline thereby holding the standard level of gasoline The fuel level in the bowl assists in controlling the amount of fuel in the fuel mixture Too high a level allows more fuel than necessary to leave the nozzle enriching the mixture Too low a level results in a leaner mixture since
271. dicator 9 Remove the dial indicator and install in PTO cylinder Repeat finding TDC process Note the degree wheel indication when the dial indicator reads 100 ATDC It should be 180 2 from the MAG cylinder mark WINNING PERFORMANCE gt POLARIS Engine and Cooling Systems 100 ATDC 9 100 Crankshaft center line Cylinder Honing until stone contacts the cylinder walls DO NOT OVERTIGHTEN Cylinders may be wet or dry honed The cylinder bore must be de glazed whenever new pis depending on the hone manufacturer s recommendations ton rings are installed A light honing with fine stones re Wet honing removes more material faster and leaves a more moves only a very small amount of material A proper distinct pattern in the bore Using a 50 13 mm drill motor crosshatch pattern is important to provide a surface that rotating at a speed of 300 500 RPM run the hone in and will hold oil and allow the rings to seat properly If the out of the cylinder rapidly until cutting tension decreases crosshatch is too steep oil retention will be reduced A Remember to keep the hone drive shaft centered to prevent crosshatch angle which is too shallow will cause ring vi edge loading and always bring the stone approximately 5 bration poor sealing and overheating of the rings due to 1 2 cm beyond the bore at the end of each stroke blow by and reduced contact with the cylinder wall Ser 4 vice life of the pis
272. ds Detonation Sensor Located on the cylinder head the detonation sensor transforms internal acoustic WINNING PERFORMANCE gt POLARIS information into a signal the ECU uses to determine the amount of engine knock Exhaust Valve Solenoid Activated by the ECU the solenoid controls the VES venting When powered the solenoid is open allowing cylinder pressure to vent thus keeping the exhaust valves closed When power is removed the solenoid closes and the exhaust valves are allowed to open Throttle Position Sensor TPS The TPS relays the position of the throttle plates operator throttle input to the ECU Coolant Temperature Sensor Relays the engine temperature to the ECU Exhaust Temperature Sensor Relays the temperature of the exhaust pipe to the ECU Temperature Barometric Air Pressure T BAP Sensor Relays the current intake air temperature and ambient air pressure to the ECU The sensor is located on the airbox Vehicle Speed Input The ECU monitors the vehicle speed supplied by the vehicle speed sensor Fuel Pump Supplies fuel to the fuel injectors Power to the fuel pump is supplied by the regulator rectifier Diagnostic Connector The ECU can communicate with the Polaris Digital Wrench software and can be re flashed monitored and will display trouble codes 4 15 Fuel Systems Diagnostic Trouble Codes DTCs CFI Diagnostic Trouble Codes MFD BLINK
273. e This needle example is a 01 57 The first number is the approximate overall length in 10mm increments of the jet needle The 9 indicates the needle is approximately 90mm but less that 100mm in length The letters on the jet needle indicate the angle of both tapers The first letter designates the taper angle of the top section closest to the grooves and the second letter designates the angle of the bottom taper The taper angles are graduated in 15 15 minute increments The jet needle marked 9DH01 57 would have a top taper of 1 0 and a bottom taper of 2 0 4 8 The number following the letters on the jet needle is the serial number and it varies with individual jet needles The last number 57 indicates that the outside diameter is 2 57mm The smaller the O D the richer the mixture 9DH01 57 Richer OD Straight Portion DESIGNATOR DESCRIPTION 9 Overall length in 10mm increments D Taper of the top section of the needle H taper of the bottom section of the needle 01 Serial number 57 Outside diameter O D of the straight portion Needle Jet The needle jet works in conjunction with the jet needle WINNING PERFORMANCE gt POLARIS Fuel Systems Throttle Opening Vs Fuel Flow i Large Clearance Clearance Clearance Closed One half Full Throttle Throttle Throttle Fuel flow 75 100 Throttle Valve Opening D lt
274. e If flyweight bushing is damaged both the flyweight pin and nut will need to be replaced 19 Inspect to see if the roller and bushing are separating 20 Bushing must fit tightly in roller 21 Replace roller and pin if roller fails to roll smoothly no flat spots or if the bushing is loose or worn 7 14 PEL ARIS The Way Out PVT System Roller Removal BUTTON 1 With the spider in a vise start removing the spider buttons by drilling a 0 18 hole in the center of a button on one side of the spider Place spider on a vise or in an arbor press 3 Place a pin punch through the spider button hole and drive the opposite button and pin out Remove shims if any are installed and note their location 5 Flip the spider over and tap out the holed button Roller Installation NOTE CAUTION Use care to start the pin straight Aluminum burrs could pass through into the roller bushing causing it to bind and stick Also use care to make sure the roller remains aligned when the pin is driven through The roller busing could be damaged causing premature wear and roller failure 1 Drive pin into the spider leg 100 125 0 25 0 32cm beyond the first land of the spider leg 2 Install one washer on the portion of the pin that is protruding from the spider leg Install new buttons into the spider Place roller in spider leg and center it on the pin Place a second washer on the other side of the roller
275. e coloring of your spark plug The piston wash is by far the most valuable tool in concluding EGTs with the spark plug color running a distant second Use the illustrations below to help you establish the EGTs for your machine Once the proper jetting is established you can reference the EGT gauge for your baseline numbers Then if there is a rise or fall of 25 degrees you must jet accordingly to return your EGTs to the baseline numbers Piston Wash Spark Plug Color Correct 3 4 Correct WINNING PERFORMANCE gt POLARIS SERVICE PRECAUTIONS GENERAL PRECAUTIONS In order to perform service work efficiently and to prevent costly errors the technician should read the text in this manual thoroughly familiarizing him herself with procedures before beginning Photographs and illustrations have been included with the text as an aid Notes cautions and warnings have also been included for clarification of text and safety concerns However a knowledge of mechanical theory tool use and shop procedures is necessary to perform the service work safely and satisfactorily Use only genuine Polaris service parts CAUTION Cleanliness of parts and tools as well as the work area is of primary importance Dirt and foreign matter will act as an abrasive and cause damage to precision parts Clean the snowmobile before beginning service Clean new parts before installing CAUTION Watch for sharp edges
276. e Be mm mm VIT A y HH B 55 WH GY 1 SSES gt 1 OFF eee Wee e ee Z IRDp i LOW 1 T 8 sqa F DETONATION MN ze eem e 451414 EI SENSO MED VU GY a a a ISS ELE DG c 810 000 OHMS R 1 HANDWARMER I 5 l TORQUE TO 2045 N M 1543 FT LBS HIGH e J M c 28 PK H 9 24 4 4 4 1 4 THROTTLE REVERSE E s 1 29 YE E POSITION 5 POTENTIOMETER SPLICE 63 BN 1 l ET GY i E30 BK LH SENSOR LEFT HANDLEBAR 67 Ee d SWITCH ASSEMBLY I 68 BN E6 orm 110020 I COL pue a eee ie if BLACK TO WHITE 3 Q m A 41 BN WH i EMI i PLUG LEAD TO PLUG LEAD 5K ECL dps 1 mmis RESISTANCE 201 1 o DOMNUS wam 30 POWER IN PIN AT 14 3 pu x M Lr i E 7 by m aa 1 t EE MOTEL dE i 17 3 i Az hs v Rm i
277. e Mikuni TM38 yp E clip one position If the chart recommends clip 1 install washer Main Jet 400 on top when using RON 93 Pilot Jet 45 Clutch Settings Jet Needle Clip position 9DGN6 57 3 Needle Jet ALTITUDE DRIVE CLUTCH DRIVEN CLUTCH mes Shift Clutch Clutch Driven Gearing Throttle Gap Under Cutaway in mm 082 2 1 deep Weight Spring Spring Helix 0 600 64 42 36 Cutaway 2 0 0 2000 10 62 9 Valve Seat 1 5 600 1200 2000 4000 10 60 22 39 76 Starter Jet 145 10 58 BLK GRN RED BLK i 4000 6000 Pilot Air Jet 1 0 120 340 140 240 224076 Fuel screw Turns Out 1 0 60008000 1055 win 91 2400 3000 Recommended Fuel Octane R M 2 Non Oxygenated 8000 10 000 9 54 b 3000 3600 p 10 000 12 000 10 AL Drive Clutch Bolt Torque 50 Ib ft 68Nm 1 20 WINMING PERFORMANCE C POLARIS Model Specifications General Front Suspension Width in cm 48 5 123 2 Suspension Type 10 42 5 Length in cm 115 292 1 Shocks Ryde FX MPV Height 48 121 9 pnis Rate 100 17 5 Estimated Dry Weight s in N mm 466 211 6 Spring Installed Length Inch 10 5 26 67 Fuel Gallons Liters 11 7 44 3 nches cm Oil Quarts Liters 3 28 Front Vertical Travel 10 25 4 DUE Inches cm oolin stem Capacit ORE 2 dno 8 5 8 Ski Center D
278. e Oil Level Replacement 3 15 Choke and Choke Cable 3 15 Drive Chain Tension Adjustment 3 15 Driveshaft Bearing 3 14 Rear Suspension 3 14 Throttle Cable 3 15 Cleanfire Fuel Injection 4 15 2007 700 CFI Fuel Pump Service 4 32 2007 700 CFI Fuel System 4 32 CFI Drop In Fuel Pump Fuel System 4 34 CFI Drop In Fuel Pump Removal 4 34 WINNING PERFORMANCE gt POLARIS CFI Drop In Fuel Pump Service 4 34 CFI Ignition Coils 4 27 CFI Regulator Rectifier 4 27 Chassis Power Capacitor 4 27 Chassis Relay 4 22 Clutch Guard Electrical Center 4 19 Crankshaft Position Sensors 4 25 Diagnostic Trouble Codes 4 16 Diagnostic Trouble Code Troubleshooting 4 18 ECU CNA Connector 4 20 ECU CNB Connector 4 21 Engine Coolant Temperature Sensor 4 28 Exhaust Temperature Sensor 4 25 Exhaust Valve Assembly 4 27 Fuel Hose Disconnect Fittings 4 29 Fuel Injectors 4 28 Fuel Rail Fuel Injector Removal and Installation 4 30 Knock Sensor 4 28 MED Blink Codes 4 18 Stator Assembly 4 26 System Overview 4 15 Temperature Air Pressure Sensor 4 25 Throttle Ignition Kill System 4 23 Vehicle Speed Sensor 4 24 Console Assembly 10 4 Conventional Battery 11 3 Cooling System Bleeding 3 7 Cooling Systems 5 41 2007 2008 600 700 5 45 2007 2008 CFI Touring 5 44 2007 600 IQ Switchback LX 2008 CFI LX 5
279. e a rex tiU e Race ee 5 5 CYLINDER HEAD 1 5 5 CYLINDER 5 5 CRANKSHAFT RUNOUT INSPECTION 5 5 PISTON INSPECTION eR Sets ated eS inte 5 6 PISTON RING INSTALLED 5 6 REED VALVE INSPEGTION u aq Beate Ae ae EE 5 6 BEARING q has lati der Mais 2 irte tee br 5 6 MAIN BEARING il area ED a a T Ni UR 5 7 CONNECTING ROD LOWER 5 7 PISTON NEEDLE BEARING 5 7 CRANKSHAFT INDEX egoti ue areata rte ns he en qaa e des Erba 5 7 CHECKING CRANKSHAFT 5 8 CYLINDER HONING ee bier 5 9 HONING 5 9 CLEANING THE CYLINDER AFTER HONING 5 9 CRANKSHAFT 5 9 HECOIE ASSEMBLY sus ps BR miseia 5 11 EXHAUST VALVE MAINTENANCE 5 12 EXHAUST VALVE ASSEMBLY 5 12 EXHAUST VALVE
280. e crankcase Reinstall the crankshaft back into the lower crankcase using two new crankcase seals Apply a thin bead of Three Bond 1215 to the lower crankcase mating surface Install the upper crankcase Loosely install the crankcase fasteners then torque to the specifications at the beginning of the chapter Use the correct torque sequence when tightening the screws WINNING PERFORMANCE gt POLARIS 600 HO Carbureted Water Oil Pump Engine and Cooling Systems SEAL WASHER MECHANICAL SEAL WASHER OIL PUMP WATER PUMP COVER GASKET WATER PUMP COVER NUT 0 CROSS SHAFT WASHER WASHER ey T A 7 Ft Lbs 9 5 Nm B 10 Ft Lbs 13 Nm C 9 Ft Lbs 12 Nm Disassembly Assembly Process IMPORTANT Use the mechanical seal installation tool to install the water pump seal PN 2872010 1 Remove the coolant from the engine using a siphon wet dry vac or a drain pan 2 Remove the airbox exhaust pipe and resonator Remove the hose connected to the water pump cover 3 To access the impeller and mechanical seal remove the water pump cover Discard the water pump cover gasket 4 Remove the impeller nut impeller and washers from the cross shaft 5 Carefully pry the mechanical seal and seal out of the crankcase 6 Water pump assembly is the reverse of disassembly WINNING PERFORMANCE gt POLARIS Always use new seals and gaskets during assembly
281. e idling at approximately 2000 RPM a steady flow of fuel should be visible Cleaning The impulse line must be disassembled and cleaned of foreign material in the event of piston or other internal engine part failures which produce fragments nspection Disconnect impulse line from pump Connect a Mity Vac to impulse fitting or line and apply 4 6 PSI pressure Diaphragm should hold pressure indefinitely WINNING PERFORMANCE gt POLARIS Fuel Systems CARBURETOR SERVICE NOTE Keep track of the plastic washer 9 and place it so it is on the top of the throttle valve when Disassembly installing the needle and e ring back into the carburetor A CAUTION 4 Inspect the needle 7 e clip 8 and plastic washer 9 for wear WEAR EYE PROTECTION WHEN USING COMPRESSED AIR OR WHEN USING CLEANING SOLVENTS REVIEW ALL FUEL SYSTEM WARNINGS LOCATED AT THE BEGINNING OF THIS CHAPTER BEFORE PROCEEDING 1 Remove the carburetor from the engine before disassembling Clean the outside of the carburetor thoroughly with solvent Do not use compressed air to dry at this time 2 Remove all top cap screws 1 top cap 2 and gasket 3 5 Remove the four screws 10 on the funnel face 6 Turn throttle shaft so the throttle slide 11 slides open all the way 7 With slide fully open pull funnel 12 out from the bottom first Inspect the gasket 13 8 Check for wear on the faces of the slides 3 L
282. e lower right 6 13 Final Drive and Brakes Brake Fluid 16 Follow the bleeding procedure See Replacement amp Bleeding on page 6 11 Brake Light Switch Replacement 1 Remove the 4 screws that hold the master cylinder to the handlebar This will separate the master cylinder from the switch pack Unplug the brake light switch harness from the master cylinder 3 Unplug the brake light switch from the master cylinder Replace faulty brake light switch into the master cylinder and route wires correctly 5 Plug the brake switch back into the harness Replace the master cylinder to the switch pack and insert the smaller screws on the top the longest one goes into the lower right side 6 14 Caliper Removal Caliper 1 Remove the two caliper bolts that hold the caliper to the chaincase 2 Remove the caliper from the brake disc Caliper Replacement The only serviceable item in the brake caliper is the brake pads piston and seals If any service is required of the caliper a new caliper is available 1 The brake line will need to go in the same orientation as it was when it is replaced Note the orientation of the brake line before removing it 2 Remove the banjo bolt from the brake line and tie up so that all the brake fluid does not leak out 3 On a liquid cooled caliper you will need to drain the coolant from the coolant hoses 4 Remove the two bolts 1 holding the caliper 2
283. e should not exceed 060 3mm NOTE If the front of the alignment bar does not touch the driven sheave the maximum clearance cannot exceed 025 Offset Adjustment 1 Determine direction driven clutch needs to be adjusted Remove driven clutch retaining bolt and remove driven clutch 3 Add or remove washers from the jackshaft between the driven clutch and jackshaft bearing to achieve proper offset 4 After adjusting offset add or remove shim washers from the retaining bolt to provide a 0 030 75mm of float on the jackshaft A CAUTION Always verify the driven clutch floats on the jackshaft after securing the fastener The jackshaft bearing will fail due to side loading if the driven clutch is not allowed to float 7 12 0 060 PS 46998 Shown POLARIS The Way Out PVT System DRIVE CLUTCH Identification Every clutch will have the last three digits of the clutch part number etched on to the cover A The X B marking is an index mark where the clutch cover C clutch spider D and the stationary sheave E should line up when the clutch is assembled Drive Clutch Removal NOTE All clutch tools can be found at the beginning of this chapter 1 Remove the belt 2 Place the clutch holding tool PN 9314177 A on the drive clutch 3 Remove the drive clutch retaining bolt Note the placement and
284. e the pressure valve assembly from the lower end mount Account for an O ring Using an adjustable face spanner PN PS45262 fully loosen and remove cylinder head assembly Pour the oil out of the shock body Discard old oil into an approved storage container and dispose appropriately Never reuse damper oil during shock rebuild Using the I F P extraction tool thread the tool into the L F P and pull upwards removing the I F P from the shock body Account for wear band and an O ring Note Not applicable for emulsion shock Clean the inside of the shock body using clean parts cleaning solvent and blow dry using compressed air Place the shock piston rod upper mount in bench vise begin piston and valve removal Arrange parts removed in the sequence of disassembly The piston should have the flat slots facing the nut end as highlighted in black Items to inspect Piston rod for straightness nicks or burrs Cylinder Head Assembly DU Bearing clean inspect or replace Inside of shock body for scratches burrs or excessive wear Teflon piston and I F P wear band for cuts chipped or nicked edges or excessive wear O rings for nicks cuts or cracks Cap and rod seals for nicks cuts or cracks Valve discs for kinks or waves Compression bumpers ski shocks only for chipping cracking or missing Should any of these items be in question replacement is recommended WINNING gt POLARIS PERFORMANCE Shocks RYDE FX MONO
285. e water oil pump Long Stud Height Exhaust side 4 13 105mm 3 Remove the intake boots reed stuffers and reed assemblies Small Stud Height Intake side 2 16 55mm from the intake tracks Discard any seals or gaskets 4 Remove the fasteners from the bottom of the crankcase T Carefully pry apart the crankcase halves Discard the PTO and MAG crankshaft seals A 9 FtLbs 12 Nm 5 Remove the crankshaft Inspect as required B 22 Ft Lbs 80 Nm 6 Thoroughly clean the two crankcase mating surfaces with C 10 Ft Lbs 13 Nm Apply Pipe Sealant carburetor cleaner and a gasket remover Flush out the crankcase galleries eres 5 27 Engine and Cooling Systems 7 Reinstall the crankshaft back into the lower crankcase using two new crankcase seals 8 Apply a thin bead of Three Bond 1215 to the lower crankcase mating surface Install the upper crankcase 9 Loosely install the crankcase fasteners then torque to the specifications at the beginning of the chapter Use the correct torque sequence when tightening the screws 10 Liberally coat the crankshaft bearings and components with Polaris two stroke engine oil gt POLARIS 2008 800 CFI Crankcase Crankshaft Engine and Cooling Systems GEAR CLAMPS 00 REED BLOCKS OIL INJECTION CHECK VALVE QTY 5 MAG SEAL 9 FLYWHEEL KEY MAG BEARING ALIGNMENT DOWELS SEAL GUARD e 9 Ft Lbs 12 Nm B 22 F
286. ease the main jet number in the above chart by 10 and raise the E clip one position If the chart recommends clip 1 install washer on top when using RON 93 Clutch Settings Type Mikuni TM38 Main Jet 420 Pilot Jet 50 Jet Needle Clip position 9DGN6 57 2 Needle Jet P 8 Throttle Gap Under Cutaway in mm 0 08 2 1 Cutaway 1 5 Notch Valve Seat 1 5 Starter Jet 145 Pilot Air Jet 6 Fuel screw Turns Out 1 25 Recommended Fuel Octane R M 2 Non s d ALTITUDE DRIVE CLUTCH DRIVEN CLUTCH meters Shift Clutch Clutch Driven feet Weight Spring Spring Helix 8 0 600 64 42 36 0 2000 10 62 292626 600 1200 2000 4000 10 60 1200 1800 4000 6000 BLK GRN RED BLK 120 340 140 240 22 40 76 1800 2400 10 56 7042083 7043058 56 42 36 6000 8000 LWER 2400 3000 3000 10000 10 54 20 41 76 3000 3600 10000 12000 101 1 2 Drive Clutch Bolt Torque 50 Ib ft 68Nm WINNING C POLARIS PERFORMANCE Model Specifications General Front Suspension Width in cm 48 121 9 Suspension Type IQ 42 5 Length in cm 115 292 1 Ryde FX HPG w IFP STD Height 48 121 9 Shocks Fox Compression Adj Remote Estimated Dry Weigh
287. ed Clutch Settings General Width in cm 48 121 9 Length in cm 125 317 5 Height in cm 48 121 9 Estimated Dry Weight Ib kg 485 220 2 Fuel Gallons Liters 11 7 44 3 Oil Quarts Liters 3 4 3 2 Cooling System Capacity 63 6 Quarts Liters Brake Fluid DOT 4 Drive Belt Part Number 3211080 Width inches cm 1 438 3 65 Side Angle 28_ Circumference inches cm 46 625 118 4 Center Distance inches cm 11 5 29 2 Chaincase Center Distance inches 8 373 Top Gear Stock 22 Bottom Gear Stock 39 Chain Stock 76 Gear Lube Polaris Synthetic Capacity oz ml 11 325 3 Reverse System Perc Electrical Alternator Output Operating Voltage 13 5 14 5 Watts 13 5 Vdc Total 400 18 1700 RPM Ignition Timing Coolant Temp 120_F 49_C Spark Plug Gap in mm 027 70 Spark Plug Champion RN57YCC Track Width Inches cm 15 38 Length Inches cm 144 366 ATITUDE DRIVE CLUTCH DRIVEN CLUTCH meters Shift Clutch Clutch Driven Weight Spring Spring Helix g 0 600 64 42 36 0 2000 LWER 22 39 76 600 1200 2000 4000 19 60 1200 1800 4000 6000 1038 BLK GRN RED BLK 22 40 76 120 340 140 240 1800 2400 10 56 7042083 7043058 56 42 36 6000 8000 LWER 2400 3000 8000 10000 19 54 20 41 76 3000 3600 10000 12000 0 Lug Height Inches cm 1 25 3 175 STD
288. ed to the carburetors and adjust the throttle free play by adjusting the barrel nut E and lock nuts F 3E POLARIS The Way Out Maintenance 4 Once you achieve the proper free play of 0 010 0 030 25 80mm tighten the lock nuts 5 Verify the oil pump index marks are within specification 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 Models 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 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 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 counte
289. el Bleed the pressure from the fuel rail See Fuel Rail Bleeding Pressure Testing on page 4 29 Lift and move the tank back to gain access to the fuel lines Disconnect the fuel supply and return hoses from the pump flange See Disconnect Fittings on page 4 29 Disconnect the wiring harness then remove the tank from the snowmobile Place tank in a well ventilated area WINNING PERFORMANCE gt POLARIS Fuel Systems 8 10 Using the PFA spanner wrench and nut socket PS 48459 carefully remove the PFA nut Carefully extract the PFA out of the tank making sure the float and fuel hoses do not become kinked or bent Remove the old gasket and destroy A WARNING Never re use a used PFA gasket 11 12 13 14 15 Clean the tank s gasket mating surface with isopropyl alcohol Allow the surface to dry completely Install a new gasket ensuring the inside portion of the gasket hooks onto the bead on the inside diameter of the neck Remove any containments from the gasket with isopropyl alcohol Carefully place the PFA back into the tank Push the float assembly against the hoses to fit it into the hole Hand tighten the PFA nut keeping the arrow between the PFA alignment marks SUPPLY FITTING ALIGNMENT LINES WINNING PERFORMANCE POLARIS 16 Using the PFA spanner wrench and nut socket PS48459 tighten the PFA to specification
290. er Models 3 12 Fuel Tank Vent System 3 13 Oil Filter 3 12 Water Sediment Trap 3 11 Fuel Pump Overview 4 10 Fuel Rail Bleeding 4 29 Fuel Systems Service Warnings and Precautions 4 2 Fuel Tank Pressure Test 4 30 G Gearing Charts 6 2 General Reference 2 8 Fuel Oil Premix Ratios 2 8 Gasoline Volatility 2 8 Measurement Conversion Chart 2 10 WINNING PERFORMANCE Engine Inspections 5 5 Metric Tap Drill Sizes 2 9 Cylinder Head 5 5 SAE Tap Drill Sizes 2 9 Engine Installation 5 36 Standard Bolt Torque Specification 2 8 Engine Maintenance 3 7 Coolant Surge Tank 3 7 IX 2 gt POLARIS H Handlebar Assemblies 8 9 Honing Procedure 5 9 Cleaning the cylinder after honing 5 9 Hood Repair 10 3 Hood Assembly 10 3 IFS Adjustable Shocks 8 3 05 55 ee Aas 8 2 Ignition Timing 11 5 IQ 121 Heavy Torsion Spring Installation 8 39 IQ Fixed Steering Post Assembly 8 6 IQ Rider Select Steering Post Assembly 8 7 IQ Steering Linkage 8 8 J Jetting Guidelines 4
291. es Loosely install two new fasteners NOTE On IQ 121 and Switchback skids verify the rear track shock pivot and brackets are rotated forward before attempting to collapse the rear torque arm 3 Setthe machine upright Install the remaining two new torque arm mounting fasteners 5 Torquetherear suspension mounting bolts to specification Align the track guides clips with the suspension rails n Adjust the rear idler to achieve the correct amount of track sag WINNING PER gt POLARIS FORMANCE Shocks CHAPTER 9 Shocks SPECIAL TOOLS eee esis 9 2 SHOCK REBUILDING 15 9 2 VALVE SHIMS pi oh Saha ae 6 9 3 RYDE FX SHOCK VALVE PART 8 9 3 FOX SHOCK VALVE PART 8 9 4 WALKER EVANS SHOCK VALVE PART 5 9 5 WALKER EVANS SHOCK VALVE PART NUMBERS 7 16 1 9 6 VALVE SHIM 1 9 7 PISTON 9 7 9 8 2007 SHOCK 1 9 8 2007 SHOCK VALVE SHIM STACK CONFIGURATIONS 9 9 2008 SHOCK 6
292. es 7 7 Special Tools 7 4 Team Driven Springs 7 8 PVT System Adjustments 7 12 Clutch Alignment Offset 7 12 PVT System Overview 72 R Rail Sliders Break In 8 42 Removal and Installation 8 42 Wear Limit 8 42 Rear Suspension Assembly Illustrations IQ 121 Front Rear Torque Arms 8 17 IQ 121 Pivots Rear Idler 8 13 8 14 IQ 121 Rail Assembly 8 15 8 16 IQ 136 Comfort Front Rear Torque Arms 8 29 IQ 136 Comfort Pivots Rear Idler 8 27 IQ 136 Comfort Rail Assembly 8 28 IQ 136 Coupled Front Rear Torque Arms 8 32 IQ 136 Coupled Pivots Rear Idler 8 30 IQ 136 Coupled Rail Assembly 8 31 IQ 144 155 163 Front Rear Torque Arms 8 35 IQ 144 155 163 Pivots Rear Idler 8 33 IQ RMK 144 155 163 Rail Assembly 8 34 IQ Switchback Front Rear Torque Arms 8 26 IQ Switchback Pivots Rear Idler 8 24 IQ Switchback Rail Assembly 8 25 10 128 Front Rear Torque Arms 8 20 M 10 128 Pivots Rear Idler 8 18 M 10 128 Rail Assembly 8 19 M 10 136 Front Rear Torque Arms 8 23 M 10 136 Pivots Rear Idler 8 21 M 10 136 Rail Assembly 8 22 N Rear Suspension Adjustment Procedure 8 37 Nose Bumpers Rear Suspension Coupling 8 36 Assembly Illustration 10 2 Rear Suspension Installation 8 42 Rear Suspension Operation 8 36 Off Season Storage LH Tae eee a 3 21 Rear Suspension Removal
293. es with 2 stroke engine oil when assembling Clean the oil residue and debris out of the engine compartment To assure a smooth transition of the engine into the engine compartment secure all loose hoses that are inside the engine compartment NOTE You may need a helper with the installation of the throttle and oil cables 5 6 Place the engine on the shock tower brace With the throttle body or carburetor rack separated from the intake adapters route the throttle cable behind the fuel rail or under the carburetor rack and insert the throttle cable into the throttle pulley located in the center of the throttle bodies Insert the throttle body into the adapters and tighten the clamps in the orientation as shown below Adjust the throttle cable adjuster nut so that you have the correct throttle free play Place the oil cable into the oil pump arm The oil pump arm has a slot in the back to slide the cable through for installation The plastic end of the throttle cable is inserted so that the large flat is facing the engine and the small end is facing the out side WINNING PERFORMANCE gt POLARIS 10 Using a 10mm open end wrench tighten the lock nut while 15 holding the other nut with a 10mm open end wrench Make sure that the oil cable angle is tilted slightly toward the engine 11 Thread on the adjuster nut and adjust the oil pump and 17 adjust the oil pump 18 12 Carefully place the engine i
294. etonation broken ring lands etc Excessive vibration of engine back firing etc Rough idle poor top speed Checking Crankshaft Index 1 Remove the drive belt and drive clutch Securely fasten a large degree wheel on the flywheel or PTO end of the crankshaft Make sure that it is mounted concentrically with the crankshaft center line 5 8 3 With a section of wire wire coat hanger anchor it to a convenient spot Bend one end at the outer perimeter of the degree wheel as shown below 4 Install a dial indicator into the magneto end cylinder spark plug hole The ignition timing is referenced by the magneto end 5 Locate TDC as accurately as possible by finding the center of the point where there is no piston movement note the Zero the dial indicator at this point 6 Continue to rotate the crankshaft in the normal direction of rotation until the dial indicator reads 100 2 54mm after top dead center ATDC 7 Bendthe pointeror move the degree wheel until the pointer aligns with a 180 mark on the degree wheel 8 With the pointer aligned make sure the degree wheel and pointer are secured and will not move out of position Re check accuracy of this location a few times The pointer should align with the 180 mark when the dial indicator reads 100 2 54mm ATDC NOTE Do not move the crankshaft degree wheel or pointer after the initial setting on the MAG end cylinder simply read the wheel and dial in
295. etor jetting guidelines Do not modify the engine or exhaust system with non approved Polaris modifications Verify there is no water or foreign material in the fuel Verify there is no internal engine damage Verify the cooling system is working properly WINNING PER POLARIS FORMANCE NOTE Install the knock sensor fastener clean and dry without applying thread locker or oils VARIABLE EXHAUST SYSTEM VES Overview The Polaris VES system uses exhaust valves 1 per cylinder to control the exhaust port height The valves are actuated by controlling cylinder pressure with a solenoid bellows and a series of hoses At idle speed and up to a pre determined level the solenoid is powered by the ECU or CDI This action opens the solenoid s internal valve and allows the cylinder pressure to vent into the atmosphere During this time the valves are down To raise the valves the ECU or CDI will cut power to the solenoid which will close the vent path to atmosphere The cylinder pressure will then act upon each valve bellows which will raise each valve On CFI engines the timing at which the solenoid is turned off is determined by engine RPM TPS position and pipe temperature On carbureted engines the CDI will turn the solenoid off at 6700 RPM when the throttle flipper is at least 3 4 throttle or at 7200 RPM when the throttle flipper is at least 1 2 throttle NOTE Solenoid Powered Vent Path Open Solenoid Off
296. ever reserve should be no less than 1 2 1 3 cm from the handlebar Verify that the sight glass indicates a full reservoir Check brake system for any fluid leaks Master Cylinder Lever Service COVER SCREWS 2 PARKING BRAKE LEVER LEVER PIN SWITCH CARTRIDGE BRAKE LEVER To remove the brake lever remove the E clip from the lever pin Extract the pin from the housing then remove the lever To remove the parking brake lever the housing cover must be removed Once removed carefully extract the spring noting it its position inside the housing Remove the parking brake lever To remove the cartridge completely drain the brake fluid from the housing Remove the brake and parking brake levers Disconnect the brake hose from the cartridge Carefully pop the cartridge out of the housing To install the cartridge lubricate the entire surface with DOT 4 brake fluid Align the cartridge with the housing tabs then firmly press the cartridge back into the housing until the cartridge is engaged with the tabs Refill and bleed the brakes system as outlined in this chapter See Brake Fluid Replacement amp Bleeding on page 6 11 WINNING PERFORMANCE gt POLARIS Final Drive and Brakes Brake Line Replacement Follow these steps if the brake line is to be replaced 1 Pp a If needed bleed the brake system by attaching a clear hose to the caliper bleed fitting Attach the other end to
297. face of the engine _ In mm Rear Torque Stop Clearance 010 030 25 75mm NOTE new torque stop is installed install it so that the nub is touching the engine This nub is 030 75mm long 25 Adjust the engine isolator limiter if equipped so the stop is bottomed out on the brace Stop touching base 5 38 rol Engine and Cooling Systems 26 Install the front torque stop assembly and torque the plate 37 Connect the regulator rectifier connections fasteners to specification 4 S e Front Torque Stop Fasteners 28 ft lb 37 9 N m 27 Install the air box onto the carburetor rack Make sure to line up the air box tabs with the air box plate 28 Install the drive clutch See Drive Clutch Installation on page 6 20 29 Install the driven clutch See Driven Clutch Installation on page 6 21 30 Install the drive belt 31 On FI models connect he fuel filter and fuel return line by pushing them together until you hear a audible click 32 Secure the fuel return line clamp onto the side of the airbox 33 Place the fuel filter back into the airbox mounted holder 34 Connect the ECU connection into the ECU 35 Connect the EV solenoid connection to the EV solenoid 36 Connect the coil connections to the coils NOTE The WHITE connector goes to the MAG coil upper The BLUE connector goes to the PTO coil lowe
298. from the hood where the decal is to be applied or heat gun is required If heat is not applied the decal Left over debris will be magnified through the chrome will be very hard to remove and paint from the hood may decals peel off with the decal 4 After the decal is removed apply 3Mt 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 it ina paper shop towel You may have to repeat this process 1 Make sure the surface area of the hood where the decal is several times to remove all of the adhesive from the hood to be placed is free of any dirt debris or adhesive Use care not to get the cleaner on any other decals d 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 2 Place the decal in the area to be installed and make sure that everything lines up properly 5 When the bulk of the adhesive is removed from the hood 3 Carefully peel away the adhesive side of the decal by using the squeegee remove any left over residue with a clean non abrasive shop towel or cheese cloth that is wet with the 3Mt cleaner 1
299. from the reed cage NOTE Measure the air gap between the fiber reed and the reed block The air gap should not exceed 015 38mm If clearance is excessive DO NOT attempt to reverse the reeds to reduce the air gap Always replace them if damaged or worn Check each fiber reed for white stress marks or missing material The air gap should not exceed 015 30mm 7 Ifdamaged remove and replace the reeds on the reed cage Bearing Fit Any time crankshaft bearing failure occurs and the case is reused check the bearing fit into the case halves using the following procedure With case halves cleaned reinstall the main bearings with a piece of Plastigage between the bearing race and crankcase Install and torque the crankcase fasteners to specifica tion Take the crankcase apart and then measure the Plastigage Compare Plastigage width to interference fit WINNING PERFORMANCE gt POLARIS specification 5 In mm gt Bearing Interference Fit Carbureted 001 002 026 051mm CFI 0014 0024 061mm Main Bearing Clean crankshaft thoroughly and oil main and connecting rod bearings with Polaris engine oil Carefully check each main bearing on the crankshaft Due to extremely close tolerances the bearings must be inspected visually and by feel Look for signs of discoloration scoring or galling Turn the outer race of each bearing The bearings should turn smooth
300. ft rotation to retard the timing or against rotation to advance it NOTE Rotate stator plate approximately the same distance as the marks must move In most cases the recoil starter housing recoil drive hub and flywheel must be removed to loosen the stator bolts and change the timing On some engines the stator plate WINNING PERFORMANCE POLARIS retaining screws can be accessed through the flywheel 10 Torque stator plate screws and flywheel nut to specified torque Apply Loctite 262 red to crankshaft fly wheel taper if required Refer to the Specifications section for torque specifications and flywheel installation procedure for engine type Timing Procedure CFI Engines NOTE Before performing procedure verify there are no current trouble codes and that all of the engine electrical connections are clean and tight 1 Reference the timing specification chart and locate the piston BTDC measurement for 18 2 Install a dial indicator gauge into the MAG spark plug hole 3 Place the MAG piston at 18 BTDC Mark the flywheel NOTE Each 10 degree mark is separated by lines every 2 degree Acceptable timing variance is 2 degrees 4 Connect a good quality timing light to the engine according to manufacturer s instructions 5 Start and run the engine at idle speed until the engine temperature is 120 F 49 C Verify the throttle lever is closed and the engine is at idle speed 1700 100 RPM
301. ft torque and PVT system assembly information 6 6 WINNING PERFORMANCE POLARIS Final Drive and Brakes DRIVE TRAIN Speedometer Cable Type Drive Train Assembly SPACER FASTENER FASTENER WASHERS BEARING FLANGE JACKSHAFT RETAINING RING SEAL SLEEVE O RING SPEEDOMETER DRIVE s 7 5 212 HOUSING TAN GASKET 29 0 BEARING DRIVESHAFT KEY FASTENER NOTE Set driven clutch offset following procedure T in the PVT System Chapter Lubricate components as outlined in the Periodic A Driven Clutch Fastener 17 Ft Lbs 23 Nm Maintenance Table B Jackshaft Flange Nuts 17 Ft Lbs 23 Nm Tighten chaincase mounting nuts using a criss C Speedometer Housing Nuts 17 Ft Lbs 23 Nm cross pattern D Driveshaft Housing Nuts 17 Ft Lbs 23 Nm Install jackshaft seal sleeve with beveled edge E Chaincase Mounting Nuts 28 Ft Lbs 38 Nm towards brake disc then install o ring inside sleeve CAUTION Do not over torque the chaincase mounting nuts WINNING PERFORMANCE 7 gt POLARIS 6 Final Drive and Brakes Electronic Speedometer Drive Train Assembly WASHERS SPACER FLANGE WASHERS DRIVEN CLUTCH SPEEDOMETER FLANGE C a Nal e Q 9 GL N 7 SPEEDOMETER SENSOR DRIVESHAFT 55 soe BRAKE DISC FLANGE Ra en Oo Driven Clutch F
302. ge fluid or bleed brakes Contaminated brake discs or brake pads greatly during regular maintenance or after complete brake service reduce braking performance and increase stopping Brake fluid may damage painted or plastic surfaces Take care distance Do not attempt to clean contaminated pads not to spill and wipe up any spills immediately Cover parts to Replace them Clean the brake disc with brake cleaner avoid damage This brake system requires ethylene glycol based fluid 1 Clean the reservoir cover DOT 4 Do not use or mix different types of fluid such as silicone based or petroleum based Do not use brake fluid taken from old used or unsealed containers Never reuse brake fluid A CAUTION Pressure bleeding is not recommended When fluid surges through the fittings it is possible to cavitate the fluid and create air in the system In addition the fluid stored in a pressure bleeder may be contaminated Al ways use fresh DOT 4 brake fluid from a sealed con tainer Remove the two 15 Torx screws from the cover Keep these points in mind when bleeding hydraulic brakes 3 Carefully remove the cover and diaphragm assembly from the reservoir The master cylinder reservoirs have limited capacities 4 Under the cover inspect the vent slots under the bellows It is easy to empty them during the bleeding procedure and remove any debris or blockage This introduces air into the system which you are
303. gs are damaged worn Press the end cap into the reservoir to access the snap ring 5 Remove the snap ring then remove the cap from the body 11 Place the shock rod in a vise so that the threaded part is facing upward 12 Place the valve stack on a clean shop towel in order of removal NOTE Place the valve stack on a clean shop towel in case you have to move them This will also help when assembling them back onto the shock rod cce 9 21 13 Inspect the valves for kinks waves pits or foreign material 14 Inspect the piston wear band and replace if damaged or worn 5 Secure the shock body by its lower mount 1 6 Set the compression damping adjustment selector to Walker Evans Remote Reservoir Piggy position 1 Back Shock Assembly 7 Fill the shock body and remote reservoir 1 2 full of Walker Evans 5w shock oil PN 2874522 Apply a thin film of oil to the IFP o ring and floating wear band located on the shock rod piston 1 Secure the shock rod in a vise with the threads of the rod 8 facing up 2 Placethe compression valve stack on the rod in the reverse order of disassembly 9 Compress the wear band and insert the IFP into the reservoir Allow as much air as possible to escape as you install the piston 3 Place the valve piston on top of the compression stack 4 Place new lock nut onto the shock rod Torque the new 10 Screw the tool PN PS 45908 into the lock n
304. he pressure drops carefully inspect the needle and the needle seat The needle can be replaced needle supplied with float and seat 5 Carefully inspect float bowl gasket and replace if necessary 6 Install float bowl 16 on carburetor with water trap drain plug 15 and single screw 16 on the bottom of the carburetor 7 If throttle slide was removed install throttle slide 11 so that the wider face is facing the engine side of the carburetor 8 Install the funnel gasket 13 and funnel 12 onto the carburetor You will have to lift the throttle slide up and place the smaller face into the funnel area 9 Install funnel screws 10 10 Install the e clip 8 in the desired position on the jet needle 7 11 Slide the plastic washer 9 on the jet needle so that it is positioned to rest on top of the throttle valve when assembled 12 Install carburetors on engine 13 Replace top cap gaskets 3 cover 2 and screws 1 14 Check throttle lever free play ons 4 13 Fuel Systems CARBURETOR ADJUSTMENT Throttle Valve Synchronization All throttle valve synchronization adjustments are made to the MAG throttle valve The PTO throttle valve is non adjustable and considered the base throttle valve Throttle valve synchronization can be performed with the carburetor rack installed or removed from the engine If running turn off engine Remove the air box Remove the carburetor covers Hold the throt
305. he protective outer boot is not torn or damaged If damaged inspect the shock shaft for damage Replace shock shaft if damage is found 1 Place the body 1 of the shock in the vise so that the shock rod 2 is facing downward 2 Remove the service port screw 3 and release the pressure with the shock charging needle Verify all pressure is released 3 Place the body cap 1 in the vise so that the shock rod 2 is facing upward 4 Slowly loosen the shock rod bearing cap 4 and remove from the shock 5 Empty all the shock oil from the shock body and discard the old oil 6 Inspect the valve stack 5 as needed Replace any worn wavy bent valve shims 7 If valve shim service or adjustment is done torque the piston retaining bolt 6 to 25 30 ft lb 34 41 N m e T Piston Retaining Bolt 25 30 ft lb 34 41 Nm 8 Ifrequired replace the bearing cap seal 7 and o ring 8 Walker Evans Air Shock Assembly 1 Place the specified amount of fluid into the shock body CAUTION Do not overfill the shock oil level Too much shock oil may cause the shock rod to hydro lock 2 Insert and torque down the bearing cap 4 assembly into the shock body 9 ey T Bearing Torque 85 ft Ib 115 N m Ad CAUTION Do not over torque the shock rod bearing cap or shock performance will be compromised 3 Flip shock over in the vise so th
306. he rear track shock pivot may cause the rear torque arm to lock All IQ rear track shock pivots with the exception of IQ RMK and race suspensions must be located as shown below On IQ REAR TRACK SHOCK PIVOT IQ 136 COMFORT REAR SUSPENSION 8 4 and race rear suspensions the shock pivot is orientated upwards Always verify the rear torque arm scissor is pushed forward so that it is either straight up IQ IQ Shift or against the FRSS 10 121 IQ 136 Coupled IQ Comfort and not collapsed rearward when installing the rear skid assembly WINNING PERFORMANCE gt POLARIS Steering and Suspension FRONT SUSPENSION ASSEMBLY ILLUSTRATIONS IQ Front Suspension 5 BUSHING LOWER CONTROL ARM SNAP RING WASHER lt NOTE 2008 IQ Front Suspension Shown CAUTION Never re use lock nuts Always re assemble using new lock nuts ey T A 29 Ft Lb 39 Nm Shock Mounting Fastener Nuts B 40 Ft Lb 54 Nm C 45 Ft Lb 61 Nm Sway Bar Block Fastener Nuts Hand Tight NOTE Assembly Notes Note washer installed between fastener and pivot bushing on the rear lower control arm mount to allow sufficient clearance between nut and sway bar WINNING PER POLARIS FORMANCE WASHER qoo PIVOT SHAFT eB LOCK NUT do 582 SPHERICAL BEARING LOCK NUT FASTENER n co
307. he skis It also influences the stiffness of the ride by controlling increased control and less transfer the amount of coupling action between the front and rear torque arms To decrease weight transfer the RRSS should be set in the Torsion Spri ng Adjustment high position To adjust the rear torsion spring rotate the adjuster cam to the The RRSS can be removed for maximum weight transfer desired adjustment The cam has three sides LOW MEDIUM However unless the torsion springs and rear shock valving are and HIGH changed the ride will be compromised Always maintain equal adjustment on both sides The dot is an indicator of the HIGH position The sides are the LOW position and the bottom is the MEDIUM position Cam in LOW Position MEDIUM Limiter Strap Adjustment HIGH POSITION STANDARD POSITION LOW POSITION One method of changing ski to snow pressure is to change the length of the front limiter straps Lengthening the straps decreases ski pressure under acceleration Shortening the straps increases ski pressure under acceleration Set up Recommendations for Optimum Performance RMK Switchback Rear Suspensions 8 38 oo Steering and Suspensions IQ 121 Heavy Torsion Spring Installation Please reference the following information when installing heavy torsion springs on IQ sleds The issue that arises when installing the heavy spring on a Fusion sled is that the coi
308. height is IQ 121 136 4 5 10 13 10 RMK Switchback 5 13cm IQ 10 3 4 8 10cm 5 Adjust for the desired ride height by rotating the torsion spring cams located on the rear of the torsion spring If the rear suspension ride height cannot be adjusted to the correct dimension optional torsion springs may be required This is only an initial setup and final spring preload may vary based on rider preference and riding conditions WINNING PERFORMANCE POLARIS ROTATE The front rear scissor stop FRSS controls the bump attitude of the rear suspension As the front torque arm FTA hits the bump it forces the rear scissor to collapse a predetermined amount depending on the FRSS block position This accomplishes two important things First it allows a lighter spring rate on the FTA because it can borrow spring rate from the 8 37 Steering and Suspensions rear torsion springs Second it prepares the rear portion of the DEEP POWDER SNOW Limiter strap in LOW suspension for the bump reducing secondary kick back position for maximum lift and flotation The FRSS is made of a resilient material allowing smooth action POWDER HARDPACK Limiter strap in STANDARD and preventing any suspension component damage position for overall handling and speed over snow The RRSS controls weight transfer from the rear suspension to HARDPACK Limiter strap in HIGH position for t
309. hift Clutch Clutch Driven Genin feet Weight Spring Spring Helix 8 0 600 0 2000 0 08 600 1200 2000 4000 0 66 1200 1800 or 4000 6000 140 330 BLK PUR 7043342 160 240 56 42 36 20 41 76 1800 2400 0 62 7043363 6000 8000 2400 3000 8000 10 000 0 60 3000 3600 10 000 12 000 0 58 Drive Clutch Bolt Torque 80 Ib ft 108 Nm 1 40 Track tension sag in cm with 10 Ibs 4 54kg placed 16 in 40cm ahead of rear idler shaft 3 8 1 2 1 1 3cm WINNING PERFORMANCE C POLARIS Model Specifications Front Suspension Inches cm Suspension Type IQ Shocks Walker Evans Air Oil Volume 95cc Nitrogen Charge 220 psi Front Vertical Travel 9 22 9 Ski Center Distance Inches cm Setup Width 39 99 1 40 101 6 41 104 1 38 67 98 2 Camber Inches cm 2 17 0 31 55 7 9 Toe Out Inches cm 0 0 12 0 0 31 Rear Suspension Suspension Type IQ RMK 155 163 Front Track Shock FTS Walker Evans Air Oil Volume 60cc Nitrogen Charge 217 5 psi Rear Track Shock RTS Walker Evans w IFP Nitrogen Charge 200 psi Torsion Springs 359 Square 77 Stock 347 177 1 Soft PN 7041627 067 PN 7041628 067 375 77_ Firm PN 7041942 067 PN 7041943 067 Rear Travel Inches cm 15 5 39 4 155 16 5 41 9 163 WINMING PERFORMANCE gt POLARIS
310. hould be clean and dry Do not use harsh cleaners which may cause clutch taper to corrode or damage the crank seal 4 Clean clutch taper with lacquer thinner or isopropyl alcohol 5 Slide clutch onto crankshaft taper Install the retaining bolt with all spacers and washers or o rings that were on the bolt when it was removed 7 Hold the clutch with the holding wrench PN 931417 A 8 Torque bolt to specification 9 engine specification DRIVEN CLUTCH Driven Clutch Removal then re torque the retaining bolt to 1 Remove the drive belt 2 Apply and lock the parking brake 3 Remove the driven clutch bolt and washers A NOTE Count the number and location of the spacer washers located on the fastener and behind the clutch 4 Slide the driven clutch off the jackshaft 5 Inspect the splines and replace jackshaft if damage is found Driven Clutch Installation 1 Install the driven clutch bolt with the same amount of washers at removal Torque the bolt to specification 3 Check for correct belt deflection 7 18 TV PSLARIS The Way Out PVT System Team LWT Components SCREWS DEFLECTION SPACER STATIONARY SHEEVE MOVEABLE SHEEVE BELT DEFLECTION SCREW 10 Install and torque helix fasteners to 60 80 in Ibs 7 9 DT Nm Helix Fasteners 60 80 In Lbs 7 9 Nm Driven Clutch Retaining Fastener 17 Ft Lbs 23 Nm Disassembly an
311. ical center cover piece 5 Remove the rear 2 lower clutch guard mounting screws and 3 forward mounting nuts and plate 6 Remove the 3 screws securing the lower clutch guard to the upper plate leaving the electrical center components in place 7 Loosen and remove the throttle body assembly and set aside 8 Using a mirror or a bore scope and a light visually inspect the current oil pump setting A CAUTION The oil pump lever and pump boss marks must be 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 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 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 7 WRENCHES 11 When adjusting the lever make adjustments 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 p
312. ification 5 Place the same number of spacers on top of the stepped spacer onto the shaft of the stationary sheave zT Cover Fastener Torque CLUTCH SPACER 100 In Lbs 11 Nm NOTE Do not allow side loading or mis alignment of the cover or the bushing may become damaged JAM NUT 6 Thread the spider onto the stationary sheave shaft Index the spider See Spider Indexing on page 7 17 8 Using the spider tool PN 2870341 torque to the spider to specification 6 1 Spider Torque All Except 800 CFI 200 225 Ft Lbs 271 305 Nm Apply Loctite 620 to Threads 800 CFI 280 300 Ft Lbs 380 407 Nm Apply Loctite 242 to Threads PVT System Spider Indexing NOTE Spider indexing effects belt to sheave clearance and clutch balance Please read all procedures before proceeding 1 Remove and disassemble clutch Add or remove spider washers as required to achieve desired belt to sheave clearance Make sure that the stepped washer A is on the bottom of the spacer stack B For example If belt to sheave clearance is 020 too large removing one 020 shim will position the movable sheave closer to the fixed sheave reducing belt to sheave clearance by 020 3 Placethe correct number of spacer washers B beneath the spider The following washers are available for fine tuning 5210752 020 51mm 5242981 025 63mm 5210753 032 81mm 5210754 050 1 27mm
313. il the value indicator knob comes in contact with the shock body The piston should now be located correctly 6 Screw the pressure valve assembly into the valve port by hand with a slotted head screwdriver and tighten to 100 110 in Ib of torque 7 the shock body with shock oil Internal Floating Piston Shocks Fill the shock body with shock oil to the bottom of the thread within the cylinder Emulsion Shocks Fill shock body with 110cc s of oil This will allow for the required air space to properly gas charge the shock with nitrogen gas NOTE After filling the shock body with oil allow a couple of minutes for all air bubbles to rise to the top 8 With the cylinder head assembly pushed down against the piston carefully insert the piston rod and assembly into the cylinder Slightly oscillating the piston rod to allow piston to enter shock body bore A light coating of oil on the piston wear band will ease installation 9 Slowly push the piston rod and assembly into shock body until the cylinder head assembly bottoms on the cylinder counterbore Slight up and down movement may be required to allow all air to pass through piston assembly 10 During installation some shock oil will overflow Wrap a WINNING PERFORMANCE C POLARIS 11 12 13 14 15 16 shop cloth around shock body to catch possible oil overflow Fast installation of the piston rod and assembly may displace the floating piston from
314. in the periodic maintenance table d cn 8 13 Steering and Suspensions IQ 121 Shift Pivots Rear Idler SHOCK PIVOT SPACER 0 IDLER WHEEL Sa IDLER WHEEL A 45 Ft Lb 61 Nm 35 Ft Lb 47 Nm Assembly Notes Never re use Nylock nuts Always replace with new parts All pivots must rotate freely after tightening fasteners Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table 8 14 WINNING PERFORMANCE gt POLARIS IQ 121 Rail Assembly Steering and Suspension 5 BOGIE WHEEL X BUMPER RAIL CAP RAIL SLIDER T A23 6Ft Lb 4 8 Nm B 19 Ft Lb 26 Nm C 35 Ft Lb 47 Nm D 35 In Lb 2 Nm Assembly Notes Never re use Nylock nuts Always replace with new parts All pivots must rotate freely after tightening fasteners Apply Polaris Premium All Season Grease to all grease Zerks as outlined in the periodic maintenance table WINNING PER POLARIS FORMANCE 8 1 5 Steering and Suspensions IQ 121 Shift Rail Assembly 2 per Rail WHEEL MOUNT lt So lt RRSS CAM b BOGIE WHEEL X A lt 2 IDLER BOLT ADJUSTER 3 SPRING ROLLER RAIL CAP 2 S S A RAIL SLIDER T A 3 6 Ft Lb 4 8 Nm B 19 Ft Lb 26 Nm C 35 Ft Lb 47 Nm D 35 In Lb
315. ion Closed 163 360 163 2197 Duration Open 197 Percent Open Duration Open 197 Total Duration 360 x 100 197 360 0 54722 x 100 54 722 Percent Open 54 722 WINMING PERFORMANCE gt POLARIS General Information TORQUE CONVERSION US to Metric ft lb Nm FT LB Nm FT LB 1 1 4 46 62 4 2 27 47 63 7 3 4 1 48 65 1 4 5 4 49 66 4 5 6 8 50 67 8 6 8 1 51 69 2 7 9 5 52 70 5 8 10 8 53 71 9 9 12 2 54 73 2 10 13 6 55 74 6 11 14 9 56 75 9 12 16 3 57 77 3 13 17 6 58 78 6 14 19 0 59 80 0 15 20 3 60 81 4 16 21 7 61 82 7 17 23 1 62 84 1 18 24 4 63 85 4 19 25 8 64 86 8 20 27 1 65 88 1 21 28 5 66 89 5 22 29 8 67 90 9 23 31 2 68 92 2 24 32 5 69 93 6 25 33 9 70 94 9 26 35 3 71 96 3 27 36 6 72 97 6 28 38 0 73 99 0 29 39 3 74 100 3 30 40 7 75 101 7 31 42 0 76 103 1 32 43 4 77 104 4 33 44 7 78 105 8 34 46 1 79 107 1 35 47 5 80 108 5 36 48 8 81 109 8 37 50 2 82 111 2 38 51 5 83 112 5 39 52 9 84 113 9 40 54 2 85 115 3 41 55 6 86 116 6 42 57 0 87 118 0 43 58 3 88 119 3 44 59 7 89 120 7 45 61 0 90 122 0 NING PERF ORMANCE gt POLARIS Nm FT LB FT LB 91 123 4 96 130 2 92 124 8 97 131 5 93 126 1 98 132 9 94 127 5 99 134 2 95 128 8 100 135 6 2 7 General Information GENERAL RE
316. ion also must provide weight transfer and maintain track tension Rear suspensions have many adjustable features for fine tuning to achieve optimum comfort The suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions However suspension adjustments always involve compromises A rear suspension set up to perform well in moguls would not suit the preference of a groomed trail rider Weight Transfer The shifting of weight from the skis to the track is called weight transfer As engine torque is applied to the drive axle the torque is transferred to the track pulling it forward This energy also tries to pull the suspension forward The front torque arm reacts to this force by pushing down on the front of the track in effect applying more weight to the front of the track and reducing the weight on the skis It is important to note that energy used to lift the front of the machine is not available to push the vehicle forward Changing the angle of the front torque arm changes the suspension s reaction to the force Adjusting the length of the limiter strap will change the front torque arm angle Shortening the strap limits the extension of the front of the suspension reducing the angle of the torque arm and increasing ski pressure during acceleration Lengthening the strap allows the front of the suspension to extend further increasing the angle of the torque arm and decreasing ski
317. ion when using a scribe to remove seals Always spear the seal with the point of the scribe Do not wedge the point of the scribe in behind the seal This can scratch the surface of the seal groove which will compromise the performance and reliability of the shock absorber Use the scribe to remove the u cup wiper and o ring seals from the bearing housing Be careful not to scratch the seal grooves or the DU bushing that is pressed into the bearing 3 Thoroughly clean the FIST scraper bearing housing and piston assembly with solvent Dry with compressed air in a well ventilated area If compressed air is not available dry parts using clean lint free paper towels and let sit in a well ventilated area to allow the remaining solvent to evaporate Use a scribe or dental pick to remove the o ring seal from the IFP Install the new well lubricated o ring into the FIST scraper Check to make sure the seal is properly seated and is not twisted If a tool is required to aid in proper seating of o ring use the non writing end of a pen or a similar soft blunt object to push it in Install the new well lubricated o rings into the bearing housing Correct placement of the shaft seal o ring is in the groove next to the DU bushing Check to make sure the seals are properly seated and are not twisted If a tool is required to aid in proper seating of o ring use the non writing end of a pen or a similar soft blunt object to push it in
318. ire removal of retaining rings or clips Because removal weakens and deforms these parts they should always be replaced with new parts When installing new retaining rings and clips use care not to expand or compress them beyond what is required for installation AX CAUTION Because removal damages seals replace any oil or grease seals removed with new parts Ay CAUTION Polaris recommends the use of Polaris lubricants and greases which have been specially formulated for the top performance and best protection of our machines In some applications such as the engine warranty coverage may become void if other brands are substituted CAUTION Grease should be cleaned from parts and fresh grease applied before reassembly of components Deteriorating grease loses lubricity and may contain abrasive foreign matter 2 11 General Information NOTES POLARIS Maintenance CHAPTER 3 Maintenance PERIODIC 55222605 ka eee S Seed eee She 3 2 PERIODIC MAINTENANCE 5 3 2 MAINTENANCE PRODUCTS a WE Ge ee PRSE cen 3 4 ENGINE OILS LUBRICANTS MISC 3 4 DBHIVEJ DRIVEN CLUTCHES tease tie pe A 3 5 BELT DEFLECTION INSPECTION 3 5 DEFLECTION ADJUSTMENT TEAM DRIVEN
319. istance Inches cm 42 5 108 Brake Fluid DOT4 Setup Width cm 41 16 104 5 Drive Belt Camber Inches cm 2 25 0 31 57 7 9 Part Number 3211122 Width inches cm 1 460 3 7 Toe Out Inches cm 0 0 12 0 E 0 31 Side Angle 26 Circumference inches cm 46 77 118 8 Rear Suspension Center Distance inches cm 11 5 29 2 Suspension Type 1Q 121 Chaincase Front Track Shock FTS Ryde FX MPV Center Distance inches 8 373 Top Gear Stock 23 Seats Dale 170 29 75 Bottom Gear Stock 39 Ibs in N mm Chain Stock 76 Rear Track Shock RTS Ryde FX MPV Gear Lube Polaris Synthetic 347 Square 80_ Stock Capacity oz ml 11 325 3 PN 7043070 067 Reverse System Perc PN 7043071 067 N 347 Square 77_ Soft Electrical Torsion Springs PN 7043240 067 Alternator Output PN 7043241 067 Operating Voltage 13 5 14 5 Vde 359 Square 12 5 Firm Watts 13 5 Vdc Total 280 VEI D ST Ignition Timing 26 93500RPM TPS Un plugged PN 7043080 067 Rear Travel Inches cm 13 9 35 3 Spark Plug Gap in mm 027 70 Spark Plug Champion RN57YCC CDI Marking 4011033 Flywheel Marking 4010677 Track Width Inches cm 15 38 Length Inches cm 121 307 Lug Height Inches cm 91 2 3 Track tension sag in cm with 10 155 4 54 placed 16 in 40cm ahead of rear idler shaft 7 8 1 18 2 2 2 9cm WINNING
320. iston to enter the shock body bore as it purges the air out Slight up and down movement may be required to allow all the air to pass through the piston assembly Slowly open the pressure valve assembly Allow all of the nitrogen gas to escape from the reservoir and shock assembly 15 Slowly push the piston rod and assembly into the shock body until the threads can be engaged NOTE During installation some shock oil will over flow Wrap a shop cloths around the shock body to catch any oil overflow IMPORTANT Fast installation of the piston rod and assembly may displace the internal floating piston IFP from its original position Performance issues will be a result if the IFP is not in its specified position 16 Tighten the cylinder head onto the shock body 17 Verify the IFP is set at the specified depth If not verify there is oil on top of the IFP then open the bleed screw Shocks 4 When all of the gas has escaped the reservoir carefully push the reservoir cap down to expose the c clip Using a pick remove the c clip from the reservoir body 5 Remove the cap from the reservoir body 6 Using an adjustable wrench slowly remove the shock rod bearing cap from the shock body 7 using a 1 8 Allen Wrench remove the bleed screw from the IFP inside the reservoir Verify the o ring comes out with the screw 8 Use a pliers to remove the IFP fro
321. it Displacement Cylinders 599 2 Gan 9 0 8 5 inches mm 3 04 77 25 Brake Fluid DOT 4 Stroke inches mm 2 52 64 Drive Belt Piston to Cylinder Clearance Part Number 3211122 inches mm sly Width inches cm 1 460 3 7 Side Angle 26 Installed Ring Ga inches ies E 014 020 356 508 Circumference inches cm 46 77 118 8 Center Distance inches cm 11 5 29 2 Operating RPM 200 8250 Chaincase Idle RPM 1700 Center Distance inches 8 373 Engagement RPM 200 3800 Top Gear Stock 23 Exhaust Valve Spring Purple Bottom Gear Stock 39 Chain Stock 76 Fuel Delivery Gear Lube Polaris Synthetic Capacity oz ml 11 3325 3 Type Cleanfire Direct Injection Reverse System Perc Throttle Body Marking 1203213 Electrical Throttle Body Bore 46mm TPS Voltage Idle 0 95 0 01 Vde Alternator Output Operating Voltage 13 5 14 5 Vdc Fuel Pressure PSI bar 58 4 0 Watts 13 5 Vdc Total 400 Recommended Fuel Octane 18 1700 RPM 91 Non Oxygenated Ignition Timing Coolant Temp 120 F 49 C Spark Plug Gap in mm 027 70 Spark Plug Champion RN57YCC Track Width Inches cm 15 38 Length Inches cm 136 345 4 Lug Height Inches cm 1 25 3 175 R M 2 Clutch Settings ALTITUDE DRIVE CLUTCH DRIVEN CLUTCH meters Shift Clutch Clutch Driven eee feet Weight Spring Spring Heli
322. its original position This must not occur if the damper is expected to perform as designed Using an open face spanner wrench tighten cylinder head securely into the shock cylinder Pressurize the shock through the pressure valve with nitrogen gas to the specified pressure If using RydeFX inflation tool Refer to Procedures for use of replaceable inflation needle instruction manual found in the RydeFX inflation tool case After being compressed the piston rod should fully extend from the shock body once the shock has been pressurized Install the small button head screw in the pressure valve assembly and tighten securely Reinstall sleeve and bushings in lower shock mount FOX PS 5 DISASSEMBLY 1 Remove the shock from the vehicle Remove the steel sleeve from the eyelet using the mallet and an appropriate sized socket Pry the polyurethane bushings out using the flat blade screwdriver being careful not to scratch the body cap Clean the entire shock assembly with soapy water Try to remove as much dirt and grime as possible by scrubbing with a soft bristle brush Never pressure wash your shock as this can force water and debris inside which will damage the seals Dry the shock assembly with compressed air if available or use clean towels Use a 3 32 Hex Key to remove the button head screw from the FOX air valve in the shock body Securely clamp Fox Nitrogen Safety Needle in vice Point air valve away from face
323. k nut B while maintaining the voltage setting 4 Reinstall the throttle cable then install the throttle body back on to the engine Throttle Plate Synchronization The throttle plates are synchronized at the time of throttle body manufacture Adjustment should never be required unless it is believed the plates are out of sync To adjust throttle plate synchronization follow these steps 1 Perform the TPS Baseline Adjustment The TPS must be set to specification 2 Carefully back the synchronization screw out so it no longer touches the tab but do not remove the screw or the spring 3 Verify the TPS voltage is set to 0 70 0 01 Vdc If it is not re perform the baseline adjustment 11 10 Synchronization Screw Throttle Arm Tab e C Screw Mount 4 Slowly turn the synchronization screw inwards until the instant the voltage on the multimeter changes Back the screw out so the voltage reads 0 70 0 01 Vdc NOTE When turning the synchronization screw do not push the screwdriver with enough force to move the throttle cable cam Doing so will affect the TPS voltage reading on the multimeter WINNING PERFORMANCE POLARIS Battery and Electrical Systems ELECTRIC START IQ CARBURETED CFI System Schematic 600 Carbureted JUMPER HARNESS BLACK REGULATED AC VOLTAGE AC VOLTAGE FROM STATOR YELLOW IGNITION SWITCH REAR VIEW SOLENOID
324. ki Center Distance 42 5 108 Camber Inches cm 2 25 0 31 57 7 9 Toe Out Inches 0 0 12 0 0 31 Rear Suspension Suspension Type IQ 121 Ryde FX HPG w IFP STD Front Track Shock FTS 05 Rebuildable FTS Spring Rate Ibs in N mm 130 270 2 3 4 8 FTS Spring Installed Length Inches cm 7 97 20 2 Fox PS5 w IFP STD Rebuildable Rear Track Shock RTS Fox Compression Adjustable Remote Resevoir HPG OPT Rebuildable Torsion Spring Diameter 374 Tail Angle 80_ Rear Travel Inches cm 13 9 35 3 WINMING PERFORMANCE gt POLARIS 1 9 Model Specifications 2007 600 HO Switchback CFI Model Number 507 56 5 A B Engine Engine Type suse eed slit Model Number 53206 6044 6 Displacement Cylinders 599cc 2 Bore inches mm 3 04 77 25 Stroke inches mm 2 52 64 Piston to Cylinder Clearance inches mm 004 006 105 159 Installed Ring Gap inches mm 014 020 356 508 Operating RPM 200 8250 Idle RPM 1700 Engagement RPM 200 3800 Exhaust Valve Spring Purple Fuel Delivery Type Cleanfire Direct Injection Throttle Body Marking 1203213 Throttle Body Bore 46mm TPS Voltage Idle 0 95 0 01 Fuel Pressure PSI bar 58 4 0 EU Fuel Octane 91 Non Oxygenat
325. l hoses on CFI engines feature disconnect fittings that require special tools to remove The fuel line disconnect tool kit PS 47152 supplies one 5 16 and one 3 8 quick disconnect tool These tools are also commercially available at local auto parts stores HED 1 disconnect a fuel hose from the fuel pump or fuel rail insert the tapered end of either the 5 16 or 3 8 tool into the female housing 2 Firmly press the tool into the housing while carefully pulling the male hose outwards PS 47152 3 Reconnect the fuel hoses by coating each hose end with a light film of two stroke engine oil 4 Carefully install the male end of the hose into the center of the female housing Firmly push the hoses together until the male nozzle fully seats behind the spring tabs 5 Grasp both hoses and gently pull to verify positive engagement 4 29 Fuel Systems Fuel Tank Pressure Test 1 Connect a Mity Vac hand pump to the fuel tank vent fitting 2 Connect a eight inch piece of 5 16 fuel hose and two gear clamps across the fuel supply and return fittings at the fuel pump flange 3 Pressurize the tank to 5 PSI NOTE Fuel tank deformation will occur when the tank is pressurized A WARNING Do not over pressurize the fuel tank past 6 PSI NOTE Using a hand pump to pressurize the fuel tank may take a very long time The installation of an in line Schrader Valve PN 2872602 and the use of
326. l needle bearing and pin in connecting rod Rotate pin slowly and check for rough spots or any resistance to movement 5 Slide pin back and forth through bearing while rotating and 5 7 Engine and Cooling Systems check for rough spots 6 With pin and bearing centered in rod twist ends back and forth in all directions to check for excessive axial play 7 Pull up and down evenly on both ends of pin to check for radial play 8 Replace pin and bearing if there is any resistance to rotation or excessive axial or radial movement If play or roughness is evident with a new pin and bearing replace the connecting rod Crankshaft Index Polaris crankshafts are pressed together The connecting rod journal center lines are indexed 180 apart from each other It is sometimes necessary to check multi cylinder crankshafts to verify that one cylinder has not been forced out of position relative to the other cylinder Some causes for a out of index crankshaft include but are not limited to the following Hydrolock from water or fuel Impact to drive clutch from object or accident Abrupt piston or other mechanical failure Engine lock up due to drive belt failure Symptoms of an out of index crankshaft can include but are not limited to the following Difficulty calibrating carburetor repetitive plug fouling on one cylinder with no other cause Unexplained piston failure on one cylinder i e severe d
327. l stack of the torsion spring is wide enough to interfere with the Parts Needed DESCRIPTION SHAFT ARM SCREW THRUST WASHER LOCK WASHER Large step facing toward center of suspension Spring Sleeve poe r Torsion spring sleeve NOTE Install so that the larger step is toward the center of the suspension WINNING PERFORMANCE gt POLARIS suspension arm clamp nut To work around this issue you will need to order two one for each side of the following parts Relocate the two washers that are next to the clamp nut to the outside of the link arm PART NUMBER 5132972 7517917 7555945 7552614 NSIDE FLAT WASHER 1552614 1555945 7511311 UTSIDE FLAT WASHER 5132972 7552614 7555945 4 gt Relocated flat washers 7517917 8 39 Steering and Suspensions M 10 SUSPENSION M 10 OVERVIEW The FAST M 10 rear suspension has been designed and set up to deliver a soft ride under average riding conditions Rider weight riding styles trail conditions and vehicle speed each affect suspension action The suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions It should be noted however that suspension adjustments involve a compromise or trade off A machine set up to perform well in the moguls would not suit the preference of a groomed trail rider M 10 ADJUSTMENTS Full Range Adjuster FRA
328. learance Grchestim 004 006 105 159 600 1200 410 400 390 370 360 350 340 330 2000 4000 3 3 2 2 2 2 1 1 Installed Ring Gap inches mm 014 020 356 508 1200 1800 370 360 350 340 330 320 310 300 4000 6000 3 2 2 2 2 1 1 21 1800 2400 340 320 310 300 280 280 270 260 6000 8000 3 2 2 2 41 1 1 1 2400 3000 310 300 290 280 270 260 250 240 8000 10000 2 2 2 41 41 1 1 21 Operating RPM 200 8100 Idle RPM 1500 Engagement RPM 200 3800 Exhaust Valve Spring Pink Carburetor Settings 3000 3700 290 280 270 250 240 230 220 210 10000 12000 2 2 1 1 Clip in 1 position with washer placed on top of clip When using non oxygenated fuel with a RON greater than 93 decrease the main jet number in the above chart by 10 and raise the E clip one position If the chart recommends do nothing with the clip when using RON 93 Clutch Settings Type Mikuni TM38 Main Jet 280 Pilot Jet 50 Jet Needle Clip position 9DGN6 57 1 Needle Jet P 8 Throttle Gap Under Cutaway in mm 0 13 3 2 Cutaway 2 5 Valve Seat 1 5 Starter Jet 145 Pilot Air Jet 6 Fuel screw Turns Out 1 Recommended Fuel Octane R M 2 Non Fo d
329. lectrolyte is added After charging the battery only add distilled water 4 Charge battery at 1 10 of its amp hour rating Example 1 10 of 9 amp battery 9 amps 1 10 of 14 amp battery 1 4 amps 1 10 of 18 amp battery 1 8 amps recommended charging rates 5 Check specific gravity of each cell with a hydrometer to ensure each has a reading of 1 270 or higher 6 Install vent covers Specifications Battery PN 4140006 Battery Type YB14A A2 Conventional Nominal Capacity 12Vdc 14AH Electrolyte Volume 30 40z CCA OF 18C 195 AMPS Charging Current 1 4 AMPS Battery PN 4140005 Battery Type Y50 N18L A Conventional Nominal Capacity 12Vdc 20AH Electrolyte Volume 47 302 Charging Current 2 AMPS WINNING PER POLARIS FORMANCE Refilling a Conventional Battery The normal charge discharge cycle of a battery causes the cells to give off gases These gases hydrogen and oxygen are the components of water Because of the loss of these gases and the lowering of the electrolyte level it will be necessary to add pure clean distilled water to bring the fluid to the proper level After filling charge the battery to raise the specific gravity to 1 270 or greater FRESH PACK BATTERY NOTE Do not service the battery unless it will be put into regular service within 30 days Battery Preparation Some models are equipped with a fresh pack battery These b
330. left side and the rear skid removed remove the drive shaft 14 Assemble in reverse order WINNING PERFORMANCE 6 POLARIS 9 Final Drive and Brakes BRAKE SYSTEM Overview The Polaris snowmobile hydraulic brake system consists of the following components or assemblies brake lever master cylinder hydraulic hose brake caliper slave cylinder brake pads and a brake disc which is secured to the drive line When the hand activated brake lever A is applied it contacts a piston B within the master cylinder As the master cylinder piston moves inward it closes a small opening called a compensating port C within the cylinder and starts to build pressure within the brake system As the pressure within the system is increased the pistons D located in the brake caliper move toward the disc and applies pressure to the moveable brake pads As the lever pressure is increased the braking effect is increased The friction applied to the brake pads will cause the pads to wear As the pads wear the piston within the caliper self adjusts and moves further outward Brake fluid level is critical to proper system operation A low fluid level allows air to enter the system causing the brakes to feel spongy Compensating Port Located within the master cylinder is a small compensating port C which is opened and closed by the master cylinder piston assembly The port is open when the brake lever is released
331. ly Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table 8 24 SPACER WASHER WINNING PERFORMAN Steering and Suspensions IQ Switchback 144 Rail Assembly lt 2 BOGGIE WHEEL WHEEL MOUNT RAIL SLIDER ey A 3 6Ft Lb 4 8 Nm B 19 Ft Lb 26 Nm C 35 Ft Lb 47 Nm D 35 In Lb 4 Nm Assembly Notes Never re use Nylock nuts Always replace with new parts All pivots must rotate freely after tightening fasteners Apply Polaris Premium Season Grease to all grease zerks as outlined in the periodic maintenance table 8 25 Steering and Suspensions IQ Switchback 144 Front Rear Torque Arms Assembly Notes Never re use Nylock nuts Always replace with new parts All pivots must rotate freely after tightening fasteners 8 26 SS FRONT TORQUE ARM C N B UPPER SHAFT sO WO ARIT 2 o d lt reg 1979 9t LF CN LOWER SHAFT i B SHOCK ASSEMBLY Q9 v if o CIMITERISTRARS 2 0 REAR TORQUE ARM E REAR PIVOT SCISSOR s E 4 B 96 MJ gt 2 De gt QS SHOCK ASSEMBLY 9 2 RN Z v 7 2 ADJUSTER 778 ROD SLEEVE 6 SPACER SET SCREW SPRING Apply
332. ly and quietly The inner race of each bearing should fit tightly on the crankshaft The outer race should be firm with minimal side to side movement and no detectable up and down movement Replace any loose or rough bearings Connecting Rod Lower Bearing Measure connecting rod big end side clearance with a feeler gauge on both sides of the connecting rod The side clearance on either side of the connecting rod cannot exceed the connecting rod side clearance specification The difference between the two clearance measurements WINNING PERFORMANCE POLARIS Engine and Cooling Systems cannot exceed the maximum clearance differential specification 1 lt gt In mm Connecting Rod Side Clearance 0114 0295 289 749mm Maximum Clearance Differential 002 051mm Rotate the connecting rod on the crankshaft and feel for any rough spots Check radial end play in rod by supporting rod against one thrust washer and alternately applying up and down pressure Replace bearing pin and thrust washers if side clearance is excessive or if there is any up and down movement detectable in the big end bearing Piston Needle Bearing 1 Clean the end of the connecting rod and inspect inner bore with a magnifying glass Look for any surface irregularities including pitting wear or dents 2 Runa fingernail around the inside of the rod and check for rough spots galling or wear 3 Oil and instal
333. m Idle RPM Carburetor Adjustments Throttle Lever Chock Lever Oil Pump Arm I Throttle Choke Cables I L L L 42 00896 Way Out Maintenance Periodic Maintenance Table Frequency Item 150 mi 500 mi 1000 mi 2000 mi 240km 800km 1600km 3200km Pre Season Fuel Vent Hoses I I I I I Oil Hoses I I I I I Air Box I I I Carburetor Drains Water Traps I I I I Electrical System Auxiliary Shut Off I I I I I Throttle Safety Switch I I I I I Ignition Switch I I I I I Headlights Brake light Taillights I I I I I Hand Thumbwarmers I I I I I Perc Reverse System I I I I I Chassis Ski Toe Alignment I I I Suspension Mounting Bolts I I I I I Steering Fasteners Linkage Handlebars I I I I I Driveshaft Jackshaft Bearings L L L L Ski Fasteners I I I I Drive Chain Tension I I I I I Chaincase Gearcase Oil I I I R I Track Alignment Track Tension I I I I I Rail Slide Condition I I I I I Bogie Wheel Condition Fastener Bolts I I I I I Hood Seat Chassis Engine Compartment L Lubricate I Inspect Adjust Replace Clean 3 3 GE POLARIS The Way Out Maintenance MAINTENANCE PRODUCTS Engine Oils Lubricants Misc DESCRIPTION PART NUMBER Premium All Season
334. m Recoil Housing 9 Ft Lbs 12 Nm Recoil Hub 9 Ft Lbs 12 Nm Flywheel Nut 90 Ft Lbs 122 Nm Loctite 242 Magneto 12 Ft Lbs 16 Nm 5 Ft Lbs 7 Nm Loctite 242 Crankcase 9 Ft Lbs 12 Nm M6 Apply Loctite 242 M8 22 Ft Lbs 30 Nm 22 Ft Lbs 30 Nm Apply Loctite 242 Engine Straps 30 Ft Lbs 41 Nm 45 Ft Lbs 61 Nm Loctite 242 Fuel Rail 9 Ft Lbs 12 Nm N A Crankcase Drain Plugs 60 In Lbs 7 Nm Apply Pipe Sealant Air Intake Gear Clamps 11 In Lbs 1 2 Nm 5 2 WINNING PERFORMANCE gt POLARIS Engine and Cooling Systems Engine Specifications PISTON TO ENGINE MODEL INSTALLED HEAD HEAD SQUISH CYLINDER PISTON RING END TRIGGER TO VOLUME GAP FLYWHEEL GAP NUMBER cc INCHES MM CLEARANCE INCHES INCHES MM 3273 6044 PU6F 53274 6044 6 050 060 S3466 6044 PUGF 21595209 1 283 1 544 ae S3467 6044 PU6F 004 006 014 020 105 159 356 508 53206 6044 6 045 058 53468 6044 6 26 65 28 15 1 143 _ 482 53469 6044 6 2 0044 0059 017 026 3470 7044 PU7J 112 151 44 650 53471 7044 7 046 059 36 1 34 29 3 30 85 1 17 1 51 Pee ds y S3322 7044 PF7J 109 163 d 014 020 35 50 3489 8044 PU8E 333 353 049 065 0037 0053 017 025 S3741 8044 PU8E 1 25 1 64 095 135
335. m the reservoir Verify the wear band and o ring come out with the IFP 9 Pour out all of the shock oil into an appropriate storage container Dispose of oil properly NOTE Do not reuse shock oil 10 Place the shock rod in soft jawed bench vise Remove the valve shim stack and piston nut Remove the shims and piston as they are arranged on the shaft 9 24 11 With the shock disassembled inspect the following items Piston rod for straightness nicks or burrs Cylinder head assembly bearing Inside of shock body for scratches burs or excessive wear Teflon piston and IFP wear band for cuts chipped or nicked edges or excessive wear O rings for nicks cuts or cracks Valve discs for kinks or waves Hose for kinks or cuts Ryde FX Remote Reservoir Shock Assembly 1 Install the shock rod in a soft jawed bench vise Reassemble the valve shim stacks and piston in the order in which they were removed 3 Torque nut to specification DONOT OVERTIGHTEN THENUT DAMAGE TO THE CAUTION SHOCK ROD MAY OCCUR ey T Shock Rod Lock Nut Torque 15 20 Ft Lbs 21 28 Nm 4 Secure the shock body in a soft jawed bench vise WINNING PERFORMANCE gt POLARIS Shocks 5 the shock body with new Ryde FX shock oil Fill until the level of the oil is one inch below the top of the reservoir body 6 Using a Vernier Caliper set the caliper leg to the specifie
336. mall square knot at one end Push the knot firmly into begins to bind Unwind the pulley clockwise two the pocket on the pulley revolutions 3 n juu rng Kio during 22 17 Pull on rope to disengage it from the notch in the pulley Instali thesprng by Spi ingt C Spring Counter EWIE Un tie the knot in the rope and allow it to retract into the toward the center of the housing fads ousing 6 Lubricate the center shaft and spring with Premium grease 18 Pull on the handle to verify proper operation 7 Wind the rope counterclockwise around the pulley as WINNING PERFORMANCE gt POLARIS 5 11 Engine and Cooling Systems EXHAUST VALVE MAINTENANCE Exhaust Valve Assembly VERTICAL SCREW M HORIZONTAL SCREWS 23 BELLOWS BELLOWS WASHER PU ss a 2 EV BASE w FITTING CAE GASKET GUILLOTINE Exhaust Valve Disassembly CAUTION EV spring under tension Use care when removing housing from assembly base 1 Remove the vent hose from the base Remove the two horizontal cover fasteners securing the valve assembly to the cylinder 3 Remove exhaust valve assembly from cylinder Remove the gasket and discard Remove the two vertical cover screws to access the spring and bellows 5 Secure the guillotine then apply heat to remove the bellows cap nut 6 Separate the cap nut bellows and bello
337. ments 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 After setting the oil pump lever correctly apply a small drop of Loctite 242 to the cable barrel threads then secure the jam nuts Re check the oil pump alignment marks after securing the jam nuts to verify the marks are set correctly Re assemble the removed components in the reverse they were removed Reference the appropriate service manual chapter for component assembly fastener torques 3 10 Maintenance Oil Pump Bleeding Verify oil tank is filled with oil Loosen the bleed screw A Verify a stream of oil flows from the bleed screw Ne 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 important to purge air within the hoses and oil pump 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 AD Turn the fuel tank supply valve to the
338. moving 9 If the signal readings are erratic replace the TPS sensor 11 7 Battery and Electrical Systems TPS Adjustment Carbureted Models 1 Click on the TOOLBOX icon 2 Click on TPS INITIALIZATION NOTE Always verify the engine idle speed is set at 3 Follow the st d d displayed on th 2 engine operating temperature and the throttle cable freeplay is set to 0 10 0 30 TPS Baseline Adjustment CFI Models 1 Connect the TPS test tool to the TPS NOTE The TPS baseline and idle speed 2 Slightly loosen the screws securing the TPS to carburetor adjustments must be performed whenever the TPS body is moved or replaced 3 Have an assistant hold the throttle flipper in the WOT position 1 Remove the drive belt driven clutch airbox and adapter 4 Turn the TPS clockwise to decrease voltage plate counterclockwise to increase voltage 2 Ifthe TPS requires replacement remove the throttle body 5 Carefully tighten the TPS screws when the WOT Vdc is and replace the TPS 4 00Vdc NOTE If only verifying the TPS voltage setting the throttle body can remain on the engine 3 The TPS fasteners can be accessed through a set of access holes in the TPS guard if adjustment is required 4 Unplug the TPS connector B and connect the TPS test tool NOTE The guard may need to be flexed to align the holes with the TPS fasteners TPS Adjustment CFI Models Using Digital Wrench
339. mpress 4 5 inches A 150 in spring will compress 3 inches If the suspension had 4 inches of spring travel the 100 in spring would bottom out while the 150 in spring would have one inch of travel remaining Free length the length of a coil spring with no load applied to the spring Installed length the length of the spring between the spring retainers If the installed length of the spring is less than the free length it will be pre loaded Spring rate the amount of force required to compress a coil spring one inch For example if 150 pounds of force are required to compress a spring 1 inch the spring rate would be 150 in Straight rate spring the spring requires the same amount of force to compress the last one inch of travel as the first one inch of travel For example if a 150 in spring requires 150 pounds of force to compress it one inch 300 pounds of force would compress it two inches 450 pounds of force would compress it three inches etc Progressively wound spring the rate of the spring increases as it is compressed For example a 100 200 in rate spring requires 100 pounds of force to compress the first one inch but requires 200 additional pounds to compress the last one inch WINNING PER gt POLARIS FORMANCE Steering and Suspensions Adjustable Shocks Snowmobiles equipped with adjustable Ryde FX shocks allow the driver to make adjustments to the compression valving b
340. n 9 7 Shock Rebuilding Tools 9 2 Shock Specifications 9 8 2007 Shocks 9 8 Valve Shim Stacks 9 9 2008 Shocks 9 12 Valve Shim Stacks 9 13 Shock Valve Shim Arrangement 9 7 Snowmobile Number Designations 2 2 Model Number Designation 2 2 Spark Plug Reading 2 10 Spindle Assembly 8 12 Spindle Disassembly 8 12 Steering Suspension Maintenance 3 18 Handlebars 3 18 Rider Select Steering U Joint 3 18 Ski Ski Skags 3 19 Track Alignment 3 20 Track Tension 3 19 Steering Inspection 8 2 Suspension Mounting Fastener Torque 8 3 Team LWT Driven Clutch Components 7 19 5 41 Throttle and Choke Cable Adjustments 3 16 Throttle Body Removal 4 35 Throttle Lever Freeplay 3 16 Throttle Lever Freeplay Models 3 17 Throttle Opening vs Fuel Flow 4 9 Throttle Position Sensor 11 7 Torque Conversions 2 7 US to Metric 2 7 Torsion Spring Adjustments 8 38 Track Alignment 3 20 U Upper Lower Control Arm Installation 8 12 Upper
341. n Pink 3000 3700 200 prng 55Pj 55Pj 55 55Pj 55 2 2 2 41 1 1 H 41 Carburetor Settings 9 When using oxygenated fuel with RON greater than 93 Type Mikuni TM38 decrease the main jet number in the above chart by 10 and raise the E clip one position If the chart recommends clip 1 install washer on Main Jet 280 top when using RON 93 Pilot Jet Pj 50 Jet Needle Clip position 9DGN6 57 2 Clutch Settings Needle Jet 8 ALTITUDE DRIVE CLUTCH DRIVEN CLUTCH mes Shif Clutch Clutch Dri Throttle Gap Under Cutaway in mm 125 3 2 feet Spee ae dr Gearing Cutawa 2 5 0 600 of 0 2000 10 62 Valve Seat 1 5 m Starter Jet 145 2000 4000 Pilot Air Jet 9 1200 1800 10 58 2000 0000 140 330 BLACK 5642 36 19 4 76 Fuel screw Turns Out 5 1800 2400 6000 8000 91 R ded Fuel Oct R M 2 2400 3000 ecommended Fuel Octane 2 Non Oxygenated 8000 10 000 Ios 3000 3600 10 000 12 000 Drive Clutch Bolt Torque 50 Ib ft 68Nm 1 22 WINMING PERFORMANCE C POLARIS Model Specifications General Front Suspension Width in cm 46 5 115 6 Suspension Type IQ RMK EE Galen 202 Shocks Ryde FX 7 155 IFS Spring Rate
342. nction P0351 9 Failure within the primary circuit Can be caused by PTO Ignition Coil Circuit Malfunction P0352 faulty wiring ignition coil or ECU Engine is running but there is no signal from the 5 5 Tooth CPS Signal Missing P0335 10 tooth CPS Can be caused by a faulty stator wiring or ECU Engine is running but the pulses from the 5 tooth CPS are incorrect Can be caused by a faulty stator wiring harness or there is no 2 tooth CPS signal If 5 Tooth CPS Signal Intermittent P0336 there is no 2 tooth CPS signal the engine will not run but the P0336 code will be set because the ECU receives extra 5 tooth signals without any 2 tooth signals Sensor supply voltage is below an acceptable limit EON Ed Can be caused by faulty wiring or ECU Steady LED i Chas is Voltize High P0563 System voltage is too high Can be caused by faulty wiring or regulator rectifier Chassis Voltage Low P0562 System voltage is too low Can be caused by a faulty wiring or regulator rectifier Engine is running but a problem is found with the Ignition Voltage Circuit Malfunction P0350 ignition coil power circuit Can be caused by faulty wiring or ECU Chassis Relay Coil Open Circuit P1611 The chassis relay control circuit is open Can be caused by faulty wiring or a faulty relay WINNING PERFORMANCE gt POLARIS 4 17 Fuel Systems MFD Blink Codes The check engine LED will display a blink code whenever
343. nd torque to specification ey T Pressure Valve Assembly Torque 100 110 In Lbs 15 Slowly fill the shock body with Ryde FX shock oil up to the level of the outer threads NOTE Allow the shock to stabilize for several minutes and allow the air bubbles to escape to the top Wrap the shock body with clean shop towels to catch any shock oil spillage WINNING PERFORMANCE gt POLARIS 16 Invert the 36mm piston rod assembly and pour a small amount of shock oil into the center of the locking piston bolt until the oil flows back out of the hole 17 Hold a finger over the bolt hole then carefully insert the piston rod into the shock body cylinder Slightly oscillate the piston rod to allow the piston to enter the shock body bore 18 Slowly push the piston rod into the shock body until the cylinder head assembly bottoms on the cylinder counterbore Slight up and down movement may be required to allow all air to pass through the piston assembly 19 Using interlocking channel pliers securely tighten the cylinder head on the shock body 9 19 Shocks 20 Pressurize the shock body cylinder with nitrogen gas to specification 21 Install the small button head screws back into each valve assembly 22 Reinstall the eyelet hardware and test shock After being compressed the piston rod must fully extend from the body Walker Evans Air Shock Disassembly IMPORTANT Verify t
344. nd flat washers from the lower attachments of the limiter straps and relocate the straps to the desired position i e move from position 4 to 3 Replace the nut and washer Tighten securely setting for 3 For half hole increments such as 3 4 the limiter straps have slots at the upper pinch bolt These slots allow the bolts to be loosened rather than removed for half step adjustments Re tighten the pinch bolts 4 There are also two front arm mounting holes in the slide rail that can adjust ski pressure The lower hole A increases ski pressure while the upper hole B decreases ski pressure 8 41 Steering and Suspensions NOTE By design the BIASED COUPLE design of the M 10 suspension displaces the rear arm as the front arm is compressed This means that when you raise the front limiter strap at some point you will collapse the rear suspension arm which will affect SAG height and reduce rear suspension travel RAIL SLIDERS Wear Limit Replace sliders when wear exceeds notch If sliders look wavy in appearance check and adjust track tension or consider adding more bogie wheels Removal 1 Remove the rear suspension NOTE Some models may allow the rail sliders to be removed by sliding it through track windows with the suspension mounted in the machine 2 Remove front rail slider retaining bolt located at the rail tip 3 Use a block of wood or a drift punch and hammer to drive the slider rearw
345. nder replacement or re chroming The assembly process is the reverse of disassembly Always use new gaskets and o rings during assembly Liberally coat the inside of each cylinder and the outside of each piston with Polaris two stroke engine oil When installing a piston into a cylinder verify each piston ring opening is located at each piston ring locating pin Squeeze the top ring then carefully slide the cylinder over the compressed ring Do the same with the bottom ring Follow the torque specifications and torque sequences located at beginning of chapter when tightening fasteners WINNING PERFORMANCE gt POLARIS 5 23 Engine and Cooling Systems 2008 800 CFI Cylinder Head Cylinder Pistons co cto THROTTLE BODY HOSE SEE NOTE BLEED SCREW THERMOSTAT COVER B i SPARK PLUGS HEAD COVER 2 22 MET IE TEMP AN D gt O RINGS e ey 70 In Lbs 8 Nm B 9 Ft Lbs 12 Nm Apply Loctite 242 C 25 Ft Lbs 34 Nm Apply Loctite 242 D 18 Ft Lbs 24 Nm Apply Pipe Sealant E 168 In Lbs 19 Nm Clean and Dry F 42 Ft Lbs 57 Nm NOTE Engines with serial number beginning with S3489 feature a bypass nozzle Engines with serial number beginning with S3471 feature a plug Engine Model Piston PN Piston ID 53489 8044 05085 2923 07 3471 8044 PU8E Single Ring 5 24
346. ndicator tells you what action is required to straighten the shaft Truing Examples To correct a situation like this Strike the shaft at point A with a brass hammer To correct a situation like the one shown in this Squeeze the crankshaft at point A You will use the tool from the alignment kit PN 2870569 y 4 HIGH 004 1mm HIGH 004 1mm AA SUPPORT CRANKSHAFT AT THESE TWO BEARINGS HIGH 002 05mm 005 13mm If the crank rod pin location is 180 from the dial indicator opposite of above it will be necessary to spread the crankshaft at the A position as shown in illustration 3 When rebuilding and straightening a crankshaft straightness is of utmost importance Runout must be as close to zero as possible 5 10 HIGH 002 05mm A HIGH 005 13mm WINNING PERFORMANCE gt POLARIS Engine and Cooling Systems RECOIL ASSEMBLY Rope Removal and Installation TAB ENGAGES INSIDE PULLEY VZ 4 FRICTION PLATE gt RATCHET amp 2 ROPE GUIDE HOLE lt w RATCHET SPRING RECOIL SPRING 4 ENGAGES INSIDE HOUSING viewed from the ratchet side of the pulley A CAUTION 8 Pass the end of the rope through the hole in the housing If the rope guide was removed from the housing reinstall it Recoil spring under high tension Always wear eye before attaching the
347. ne cannot be driven completely onto trailer it may need to be pulled or pushed to avoid belt wear burning Clutch malfunction Check for correct clutch components or damage on the clutch Slow easy belt engagement easing on the throttle Use fast effective throttle to engage the clutch PVT System Drive Belt Removal Team Driven Clutch NOTE Turn the key to the OFF position and allow the engine to come to a complete stop 1 Verify the driven clutch is not in reverse Open the clutch guard Ay CAUTION Damage to the driven clutch or L wrench will occur when attempting to open the driven clutch when the driven clutch is in the reverse position 2 Insert the L wrench PN 2874857 A into the threaded hole B located on the driven clutch and turn it clockwise until the clutch sheaves are in the open position 3 Remove the drive belt Drive Belt Installation Team Driven Clutch 1 With the L wrench inserted into the threaded into hole and the sheaves in the open position install the drive belt NOTE Install belt so that the numbers can be read correctly on the left side of the machine or in the direction in which the belt was originally installed 2 Remove the wrench Wiggle the belt to remove slack while removing the wrench 3 Close the clutch guard POLARIS The Way Out
348. not enough fuel leaves the nozzle Therefore the predetermined fuel level should not be changed arbitrarily 4 6 Fuel Metering THROTTLE VALVE PILOT AIR JET NEEDLE JET VALVE SEAT PILOT JET MAIN JET Mikuni carburetors use a starter enricher system rather than a choke In this type of carburetor fuel and air for starting the engine are metered with entirely independent jets The fuel metered in the starter jet is mixed with air and is broken into tiny particles in the emulsion tube The mixture then flows into the plunger area mixes again with air coming from the air intake port for starting and is delivered to the engine through the fuel discharge nozzle in the optimum air fuel ratio The starter is opened and closed by means of the starter plunger The starter type carburetor is constructed to utilize the negative pressure of the inlet pipe so it is important that the throttle valve is closed when starting the engine Fuel Delivery The pilot system s main function is to meter fuel at idle and low speed driving Though its main function is to supply fuel at low speed it does feed fuel continuously throughout the entire operating range Fuel for the pilot jet is drawn from the float bowl mixed with air jet and delivered to the engine through the pilot outlet FUEL DELIVERY The mixture is regulated to some degree by adjusting the fuel screw WINNING PERFORMANCE POLARIS
349. nsor or ECU Connections A B Diagnose this Trouble Code acm Click on A to activate guided diagnostics Click on B to view a wiring schematic of the component or system Click on to exit the current screen WINNING PERFORMANCE gt POLARIS Fuel Systems CFI Clutch Guard Electrical Center COVER SPARE BELT HOLDER FtLbs 10 Nm W _ CAPACITOR IGNITION COILS 6 Ft Lbs 10 Nm COIL MOUNT ons 4 19 Fuel Systems 34 Pin CNA ECU Connector NOTE Wire Entry View PIN COLOR GOES TO CONNECTOR FUNCTION 3 RED BLUE SPLICE K LINE POWER 4 ORANGE ECU POWER EXTERNAL POWER 5 WHITE BLACK EXHAUST TEMP SENSOR SIGNAL 6 BLUE TBAP AIR TEMP SIGNAL 7 GREEN BLUE IGNITION SWITCH STARTER LOCKOUT 8 RED WHITE TBAP 5 VDC POWER SUPPLY 9 GREEN RED GROUND SPEED SENSOR SPLICE SPEED SIGNAL 10 RED BLACK ELECTRIC START BATTERY VOLTAGE 11 WHITE BLUE CHASSIS RELAY COIL GROUND 12 RED BLACK THROTTLE FLIPPER SAFETY SWITCH SOFTWARE BASED IGNITION KILL SIGNAL 13 BROWN ECU GROUND SPLICE ECU GROUND 14 RED BLUE CHASSIS HOOD 2 WATER TEMP SIGNAL 16 YELLOW RED CHASSIS HOOD 1 TACHOMETER SIGNAL 17 ORANGE REGULATOR RECTIFIER VOLTAGE BOOST POWER 21 PINK DIAGNOSTIC K LINE 22 GRAY GRAY SPLICE MODE SELECT 23 WHITE CHASSIS HOOD 1 PERC LED 24 GREEN TBAP PRESSURE SENSOR SIGNAL 25 BLUE WHITE CHASSIS HOOD 1 OVERHEA
350. nto the engine compartment and 19 line up the engine mount studs with the engine straps on the engine NOTE Make sure that all hoses lines and wires are not pinched or interfere with installation 13 Route the oil supply line from the engine through the hose guide 14 Install the oil bottle and hook up the supply line Open and slide the hose clamp onto the hose and oil bottle fittings WINNING PERFORMANCE POLARIS 16 If applicable place the coolant hose from the throttle bodies 20 Engine and Cooling Systems Secure the oil bottle to the chassis by installing the two torx fasteners located at the top of the bottle Connect the oil sender Yellow and Purple wires to the chassis connection Purple and Brown wires Connect all the coolant hoses Place panduit straps in the locations shown to the coolant bottle Secure the hose clamp over all coolant hose and fittings 5 37 Engine and Cooling Systems 21 Place the engine mount washers and fasteners 8 onto the 23 Apply Blue Loctite to the rear fasteners install all the engine mount studs Torque to specification rear torque stop fasteners and torque to specification Engine Mount Fasteners 28 ft lb 37 9 Rear Torque Stop Fasteners 28 ft lb 37 9 24 Adjust the rear torque stop so that you have a clearance of 010 030 25 75mm from the face of the torque stop to the sur
351. number of washers on retaining bolt Insert the correct clutch puller into the retaining bolt hole 5 Tighten the puller into the clutch If the clutch does not come off strike the clutch puller head with a hammer If the clutch does not pop off continue to tighten the clutch G POLARIS Way Out puller and repeat this step CAUTION Do not use an impact wrench to remove or install the clutch bolt or clutch puller Damage to the clutch and or crankshaft can occur 7 13 PVT System Drive Clutch Disassembly ROLLER WASHER SPIDER BUTTON SPIDER COVER BEARING RETAINER CLUTCH SPACER CAUTION Wear eye protection when servicing the drive clutch Sheaves must be marked to provide a reference point for dutch balance and spider indexing If the sheaves are not marked and the spider washers are changed or misplaced the clutch may be out of balance and dam age to the clutch may result A WARNING Clutch spring is under extreme tension use caution when disassembling the clutch 1 Ina straight line mark the sheaves and the cover with a black marker or etched with a scribe Remove the clutch 3 Place the drive clutch in the clutch compression tool PN 8700220 4 Compress the clutch in the compression tool then secure the chain 5 Evenly remove the cover fasteners The cover bushing may be damaged if the cover is side loaded or mis aligned 6
352. o off pulls the tether or pushes the safety The first is the software stop system The software stop system slap switch down the ignition system is immediately killed only applies to the throttle flipper switch The software stop system is activated when the throttle flipper switch is closed closed throttle but the TPS throttle plate position is still above idle When this occurs the ECU software will determine the throttle cable is stuck and kill the ignition system 4 23 Fuel Systems Vehicle Speed Sensor ECU CNA CONNECTOR 4 24 MULTIFUNCTION INSTRUMENT GROUND SPEED CAPACITOR GROUND SENSOR CHASSIS VOLTAGE SIGNAL RETURN CHASSIS ENGINE GROUND WINNING PERFORMANCE POLARIS Fuel Systems Exhaust Temperature Sensor 0 _ coe Sensor Specifications 2 3 392 F 200 C 760 Resistance Values 1652 900 ey T Exhaust Temperature Sensor Torque 32 Ft Lbs 44 Nm Temperature Air Pressure Sensor TBAP TEMP 5151 49 N J D PIN Sensor Specifications 59 F 15 C 30000 68 20 C 25000 77 25 20000 Pins 1 to 2 Temperature Pins 1 to 4 Pressure Pins 3 to 4 Pressure 2400 8200Q 3400 82000 WINNING PERFORMANCE gt POLARIS
353. o 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 3 7 Maintenance 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 another 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 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 1 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 Removetherearengine torque stop plate from the bulkhead the bulkhead 4 Remove the 2 left hand console mounting screws and electr
354. ocate the arm screw 4 and loosen it just enough to move the arm 5 out of the way so that you can remove the needle 6 e clip and the plastic washer from the throttle slide once n Fuel Systems 9 Inspect e rings plate spring and rings 14 connecting the 13 Inspect the contents for wear and debris slide to the lever if needed 14 Remove and inspect the main jet 20 pilot jet 21 and 10 Remove water trap drain plug 15 and single screw 16 starter jet 22 Clean them out on the bottom of the carburetor 15 Remove the air jet screw if so equipped 11 Remove and drain the float bowl 17 NOTE Float bowl will not come off unless the water trap drain plug and screw are removed 16 Clean out all passages in carburetor body with carburetor cleaner Dry all passages and jets with compressed air 17 Replace gaskets and any parts that show wear or damage 12 Remove the two screws 18 holding the float needle and i 207 Sela Tape Ol ton seat assembly 19 in position and remove this assembly 4 12 Fuel Systems Assembly 1 Install the main jet 20 pilot jet 21 and starter jet 22 2 Install float needle amp seat assembly 19 3 Place carburetor in an inverted position 4 Connect a pressure tester PN 2870975 to fuel inlet fitting Apply 5 psi pressure and observe for one minute The needle and seat should hold pressure indefinitely If t
355. oe EM 0781 2mm 0787 2 56 51 9 16 18 33 64 7 0938 2 64 50 5 8 11 17 32 7 64 1094 3mm 1181 3 48 5 64 5 8 18 37 64 22 1 8 1250 a 3 56 45 3 4 10 2032 ss ee ee 1563 4 mm 1575 4 40 43 3 4 16 11 16 ll 64 222 1719 4 48 42 7 8 9 49 64 3 16 us ec 1875 5mm 1969 5 40 38 7 8 14 13 16 13 64 2031 5 44 37 1 8 Z8 1 2286 2188 _ 6 32 36 1 12 59 64 chee yor oye 6 40 33 1 1 8 7 63 64 IUe anim 2656 7 mm 2756 8 32 29 1 1 8 12 13 664 0 40 nic onere sii 2813 88 36 29 11 4 7 17 64 19 64 ee eet 2969 10 24 24 1 1 4 12 1 11 64 TTI JA e 8mm 3150 10 32 21 1 1 2 6 444 32 11 432 3438 se 9 mm 3543 12 24 17 1 1 2 12 1 27 64 3504 12 28 4 6mm 1 3 4 5 1916 __ 3 8 375 1 4 20 7 1 3 4 12 1 43 64 28161 m 3906 10 mm 3937 1 4 28 3 2 4 1 2 125 32 212 erep p m ee E 49 27 64 5 mm 4 4 NEN 5 gt E 4531 3 8 16 2 1 2 4 2414 15 525 r o uuu 4688 12 mm 4724 3 8 24 Q 2 3 4 4 21 2 secs es 4844 7 16 14 U 3 4 234 1 2 5 13mm 5118 7 6 2 25 64 33 64 boss eee 5156 716569 SOM ae or ud E dde ses ecce aedes 5313 1 WES
356. of engine at room temperature 68 F 20 C and at the specified RPM If applicable make sure the key switch is in the PREMIUM mode and the TPS is unplugged 1 Reference the timing specification chart Install a dial indicator gauge into the MAG spark plug hole 3 Place the MAG piston in the proper timing position then mark the flywheel at this point EXAMPLE 600 HO Carbureted 26 3500RPM Place the MAG piston 4 0096mm 0 1579in BTDC NOTE Each 10 degree mark is separated by lines every 2 degrees not shown Acceptable timing variance is 2 degrees Flywheel Rotation 4 Connect an accurate tachometer a good quality timing light to the engine according to manufacturer s instructions 5 Disconnect the throttle position sensor TPS if equipped 6 Start engine and increase RPM to the point specified in the timing specifications Hold the throttle to maintain specified timing RPM 7 Point the timing light at the timing inspection hole 8 With your head positioned so there is a straight line between your eye the stationary pointer and the crankshaft center line note the relative position between the marked flywheel line and the pointer If the stationary pointer is aligned with the mark made in Step 3 or within the acceptable variance ignition timing is correct 9 Ifthe pointer is outside the variance the stator will have to be rotated either with cranksha
357. ogging oil PN 2870791 3 18 POLARIS Maintenance Ski Ski Skag Fasteners Periodically inspect the ski to spindle fasteners for proper torque WASHERS PROVIDED FOR BLOW MOLDED SKIS Ski to Spindle Fastener Torque 36 Ft Lbs 49 Nm Inspect ski skags and skag fasteners for abnormal wear and tear Replace skags when carbide edge is worn away Always use new Nylock nuts and secure hand tight Track Tension Track tension is critical for maintaining correct suspension 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 down the rail slides reduce top speeds cause rear suspension vibration and cause track and rear suspension durability problems Gh POLARIS The Way Out E 2 o 9 D 9o pc ee X TRACK 16 41cm 1 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 Shutoff the engine Place a 10 Ib 4 54kg weight 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
358. olor code CONTROLLER 8 Locate the program enable or mode change jumper connector Jump the two pins using a short length of wire Click CONTINUE AM ENA JUMPER BLACK TWO PIN PLUG CAUTION Do not allow the jumper wire to touch the exhaust pipe or any other grounded metal ECU damage may occur WINNING PERFORMANCE POLARIS Fuel Systems 9 request code will be generated Record the code 13 The website will generate an authorization code Record the code 14 Enter the authorization number in the box on Digital Note the Request Code below and obtain an Authorization Key from the Wrench Click on CONTINUE Dealer Web Site Enter the Authorization Key in the Proper Field to Continue DO NOT SHUTDOWN THE SOFTWARE UNTIL REPROGRAMMING IS COMPLETE OR THE AUTHORIZATION KEY WILL BE LOST Engine Controller Reprogramming Note the Request Code below and obtain an Authorization Key from the Dealer Web Site Enter the Authorization Key in the Proper Field to Continue DO NOT SHUTDOWN THE SOFTWARE UNTIL REPROGRAMMING IS COMPLETE OR THE AUTHORIZATION KEY WILL BE LOST Request Code AIBAFDBN 8 3 Enter Authorization Key 4 Prepare Vehicle Request Code Authorization Key 5 Reprogram 6 Verify Success 9 3 Enter Authorization Key 1 Prepare Vehicle
359. omponent 4 27 Fuel Systems Engine Coolant Temperature Sensor Fuel Injectors COLOR DOT Sensor Specifications Specifications 22 F 4248 30 C Resistance 120 68 F 20 C Operating Temperature Range 120 Fuel injectors are flow tested and then color coded RED Resistance 2 4 2 6KQ 68 F Q0 C BLUE or YELLOW based on how much fuel the injector flows Measure in stirred water during the test Installation Torque 29 ft Ibs 39 2Nm 800 CFI fuel injectors all colors are a high flow version of the Knock Sensor fuel injectors used on 600 700 CFI engines When replacing a faulty fuel injector always verify the part number of the injector for the engine application and use the same color code replacing an injector with a different color 4 870 000 OHMS code all four fuel injectors must be replaced with the new color TORQUE TO 2045 N M 15 3 FT LBS so all four injectors are the same color After replacing all four injectors the ECU must be re flashed so the fuel calibration map matches the new color coded fuel injectors CAUTION 800 CFI ENGINES USE HIGH FLOW FUEL INJECTORS ALWAYS CHECK THE INJECTOR PART NUMBER TO VERIFY ENGINE APPLICATION REGARDLESS OF COLOR CODE NEVER RUN THE ENGINE WITH DIFFERENT COLOR CODED FUEL INJECTORS SEVERE ENGINE DAMAGE WILL OCCUR ALWAYS VERIFY THE ECU CALIBRATION FILE MATCHES THE FUEL INJECTOR COLOR CODES
360. on again Operation A WARNING Reverse operation even at low speeds may cause loss of control resulting in serious injury or death To avoid loss of control always LOOK BEHIND BEFORE AND WHILE BACKING AVOID SHARP TURNS SHIFT TO OR FROM REVERSE ONLY WHEN STOPPED APPLY THROTLE SLOWLY AX CAUTION To avoid personal injury and or engine damage do not operate the electric start or recoil while engine is running 1 Ensure that the vehicle is stopped and the engine is warmed up and running at idle NOTE The system will only engage in reverse if the engine is below 4000 RPM If engine is above 4000 RPM the system can not be activated Ensure that the path behind you is clear 3 Push and hold the yellow reverse button on the left hand control for 1 second and then release the button The reverse light on the instrument panel will flash when engine is in reverse motion NOTE The engine will automatically reduce RPM and it will reverse the rotation of the engine when the RPM is at the lowest RPM point 4 Ensure that the path behind you is clear 5 Slowly apply throttle until the sled starts to move in reverse and carefully direct the sled in the direction that you want NOTE Maximum RPM in reverse is 6000 RPM WINNING PERFORMANCE POLARIS Battery and Electrical Systems NOTE If the engine stops running or is shut off while in reverse The engine will start in forward ge
361. on the bulb and cause bulb failure If you do touch 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 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 clutches with light oil or rust inhibitor All lubrication applied as a rust preventative measure must be cleaned off before installing belt for service and operating machine Controls And Linkage All b
362. ontained within whether whole or in part is expressly prohibited Printed in U S A UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS Throughout this manual important information is brought to your attention by the following symbols A WARNING SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator bystander or person s inspecting or servicing the vehicle CAUTION SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle CAUTION CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage NOTE NOTE provides key information by clarifying instructions IMPORTANT IMPORTANT provides key reminders during disassembly assembly and inspection of components _ In MEASUREMENT provides key for a determined measurement specification ey T TORQUE provides a key for required torque value TRADEMARKS POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL Loctite Registered Trademark of the Loctite Corporation Nyogel Trademark of Wm F 0 Fluke Registered Trademark of John Fluke Mfg Co Mity Vac Registered Trademark of Neward Enterprises Inc Torx Registered Trademark of Textron M 10 Registered Trademark of FAST Inc WD 40 Registered Trademark of WD 40 Company
363. orque to 35 ft lbs 47 Nm NOTE When the M 10 suspension is new it will take 25 to 200 miles 40 300 km to properly break in the springs and shocks at which time the suspension WINNING PERFORMANCE gt POLARIS will be softer and may require FRA adjustment M 10 REAR SPRING PRELOAD If FRA position alone does not allow the setup of the proper amount of sag the center retainer of the rear track shock can be replaced with optional retainers to adjust the preload and change the sag Optional Retainers Retainer insert Retainer part Part Number Number Ploan Sag 5135077 std on 10 128 Least Most 5436109 5134923 Middle Middle 5135080 std on 10 136 Most Least NOTE Whenever ordering any of the retainers listed in the chart always order the retainer insert as well The insert is not removable once installed so a new insert is needed when installing a new retainer M 10 SKI PRESSURE Ski pressure is set at the factory to deliver the optimum balance between ride and handling If rider prefers 2 more ski pressure for improved 4 3 O steering performance adjustments can 1 be made to the front limiter strap and front arm mount 2 1 Determine if the rider prefers 3 comfort or control Lean toward the 4 setting for comfort and 4 toward the 3 aggressive riding 2 For full hole adjustments remove the 5 16 nut a
364. os Spark Plug Gap in mm 027 70 Spark Plug Champion RN57YCC Track Width Inches cm 15 38 Length Inches cm 155 393 7 Lug Height Inches cm 2 4 6 1 Drive Clutch Bolt Torque 80 Ib ft 108Nm 1 32 Track tension sag in cm with 10 155 4 54 placed 16 40cm ahead of rear idler shaft 3 8 1 2 1 1 3cm WINNING PERFORMANCE C POLARIS Model Specifications Front Suspension Suspension Type IQ Shocks Ryde FX IFS Spring Rate Ibs in N mm Spring Installed Length Inches 10 35 26 3 Front Vertical Travel Inches cm 2 22 9 Ski Center Distance Inches cm 39 40 41 99 1 101 6 104 1 Setup Width 38 67 98 2 Camber Inches cm 2 17 0 31 55 7 9 Toe Out Inches cm 0 0 12 0 0 31 Rear Suspension Suspension Type IQ RMK 155 Front Track Shock FTS Ryde FX FTS Spring Rate Ibs in N mm Rear Track Shock RTS Ryde AFX 359 Square 77 Stock 347 71_ Soft PN 7041627 067 Torsion Springs PN 7041628 067 375 77_ Firm PN 7041942 067 PN 7041943 067 Rear Travel Inches cm 15 5 39 4 190 33 25 WINMING PERFORMANCE 1 gt POLARIS de Model Specifications 2008 700 IQ 700 Dragon IQ Model Number Base SO8PB7JS SO8PB7JE Dragon SO8PP7JS SO8PP7JE Engine
365. ple 2 6 Port Opening Duration 2 6 Cooling System Bleeding 3 7 Exhaust Valves 3 7 Oil Pump Adjustment Carbureted Models 3 8 Oil Pump Adjustment CFI Models 3 9 Recommended Coolant 3 7 Engine Mounting Systems 5 13 2007 700 IQ CFI 2008 IQ CFI 5 16 2007 IQ 600 CFI 5 14 2007 IQ Carbureted 5 13 2008 IQ 600 Carbureted 5 15 Engine Removal 5 33 Engine Specifications 5 2 Component Torque Sequences 5 4 Fastener Torque Guide 5 2 Service Specifications 5 3 Exhaust System Assembly View 5 48 Exhaust Valve Maintenance 5 12 Assembly 5 12 Disassembly 5 12 Optional Springs 5 12 F Fenders and Side Panels 10 6 FOX PS 5 Assembly 9 28 FOX PS 5 Disassembly 9 27 Fresh Pack Battery 11 3 Front Bumper Assembly 10 4 Front Suspension Alignment Bar Specifications 8 10 Assembly Illustration 8 5 Camber and Toe Specifications 8 2 Setup and Adjustments 8 10 Camber 8 10 Camber Adjustment 8 11 Handlebar Centering 8 11 Rod End Engagement 8 11 Rod Ends 8 11 Toe Adjustment 8 11 Front Suspension by Model 8 3 Front Torque Arm Limiter Strap Adjustments 8 38 Fuel Intake System Maintenance 3 11 Air Intake Pre Filters 3 13 Fuel Filter Carbureted Models 3 11 Fuel Filt
366. pressure during acceleration Limiter strap adjustment has a great affect on weight transfer Limiter straps only affect acceleration It is important to check track tension whenever limiter strap length is changed Front track shock spring preload also affects weight transfer A stiffer spring and or more preload on the spring transfers more weight to the track A softer spring and or less preload keeps more weight on the skis Keep your riding application in mind when choosing springs and setting spring preload Soft springs preload will increase ski pressure but may bottom out Stiff springs preload will provide more track pressure reduced ski pressure but may result in a less comfortable ride During acceleration the rear of the suspension will compress and the IFS will extend pivoting the machine about the front torque arm Because of this pivoting effect rear spring and spring preload also have some effect on weight transfer Softer rear springs or less preload allow more weight transfer to the 8 36 track and reduce ski pressure Stiffer rear springs or increased preload allow less weight transfer to the track and increase ski pressure The main function of the rear torque arm is to support the weight of the vehicle and rider as well as to provide enough travel to absorb bumps and jumps Shock valving also has an effect on weight transfer Refer to shock tuning information in this chapter Scissor stops also affect weight t
367. r idi Engine and Cooling Systems 39 Connect the EV solenoid vent lines back onto the EV bases and install the panduit strap around the spark plug wires as shown 40 Install the electrical center belt holder over the electrical center by aligning the rear buttons to the rear of the clutch cover and installing the two fasteners 41 Install the Nylock nuts and two T40 Torx bolts to the front and the two T40 to the rear of the LH and RH chassis brace and install the braces NOTE Install the long bolts and the spacer on the front portion of the bar before inserting it into the mounting area 5 40 42 43 44 45 46 47 48 Replace the nosepan plugs were removed to access the front chassis brace fasteners Route the recoil rope through the eyelet on the chassis brace and secure handle once past the console Install the exhaust system Add coolant and bleed system See Cooling System Bleeding on page 3 6 Premix the first tank of fuel See 2 Stroke Gasoline Oil Pre Mix on page 2 7 Test run the unit and clear any codes with Digital Wrench After test running check drive and driven clutch torque WINNING PERFORMANCE gt POLARIS Engine and Cooling Systems COOLING SYSTEMS Thermostat Replacement 9 BLEED SCREW WASHER HOUSING COVER THERMOSTAT CAUTION Allow engine to cool completely before working with
368. r clockwise will decrease throttle lever free play POLARIS 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 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 1 8 1 41 3 2 6 4mm free play 3 NOTE Verify the cable does not lift the plungers when checking the free play 4 Tighten adjustment locknut 2 3 17 Maintenance 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 T Handlebar Clamp Fastener Torque 16 Ft Lbs 21 Nm 5 If equipped reinstall the handlebar cover Rider Select Steering U Joint APPLY FOGGING OIL The rider select steering U joint should be lubricated with Polaris f
369. r start the engine or let it run in an enclosed area Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time If you spill gasoline on your skin or clothing immediately wash it off with soap and water and A main jet that is too small will cause a lean operating CAUTION condition and may cause serious engine damage Jet according to the jetting charts provided for each snowmobile Most Polaris snowmobile engines are calibrated to run using 91 octane oxygenated or 89 octane non oxygenated fuels Polaris snowmobiles requiring higher octane fuel have the required octane level noted on the fuel tank filler cap Never use fuel containing more than 10 ethanol or E85 fuels All four fuel injectors must share the same color code Yellow Blue or Red 800 CFI engines use high flow injectors regardless of color coding Always verify the fuel injector part number prior to installation change clothing 4 2 WINNING PERFORMANCE C POLARIS Fuel Systems CARBURETOR FUEL SYSTEMS Mikuni Main Jets m m m m m m m m a a a 95 3130102 175 3130118 310 3130134 470 3130147 100 3130103 180 3130119 320 3130135 490 3130148 105 3130104 185 3130120 330 3130136 500 3130149 110 3130105
370. rack tension sag in cm with 10 Ibs 4 54kg placed 16 in 40cm ahead of rear idler shaft 3 8 1 2 1 1 3cm Drive Clutch Bolt Torque 80 Ib ft 108Nm 1 18 WINNING PERFORMANCE C POLARIS Model Specifications Front Suspension Suspension Type IQ Shocks Walker Evans Air Oil Volume 95 Nitrogen Charge Stock 215 psi Optional 220 225 psi Front Vertical Travel Inches cm 9229 Ski Center Distance Inches cm 39 99 1 40 101 6 41 104 1 Setup Width 38 67 98 2 Camber Inches cm 2 17 0 31 55 0 79 Toe Out Inches cm 0 0 12 0 0 31 Rear Suspension Suspension Type IQ 155 Front Track Shock FTS Walker Evans Air Oil Volume 70 FTS Nitrogen Charge Stock 215 psi Optional 210 220 psi Rear Track Shock RTS Walker Evans w IFP RTS Nitrogen Charge 200 psi 359 Square 77 Stock 347 77_ Soft PN 7041627 067 Torsion Springs PN 7041628 067 375 77_ Firm PN 7041942 067 PN 7041943 067 Rear Travel Inches cm 15 5 39 4 WINMING PERFORMANCE 1 1 gt POLARIS 9 Model Specifications 2008 IQ Shift Carburetor Jetting Model Number SO8PB6FS SO8PB6FE Ambient Temperature
371. rall in cm in cm 3211080 1 438 36 5 28 _ 11 5 29 2 46 625 118 4 Double Cog CVT version of 3211078 3211078 1 438 36 5 28 _ 11 5 29 2 46 62 118 4 Standard Drive Belt 3211117 1 46 37 1 26 11 27 9 45 79 116 MBL High Performance Belt Sanded Finish 3211121 1 46 37 1 26 11 27 9 45 79 116 MBL Kevlar Belt Cut Finish 3211122 1 46 37 1 26_ 11 5 29 2 46 77 118 8 MBL Kevlar Belt Cut Finish 3211114 1 438 36 5 26 10 625 27 45 2 114 Sanded Finish 3211115 1 46 37 1 26_ 11 5 29 2 46 77 118 8 MBL High Performance Belt Sanded Finish Belt dimensions are given in nominal dimensions There is a variance for all critical dimensions Clutch set up must be inspected when a new belt is installed and if necessary adjusted The drive belt is an important component of the converter system In order to achieve maximum efficiency from the converter drive belt tension deflection clutch offset and alignment must be adjusted properly Belt Inspection Projected Belt Wiath BELT A B 1 Measure the belt width and replace it if it is worn severely Generally a belt should be replaced if the clutches can no longer be adjusted to provide the proper belt deflection Project the side profiles and measure from corner to corner Place a straight edge on each side of the drive belt and measure the distance where the straight edges intersect at the top A B 2 Inspe
372. ransfer See scissor stop information also in this chapter Coupling On all Polaris snowmobile rear suspensions there are two torque arms that control the movement of the rail beam Prior to the advent of suspension coupling these torque arms could move independently of each other Rear suspension coupling links the movement of the front and rear torque arms to each other The front rear scissor stop FRSS couples the movement of the front torque arm with the rear torque arm and limits the amount of independence between the movement of the front torque arm and the rear torque arm When hitting a bump the front torque arm starts to compress The FRSS links that movement to the rear torque arm causing it to compress and raise the rear suspension up as one allowing the suspension to hit the bump only once and eliminating kickback The factory setting are usually adequate for all riders in all conditions The rear rear scissor stop RRSS couples the movement of the rear torque arm with the front torque arm and limits the amount of independent movement between the rear torque arm and the front torque arm Adjusting the RRSS to a lower setting allows more weight to transfer to the rear for more traction Adjusting the RRSS to a higher position will reduce weight transfer improve chatter bump ride and improve cornering performance WINNING PER FORMANCE gt POLARIS Steering and Suspensions REAR SUSPENSION ADJUS
373. requires cylinder replacement or re chroming 13 Inspect the crankcase and cylinder mating surfaces for warping 14 The assembly process is the reverse of disassembly 15 Always use new gaskets and o rings during assembly Liberally coat the inside of each cylinder bore and the outside of each piston with Polaris two stroke engine oil 16 When installing a piston into a cylinder verify each piston ring opening is located at each piston ring locating pin Squeeze the top ring then carefully slide the cylinder over the compressed ring Do the same with the bottom ring 17 Follow the torque specifications and torque sequences located at beginning of chapter when tightening fasteners rarus 5 25 Engine and Cooling Systems 2007 2008 600 700 800 CFI Recoil Stator Assembly RATCHET GUIDE REEL w ROPE BUSHING ey A 9 Ft Lbs 12 Nm B 5 Ft Lbs 7 Nm C 90 Ft Lbs 122 Nm Apply Loctite 242 D 12 Ft Lbs 16 Nm Apply Loctite 242 Disassembly Assembly Process 1 Remove the exhaust pipe and resonator If the recoil assembly does not require attention the recoil rope can remained attached to the handle If recoil component work is desired reference the Recoil Assembly section 3 Remove the recoil magneto housing cover The recoil assembly is located inside the housing 4 Remover the recoil hub from the flywheel Secure the flywheel with a strap wrench PN
374. 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 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 POLARIS The Way Out 4 The measurement should be 1 1 4 3 2cm In mm Belt Deflection 1 25 3 2cm 5 the measurement is not correct adjust driven clutch Deflection Adjustment 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 snowmo
375. rminal Voltage should read 4 99 to 5 01 Vdc Use a new battery if voltage is below 4 99 Vdc Black Red Pink WINNING PERFORMANCE gt POLARIS Battery and Electrical Systems 3 Connect the test tool to the TPS on the carburetor or throttle body NOTE Always disconnect the 9 volt battery when tool is not in use Using the TPS Test Tool 1 Remove the wiring harness connector from the TPS Verify the throttle cable is not kinked and the throttle flipper is closed Disconnect the throttle cable from the throttle flipper Connect the test tool to the TPS Insert the black multimeter probe into the black terminal port then insert the red multimeter probe into the yellow terminal port gt 5 Reference the specifications to determine if the TPS requires adjustment or replacement 6 Reconnect the throttle cable with throttle flipper TPS Setting Specifications ENGINES VOLTAGE SETTINGS Carbureted Engines 4 00 0 1 Vdc WOT CFI Engines 600 700 0 95 0 01 Vdc Idle 800 0 93 0 01 Vdc Idle 7 verify the TPS is sending a linear signal slowly move the throttle flipper from the closed to WOT position then back down to the closed position 8 The voltage readings displayed on the multimeter should rise and fall without erratically jumping from high to low NOTE The multimeter display may change scales and show O L momentarily when throttle flipper is
376. ry Disconnect and remove the battery Clean the terminals and cables Apply dielectric grease to the terminals Store in a cool dry place for storage 3 21 Maintenance NOTES Fuel Systems CHAPTER 4 Fuel Systems SERVICE WARNINGS AND 5 4 2 SERVICE 6 4 2 CARBURETOR FUEL SYSTEMS 644 2405 Ee Rm REESE Rx a sew acd olen 4 3 MIKUNI TM PE RR Eee 4 6 2505 nin arti QR x 4 10 CARBURETOR SERVICE ziehe es y notes e La Yrs 4 11 CARBURETOR ADJUSTMENT o eres eo ret C 4 14 CLEANFIRE FUEL INJECTION c esau det Errore mc m ee rite fees 4 15 SYSTEM OVERVIEW m chloe riyu ences ERES 4 15 DIAGNOSTIC TROUBLE CODES 8 4 16 MFD B INK CODES 2 fice eed Sh SR E EAR NR EAS 4 18 TROUBLESHOOTING eh oe eet de nrbe red 4 18 CFI CLUTCH GUARD ELECTRICAL 4 19 34 PIN 4 20 26 CNB ECU 4 21 CHASSIS RELAY et Avie eee ase NTC E cin 4 22 THROTTLE
377. s Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table 8 34 Steering and Suspensions IQ RMK 144 155 163 Front Rear Torque Arms LIMITER STRAPS SHOCK ASSEMBLY 9 99 T 12 Ft Lb 16 Nm B 19 Ft Lb 26 Nm C 45 Ft Lb 61 Nm D 35 Ft Lb 47 Nm E 25 Ft Lb 34 Nm Assembly Notes Never re use Nylock nuts Always replace with new parts All pivots must rotate freely after tightening fasteners WINNING PERFORMANCE POLARIS lt 0 SHOCK ROD FRONT TORQUE ARM Se LOWER SHAFT SHOCK ASSEMBLY 0 SA REAR TORQUE ARM Q SHAFT REAR PIVOT SCISSOR CC ADJUSTER 6 E SPACER SET SCREW SPRING lt Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table CAUTION The fasteners securing the rear suspension to the tunnel are pre coated with a locking agent when new Never re use these fasteners when removed Always use new pre coated fasteners when mounting the suspension to the tunnel 8 35 Steering and Suspensions REAR SUSPENSION OPERATION Operation The primary function of the rear suspension is to provide a comfortable ride in all types of riding conditions It separates the rider from the ground while allowing for complete vehicle control The rear suspens
378. sing new screws supplied with the new gasket thread in 11 Carefully extract the fuel pump assembly out of the tank one of the top two screws to locate the gasket and flange in 5 is sufficient 12 Discard the fuel pump flange gasket If the pump has failed mie Fe Wits OF ANE discard the fuel pump If the fuel tank is to be replaced 17 Thread the remaining five screws in by hand obtain the new fuel tank 18 Using a nut driver or socket and following the specified torque sequence sequentially turn each screw a few A CAUTION revolutions at a time until the gasket is just seated between the flange and the fuel tank NEVER RE USE THE FUEL PUMP FLANGE GASKET 19 Using a torque wrench and the specified torque sequence ALWAYS INSTALL FUEL PUMP USING A NEW tighten all screws to 10 in Ibs 1 13 Nm Tighten each FALNGE GASKET screw in one continuous quick motion 20 After completing the initial torque sequence tighten each 13 Saturate a clean rag with isopropyl alcohol and clean the screw to 23 in lbs 2 6 Nm in one continuous quick surface of the fuel pump flange area and the fuel pump motion flange Dry all surfaces with a clean rag Allow adequate drying time for the alcohol 14 Install a new clean gasket by carefully sliding it over the fuel lines and pump components Position the gasket with the barbs locating pins facing the flange Align the pins barbs with the holes then
379. specific engine model Therefore modifications or variations of components at random are never recommended Proper clutch setup and adjustments of existing components must be the primary objective in clutch operation diagnosis Drive Spring The drive spring opposes the shift force generated by the clutch weights and determines the neutral RPM engagement RPM and wether the engine RPM remains flat rises or falls during shift out When changing only the drive spring installing a spring with a lower pre load rate will result in a lower engagement RPM speed while installing a spring with a higher pre load rate will result in a higher engagement RPM Clutch Weight The clutch weights generate centrifugal force as the drive clutch rotates The force generated changes in relation to the engine RPM and with specified weight of each clutch weight When changing only the clutch weights a lighter weight will result in ahigher engagement RPM lower shifting force and higher shift out RPM Installing heavier weights has the opposite effect Neutral Speed Engine RPM when the force generated by the clutch weights is less than the pre load force generated by the drive spring In this mode the drive clutch is disengaged Engagement RPM Engine RPM when the force generated by the clutch weights overcomes the drive spring pre load force and the moveable sheave begins to close or pinch the drive belt The engagement 7 2 mode continues
380. ssure to grip the belt and prevent slippage during initial acceleration A higher spring rate will provide more side pressure and quicker back shifting but decreases drive system efficiency If too much spring tension exists the driven clutch will exert too much force on the belt and can cause premature belt failure Back Shifting Back shifting occurs when the track encounters an increased load demand for more torque Back shifting is a function of a higher shift force within the driven clutch then within the drive clutch Several factors including riding style snowmobile application helix angles and vehicle gearing determine how efficient the drive system back shifts The desired engine operating RPM should never fall below 200 RPM when the drive system back shifts The Way Out PVT System Final Gearing The final drive gear ratio plays an important role in how much vehicle load is transmitted back to the helix A tall gear ratio lower numerical number typically results in lower initial vehicle acceleration but a higher top end vehicle speed A lower gear ratio higher numerical number typically results in a higher initial vehicle acceleration but a lower top end vehicle speed Choosing the proper gear ratio is important to overall drive system performance When deciding on which gear ratio to use the operator must factor in the decision where the snowmobile will be ridden what type of riding will be encountered an
381. st Valve Spring Purple Recommended Fuel Octane R M 2 Type Cleanfire Direct Injection Throttle Body Marking 1203213 Throttle Body Bore 46mm TPS Voltage Idle 0 95 0 01 Fuel Pressure PSI bar 58 4 0 91 Non Oxygenated Clutch Settings General Width in cm 46 5 118 1 Length in cm 129 327 7 Height in cm 48 121 9 Estimated Dry Weight Ib kg 484 219 5 Fuel Gallons Liters 11 5 33 5 Oil qts l 3 2 8 Cooling System Capacity Quarts Liters PAS Brake Fluid DOT 4 Drive Belt Part Number 3211115 Width inches cm 1 460 3 7 Side Angle 26_ Circumference inches cm 46 77 118 8 Center Distance inches cm 11 5 29 2 Chaincase Center Distance inches 8 373 Top Gear Stock 20 Bottom Gear Stock 41 Chain Stock 76 Gear Lube Polaris Synthetic Capacity oz ml 11 325 3 Reverse System Perc Electrical Alternator Output Operating Voltage 13 5 14 5 Watts 13 5 Vdc Total 400 18 1700 RPM Ignition Timing Coolant Temp 120_F 49_C ALTITUDE DRIVE CLUTCH DRIVEN CLUTCH meters Shift Clutch Clutch Driven Gearin feet Weight Spring Spring Helix 5 0 600 0 2000 10764 600 1200 2000 4000 1200 1800 10 50 4000 6000 14023501 7043342 160 240 iwer 2041 76 1800 2400 7043363 6000 8000 2400 3000 8000 10000 10 50 3000 3600 10000 12000 n
382. steners WINNING PERFORMANCE gt POLARIS 8 29 Steering and Suspensions IQ 136 Coupled Pivots Rear Idler SHOCK PIVOT SPACER BLOCK IDLER WHEEL H BRACKET SPACER INNER SHAFT T A 35 Ft Lb 47 Nm B 45 Ft Lb 61 Nm Assembly Notes Never re use Nylock nuts Always replace with new parts All pivots must rotate freely after tightening fasteners Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table corvum Steering and Suspensions IQ 136 Coupled Rail Assembly gt BOGIE WHEEL CAM RRSS Cm WHEEL MOUNT amp o FRSS 0 BUMPER RAIL TIP RAIL SLIDER A 2 19 Ft Lb 26 Nm B 235 Ft Lb 47 Nm C 238 6 Ft Lb 4 8 D 35 In Lb 4 Nm Assembly Notes Never re use Nylock nuts Always replace with new parts All pivots must rotate freely after tightening fasteners Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table 8 31 Steering and Suspensions IQ 136 Coupled Front Rear Torque Arms FRONT TORQUE ARM BUSHING UPPER SHAFT REAR PIVOT SCISSOR LIMITER STRAPS REAR TORQUE ARM REAR TRACK SHOCK X 7 f SHOCK ROD CARRIER WHEEL TORSION SPRING MOUNTING ARM Apply
383. stments to the suspension 8 40 This chart is a guideline to be used for initial suspension setups Your setup may vary based on your desired riding style M 10 128 Rider weight with gear Suggested FRA Range Ibs Lower number is softer Under 100 1 to 1 1 2 100 150 1 1 2to2 150 200 2 to 2 1 2 200 250 2 1 210 3 250 300 3 to 3 1 2 300 350 3 1 2 to4 Over 350 4105 WINNING PER FORMANCE gt POLARIS Steering and Suspensions M 10 136 Rider weight with gear Suggested FRA Range 158 Lower number is softer Under 100 1 to 11 2 100 150 1 1 2to2 150 200 2 to 2 1 2 200 250 2 1 2 to 3 250 300 3 to 3 1 2 300 350 3 1 2 to 4 Over 350 4105 Optional rear track middle spring retainer available See Optional Retainer Table M 10 FRA INITIAL SET UP REFERENCE Adjusting the FRA will have the MOST effect on the rear suspension performance To adjust the FRA 1 Refer to the initial set up reference chart see Table and Table to determine the desired FRA position 2 adjust loosen the hex bolts A attaching the rear lower shock cross shaft to the rail beam 3 Using a 9 16 wrench loosen the jam nuts B on the preload bolts 4 Adjust the preload bolts C to the desired FRA position 5 Tighten the jam nuts NOTE Make sure the preload bolt contacts the slide block before tightening the jam nut 6 Tighten the hex bolts and t
384. straight edge along the one side of the track Make sure that the straight edge is touching along the length of the track 1 Raise the front of the machine so that the skis are off the floor 3 7 62cm The shocks should be at full extension 2 Remove the skis one 8 11 Steering and Suspensions 4 Record measurements from the edge of straight edge to the forward ski mark and the rearward ski mark Adjust the tie rod so that both measurements are the same Place the straight edge on the opposite side of the track and measure the opposite ski marks Adjust the tie rod so that both measurements are the same Verify that the ski center distances are within specification from the forward marks and the rearward marks DISASSEMBLY AND ASSEMBLY Spindle Removal gt gt Securely support the front of the machine up off the floor Remove the ski s Remove the upper control arm UCA to spindle fastener Remove the fastener securing the lower control arm LCA to the spindle Note the orientation of the fastener and nut Remove the tie rod from the spindle by removing the nut and bolt Spindle Assembly 1 Assembly is the reverse order of disassembly Reference the front suspension assembly illustration for fastener torque values Spherical Bearing Replacement 1 Bow 8 12 Remove the fastener securing the lower control arm LCA to the spindle Remove the lower shock
385. sure 36mm Cylinder 145 psi 47mm Cylinder 60 psi Front Vertical Travel Inches cm 1029 9 Ski Center Distance Inches cm 42 5 108 41 16 104 5 Camber Inches cm 2 25 0 31 57 7 9 Toe Out Inches cm 0 0 12 0 0 31 Rear Suspension Suspension Type IQ 121 Front Track Shock FTS Ryde FX HPG w IFP FTS Spring Rate Ibs in N mm 130 270 23 47 FTS Spring Installed Length inches cm 7 97 Rear Track Shock RTS Ryde FX Compression Adjustable w Remote Res Torsion Springs 347 Square 80 Soft PN 7043070 067 PN 7043071 067 347 Square 77 Softest PN 7043240 067 PN 7043241 067 359 Square 12 58 Stock PN 7043079 067 PN 7043080 067 Rear Travel Inches cm 13 9 35 3 WINNING PERFORMANCE gt POLARIS 1 25 Model Specifications 2008 600 Switchback General 600 Dragon Switchback Width in cm 48 121 9 Model Number SO8PROHS 508 6 nsn n T ONE Dragon SO8PS6HS SO8PS6HE Height in cm 48 5 1232 Engine Estimated Dry Weight 490 222 5 lb kg 494 224 3 Dragon i Ai olea Fuel Gallons Liters 117 443 Type Case Reed Induction Oil qts l 3 2 8 Model Number 53468 6044 6 Gunes oolin stem Capac
386. t 47512157 Resevoir Ib kg Rebuidable Fuel Gallons Liters 10 8 40 9 IFS Spring Rate 0055 Oil Quarts Liters 3 4 3 2 lbs in N mm Cooling System Capacity Spring Installed Length Quarts Liters Inches cm 10 55 26 8 Brake Fluid DOT 4 Front Vertical Travel 10 25 4 Drive Belt Inches cm Part Number 3211080 Suspension Setup Width inches cm 1 438 3 65 Width 41 16 104 54 Side Angle 28_ Inches cm Circumference inches cm 46 625 118 4 Camber Inches cm 2 25 0 31 57 7 9 Center Distance inches cm 11 5 29 2 Toe Out Inches cm 0 0 12 0 0 31 Chaincase Center Distance inches 8 373 Rear Suspension Top Gear Stock 23 Bottom Gear Stock 39 Suspension Type IQ 121 m Ryde FX HPG w IFP STD Gear Lube Polaris Synthetic Rebuildable Capacity oz ml 11 325 3 Front Track Shock FTS Fox HPG Reverse System Perc Rebuildable i FTS Spring Rate Electrical prng Ibs in N mm 130 270 23 47 Alternator Output FTS Spri pring Installed Operating Voltage 13 5 14 5 Vdc Length Inches cm 7 97 20 2 Watts 13 5 Vdc Total 280 26 GBSQRREM Fox PS5 w IFP STD Ignition Timing TPS Un pl d Rebuildable n plugged Rear Track Shock RTS Fox Compression Adjustable Spark Plug Gap in mm 027 70 Remote Resevoir HPG OPT Spark Plug Champion RN57YCC pune CDI Marking 4011033 Torsion Spring Diameter 374 Tail Angle 80 Flywheel Marking 4
387. t Injection Gear Lube Polaris Synthetic Capacity oz ml 11 3325 3 Throttle Body Marking 1203213 Reverse System Perc Throttle Body Bore 46mm TPS Voltage Idle 0 95 0 01 Vde Electrical Fuel Pressure PSI bar 58 4 0 Alternator Output Recommended Fuel Octane Operating Voltage 13 5 14 5 Vdc R M 2 91 Non Oxygenated Watts 13 5 Vdc Total 400 18 1700 RPM Clutch Settings Ignition Timing Coolant Temp 120_F 49_C Spark Plug Gap in mm 027 70 Spark Plug Champion RN57YCC Track Width Inches cm 15 38 Length Inches cm 121 307 3 Lug Height Inches cm 1 25 3 175 ALTITUDE DRIVE CLUTCH DRIVEN CLUTCH meters Shift Clutch Clutch Driven feet Weight Spring Spring Helix 5 0 600 0 2000 10 64 23 39 76 600 1200 2000 4000 1962 223318 1200 1800 4000 6000 BLK GRN RED BLK 56 42 36 120 340 140 240 EWER 22 40 76 1800 2400 10 58 7042083 7043058 6000 8000 2400 3000 3000 10000 10 56 20 41 76 3000 3600 10000 12000 10 AL Drive Clutch Bolt Torque 80 Ib ft 108Nm 1 24 Track tension sag in cm with 10 156 4 54 placed 16 in 40cm ahead of rear idler shaft 7 8 1 18 2 2 2 9cm WINNING PERFORMANCE gt POLARIS Model Specifications Front Suspension Setup Width Suspension Type IQ 42 5 Shocks Ryde FX Air 2 0 Air 2 0 Nitrogen Pres
388. t Lbs 30 Nm Apply Loctite 242 C 10 Ft Lbs 13 Nm Apply Pipe Sealant WINNING PERFORMANCE POLARIS 5 29 Engine and Cooling Systems Disassembly Assembly Process 2008 800 CFI Crankcase Crankshaft 1 Remove the engine from the engine compartment Follow the process for removing the cylinder head cylinders pistons flywheel recoil housing and the water oil pump 3 Remove the intake boots reed stuffers and reed assemblies from the intake tracks Discard any seals or gaskets 4 Remove the fasteners from the bottom of the crankcase Carefully pry apart the crankcase halves Discard the PTO and MAG crankshaft seals 5 Remove the crankshaft Inspect as required Thoroughly clean the two crankcase mating surfaces with carburetor cleaner and a gasket remover Flush out the crankcase galleries 7 Reinstall the crankshaft back into the lower crankcase using two new crankcase seals 8 Apply thin bead of Three Bond 1215 to the lower crankcase mating surface Install the upper crankcase 9 Loosely install the crankcase fasteners then torque to the specifications at the beginning of the chapter Use the correct torque sequence when tightening the screws 10 Liberally coat the crankshaft bearings and components with Polaris two stroke engine oil 5 30 WINNING PERFORMANCE gt POLARIS Engine and Cooling Systems 2007 2008 600 700 800 CFI Water Oil Pump Assembly
389. t durations for initial cold drive away Towing another machine at or about engagement RPM When possible do not go in deep snow when towing another machine Use fast effective throttle to engage the clutch Not all machines are intended for pulling heavy loads or other machines Spinning track while vehicle is stuck high RPM low vehicle speed high ambient temp Example 8000 RPM 10mph actual vehicle speed and 60 m p h indicated on speedometer Lower the gear ratio Remove windage plates from driven clutch If possible move to better snow conditions and reduce RPM Avoid riding in very high ambient temperatures Ice and snow piled up between track and tunnel overnight or after stopping for a long period of time enough to re freeze the snow Break loose snow and ice under tunnel Allow longer than normal warm up Allow belt to warm sufficiently and increase grip ability on clutch sheaves Use fast effective throttle when engaging clutch Poor running engine Bog Miss Backfire etc Maintain good state of tune including throttle and choke synchronization Check for fouled spark plug s Check for foreign material in carburetors Make sure no water or ice is present in the fuel tank lines or carburetors Loading machine on trailer Use caution when loading machine Carbide skags may gouge into trailer and prevent drive train from spinning freely Use enough speed to drive completely onto trailer If machi
390. 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 WINNING PERFORMANCE gt POLARIS Using masking tape tape off all decals that are not going to be replaced If you do not tape off the other decals the cleaning solution used later in the process may cause the Chassis Once all of the adhesive is removed from the decal area follow with a cleaning solution of 99 water to 1 mild dishwasher detergent Use a non abrasive cloth with the adhesive to break down in the non affected decals solution to remove dirt grease cleaning solvent and finger prints Always clean the surface where the decal will be applied 2 Using ahair 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 CAUTION 3 Once the decal is warm to touch and the adhesive is loose Itis extremely important to remove all traces of dirt and peel the decal off slowly and evenly Use of a hair dryer debris
391. thetic Capacity oz ml 11 325 3 Reverse System Perc Electrical Alternator Output Operating Voltage 13 5 14 5 Watts 13 5 Vdc Total 400 18 1700 RPM Ignition Timing Coolant Temp 120_F 49_C ALTITUDE DRIVE CLUTCH DRIVEN CLUTCH meters Shift Clutch Clutch Driven feet Weight Spring Spring Helix 0 600 64 42 36 0 2000 10 62 600 1200 2000 4000 10 60 2295516 1200 1800 a 4000 6000 BLK GRN RED BLK 120 340 140 240 22 40 76 1800 2400 10 56 7042083 7043058 56 42 36 6000 8000 LW ER 2400 3000 3000 10000 10 54 20 41 76 3000 3600 10000 12000 0 Spark Plug Gap in mm 027 70 Spark Plug Champion RN57YCC Track Width Inches cm 15 38 Length Inches cm 121 307 Lug Height Inches cm 1 0 5 STD 1 25 3 175 OPT Drive Clutch Bolt Torque 80 Ib ft 108Nm 1 8 Track tension sag in cm with 10 Ibs 4 54kg placed 16 in 40cm ahead of rear idler shaft 7 8 1 18 2 2 2 9cm WINNING PERFORMANCE C POLARIS Model Specifications Front Suspension Inches cm Suspension Type 10 42 5 Ryde FX HPG w IFP STD Rebuidlable Shocks Fox Compression Adj Remote Resevoir HPG OPT Rebuidable IFS Spring Rate Ibs in N mm Spring Installed Length Inches em 10 55 26 8 Front Vertical Travel Inches cm 10 254 S
392. tle bell crank wide open on the carburetor The bottoms of each throttle valve should be flush with the top of the intake bores 5 If adjustment is required hold the PTO carburetor flush with the top of intake bore Turn the throttle stop screw in or out to set the PTO throttle slide flush with the intake bore sa 4 14 Once the PTO carburetor slide is flush loosen the Phillips head screw located under the top cover on the MAG carburetor While holding the PTO carburetor slide flush to the top of the carburetor rotate the synchronization nut clockwise to raise the slide and counterclockwise to lower the slide Lock Screw Sync Nut Adjust the synchronization nut until it is even with the PTO slide Once this is flush lock the locking screw Replace the carburetor covers Ifremoved reinstall the fuel vent throttle and choke hose and cable connections Verify and set throttle cable free play WINNING PERFORMANCE gt POLARIS Fuel Systems CLEANFIRE FUEL INJECTION System Overview The Cleanfire fuel Injection system is a battery less engine management capacitive discharge ignition four fuel injector engine management system System components include ECU The ECU controls the ignition fuel injection angles chassis battery relays and supplies the MFD gauge with tachometer water temp PERC HOT DET diagnostic information Stator The stator
393. to the by pass out let By turning the screw in or out the cross sectional area of the air passage is varied in turn varying the fuel screw varies the amount of air fuel Main Jet When the throttle opening becomes greater and the area between the needle jet and jet needle increases fuel flow is metered by the main jet The number on the jet indicates the amount of fuel which will pass through it in one minute under controlled conditions Larger numbers give a greater flow resulting in a richer mixture Main jets are screwed directly into the needle jet base MAIN JET Jetting Guidelines Changes in altitude and temperature affect air density which is essentially the amount of oxygen available for combustion In low elevations and cold temperatures the air has more oxygen WINNING PERFORMANCE gt POLARIS In higher elevations and higher temperatures the air is less dense Verify the production setting for your specific model All carburetors must be re calibrated if operated outside the production temperature and or altitude range The main jet installed in production is not correct for all altitudes and or temperatures Refer to the jetting cart in the Specifications Chapter of this manual for correct jetting for altitude temperature ranges NOTE It is the owner s responsibility to ensure that the correct jets are installed in the machine for a geographical area Be very careful when jetting down in warm we
394. tons and rings will be greatly reduced NOTE A Nicasil cylinder can be lightly honed with a soft stone hone but an not be oversized Release the hone at regular intervals to inspect bore size and finish Cleaning The Cylinder After Honing It is very important that the cylinder be thoroughly cleaned after honing to remove all grit material Wash the cylinder in a solvent then in hot soapy water Pay close attention to areas where the cylinder sleeve meets the aluminum casting transfer port area Use electrical contact cleaner if necessary to clean these areas Rinse thoroughly dry with compressed air and oil the bore immediately with Polaris Premium 2 Cycle Lubricant EXAMPLE OF A CROSS HATCH PATTERN NOTE Always check piston to cylinder clearance and piston ring installed gap after honing or boring is complete Honing Procedure 1 Wash the cylinder with cleaning solvent Clamp the cylinder in a soft jawed vise by the cylinder studs 3 Place hone in cylinder and tighten stone adjusting knob gt POLARIS 5 9 Engine and Cooling Systems Crankshaft Truing Lubricate the bearings and clamp the crankshaft securely in the holding fixture If truing the crankshaft requires striking with a hammer always be sure to re check previously straightened areas to verify truing Refer to the illustrations below Use Crankshaft alignment kit PN 2870569 NOTE The rod pin position in relation to the dial i
395. umbers 3oz 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 with Premium All Season Grease IQ Shift Shown 3 14 POLOS Maintenance Throttle Cable Lubricate the throttle cable lightly with fresh oil With the engine off turn the handlebars to the left and lubricate well as shown m 2 8 ug 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 Verify the oil level is in the middle of the sight glass 3 Add the recommended oil as needed at the fill plug Do not overfill 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 Sv dee pa Install drain plug and hand tighten Do not over tighten the drain plug POLARIS
396. ump 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 8 POLARIS Maintenance 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 28mm Lever Pointer Oil Pump POINTER b 86 LEVER MARK ARM MARKING INDEX MARK PUMP BOSS 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 Oil Pump Adjustment Settings Models Only PART NUMBER ARM MARKING LENGTH A MM LEVER SETTING 2520552 600 33mm No Pointer Lever will not clear engine strap Pump used on all 2007 600 CFIs and some early build 2008 600 CFIs Set lever line mark to 1 full line width 050 above original oil pump boss index mark 2520831 600 28mm w Pointer Lever will clear engine strap P
397. ump phased in for 2008 600 CFIs Service replacement pump for ALL 600 CFIs Lever mark is a pointer Oil pump lever pointer is set POINTER TO LINE 2520622 700 33mm No Pointer Lever will not clear engine strap Pump used all 2007 700 CFIs and some early build 2008 700 CFIs Set lever line mark to 1 full line width 050 above original oil pump boss index mark Some 2007 700 CFI models had 2nd line scribed above original pump boss mark and were marked with red paint 2520832 700 28mm w Pointer Lever will clear engine strap Pump phased in for 2008 600 CFIs Service replacement pump for ALL 600 CFIs Lever mark is a pointer Oil pump lever pointer is set POINTER TO LINE 2520833 800 28mm w Pointer Lever will clear engine strap Early Build Engines Oil pump index mark boss is scribed with 2 lines from the factory Oil pump lever pointer is set BETWEEN the 2 scribe lines Late Build Engines Oil pump index mark boss features 1 scribe line Oil pump lever pointer is set POINTER TO LINE POLARIS The Way Out 3 9 Maintenance 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 CAUTION
398. until no more belt slippage occurs in the drive clutch Once 100 belt engagement is achieved the sled will accelerate along the low ratio line until the drive clutch up shift force overcomes the opposing shift force generated by the driven clutch Shift Out Over Rev Engine RPM that spikes above the desired operating RPM speed The shift out RPM should come down to the desired operating RPM but never below after the driven clutch begins to open Shift Out RPM Engine RPM at which the up shift force generated by the drive clutch overcomes the shift force within the driven clutch In this mode the drive clutch will move the belt outwards and the driven clutch will allow the drive belt to be pulled down into the sheaves During WOT operation the shift out RPM can be seen as the maximum sustained RPM displayed on the tachometer The shift out RPM should be the same RPM as the recommended engine operating RPM If the shift out RPM is above the recommended engine operating RPM install heavier drive clutch weights If the shift out RPM is below the recommended engine operating RPM install lighter drive clutch weights The shift out RPM should remain constant during both the upshift and back shift modes Driven Spring A compression spring Team driven clutch or torsional spring Polaris P 85 driven clutch works in conjunction with the helix and controls the shift rate of the driven clutch The spring must provide enough side pre
399. us 6 10 OVERVIEW uet eto diee ESAE Xe bru E cb eee 6 10 COMPENSATING PORT cr un zu ys sae Rede DRE M E MERE E MER RS 6 10 GENERAL GUIDELINES ee 6 11 BRAKE FLUID REPLACEMENT amp BLEEDING 6 11 MASTER CYLINDER LEVER SERVICE 6 12 BRAKE LINE 1 6 13 BRAKE LIGHT SWITCH 6 14 CALIPER REMOVAL isl Ree rerba Pee tu wee ace vibus 6 14 CALIPER REPLACEMENT a EE mss 6 14 CALIPER ASSEMBLY Papapa aspi a Penne ERES 6 15 BRAKE PAD REPLACEMENT 000000 6 15 BRAKE DISC REPLACEMENT 6 15 WINNING PERFORMANCE 6 1 POLARIS Final Drive and Brakes GEAR RATIO SPEED CHARTS 8 373 CD Chaincase Speed Charts Top Gear 26 26 25 25 25 25 25 24 24 23 23 22 22 22 21 21 21 20 20 19 19 19 19 Bottom Gear 36 40 36 37 40 41 44 41 42 39 42 39 40 43 40 41 44 41 45 38 41 42 46 Chain 76 78 76 76 78 78 80 78 78 76 78 76 76 78 76 76 78 76 78 74 76 76 78 Gear Ratio 1 38 1 54 1 44 1 48 1 60 1 64 1 76 1 71 1 75 1 70 1 8
400. ushings 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 POLARIS The Way Out 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 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 speedometer 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 Batte
401. ut of the engine compartment On CFI models disconnect the main harness at the ECU This is the smaller of the two plugs located on the ECU Remove it by pressing up on the underside of the plug and pulling straight off Disconnect the regulator rectifier connections 5 33 Engine and Cooling Systems 12 Disconnect the ignition coil connections and EV solenoid 16 from the ECU harness on CFI models 14 Disconnect the EV vent lines from the EV base and secure the vent lines out of the way 15 Remove the drive belt driven and drive clutches See Chapter 6 5 34 17 18 19 20 21 22 Remove the recoil rope from the handle and route rope through the guide on the chassis brace and secure the recoil rope by tying a knot so that it does not go into the recoil housing Drain the coolant from the engine into a suitable container Remove all coolant hoses from the coolant bottle and secure the loose hoses out of the way for engine removal Remove the four right hand chassis brace fasteners and remove the brace from the chassis Drain the oil from oil tank Remove the oil tank fasteners that hold the top of the oil tank to the chassis Disconnect the oil supply line from the oil tank located at the bottom portion of the oil tank Plug and secure the loose WINNING PERFORMANCE gt POLARIS Engine and Cooling Systems oil line so that it can come out with the engine 25 On CF
402. ut to specification 11 Hold or place the reservoir as low as possible so the air will travel upward as you slowly cycle the IFP up and down e T Be sure to bottom out the piston in the reservoir body Lock Nut Torque 14 ft lb 19N m Allow time for the bubbles to dissipate IMPORTANT Do not over torque or damage to the Repeat the process until all the air has been removed valve stack can occur 12 Set the IFP so it is approximately 1 8 from the bottom of the reservoir Install the bleed screw di Oros Shocks 18 Set the IFP to specification then close the bleed screw 19 Pour out any remaining shock oil from the reservoir 20 Install the cap making sure the o ring does not flip over Install the snap ring 21 Charge the shock to the specified pressure 22 Clean the shock of all oil reside and check for any leaks 23 Install button screw onto the reservoir cap Ryde FX Remote Reservoir Shock Disassembly 1 Remove the bushings and eyelet components from the lower shock body Mount the shock in a soft jawed bench vise 13 With the cylinder head assembly pushed down against the valve piston dip the piston assembly in shock oil 2 Remove the button head screw from the pressure valve assembly 14 Fill the shock body with oil to the bottom of the threads Carefully insert the piston rod and valve assembly into the cylinder Slightly oscillate the piston rod to allow the p
403. which can cause personal injury particularly in the area of the tunnel Protect hands with gloves when working with sharp components CAUTION If difficulty is encountered in removing or installing a component look to see if a cause for the difficulty can be found If itis necessary to tap the part into place use a soft face hammer and tap lightly Ay CAUTION Some of the fasteners in the snowmobile were installed with locking agents Use of impact drivers or wrenches will help avoid damage to fasteners Ay CAUTION Always follow torque specifications as outlined throughout this manual Incorrect torquing may lead to serious machine damage or as in the case of steering components can result in injury or death for the rider s WINMING PERFORMANCE gt POLARIS General Information A CAUTION If a torquing sequence is indicated for nuts bolts or screws start all fasteners in their holes and hand tighten Then following the method and sequence indicated in this manual tighten evenly to the specified torque value When removing nuts bolts or screws from a part with several fasteners loosen them all about 1 4 turn before removing them CAUTION If the condition of any gasket or O Ring is in question replace it with a new one Be sure the mating surfaces around the gasket are clean and smooth in order to avoid leaks CAUTION Some procedures will requ
404. will travel the entire length of the shock rod To prevent excessive bottoming out install the next highest rate spring or reduce the preload on the existing spring and change the shock valving to obtain the desired effect NOTE Shock valving can only be adjusted or changed on models that have serviceable shocks 8 10 Alignment Bar Specifications DIAMETER 623 625 15 824 15 875mm LENGTH 45 114 3cm MATERIAL 1018 Camber e 0 Neutral camber The spindle is 90 perpendicular to the ground Positive camber Spindle top is canted outward from the chassis e Negative camber Spindle top is canted inward towards the chassis WINNING PER FORMANCE gt POLARIS Steering and Suspensions Rod Ends 3 Determine which spindle requires the greatest amount of correction my installing the alignment bar through one Rod ends must be parallel to their respective mounting surface spindle to the other spindle Measure the distance from the after tightening jam nut If possible support the edge of the rod top of the alignment bar to the top of the ski mount hole with end to keep it from rotating out of position until jam nut is tight the bushing s removed Record measurement When rod ends are properly tightened the rod should rotate 4 Remove the alignment bar and install it to measure the freely approximatel
405. ws washer from the guillotine 7 Remove the guillotine from the base Exhaust Valve Assembly Clean the threads of the guillotine with Primer N Insert the base into the clean guillotine Apply Loctite 2760 to the first 3 threads on the guillotine Bo Place the bellows washer bellows and cap nut onto the guillotine 5 Torque the cap nut to specification Guillotine Cap Nut Torque 16 Ft Lbs 22 Nm 5 12 Lubricate the guillotine blade and shaft with engine oil Actuate the guillotine to ensure full and free motion Install the spring and cover Torque the vertical cover fasteners to specification e Fastener Torque 12 05 16 Nm 10 Install a new gasket on the cylinder then install the EV assembly The guillotine shaft will only fit into the cylinder the correct way If the shaft will not slide in verify it is installed correctly 11 Torque the horizontal cover screws to specification Optional Exhaust Valve Springs LOAD 1 INCH LOAD 630 SPRING COLOR INCHES LBS LBS 7041704 01 Blue 4 0 6 0 7041704 02 Orange 5 5 8 3 7041704 03 Pink 4 7 7 1 7041704 04 Purple 3 1 4 7 7041704 05 Yellow 2 4 3 6 7041704 06 White 1 6 2 8 WINNING PERFORMANCE gt POLARIS Engine and Cooling Systems ENGINE MOUNTING SYSTEMS 2007 IQ Carbureted Engine Mounting TORQUE STOP SPACE ENGINE MO
406. x 0 600 0 2000 22 39 76 600 1200 2000 4000 10 62 1200 1800 me 4000 6000 BLK GRN RED BLK 56 42 36 120 340 140 240 gg 22 40 76 1800 2400 10 58 7042083 7043058 6000 8000 2400 3000 8000 10000 10 56 m 20 41 76 000 3606 10000 12000 AL Drive Clutch Bolt Torque 80 Ib ft 108Nm 1 26 Track tension sag in cm with 10 155 4 54 placed 16 in 40cm ahead of rear idler shaft 7 8 1 1 8 2 2 2 9cm WINMING PERFORMANCE gt POLARIS Model Specifications Front Suspension Setup Width Suspension Type 10 42 5 Shocks Base Ryde FX HPG w IFP Dragon Ryde FX Air 2 0 IFS Spring Rate Ibs in N mm Spring Installed Length niches em 10 55 26 8 Air 2 0 Nitrogen Pressure 36mm Cylinder 145 psi 47mm Cylinder 60 psi Front Vertical Travel Inches cm 10 254 Ski Center Distance Inches cm 42 5 108 41 16 104 5 Camber Inches cm 2 25 0 31 57 7 9 Toe Out Inches cm 0 0 12 0 0 31 Rear Suspension Suspension Type IQ 136 Coupled Front Track Shock FTS Ryde HPG w IFP FTS Spring Rate Ibs in N mm 130 270 23 47 FTS Spring Installed Length inches cm Win Rear Track Shock RTS Base Fox PS5 Dragon Ryde FX Compression Adjustable w Remote Res Torsion Springs 347 Square 80_ Soft PN 7043070 067 PN 7043071 067
407. y turning the screw on the shock By turning the screw clockwise a small screwdriver or dime work well the compression valving is increased stiffening the ride To soften the ride reduce the compression by turning the screw counter clockwise A great deal of ride performance is accomplished with a mere 1 2 to 1 turns There are approximately 3 full turns of adjustment available If the suspension is bottoming tighten the compression screw clockwise in 1 2 turn increments until the bottoming stops Backing off 1 4 turn counter clockwise at this point should give you the best possible ride ensuring use of the full travel of the suspension The opposite procedure should be used if the suspension is too stiff upon initial set up If bottoming continues after the screw is turned in full clockwise the compression spring should be adjusted with the threaded adjustment collar Back the screw out to the original starting position after the compression spring has been adjusted Riding conditions are ever changing Keep in mind the compression damping adjustable screw can be adjusted at any time to achieve the best possible ride in any condition NOTE Install shock so the adjustment screw is facing outwards WINNING PERFORMANCE POLARIS Front Suspension Type by Model FRONT SUSPENSION MODEL ALL IQ IQ Switchback IQ LX IQ 42 5 and IQ Touring Models IQ RMK ALL IQ RMK Models Rear Suspension Type by
408. y 1 8 turn opposite side Measure the distance from the top of the alignment bar to the top of the ski mount hole with the bushing s removed Record measurement Rod End Engagement Rod ends must engage the rod a minimum of 2x the thread 5 adjust the camber unlock the lock nut and adjust the diameter when adjustment is complete camber with the adjuster nut until alignment bar measurement is within the specified range for each spindle Example 4375 11mm rod end A X 2 minimum thread 6 Once the specification is achieved tighten all jam nut s engagement B 875 22mm and torque them Ft Lb 61 Nm 7 Re check the set up width and compare to specification Handlebar Centering Raise the front of the machine off the floor so that the spindles are off the floor 3 7 62cm 2 Insertthe alignment bar through both ski bolt holes in each spindles 3 Adjust Toe until handlebar is centered Toe Adjustment B Toe is adjusted with the shocks and skis installed Track A alignment must be correct before starting this process Toe alignment is measured at ride height Camber Adjustment 1 Lift front of the machine off the floor rock the front end up and down and then set it down gently This will set the unit at ride height 2 Measure and make a mark 10 2 54cm forward of the ski mount bolt and 10 2 54cm behind the ski mount bolt preferably on the center line of the carbide skags 3 Place a
409. y View TENSIONER BLOCK FILL PLUG 4 SHAN CHAINCASE BEARING 7 SNAP RING MAGNETIC DRAIN PLUG WASHER SEAL LOCK NUT TENSIONER BOLT F COTTER PIN FASTENER e A Cover Fasteners 10 Ft Lbs 12 Nm B Lower Gear Fastener 19 Ft Lbs 26 Nm Upper Gear Castle Nut 50 Ft Lbs 62 D Fill Plug 18 25 In Lbs E Tensioner Bolt Hand Tight Tensioner Lock Nut 21 Ft Lbs 28 Nm G Drain Plug 8 Ft Lbs 11 Nm A WARNING which may result in the loss of braking control Incorrect chain tension may cause the chain to break 6 4 FASTENER Ay CAUTION Never re use Cotter pins Always replace with new parts Incorrect chain tension may cause the chain to break causing severe chaincase damage Installing gear sets not listed on the Gear Ratio Speed chart may cause premature gear chain wear NOTE Verify tensioner bolt seal is flush with mating surface prior to securing lock nut Maintain gear oil level at mid point of sight glass with vehicle on level ground Install lower gear washer with beveled side out WINNING PER gt POLARIS FORMANCE Final Drive and Brakes Chaincase Disassembly 1 Position the vehicle on level ground Drain the oil out of the chaincase into a suitable container Replace the drain plug 2 Remove the right side door panel and exhaust silencer 3 Remove the chaincase cover
410. zerks as outlined in the periodic maintenance table CAUTION The fasteners securing the rear suspension to the Assembly Notes Never re use Nylock nuts Always replace with new parts All pivots must rotate freely after tightening fasteners 8 20 tunnel are pre coated with a locking agent when new Never re use these fasteners when removed Always use new pre coated fasteners when mounting the suspension to the tunnel WINNING PER FORMANCE gt POLARIS Steering and Suspension M 10 136 Pivots Rear Idler 5 IDLER WHEEL SPACER IDLER SHAFT Qon 22 SS B SS FRA ADJUSTER x SHOCK LIMITER STRAP SHAFT 66 Sue S e 45 Ft Lb 61 Nm B 35 Ft Lb 47 Nm C 19 Ft Lb 26 Nm Assembly Notes Never re use Nylock nuts Always replace with new parts All pivots must rotate freely after tightening fasteners Apply Polaris Premium All Season Grease to all grease Zerks as outlined in the periodic maintenance table WINNING PERFORMANCE 8 21 gt POLARIS Steering and Suspensions M 10 136 Rail Assembly IDLER WHEEL ADJUSTER BUMPER COUPLER BLOCK 0 9 2 2 N FRA BLOCK COUPLER lt S se RAIL TIP SLIDER 2 A 6 1 A 3 6 Ft Lb 4 8 Nm B 19 Ft Lb 26 Nm C 35 In Lb 4 Nm D 35 Ft Lb 47 Nm Assembly Notes

Polaris 2007 2008 IQ Service Manual

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