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Polaris 340 LX 2007, Service Manual

The Polaris 340 LX 2007 Service Manual is essential for maintaining and repairing your snowmobile. Download this manual for free from manualshive.com to access detailed instructions and diagrams for troubleshooting, servicing, and repairing your vehicle. Ensure your Polaris 340 LX 2007 stays in top condition with this comprehensive manual.

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3.1

CHAPTER 3

MAINTENANCE

3

MAINTENANCE

MAINTENANCE PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

POLARIS RECOMMENDED PROGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

INSPECTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5

CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
CYLINDER MEASUREMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
CYLINDER HONING  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
HONING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
HONING TO OVER SIZE (340/500 FUJI ENGINES ONLY)  . . . . . . . . . . . . . . . . . . . . . . 3.6
CLEANING THE CYLINDER AFTER HONING  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
PISTON INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
COOLANT LEVEL  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
RECOMMENDED COOLANT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
COOLING SYSTEM BLEEDING  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
BEARING FIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
MAIN BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
CONNECTING ROD (BIG END) BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
WRIST PIN BEARING  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
CRANKSHAFT INDEXING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
CHECKING CRANKSHAFT INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
CRANKSHAFT TRUEING  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
CRANKSHAFT RUNOUT INSPECTION  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
OIL PUMP BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
OIL / FUEL FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
BRAKE LEVER TRAVEL  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
BRAKE FLUID  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
EXHAUST SYSTEM REMOVAL/INSTALLATION  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
MANIFOLD INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
BELT DEFLECTION INSPECTION  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
MEASURING BELT DEFLECTION  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14

LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3.15

REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
JACKSHAFT BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
DRIVESHAFT BEARING  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
THROTTLE CABLE  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
CHOKE AND CHOKE CABLE  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
CHAINCASE OIL  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17

ADJUSTMENTS  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3.17

CHOKE ADJUSTMENT  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
THROTTLE LEVER FREE PLAY - NON CFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
THROTTLE LEVER FREE-PLAY - CFI MODELS  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
OIL PUMP ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
TRACK ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
TRACK TENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
REAR ENGINE TORQUE STOP ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
ENGINE ISOLATOR LIMITER SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22

CLEANING  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22

AIR FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
WATER SEDIMENT TRAP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
NOSEPAN CARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22

STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22

Summary of Contents for 340 LX 2007

Page 1: ...s Sales Inc 2100 Hwy 55 Medina Minnesota 55340 You may also fill out a Comments and suggestion electronic form that can be located at www polarisdealers com in the News Forms Links area click on Servi...

Page 2: ...ing instructions IMPORTANT IMPORTANT provides key reminders during disassembly assembly and inspection of components MEASUREMENT provides a key for a determined measurement specification TORQUE provid...

Page 3: ...12 11 10 4 3 5 6 7 9 8 SPECIFICATIONS GENERAL MAINTENANCE FUEL DELIVERY ENGINE CLUTCHING FINAL DRIVE FRONT SUSPENSION REAR SUSPENSION CHASSIS HOOD ELECTRICAL ENGINE AND DRIVE TRAIN CHASSIS AND ELECTRI...

Page 4: ......

Page 5: ...6 500 XC SP 1 8 SUPER SPORT 1 10 550 LX 1 12 TRAIL RMK 1 14 TRAIL TOURING DELUXE 1 16 600 HO IQ 1 18 600 HO IQ CLEANFIRE 1 20 600 HO IQ LX CLEANFIRE 1 22 600 HO SWITCHBACK 1 24 600 HO SWITCHBACK CLEAN...

Page 6: ...0 2000 185 4 180 3 170 3 170 3 165 3 160 3 155 3 150 3 600 1200 2000 4000 175 3 170 3 160 3 160 3 155 3 150 3 140 2 140 2 1200 1800 4000 6000 165 3 160 3 155 3 150 3 145 3 140 2 130 2 130 2 1800 2400...

Page 7: ...7 9 Toe in mm 12 25 3 0 6 35 Rear Suspension Suspension type Edge 121 Front track shock FTS Arvin 7041939 FTS Spring PN 7041253 FTS Spring Free Length in cm 7 5 19 FTS Spring Rate lb in kg mm 200 240...

Page 8: ...185 4 180 3 170 3 170 3 165 3 160 3 155 3 150 3 600 1200 2000 4000 175 3 170 3 160 3 160 3 155 3 150 3 140 2 140 2 1200 1800 4000 6000 165 3 160 3 155 3 150 3 145 3 140 2 130 2 130 2 1800 2400 6000 80...

Page 9: ...r in mm 59 31 15 0 7 9 Toe in mm 12 25 3 0 6 35 Rear Suspension Suspension type Edge 136 Front track shock FTS Arvin 7041939 FTS spring rate lb in kg mm 200 240 3 6 4 3 FTS spring installed length in...

Page 10: ...2 200 2 195 2 190 2 185 2 175 2 170 2 170 1 600 1200 2000 4000 195 2 185 2 180 2 175 2 170 2 165 2 155 1 155 1 1200 1800 4000 6000 185 2 175 2 170 2 165 2 160 1 155 1 145 1 145 1 1800 2400 6000 8000...

Page 11: ...2 20 8 18 3 Toe in mm 0 12 0 3 Rear Suspension Suspension type WideTrak Front track shock FTS Arvin 7041742 FTS spring rate lbs in kg mm 181 3 2 FTS spring installed length in cm Fixed Rear track shoc...

Page 12: ...0 2 380 2 360 2 350 1 600 1200 2000 4000 420 3 400 2 390 2 370 2 360 2 250 2 330 1 320 1 1200 1800 4000 6000 390 2 380 2 360 2 350 2 340 2 330 1 310 1 300 1 1800 2400 6000 8000 370 2 350 2 340 2 320 2...

Page 13: ...0 7 9 Toe in mm 12 25 3 0 6 35 Rear Suspension Suspension type Edge 121 Front track shock Arvin 7041975 FTS Spring rate lb in kg mm 160 Var 2 86 Var FTS Spring installed length 7 46 18 9 Rear track sh...

Page 14: ...600 1200 2000 4000 260 4 250 4 240 3 230 3 220 3 220 2 210 2 200 1 1200 1800 4000 6000 250 4 240 3 230 3 220 3 210 2 210 2 200 1 190 1 1800 2400 6000 8000 230 3 220 3 220 3 210 2 210 2 200 1 190 1 180...

Page 15: ...ension Suspension type Edge 121 Front track shock FTS Arvin 7041939 FTS spring rate lb in kg mm 200 240 3 6 4 4Var FTS spring installed length in cm Fixed Rear track shock Arvin MPV 7043239 Rear trave...

Page 16: ...1200 2000 4000 260 4 250 4 240 3 230 3 220 3 220 2 210 2 200 1 1200 1800 4000 6000 250 4 240 3 230 3 220 3 210 2 210 2 200 1 190 1 1800 2400 6000 8000 230 3 220 3 220 3 210 2 210 2 200 1 190 1 180 1 2...

Page 17: ...ension Suspension type Edge 121 Front track shock FTS Arvin 7041939 FTS spring rate lb in kg mm 200 240 3 6 4 4Var FTS spring installed length in cm Fixed Rear track shock Arvin MPV 7043239 Rear trave...

Page 18: ...3 210 2 200 1 600 1200 2000 4000 260 4 250 4 240 3 230 3 220 3 220 3 210 2 200 1 1200 1800 4000 6000 250 4 240 3 230 3 220 3 210 2 210 2 200 1 190 1 1800 2400 6000 8000 230 3 220 3 220 3 210 2 210 2 2...

Page 19: ...Camber in mm 735 31 18 7 7 9 Toe in mm 0 12 Rear Suspension Suspension type Edge RMK 136 Front track shock Arvin 7042085 FTS spring rate lb in kg mm 170 3 0 FTS spring installed length in cm Fixed Re...

Page 20: ...2000 4000 260 4 250 4 240 3 230 3 220 3 220 3 210 2 200 1 1200 1800 4000 6000 250 4 240 3 230 3 220 3 210 2 210 2 200 1 190 1 1800 2400 6000 8000 230 3 220 3 220 3 210 2 210 2 200 1 190 1 180 1 2400 3...

Page 21: ...in mm 12 25 3 0 6 35 Rear Suspension Suspension type Edge 136 Front track shock FTS Arvin 7041939 FTS spring rate 200 240 3 6 4 4Var FTS spring installed length Fixed Rear track shock RTS Arvin 70421...

Page 22: ...00 370 3 360 2 350 2 340 2 330 2 320 1 310 1 300 1 1800 2400 6000 8000 340 3 320 2 310 2 300 2 280 2 280 1 270 1 260 1 2400 3000 8000 10000 310 2 300 2 290 2 280 1 270 1 260 1 250 1 240 1 3000 3700 10...

Page 23: ...Toe in mm 0 12 0 3 0 notes that shock is serviceable Rear Suspension Suspension type IQ 121 Front track shock FTS Arvin 7043244 Std Fox 7043267 Opt FTS spring rate lb in kg mm 130 270 2 3 4 8 Std Opt...

Page 24: ...k Green Red Black 64 42 36 LW ER 23 39 76 600 1200 2000 4000 10 60 Black Green Red Black 56 42 36 LW ER 22 39 76 1200 1800 4000 6000 10 58 Black Green Red Black 56 42 36 LW ER 22 40 76 1800 2400 6000...

Page 25: ...Opt FTS installed length in mm 7 97 20 2 Std Opt Rear track shock RTS Fox 7043177 Std Fox 7043266 Opt Rear Suspension Travel in cm 13 9 35 3 notes that shock is serviceable Torsion Spring Torsion spri...

Page 26: ...iven Helix Gearing 0 600 0 2000 10 62 Black Green Red Black 64 42 36 LW ER 22 39 76 600 1200 2000 4000 10 60 Black Green Red Black 56 42 36 LW ER 22 39 76 1200 1800 4000 6000 10 58 Black Green Red Bla...

Page 27: ...uspension Suspension type M 10 128 Front track shock FTS Arvin 7043243 FTS spring rate lb in kg mm 160 2 86 FTS spring installed length in cm 8 20 3 Rear track shock RTS Fox 7043216 Rear travel in cm...

Page 28: ...00 1800 4000 6000 370 3 360 2 350 2 340 2 330 2 320 1 310 1 300 1 1800 2400 6000 8000 340 3 320 2 310 2 300 2 280 1 280 1 270 1 260 1 2400 3000 8000 10000 310 2 300 2 290 2 280 1 270 1 260 1 250 1 240...

Page 29: ...Opt Front vertical travel in cm 10 25 4 Ski center distance in cm 42 5 108 Camber in cm 2 25 31 5 7 79 Toe in mm 0 12 0 3 0 notes that shock is serviceable Rear Suspension Suspension type IQ Switchba...

Page 30: ...0 62 Black Green Red Black 64 42 36 ER 22 39 76 600 1200 2000 4000 10 60 Black Green Red Black 56 42 36 ER 22 39 76 1200 1800 4000 6000 10 58 Black Green Red Black 56 42 36 ER 22 40 76 1800 2400 6000...

Page 31: ...0 FTS spring installed length in cm 7 25 18 4 Rear track shock Fox 7043246 Rear travel in cm 13 9 35 3 notes that shock is serviceable Torsion Spring Torsion spring PNs LH RH 7041629 7041630 Torsion s...

Page 32: ...330 1 1200 1800 4000 6000 370 3 360 2 350 2 340 2 330 2 320 1 310 1 300 1 1800 2400 6000 8000 340 3 320 2 310 2 300 2 280 1 280 1 270 1 260 1 2400 3000 8000 10000 310 2 300 2 290 2 280 1 270 1 260 1...

Page 33: ...type IQ RMK 144 155 Std Front track shock FTS Arvin 7043048 Std FTS spring rate lb in kg mm 190 3 4 Std Prem Front track shock FTS WE Air 7043234 Premium FTS nitrogen charge 215 psi 14 8 bar nitrogen...

Page 34: ...900 0 3000 10 62 Black Green Red Black 64 42 36 LW ER 22 43 78 900 1500 3000 5000 10 60 Black Green Red Black 56 42 36 LW ER 22 43 78 1500 2100 5000 7000 10 58 Black Green Red Black 56 42 36 LW ER 22...

Page 35: ...ension Suspension type M 10 136 Front track shock FTS Arvin 7043207 FTS spring rate lbs in kg mm 220 3 9 FTS spring installed length in cm 8 5 21 6 Rear track shock Fox 7043216 Rear travel in cm 14 35...

Page 36: ...LUTCH TEAM Shift Weight Clutch Spring Clutch Spring Driven Helix Gearing 0 600 0 2000 10 64 Dark Blue White Red Black 66 44 46 LW ER 23 39 76 600 1200 2000 4000 10 62 Dark Blue White Red Black 66 44 4...

Page 37: ...ront track shock FTS Walker 7043204 FTS spring rate lbs in kg mm 130 270 2 3 4 8 FTS spring installed length in cm 7 97 20 2 Rear track shock Walker 7043205 Rear vertical travel in cm 13 9 35 3 notes...

Page 38: ...TCH TEAM Shift Weight Clutch Spring Clutch Spring Driven Helix Gearing 0 600 0 2000 10 66 Black Green Black 56 42 36 LW ER 20 41 76 600 1200 2000 4000 10 64 Black Green Black 56 42 36 LW ER 20 41 76 1...

Page 39: ...RMK 155 Front track shock Walker 7043234 IFS nitrogen charge 215 psi 14 8 bar nitrogen FTS spring installed length in cm N A Rear track shock RTS Walker 7043235 Rear travel in cm 15 5 39 4 notes that...

Page 40: ...NOTES MODEL SPECIFICATIONS 1 36...

Page 41: ...5 TUNNEL DECAL 2 5 VIN NUMBER DESIGNATION 2 5 PUBLICATION PART NUMBERS 2 5 MISC PUBLICATIONS 2 5 2007 SERVICE PUBLICATIONS 2 6 GENERAL REFERENCE 2 7 STANDARD BOLT TORQUE SPECIFICATION 2 7 2 STROKE GAS...

Page 42: ...the jetting is staggered the main jets will be listed as PTO MAG Specifications may change after the production of this manual Any changes will be communicated by Team Tips Clutch Springs Springs are...

Page 43: ...talled Length is the length of the spring from end to end when it is ready to be installed on the snowmobile You should adjust the spring preload ring until you reach your specified spring installed l...

Page 44: ...Fuji 3A 340 F C Piston Port 4B 488 L C Piston Port 4C 440 EV L C Piston Port 5B 544 F C Cylinder Reed 5C 500 EV L C Case Reed 2 Cyl Liberty 6F 600 EV L C Case Reed HP 2 Cyl Liberty 6H 600 EV L C Case...

Page 45: ...orld Mfg ID Vehicle Descriptors Vehicle Identifiers Body Style Type Engine Size Engine Modifier Series Check Digit Model Year Mfg Location Individual Serial No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1...

Page 46: ...9920474 9916508 9920472 600 RMK 144 S07PK6FS 9920476 9920477 9920478 9919882 9920463 Dragon RMK S07PL7JS 9920911 N A 9920912 9920606 9920463 600 RMK 155 S07PM6FS A 9920476 9920483 9920478 9919882 9920...

Page 47: ...ce 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...

Page 48: ...61 64 9531 31 32 9688 25 mm 9843 63 64 9844 1 1 0 Thread Size Drill Size Thread Size Drill Size 0 80 3 64 1 2 13 27 64 1 64 53 1 2 20 29 64 1 72 53 9 16 12 31 64 2 56 51 9 16 18 33 64 2 64 50 5 8 11...

Page 49: ...there is a rise or fall of 25 degrees you must jet accordingly to return your EGTs to the baseline numbers UNIT OF MEASURE MULTIPLIED BY CONVERTS TO ft lb x 12 in lb in lb x 0833 ft lb ft lb x 1 356...

Page 50: ...ed in a rotational direction g Gram Unit of weight in the metric system gal Gallon ID Inside diameter in Inch inches in lb inch pounds A force of one pound at the end of a lever one foot in length app...

Page 51: ...2 11 GENERAL 2 SPECIAL TOOLS Special Tools...

Page 52: ...2 12 GENERAL...

Page 53: ...2 13 GENERAL 2...

Page 54: ...2 14 GENERAL...

Page 55: ...CRANKSHAFT RUNOUT INSPECTION 3 12 OIL PUMP BLEEDING 3 12 OIL FUEL FILTER 3 12 BRAKE LEVER TRAVEL 3 13 BRAKE FLUID 3 13 EXHAUST SYSTEM REMOVAL INSTALLATION 3 13 MANIFOLD INSTALLATION 3 13 BELT DEFLECT...

Page 56: ...ELECTRICAL CONNECTIONS 3 23 CARBURETOR THROTTLE BODY 3 23 FUEL SYSTEM 3 23 CORROSION 3 23 SHOCKS 3 23 BATTERY 3 23 REPLACEMENT 3 24 HEADLIGHT BULB REPLACEMENT 3 24 EDGE HEADLIGHT BULB REPLACEMENT 3 24...

Page 57: ...e or adjust your snowmobile If you re not familiar with safe service or adjustment procedures and the use of tools or if you don t feel comfortable performing these tasks yourself contact an authorize...

Page 58: ...Ski Toe Alignment I I I ITEM PRE RIDE FREQUENCY MILES KM PRE SEASON 150 240 500 240 1000 1600 2000 3200 I INSPECT CLEAN ADJUST TIGHTEN LUBRICATE REPLACE IF NECESSARY C CLEAN R REPLACE L LUBRICATE Susp...

Page 59: ...at the bottom Use the chart below and record all measurements Cylinder Honing The cylinder bore must be de glazed whenever new piston rings are installed A light honing with fine stones removes only...

Page 60: ...xceed 0004 002mm NOTE Portable rigid hones are not recommended for over sizing cylinders cylinder boring and finish honing The use of an arbor type honing machine is recommended Always check piston to...

Page 61: ...use a premium 60 40 pre mix antifreeze This premium antifreeze is mixed with deionized water for better protection for aluminum cooling This pre mix is good for temperatures down to 62 F 52 C Replace...

Page 62: ...f the recommended interference fit If the bearing falls out of the case when the case is inverted or if the crankcase bearing surface is severely galled or damaged the case should be replaced NOTE Cra...

Page 63: ...ng Polaris uses crankshafts that 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 ver...

Page 64: ...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 indicator 10 Remove the dial indicator and install in...

Page 65: ...s 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...

Page 66: ...ly 30 seconds oil should flow from beneath the screw head This will indicate the pump is free of the air 3 Tighten bleed screw A securely NOTE Any time that the engine is disassembled or repaired it i...

Page 67: ...e Brake Fluid Replacement Bleeding on page 7 20 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 Exhau...

Page 68: ...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...

Page 69: ...is Premium All Season Grease at 500 miles 800km initially every 1000 miles 1600km after that and before off season storage each year A grease gun kit complete with grease and adaptors is available to...

Page 70: ...l may take only two pumps Push the clutch back onto the shaft and replace the clutch retaining bolt Torque the retaining bolt to 18 ft lbs 24 4 N m Driveshaft Bearing Inject grease into the fitting on...

Page 71: ...equipped with a dip stick only need to be filled to the safe marks located on the dip stick 5 Clean the magnetic plug on the dipstick or fill plug 6 Reinstall the dipstick or fill plug 7 Remove the di...

Page 72: ...e slack that occurs if the cable has stretched over time 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...

Page 73: ...le 4 Verify that the oil pump alignment marks are aligned at the point where the throttle slides begin to rise from their fully closed positions 5 If they are not aligned make the necessary adjustment...

Page 74: ...off 6 Inspect track alignment by carefully looking through the track window B to make sure the rails C are evenly spaced on each side 7 If the track runs to the left loosen the left locknut and tight...

Page 75: ...e 7 Loosen up the idler shaft bolts F 8 Turn each adjuster bolt C toward the idler wheel clockwise if you need less of a measurement Turn the adjuster bolt C toward the front of the sled counterclockw...

Page 76: ...under the work area to help catch some of the contaminated gasoline 3 Slide the clamp A away from the drain plug B and remove it from the sediment tube and drain the contaminated material from the bo...

Page 77: ...ayed electrical wire and connectors Carburetor Throttle Body Fog engine with Polaris Fogging Oil aerosol type according to directions on can Fuel System Treat the fuel system with Polaris Carbon Clean...

Page 78: ...light harness 1 form the bulb 2 Remove the rubber boot 2 from the housing 3 Pinch the ends of the spring 3 together and lift it until it releases from the spring retainer 4 Lift spring carefully aroun...

Page 79: ...from the thermostat and insert it into an empty container 4 Apply 3 5 psi of air pressure to the thermostat cover until no more coolant can come out of the thermostat hose that you inserted into the c...

Page 80: ...NOTES MAINTENANCE 3 26...

Page 81: ...ENING VS FUEL FLOW 4 11 MIKUNI TM38 FLAT SLIDE SERVICE 4 12 DISASSEMBLY 4 12 ASSEMBLY 4 14 CARBURETOR SYNCRONIZATION 4 14 THROTTLE VALVE SYNCHRONIZATION 4 14 CARBURETOR COMPONENT PART NUMBERS 4 15 MIK...

Page 82: ...4 2 FUEL DELIVERY 600 CFI FUEL PUMP REPLACEMENT 4 21 FUEL TANK PRESSURE TEST 4 22 THROTTLE BODY REMOVAL 4 22 FUEL FILTER REMOVAL 4 23 FUEL FILTER INSTALLATION 4 23...

Page 83: ...ring components can result in injury or death for the rider s If a torquing sequence is indicated for nuts bolts or screws start all fasteners in their holes and hand tighten Then following the method...

Page 84: ...or clogged Red fuel line is the exterior line for outside the tank The violet line is the interior line for inside the fuel tank They cannot be interchanged The violet line used inside the tank will f...

Page 85: ...rts replace all diaphragms check valves and gaskets MIKUNI JET NEEDLE Overview This needle example is a 9DH01 57 The first number is the approximate overall length in 10mm increments of the jet needle...

Page 86: ...needles in the TM 38 carburetors are longer and are not interchangeable with VM needles To raise or lower the needle remove the top cap D and loosen the 2 5mm Allen screw holding the needle in place R...

Page 87: ...ng sure gaskets are properly positioned MIKUNI 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 t...

Page 88: ...en 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 continuou...

Page 89: ...et 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 rang...

Page 90: ...needle in the jet passage and leans the mixture Letter and number codes are stamped into the needle and the jet indicating sizes and tapers taper of needles only of each Jet Needle The jet needle tape...

Page 91: ...4 11 FUEL DELIVERY 4 Throttle Opening Vs Fuel Flow VM only...

Page 92: ...e plastic washer from the throttle slide NOTE Keep track of the plastic washer 9 and place it so it is on the top of the throttle valve when installing the needle and e ring back into the carburetor 4...

Page 93: ...o screws 18 holding the float needle and seat assembly 19 in position and remove this assembly 13 Inspect the contents for wear and debris 14 Remove and inspect the main jet 20 pilot jet 21 and starte...

Page 94: ...sitioned to rest on top of the throttle valve when assembled 12 Install carburetors on engine 13 Synchronize the carburetors See Throttle Valve Synchronization in this chapter 14 Replace top cap gaske...

Page 95: ...ER MAIN JET PART NUMBER MAIN JET PART NUMBER 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...

Page 96: ...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 AIR JET PART NUMBER 0 5 3131255 0 6 3131249 0 7 3131256 0 8 3131254 0 9...

Page 97: ...00 700 CFI Engine Removal on page 5 29 4 Replace the injectors 5 Install engine See 600 700 CFI Engine Installation on page 5 35 6 Re flash ECU with Digital Wrench 7 Test run 600 700 CFI Injector Repl...

Page 98: ...or o rings seal and mating surfaces fuel rail case sides 11 Insert the fuel rail with injectors back onto the engine 12 Apply a light amount of 262 Loctite to the fuel rail fasteners and torque to spe...

Page 99: ...ll travel back to the fuel tank through the return line Fuel Pump 700 This fuel pump on this system is non serviceable and can not be replaced If fuel pump fails the whole fuel tank assembly must be r...

Page 100: ...u will need to bleed off the fuel pressure if any service is needed to the fuel system or if engine is to be removed 1 Select the appropriate adapter for your valve type Adapter 3 is used on the shall...

Page 101: ...rom the fuel rail See Fuel Rail Bleeding on page 4 20 6 Lift and move the tank back to gain access to the fuel lines 7 Remove the fuel supply and return hoses from the top of the tank 8 Disconnect the...

Page 102: ...onnect a Mity Vac hand pump to the fuel tank vent fitting Seal the fuel supply and return fittings 2 Pressurize the tank to 5 PSI NOTE Using a hand pump to pressurize the fuel tank may take a very lon...

Page 103: ...from the fuel filter 3 Using the fuel line disconnection tool remove the filter line from the fuel sender 4 Remove the fuel filter Fuel Filter Installation 1 Dip the male end of the fuel filter line i...

Page 104: ...NOTES FUEL DELIVERY 4 24...

Page 105: ...NE REMOVAL INSTALLATION 5 11 340 550 ENGINE DISASSEMBLY 550 SHOWN 5 12 ENGINE ASSEMBLY 5 13 500 FUJI ENGINE 5 16 DISASSEMBLY 5 16 ASSEMBLY 5 17 500 600 HO ENGINE 5 19 ENGINE REMOVAL 5 19 500 600 CARBU...

Page 106: ...ew 16 ft lb 22 N m 1 2 3 4 5 6 7 8 9 1 Cover Fasteners 2 Cover 3 Spring 4 Cap Nut 5 Bellows 6 Bellows Washer 7 Exhaust Valve Base 8 Base Gasket 9 Guillotine Actuate to ensure free and full motion Appl...

Page 107: ...s 5 and cap nut 4 onto the guillotine 5 Torque the cap nut s to 16 ft lb 22 N m 6 Lubricate the guillotine blade and shaft with engine oil 7 Actuate the guillotine to ensure full and free motion 8 Ins...

Page 108: ...onto the installed reed cage NOTE 600 700 CFI engines must have the boots placed onto the case in the correct orientation The boot has a P for PTO side and M for MAG 5 If applicable replace the hose...

Page 109: ...600 CFI or 700 CFI Liberty engines the new cases will come with the cylinder studs not installed you will need to assemble the cylinder studs to a determined length You will need to thread in the Dri...

Page 110: ...that the spring side is facing the intake side of the case and press it in so that it is bottomed out in the case 2 Install the mechanical seal 8 into the case with the sealant facing the intake side...

Page 111: ...cylinders and crankcase locate the two crankcase drain screws located on the front lower crankcase halve 600 700 CFI drains are located on the bottom of the crankcase and the engine would have to be r...

Page 112: ...nspect all parts for wear or damage during disassembly Replace all seals o rings and gaskets with Genuine Pure Polaris parts during assembly Refer General chapter for general inspection procedures 1 I...

Page 113: ...5 9 ENGINE 5 COOLING SYSTEMS 500 600 700 121 Switchback RMK DRAGON 500 XC SP 600 HO IQ LX 600 HO IQ LX CFI 600 HO Switchback 600 RMK DRAGON To center tunnel cooler...

Page 114: ...5 10 ENGINE 500 600 Touring WideTrak LX Touring WideTrak...

Page 115: ...and driven clutches See Drive Clutch Removal on page 6 15 See Driven Clutch Removal on page 6 21 10 Remove the recoil handle and secure the rope so that it is on the recoil housing 11 Loosen the carbu...

Page 116: ...Engine Disassembly 550 shown NOTE Inspect all parts for wear or damage during disassembly Replace all seals o rings and gaskets with Genuine Pure Polaris parts during assembly 10 11 3 4 12 13 5 2 14 1...

Page 117: ...the head gasket 12 During the removal process note that the gasket has a EX for exhaust side and UP for the orientation 17 Remove the cylinder base nuts 13 and carefully remove each cylinder 550 only...

Page 118: ...the 12 00 or 6 00 position 14 Install the reed valves in to the intake of the crankcase 15 Install new base gaskets 16 Compress the piston rings and install each cylinder onto the crankcase 17 Torque...

Page 119: ...28 Install the oil pump onto the lower case half NOTE Install all oil pump shims 29 Apply Blue Loctite 243 to the oil pump mounting screw threads and torque to 48 72 in lb 5 5 8 3 N m 30 Route each o...

Page 120: ...flywheel puller PN 2871043 Use all flywheel bolt holes Do no install puller bolts more than 5 16 7mm into flywheel or stator damage may result 4 Mark stator plate and crankcase for reference when rea...

Page 121: ...et Mount gasket with the white sealing material facing up 8 Lubricate rings and pistons with two stroke oil Install rings with letter mark or beveled side facing upward 9 Lubricate rings and cylinder...

Page 122: ...3 95 N m using the flywheel holding tool PN 8700229 19 Install water pump and recoil starter cup make sure that the thicker end of the drive pulley is towards the flywheel NOTE Belt deflection should...

Page 123: ...exhaust valve vent lines from the top of the exhaust valve base 12 Disconnect the DET sensor connection 4 13 Remove the panduit strap and disconnect the throttle position sensor TPS from the carbureto...

Page 124: ...23 Remove the left hand rear torque stop fasteners 11 24 Remove the inside motor mount fastener 12 located under the PTO carburetor boot 25 Remove the rear torque stop plate 26 Remove the engine isol...

Page 125: ...so that the engine straps clear the motor mount studs 31 Carefully place the engine on top of the shock tower brace 32 Remove the oil cable from the oil pump lever by holding the pump open and rotatin...

Page 126: ...8 9 10 11 12 13 15 16 31 14 14 32 ft lb 22 ft lb 17 See Torque sequence 30 N m LOCTITE 242 70 in lb 7 9 N m 9 ft lb 12 2 N m 18 ft lb 24 N m 43 N m Height Installation see page 5 5 500 Liberty Engine...

Page 127: ...on is applied to all fasteners Proper torque application prevents fasteners from loosening or breaking in critical service It also minimizes wear and eliminates premature or needless repair costs Foll...

Page 128: ...straight up 12 00 position or straight down 6 00 position Make sure that the c clip is fully seated in the piston groove Use c clip installation tool PN 2872622A 9 Install the piston rings onto the pi...

Page 129: ...ing assembly Refer General chapter for general inspection procedures 1 Install the stator 9 and align the timing marks that was noted earlier 2 Apply Loctite 242 to the first few threads of the stator...

Page 130: ...ner 6 and torque to 28 ft lb 38 N m 9 Insert the front engine strap washer and Nyloc nut 7 onto the motor mount stud and torque to 28 ft lb 38 N m 10 Adjust the front torque stop so that the bumper is...

Page 131: ...the thermostat hose with a cable tie 20 Connect the exhaust valve vent lines 18 21 Install the oil supply lines to each of the carburetors 22 Install the carburetors onto the carburetor boots and tig...

Page 132: ...N m 2 DETIONATION SENSOR 168 in lb 19 N m CYLINDER BASE NUTS 32 ft lb 43 N m 3 EXHAUST VALVE COVER BOLTS 12 ft lb 16 N m EXHAUST VALVE NUT 144 in lb 16 N m 1 EXHAUST MANIFOLD BOLTS 22 ft lb 30 N m CAR...

Page 133: ...m the spark plugs 5 Remove the belt cover electrical center cover 1 6 Disconnect the intake air sensor 2 located on the MAG side of the airbox 7 Remove the return fuel line P holder 3 located on the M...

Page 134: ...t lines from the EV base 11 and secure the vent lines out of the way 15 Remove the drive belt driven and drive clutches See Chapter 6 16 Remove the recoil rope from the handle and route rope through t...

Page 135: ...secure the loose oil line so that it can come out with the engine 23 Remove the engine isolator 16 and rear torque stop 17 located on the left hand side of the engine 24 Remove the four engine mounti...

Page 136: ...enter 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 33 Remove the oil cable 23 from the oil pump...

Page 137: ...5 33 ENGINE 5 600 700 CFI Engine Disassembly 1 2 5 3 6 7 9 10 11 12 13 14 15 16 18 19 20 21 24 27 28 26 31 32 29 25 23 17 4 8 22 30 If new see installation height on page 5 5...

Page 138: ...ump Cross Shaft Assembly on page 5 6 2 Set the crankshaft assembly 24 28 into the lower crankcase 29 3 Fill the cross shaft section of the lower crankcase with cross shaft break in lube PN 2872435 4 P...

Page 139: ...point 6 With the throttle bodies separated from the intake adapters route the throttle cable behind the fuel rail and insert the throttle cable into the throttle pulley located in the center of the th...

Page 140: ...ot 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 3 Open and slide the hose clamp onto...

Page 141: ...a clearance of 010 030 25 75mm from the face of the torque stop to the surface of the engine NOTE If a new torque stop is installed install it so that the nub is touching the engine This nub is 030 75...

Page 142: ...ter and fuel return line by pushing them together until you hear a audible click 32 Secure the fuel return line P clamp 15 onto the side of the airbox 33 Place the fuel filter back into the holder 16...

Page 143: ...d 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 42 Replace the nosepan plugs were removed to access the front...

Page 144: ...LINDER HEAD 22ft lb 30 N m 1 3 BLEEDER SCREW 70 in lb 8 N m THERMOSTAT HOUSING 9 ft lb 12 N m WATER TEMPERATURE SENSOR 18 40ft lb 24 54 N m 2 WATER INLET PIPE 75ft lb 102 N m 2 DETIONATION SENSOR 168...

Page 145: ...6 Piston Ring End Gap 012 018 Compression Ratio Full Stroke 600 700 10 7 1 12 3 1 Trigger to Flywheel Gap 9mm 1 34mm MAX COMPONENT TORQUE LB FT TORQUE N M NOTES Spark Plug 18 24 Thermostat Bleed Screw...

Page 146: ...NOTES ENGINE 5 42...

Page 147: ...8 BELT WEAR BURN DIAGNOSTICS 6 9 DRIVE BELT REMOVAL 6 10 DRIVE BELT INSTALLATION 6 10 ADJUSTING BELT DEFLECTION 6 11 DRIVE BELTS 6 12 BLET PN 3211115 BREAK IN PROCEEDURE 6 13 PVT SYSTEM ADJUSTMENTS 6...

Page 148: ...red 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...

Page 149: ...ed 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 a...

Page 150: ...0402 Clutch Pin Punch 2870507 Tapered Reamer for Drive Clutch Bore 2870576 Roller Pin Tool 2870910 A Drive Clutch Button Removal Tool 2870985 Clutch Bushing Replacement Tool Kit 2871025 Primary Clutch...

Page 151: ...041168 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 Whit...

Page 152: ...321849 S45H 45 1321850 S47H 47 1321851 S49H 49 1321730 S51H 51 1321731 S53H 53 1321759 S55H 53 1322004 10 Series Weights WEIGHT GRAMS 1g PART NUMBER 10M R Bushed 44 1321530 10M W Bushed 46 1321527 10M...

Page 153: ...ixes PART NUMBER DESCRIPTION 5135438 70 44 46 66 44 46 5135480 64 38 65 64 38 46 5135486 62 40 46 64 40 55 5135521 74 50 46 74 48 46 5135522 74 44 46 74 40 46 5135523 70 50 46 70 48 46 5135524 70 44 4...

Page 154: ...extreme circular wear in at least one spot and on both sides of the belt Hour glassing occurs when the drive train does not move and the drive clutch engages the belt Example would be taking off while...

Page 155: ...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...

Page 156: ...nsert the L wrench A into the threaded hole B located on the driven clutch and turn it clockwise until the clutch sheaves are in the open position C NOTE L wrench PN 2874857 4 Remove the drive belt Dr...

Page 157: ...en the jam nut E 2 Using an 1 8 Allen head wrench turn the stud F counter clockwise to decrease belt deflection and clockwise to increase belt deflection 3 When the proper belt deflection is achieved...

Page 158: ...2_ 12 30 47 188 119 9 CVT version of 3211045 3211065 1 438 36 5 28_ 12 5 31 75 48 375 122 9 CVT Double Cog Storm belt 3211066 1 375 34 9 28_ 12 30 47 25 120 Double Cog CVT thicker than the 3211070 321...

Page 159: ...enter distance or uses a 3211080 belt The manufacturing process of this belt requires a special break in procedure 1 Clean the clutch sheaves with isopropyl alcohol 2 Position the new belt so that the...

Page 160: ...riven clutch No gap should be present in the front and the rear clearance should not exceed 060 3mm NOTE If the front of the alignment bar does not touch the driven sheave the maximum clearance cannot...

Page 161: ...Place the clutch holding tool PN 9314177 A on the drive clutch 3 Remove the drive clutch retaining bolt Note the placement and number of washers on retaining bolt 4 Insert the correct clutch puller in...

Page 162: ...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 sur...

Page 163: ...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 3 Insta...

Page 164: ...of the cover or the bushing may become damaged Spider Indexing NOTE Spider indexing effects belt to sheave clearance and clutch balance Please read all procedures before proceeding 1 Remove and disas...

Page 165: ...der 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...

Page 166: ...taper should 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 C 5 Slide clutc...

Page 167: ...the same amount of washers at removal 2 Torque the bolt to specification 3 Check for correct belt deflection Driven Clutch Disassembly 1 Helix Removal Remove the fasteners securing the helix to the m...

Page 168: ...Belt to Sheave Clearance Inspection The distance between the belt and the moveable sheave on the drive clutch is very important This distance controls the starting ratio lowers starting ratio is most...

Page 169: ...oo long or the center distance is too short The initial starting ratio will be too high resulting in performance loss This is due to the belt rising too high in the drive clutch sheaves upon engagemen...

Page 170: ...NOTES CLUTCHING 6 24...

Page 171: ...T 7 12 DRIVESHAFT REMOVAL INSTALLATION 7 12 WIDETRAK TRANSMISSION 7 13 REMOVAL 7 13 INSPECTION 7 14 LOW REVERSE SHAFT DISASSEMBLY 7 16 SHIFT FORK DISASSEMBLY 7 16 TRANSMISSION ASSEMBLY 7 17 TRANSMISSI...

Page 172: ...2 89 87 85 7000 112 109 100 98 104 102 99 96 94 92 89 87 85 98 95 93 90 88 7250 116 112 104 101 108 105 102 100 97 95 93 91 88 101 98 96 93 91 7500 120 116 107 105 112 109 106 103 101 98 96 94 92 104...

Page 173: ...72 86 84 82 80 78 76 74 69 7000 86 84 93 91 89 86 84 82 80 75 89 87 85 83 81 79 77 72 7250 89 87 97 94 92 90 87 85 83 78 93 90 88 86 84 82 80 74 7500 92 90 100 97 95 93 90 88 86 81 96 93 91 89 86 84...

Page 174: ...750 82 80 78 76 74 72 71 69 66 65 78 76 74 72 71 69 67 64 7000 85 83 81 79 77 75 73 72 69 67 81 79 77 75 73 72 70 67 7250 88 86 84 82 80 78 76 74 71 70 84 82 80 78 76 74 72 69 7500 91 89 87 85 83 81 7...

Page 175: ...55 6750 74 72 71 69 67 66 64 60 71 69 67 65 64 62 61 67 65 63 62 60 59 57 7000 77 75 73 71 70 68 66 62 73 71 69 68 66 64 63 69 67 66 64 62 61 59 7250 80 78 76 74 72 70 69 64 76 74 72 70 68 67 65 72 7...

Page 176: ...2900005 42T 3 4W 15 SPL HYVO CM 2900016 43T 3 4W 15 SPL HYVO CM 3221188 43T 3 4W 15 SPL HYVO PM 1341243 39T REVERSE 3 4W 15 SPL HYVO PM 7 92 1341227 40T REVERSE 3 4W 15 SPL HYVO PM 1341228 41T REVERS...

Page 177: ...m G Top sprocket Install so that the shoulder is facing the bearing T Lower bearing Loctite 680 when assembled H Chain tensioner adjuster Torque only finger tight during assembly U Lower c clip Insta...

Page 178: ...n so that it clears the chaincase and remove the driveshaft 25 Remove the track from the chassis 26 Remove the chaincase retaining bolts 27 Slide the chaincase out of the chassis 28 Inspect the o ring...

Page 179: ...to the LH footwell area 35 Insert the lower tabs on the cowling in the LH footwell 36 Replace the Torx screw that holds the cowling onto the steering hoop Chaincase Seal Bearing Replacement 1 Remove t...

Page 180: ...Minimum thickness 193 4 9mm Q Driveshaft Flangette Carriage Bolts E Retaining Ring included on jackshaft R Nylock Nut 11 ft lb 15 N m F Jackshaft S Speedo Pick Up Speed Sensor G Bulkhead area T Speed...

Page 181: ...t washer and castle nut 5 Tighten the castle nut securely to ensure positive bearing and jackshaft seating to chaincase 6 If shaft is not centered tap shaft with a soft faced hammer until centered Thi...

Page 182: ...11 N m 5 Remove the chaincase cover 2 6 Loosen the tensioner 3 7 Remove the lower sprocket bolt and washer 4 8 Shut off the fuel valve if so equipped 9 Remove the exhaust system 10 Remove the speedo d...

Page 183: ...adjustment bolts on both sides Back out adjustment bolts to allow rear idler assembly to come forward relieving track tension 14 Tighten idler wheel bolts so that spacers on shafts do not rotate and...

Page 184: ...track rotation for reassembly The arrow in the photo at right indicates track bottom rear of unit 30 Remove front and rear carrier shafts 31 Remove suspension by pulling rear of track out of tunnel S...

Page 185: ...ve chain from input and reverse shaft Inspect gear teeth for damage Inspect chain for worn cracked or broken link plates 11 Inspect dog gears and slots in mating gears closely Rounded edges will cause...

Page 186: ...dogs Replace gear and mating gear if rounded chipped or broken 6 Inspect needle bearings for wear or cracks on cage Shiny spots on cage indicate wear and the bearing should be replaced Inspect shaft...

Page 187: ...rings on input and output shafts Apply Polaris All Season Grease to drive shaft coupler splines 11 Reinstall transmission using care not to damage coolant hoses Be sure transmission shift linkage is p...

Page 188: ...ry air box oil tank and coolant recovery bottle 29 Loosen rear idler bolts 30 Reinstall driven clutch and spacers onto jackshaft and tighten 31 Reinstall clutch offset washers on jackshaft and install...

Page 189: ...e 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...

Page 190: ...fluid every 2 years or when fluid is dark or contamination is suspected Brake Fluid Replacement Bleeding This procedure should be used to change fluid or bleed brakes during regular maintenance or af...

Page 191: ...Replacement Follow these steps if the brake line is to be replaced 1 If needed bleed the brake system by attaching a clear hose to the caliper bleed fitting 2 Attach the other end to a Mity Vac or sim...

Page 192: ...the bleeding procedure See Brake Fluid Replacement Bleeding on page 7 20 Brake Light Switch Replacement 1 Remove the 4 screws that hold the master cylinder to the handlebar This will separate the mas...

Page 193: ...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...

Page 194: ...spacer or lifter ramp 6 Inspect balls ball spacer lifter ramp and caliper housing for galling or wear Replace if necessary Assembly 1 Apply a light film of grease to balls and ball spacer Install in c...

Page 195: ...NG 8 12 IQ FRONT SUSPENSION 8 13 SPINDLE REMOVAL 8 14 SPINDLE ASSEMBLY 8 14 LOWER SPHERICAL BEARING REPLACEMENT 8 14 UPPER LOWER CONTROL ARM REMOVAL 8 15 UPPER LOWER CONTROL ARM INSTALLATION 8 15 STEE...

Page 196: ...Front Suspension Type by Model FRONT SUSPENSION MODEL Edge LX 340 LX 340 Touring Edge 500 XC SP 550 LX SuperSport Trail Touring Deluxe Edge RMK Trail RMK Switchback 600 IQ Switchback Carb and CFI IQ...

Page 197: ...Nuts 11 ft lb 15 N m Draglink Fasteners and Tie Rod 29 ft lb 39 N m Upper and Lower Spindle and Control Arm fasteners 40 ft lb 54 N m IQ RMK Specifications ITEM MEASUREMENT Camber 2 17 31 55 8mm Toe 0...

Page 198: ...3 55 60 ft lb 75 81 N m T Draglinkfasteners Steeringarm fasteners Tie rod fasteners 28 30 ft lb 38 41 N m Trailing arm fastener 35 40 ft lb 47 54N m Upper Radius Rod fasteners 55 60 ft lb 75 81 N m Lo...

Page 199: ...4 150 ft lb 203 N m T Draglinkfasteners Steeringarm fasteners Tie rod fasteners 28 30 ft lb 38 41 N m Trailing Arm fastener 35 40 ft lb 47 54N m Upper Radius Rod fasteners 60 ft lb 81 N m Lower Radiu...

Page 200: ...lb 79 N m 1 T Draglinkfasteners Steeringarm fasteners Tie rod fasteners 29 ft lb 39 N m Upper Radius Rod Inner 38 ft lb 52 N m Trailing arm fastener 43 ft lb 58 N m Lower Radius Rod Inner 48 ft lb 65...

Page 201: ...ustment 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 For the best ride the spring preload s...

Page 202: ...10 75 283 1 89 2 75 Yes 7041553 11 46 60 11 33 283 1 89 2 75 Yes 7041554 9 09 80 10 75 283 1 89 2 75 Yes 7041571 10 40 70 10 50 263 1 89 2 53 No 7041573 9 28 160 10 331 1 89 2 91 Yes 7041574 10 32 14...

Page 203: ...mpress 4 5 inches A 150 in spring would only 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...

Page 204: ...inues 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 compressi...

Page 205: ...ROD IN IFP DEPTH IN SHAFT PN PSI 7041535 Arvin 13 3 10 64 4 47 49 N A N A N A 7042258 Arvin 18 00 11 8 6 2 49 6 92 t 1700228 200 7043054 Arvin 17 97 11 83 6 14 49 N A N A N A 7043141 Fox 18 00 11 80...

Page 206: ...012 1 300x 006 700x 015 800x 006 900x 006 1 000x 006 1 100x 008 1 250x 006 800x 008 1 100x 006 1 300x 008 800x 012 900x 012 1 000x 012 1 100x 010 1 250x 008 1 300x 010 900x 006 1 250x 008 1 300x 008...

Page 207: ...TION NOTES 1 Lower A Arm pivot bolt 2 Flat washer Critical for spacing the bolt from the sway bar Located on the leading edge 3 Pivot Shaft 4 Flanged nut 40 ft lb 54 N m 5 Pivot Bushing 6 Upper A Arm...

Page 208: ...9 on the lower spherical bearing bolt 24 and torque to 40 ft lb 54 N m 4 Place the spindle onto the upper rod end 5 Place the camber bolt 12 and torque the nut 14 to 40 ft lb 54 N m Lower Spherical Be...

Page 209: ...n do the steering arms go on weld up or weld down 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 r...

Page 210: ...rder Edge Edge LX Edge RMK Set Up Width Prior to performing steering alignment the suspension should be inspected for damage or wear and replacement parts installed as required IMPORTANT Camber width...

Page 211: ...re off the floor 3 7 62cm The shocks should be at full extension 2 Remove the skis 3 Determine which spindle requires the greatest amount of correction by installing the alignment bar through one spin...

Page 212: ...er line of the carbide skags 3 Place a straight edge along the one side of the track Make sure that the straight edge is touching along the length of the track 4 Record the measurements from the edge...

Page 213: ...e complete torque the front adjuster block bolts first then torque the rear bolts Torque the bolts to 11 13 ft lbs 15 18 Nm 1 Loosen the four bolts on the bottom 1 of the adjuster block 2 NOTE If nece...

Page 214: ...NOTES FRONT SUSPENSION STEERING 8 20...

Page 215: ...ON A IQ 121 SUSPENSION 9 12 WIDETRAK TORSION SPRING ADJUSTMENTS 9 13 M 10 SUSPENSION 9 14 M 10 OVERVIEW 9 14 M 10 RTS ADJUSTMENTS 9 14 M 10 TERMINOLOGY 9 15 M 10 ADJUSTMENTS 9 15 M 10 FRA INITIAL SET...

Page 216: ...33 9 31 RYDE FX MONO TUBE SHOCK DISASSEMBLY 9 32 RYDE FX MONO TUBE SHOCK ASSEMBLY 9 32 FOX MONOTUBE DISASSEMBLY 9 33 FOX MONOTUBE ASSEMBLY 9 33 REAR SUSPENSION TROUBLESHOOTING 9 34 REAR SUSPENSION TYP...

Page 217: ...l 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 452...

Page 218: ...m 25 ft lb 34 N m 35 ft lb 47 N m FST IQ Switchback FST IQ IQ 121 35 ft lb 47 N m 35 ft lb 47 N m 35 ft lb 47 N m 35 ft lb 47 N m 600 IQ Carb and CFI IQ Dragon IQ 121 Dragon 35 ft lb 47 N m 35 ft lb 4...

Page 219: ...b 61 N m 45 ft lb 61 N m FST IQ Switchback FST IQ IQ 121 60 ft lb 81 N m 60 ft lb 81 N m 600 IQ Carb and CFI IQ Dragon IQ 121 Dragon 60 ft lb 81 N m 60 ft lb 81 N m 600 IQ LX M10 128 70 ft lb 95 N m 7...

Page 220: ...uspensions are shown below IQ Shock Rod Below are examples of the IQ shock rod The orientation of this rod is so that the plate is facing downward 63 16 mm 45 11 4 mm Lower Upper Trail RMK lower end i...

Page 221: ...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 track and reduce ski pressure Stiffer rear springs...

Page 222: ...eload 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 su...

Page 223: ...in the fully extended position Both limiter straps must be adjusted evenly and remain equal in length to avoid improper Hi Fax and track wear Lengthening the straps decreases ski pressure under accele...

Page 224: ...H INCHES H 7042068 LH 7042069 RH 359 16 5 4 5 1 95 2 01 8 64 47 3 75 7041911 LH 7041912 RH 347 16 5 4 5 1 82 1 88 7 75 90 3 49 7041627 LH 7041628 RH 347 16 5 4 5 1 82 1 88 7 71 77 3 45 7042064 LH 7042...

Page 225: ...1941 RH 405 16 5 4 5 2 232 6 71 77 3 55 7043070 LH 7043071 RH 347 14 75 4 5 1 80 1 84 6 72 80 3 20 7042157 LH 7042158 RH 359 15 625 3 75 1 82 1 84 6 71 77 3 46 7042242 LH 7042243 RH 359 17 70 3 25 2 3...

Page 226: ...1 suspensions The issue that arises when installing the heavy spring is that the coil stack of the torsion spring is tall enough to interfere with the suspension arm clamp nut To work around this issu...

Page 227: ...d and the same spot on the running board The difference between the two readings should be approximately 1 1 2 3 8 cm If the difference is greater than 1 1 2 the rear spring should be adjusted equally...

Page 228: ...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 t...

Page 229: ...n the M 10 suspension is the Full Range Adjustment FRA Adjusting the FRA will have to MOST effect on rear suspension performance Polaris recommends that you allow between 25 to 200 miles for the suspe...

Page 230: ...iners 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...

Page 231: ...ent improper track adjustment or machine operation on surfaces without snow Rail Slide Removal 1 Remove the rear suspension NOTE Some models may allow the rail sliders to be removed by sliding it thro...

Page 232: ...9 18 REAR SUSPENSION REAR SUSPENSION REMOVAL INSTALLATION Rear Suspension Removal 1 1 2 3 2 3 2 3 1 2 3 4 5 1 2 3 6 1 2 3 7 8 9 10 11...

Page 233: ...9 19 REAR SUSPENSION 9 Rear Suspension Installation 12 1 2 T See Suspension to Chassis Fasteners Specification on page 9 5 T See Suspension to Chassis Fasteners Specification on page 9 5 3 4 5 6...

Page 234: ...9 20 REAR SUSPENSION In mm See Track Tension on page 3 21 T 35 ft lbs 48 N m o B C A D E 7 1 2 3 8 9 T 35 ft lbs 48 N m T 35 ft lbs 48 N m T 35 ft lbs 48 N m 1 2 3 10 11 1 2 3 12 1 2 3 13...

Page 235: ...6 200 7043267 Fox 12 07 306 6 8 63 219 2 3 44 87 4 50 12 7 1 8 45 7 b 1500778 200 7043204 Walker 12 10 307 3 8 60 218 4 3 50 89 625 15 9 2 25 57 2 1800316 200 7043234 Walker 12 49 317 2 8 92 226 6 3 5...

Page 236: ...012 1 200x 012 1 300x 012 1 300x 025 875x 090 1 300x 025 1 300x 025 700x 010 800x 010 900x 015 1 000x 015 1 100x 015 1 200x 015 1 250x 015 1 300x 015 1 300x 015 Piston Orifice 070 78 070 070 082 052...

Page 237: ...x 015 700x 015 700x 015 1 000x 010 1 100x 012 1 250x 012 800x 008 1 250x 008 1 300x 008 700x 015 700x 015 700x 015 900x 010 1 000x 008 1 100x 008 1 250x 010 900x 010 1 250x 008 1 300x 006 875x 090 625...

Page 238: ...00141 1 300 1700084 0 700 0 012 1700090 0 800 1700096 0 900 1700127 1 000 1700132 1 100 1700137 1 250 1700142 1 300 1700085 0 700 0 015 1700091 0 800 1700120 0 900 1700128 1 000 1700133 1 100 1700138...

Page 239: ...2 of the shaft PART NUMBER SIZE THICKNESS 1800051 700 006 1800075 800 1800076 900 1800077 1 000 1800078 1 100 1800079 1 200 1800080 1 300 1800081 700 008 1800082 800 1800083 900 1800084 1 000 1800085...

Page 240: ...e position Reservoir fitting angle 15 10 from the center line of the shock ITEM NOTE Extended Length 12 07 30 7 cm Collapsed Length 8 63 21 9 cm Stroke 3 44 8 7 cm Shock Rod 50 1 27 cm IFP Depth measu...

Page 241: ...Shaft PN 1700026 Pressure 200 psi 13 8 bar Spring 7043147 Spring Ratio 130 270 lb in Free Length 8 22 209mm Fluid 107cc Spring Installed Length 7 72 196mm ITEM NOTE Extended Length 12 51 317 8mm Coll...

Page 242: ...wt Hose clamp orientation 1 Fitting orientation 2 Clicker position position 8 1 2 1 1 ITEM NOTE Extended Length 16 60 421 6mm Collapsed Length 10 91 277 1mm Stroke 5 96 151 4mm Shock Rod 50 12 7mm IFP...

Page 243: ...60 39 6 cm Collapsed Length 10 56 26 2 cm Stroke 5 04 12 8 cm Shock Rod 50 1 27 cm IFP Depth 1 22 3 1 cm Shaft PN 1500599 PSI 200 13 8 bar ITEM NOTE Extended Length 16 71 42 4 cm Collapsed Length 10...

Page 244: ...A PHYSICIAN IMMEDIATELY EXTREME CLEANLINESS IS OF UTMOST IMPORTANCE DURING ALL DISASSEMBLY AND REASSEMBLY OPERATIONS TO PREVENT ANY DIRT OR FOREIGN PARTICLES FROM GETTING INTO THE SHOCKS KEEP THE PART...

Page 245: ...the shock or oil may spray out in step 5 4 Place the body cap 1 in the vise so that the shock rod 2 is facing upward 5 Slowly loosen the shock rod bearing cap 4 and remove it from the shock 6 Empty al...

Page 246: ...15 Clean the inside of the shock body using clean parts cleaning solvent and blow dry using compressed air 16 Place the shock piston rod upper mount in bench vise begin piston and valve removal Arran...

Page 247: ...hock body 6 Securely clamp Fox Nitrogen Safety Needle in vice 7 Insert the Fox Safety Needle squarely into center of gas valve 8 Using a blunt object depress the air valve core to release pressure 9 W...

Page 248: ...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 7 Install the new U cup seal into bearing U cup should be installed...

Page 249: ...COOLANT OIL TANK 10 5 COOLANT TANK REMOVAL 10 5 COOLANT TANK INSTALLATION 10 5 OIL TANK 10 5 OIL TANK REMOVAL 10 5 OIL TANK INSTALLATION 10 5 SEAT INFORMATION 10 5 SEAT BASE REMOVAL INSTALLATION 10 5...

Page 250: ...e released from the fender 4 3 Pull the panel straight out to release the hinge tabs 3 from the fender 4 Remove panel Side Panel Installation 1 Insert the hinge tabs 3 into the front portion of the fe...

Page 251: ...nection 2 from the instrument 3 Remove the bracket nuts 3 4 Remove the instrument s from the hood 5 Installation is the reverse of removal IQ MFD Removal Installation 1 Remove the headlight cover asse...

Page 252: ...nd remove the bumper screws 2 2 Remove the center bumper Nyloc nut and bolts 3 Remove bumper 4 Installation is reverse of removal Rear Bumper Removal Installation 1 Remove the rear coolant cover 1 if...

Page 253: ...the rear of the tank and remove the supply line 5 Disconnect the oil sender connections 6 Remove tank Oil Tank Installation 1 Attach the supply line to the supply fitting at the bottom of the oil tan...

Page 254: ...J at the fitting located at the top of the tank 2 Lift the rear of the fuel tank and carefully slide the tank far enough forward to assemble the fuel lines to the fuel pump 3 Make sure that the fuel t...

Page 255: ...er and inspect for wrinkles or imperfections If imperfections are visible remove the staples in the affected area and staple correctly 12 Trim excess vinyl from the bottom around the back of the seat...

Page 256: ...nto spindle 2 Insert the ski to spindle bolt through the ski and spindle NOTE The ski bumper is orientated so that the FRONT label is installed toward the toe of the ski 3 Tighten the nuts NOSEPAN REP...

Page 257: ...il 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 repla...

Page 258: ...squeegee to lay the decal straight and to avoid creating air bubbles Do NOT remove the decal mask until the decal is fully applied If you attempt to use a squeegee on the decal with the chrome exposed...

Page 259: ...10 11 CHASSIS HOOD 10...

Page 260: ...NOTES CHASSIS HOOD 10 12...

Page 261: ...ELS USING DIGITAL WRENCH 11 9 TPS BASELINE ADJUSTMENT CFI MODELS 11 9 TPS IDLE SPEED ADJUSTMENT CFI MODELS 11 11 THROTTLE PLATE SYNCHRONIZATION 11 11 ELECTRIC START GEN II EDGE 11 12 SYSTEM SCHEMATIC...

Page 262: ...CIRCUIT 11 41 CFI MODE SET SWITCH 11 42 CFI PERC SWITCH 11 42 DIGITAL WRENCH DIAGNOSTIC SOFTWARE 11 43 OVERVIEW 11 43 DIGITAL WRENCH CONNECTIONS 11 43 UPDATING DIGITAL WRENCH 11 44 VERSION FILESET IDE...

Page 263: ...280W 6 S3206 6044 PF6H S3305 7044 PF7J S3322 7044 PF7J 400W N A Model Specification EC34 26 5 3000 RPM EC50PL 28 3000 RPM EC55PM 27 3500 RPM 14 6500 RPM S3303 5044 PFSC 25 2500 RPM Disconnect TPS S32...

Page 264: ...eater 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 batterie...

Page 265: ...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 Off Season Storage To prevent battery damage d...

Page 266: ...tain 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 cent...

Page 267: ...0536 1 4678 0 0578 1 5938 0 0628 1 5439 0 0608 1 6606 0 0654 17 1 2106 0 0477 1 5359 0 0605 1 6548 0 0652 1 7969 0 0707 1 7406 0 0685 1 8722 0 0737 18 1 3552 0 0534 1 7195 0 0677 1 8526 0 0729 2 0117...

Page 268: ...the red multimeter probe into the pink wire terminal Voltage should read 4 99 to 5 01 Vdc Use a new battery if voltage is below 4 99 Vdc 3 Connect the test tool to the TPS on the carburetor or thrott...

Page 269: ...gap on CFI models To use Digital Wrench follow these steps 1 Click on the TOOLBOX icon 2 Click on TPS INITIALIZATION 3 Follow the steps and procedures displayed on the screen TPS Baseline Adjustment C...

Page 270: ...mes to ensure plates are completely closed 8 Using the TPS test tool verify the TPS is set to 0 70 0 01 Vdc 9 To adjust the TPS base line slightly loosen the screws then slowly turn the TPS clockwise...

Page 271: ...elieved 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 synchroni...

Page 272: ...11 12 BATTERY ELECTRICAL SYSTEMS ELECTRIC START GEN II EDGE System Schematic...

Page 273: ...S 11 Starter Motor Assembly Typical STARTER SOLENOID STARTER MOTOR MOTOR BRACKET MOTOR BRACKET GROUND CABLE 14 16 Ft Lbs 19 21 Nm 19 26 Ft Lbs 25 35 Nm 9 Ft Lbs 12 Nm COMMUTATOR CAP ARMATURE DRIVE CAP...

Page 274: ...11 14 BATTERY ELECTRICAL SYSTEMS Battery Box BATTERY BOX SOLENOID CIRCUIT BREAKER RED LEAD TO STARTER RED LEAD FROM BATTERY GROUND WIRE...

Page 275: ...rmature in a growler With the growler on position a hacksaw blade lengthwise 1 8 03 cm above armature coil laminates Rotate armature 360_ If hacksaw blade is drawn to the armature on any pole the arma...

Page 276: ...11 16 BATTERY ELECTRICAL SYSTEMS ELECTRIC START IQ CARBURETED CFI System Schematic 600 HO Carbureted...

Page 277: ...11 17 BATTERY ELECTRICAL SYSTEMS 11 System Schematic 600 700 CFI...

Page 278: ...11 18 BATTERY ELECTRICAL SYSTEMS Starter Motor Flex Drive Assembly FLEX DRIVE RED POSITIVE CABLE END PLATE MOUNTING BRACKET MOUNTING BRACKET STARTER MOTOR PINION PINION BRACKET WORM GEAR CLAMP...

Page 279: ...11 19 BATTERY ELECTRICAL SYSTEMS 11 IQ Battery Box Assembly MOUNTING BRACKET BATTERY BATTERY PAD BATTERY HOLD DOWN BRACKET CIRCUIT BREAKER SOLENOID GROUND CABLE...

Page 280: ...egulator 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...

Page 281: ...for at least 2 minutes and the engine has been running at or above 3000 RPM Exhaust Temperature Sensor Circuit Voltage Low P0545 Sensor signal is below 0 06 Vdc for at least 2 minutes and the engine h...

Page 282: ...e displayed 4 Click on A to activate guided diagnostics 5 Click on B to view a wiring schematic of the component or system 6 Click on X to exit the current screen 5 Tooth CPS Signal Intermittent P0336...

Page 283: ...ELECTRICAL SYSTEMS 11 CFI Clutch Guard Electrical Center COVER SPARE BELT HOLDER IGNITION COILS CAPACITOR REGULATOR RECTIFIER ECU COIL MOUNT GUARD PLATE 6 Ft Lbs 10 Nm 6 Ft Lbs 10 Nm 6 Ft Lbs 10 Nm 6...

Page 284: ...CE 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 SPLIC...

Page 285: ...REEN 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 GRE...

Page 286: ...11 26 BATTERY ELECTRICAL SYSTEMS Chassis Relay...

Page 287: ...tivated 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...

Page 288: ...11 28 BATTERY ELECTRICAL SYSTEMS Vehicle Speed Sensor...

Page 289: ...ll 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 picku...

Page 290: ...RN Crank Position Sensor 5 Tooth Ignition timing GRN to WHT GRN 190 WHT to WHT RED Crank Position Sensor 2 Tooth Locates TDC and RPM WHT to WHT RED 190 COILS GRN RED ExciterCoil PowerstheIgnition Coil...

Page 291: ...the initial charge If the cap does not hold a charge or drains rapidly replace the component Specifications Coil Resistance WHT YEL to RED 15 15 68 F 20 C Specifications Primary Coil Resistance Black...

Page 292: ...h the new color so all four injectors are the same color After replacing all four injectors the ECU must be reflashed so the fuel calibration map matches the new color coded fuel injectors Reference C...

Page 293: ...11 33 BATTERY ELECTRICAL SYSTEMS 11 CFI Power System CFI Ignition Injection Power...

Page 294: ...11 34 BATTERY ELECTRICAL SYSTEMS CFI Crank Position System CFI Safety Stop System...

Page 295: ...11 35 BATTERY ELECTRICAL SYSTEMS 11 CFI Full Load Fuel Injectors CFI Part Load Fuel Injectors...

Page 296: ...11 36 BATTERY ELECTRICAL SYSTEMS CFI Chassis Power CFI Ignition Coils...

Page 297: ...11 37 BATTERY ELECTRICAL SYSTEMS 11 CFI TBAP Sensor CFI TPS Engine Temp Sensors...

Page 298: ...11 38 BATTERY ELECTRICAL SYSTEMS CFI Exhaust Solenoid CFI Knock Sensor...

Page 299: ...11 39 BATTERY ELECTRICAL SYSTEMS 11 CFI Fuel Pump CFI Diagnostic Connections...

Page 300: ...11 40 BATTERY ELECTRICAL SYSTEMS CFI MFD Circuits CFI MFD Power Circuits...

Page 301: ...11 41 BATTERY ELECTRICAL SYSTEMS 11 CFI Fuel Level Circuit CFI Vehicle Speed Circuit...

Page 302: ...11 42 BATTERY ELECTRICAL SYSTEMS CFI Mode Set Switch CFI PERC Switch...

Page 303: ...ECU Chassis Power Up Cable part number PA 46355 12 volt battery Digital Wrench Connections The access point for the ECU power up and Digital Wrench connectors is located in the front left side of the...

Page 304: ...website The following selections can be made on the update website Home Digital Wrench Home Page Downloads Listing of current filesets and Digital Wrench downloadable updates Forums Member generated...

Page 305: ...oaded into Digital Wrench See Version Fileset Identification on page 11 45 2 Connect the communication cables to the snowmobile connectors See Digital Wrench Connections on page 11 43 3 Start Digital...

Page 306: ...al Wrench Select the fuel injector color and model year engine from the drop down menu 12 The website willgenerate an authorization code Record the code 13 Enter the authorization number in the box on...

Page 307: ...e engine is cold and after the engine has been running for some time Ignition Coil Packs NOTE Specifications listed for all models except EC50PL 488cc as this model features a CDI coil pack Exhaust Va...

Page 308: ..._F 30_C 120_C Resistance 2 4 2 6K 68_F 20_C Measure in stirred water Installation Torque 29 ft lbs 39 2Nm Sensor Specifications Temperature F C Resistance OHMS 22_F 30_C 22914 28006 32_F 0_C 5085 621...

Page 309: ...Retard Follow the engine timing procedure for checking running timing at recommended RPM Is the timing within limits NOJ Adjust the ignition timing by rotating the stator plate to correct the timing...

Page 310: ...is no water or foreign material in the fuel Verify there is no internal engine damage Verify the cooling system is working properly NOTE Install the knock sensor fastener clean and dry without applyin...

Page 311: ...allow the backwards rotation of the engine to move the sled in reverse To get back to forward is as easy as pushing the button again Operation 1 Ensure that the vehicle is stopped and the engine is w...

Page 312: ...instrument panel 3 You have 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 syst...

Page 313: ...isassembly 5 33 Removal 5 29 A Adjustable ski stance RMK Only 8 18 Adjustments Choke 3 17 Air Filter 3 22 Arvin Monotube Assembly 9 32 Arvin Monotube Disassembly 9 32 B Battery Testing 11 5 Bearing Fi...

Page 314: ...22 Components 6 21 Disassembly 6 21 Removal 6 21 Driven clutch installation 6 21 E Edge Headlight Bulb Replacement 3 24 EDGE RMK Front Suspension 8 4 Electric Reverse PERC 11 51 Electric Start Gen II...

Page 315: ...ni Carburetor Components 4 7 Float System 4 8 Fuel Delivery 4 8 Fuel Metering 4 8 Function 4 7 Jet Needle 4 10 Main Jet 4 9 Needle Jet 4 10 Pilot Air Screw 4 9 Pilot Jet 4 8 Piston Valve or Throttle V...

Page 316: ...ed Valve Assembly 5 4 Reed Valve Disassembly 5 3 RMK FTA set up recommendations 9 9 S SAE Tap Drill Sizes 2 8 Seat 10 5 Service Precautions 4 3 Shock Information Rear 9 21 Shock Maintenance 9 30 Shock...

Page 317: ...Throttle Lever Freeplay 3 18 Throttle Opening vs Fuel Flow 4 11 Throttle Position Sensor 11 8 Torque Stop 3 21 Track Alignment 3 20 Track Alingment 3 20 Track Tension 3 21 Troubleshooting Tables 11 4...

Page 318: ...12 1 Wiring Diagrams 2007 340 550 GEN II EDGE Models...

Page 319: ...12 2 Wiring Diagrams 2007 Wide Trak...

Page 320: ...12 3 Wiring Diagrams 2007 500 XCSP...

Page 321: ...12 4 Wiring Diagrams 2007 600 HO Carbureted 1 of 2...

Page 322: ...12 5 Wiring Diagrams 2007 600 HO Carbureted 2 of 2...

Page 323: ...12 6 Wiring Diagrams 2007 600 HO Carbureted Hood Harness...

Page 324: ...12 7 Wiring Diagrams 2007 600 700 CFI 1 of 2...

Page 325: ...12 8 Wiring Diagrams 2007 600 700 CFI 2 of 2...

Page 326: ...12 9 Wiring Diagrams 2007 600 700 CFI Hood Harness NOTE ALTIMETER AND AIR TEMP CONNECTORS WILL BE MALE AND FEMALE CONNECTOS NOT PLUGS...

Page 327: ...12 10 Wiring Diagrams...

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