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Polaris FST IQ 2007, Service Manual

The Polaris FST IQ 2007 Owner's Manual is essential for every Polaris FST IQ 2007 owner. This comprehensive manual provides detailed instructions and information on operating, maintaining, and troubleshooting the product. Download your free copy of this manual from manualshive.com to ensure a seamless ownership experience.

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5.18

Engine and Cooling Systems

600 HO Carbureted Recoil / Magneto

Disassembly / Assembly Process

1.

Remove the exhaust pipe and resonator.

2.

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.

7.

Mark the location of the magneto / stator plate in several
places using a scribe.

8.

Remove the magneto / stator from the crankcase.

9.

Clean the crankshaft and flywheel tapers with a solvent
such as clutch cleaner.

10. Assembly is reverse of disassembly. Reference the fastener

torque specifications at the beginning of the chapter.

11. Do not use an impact wrench to install the flywheel nut.

RECOIL HANDLE

ROPE GUIDE

RECOIL HOUSING

SPRING

ROPE REEL

RETURN SPRING

RATCHET

FRICTION SPRING

FRICTION PLATE

RECOIL HUB

FLYWHEEL NUT

FLYWHEEL

MAGNETO / STATOR

A

B

A

C

B

= 

T

 

A = 9 Ft.Lbs. (12 Nm)
B = 5 Ft.Lbs. (7 Nm) - Apply Loctite 242 (Stator)
C = 90 Ft.Lbs. (122 Nm) - Apply Loctite 242

Summary of Contents for FST IQ 2007

Page 1: ...ools 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 consta...

Page 2: ...ents MEASUREMENT provides a key for a determined measurement specification TORQUE provides a key for a 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 Nye Co Fluke Registered Trademark of John Fluke Mfg Co Mity Vac Registered Trademark of Neward Enterprises Inc Tor...

Page 3: ...ual Chapters Model Specifications 1 General Information 2 Maintenance 3 Fuel Systems 4 Engine Systems 5 Final Drive and Brake Systems 6 PVT System 7 Suspension and Steering 8 Shocks 9 Chassis 10 Electrical Systems 11 Wiring Schematics 12 ...

Page 4: ...00 HO IQ TOURING CFI 1 14 2007 700 HO IQ DRAGON 1 16 2007 700 HO RMK DRAGON 1 18 2008 IQ SHIFT 1 20 2008 600 RMK 144 600 RMK SHIFT 155 1 22 2008 600 DRAGON IQ 1 24 2008 600 SWITCHBACK 600 DRAGON SWITCHBACK 1 26 2008 600 IQ LX 1 28 2008 600 IQ TOURING 1 30 2008 600 RMK 155 1 32 2008 700 IQ 700 DRAGON IQ 1 34 2008 700 SWITCHBACK 700 DRAGON SWITCHBACK 1 36 2008 700 RMK 155 700 DRAGON RMK 155 163 1 38...

Page 5: ... F to 50 F 1 C to 10 C 45 F to 65 F 7 C to 18 C 60 F 16 C 0 600 0 2000 440 3 430 3 420 2 400 2 390 2 380 2 370 2 360 1 600 1200 2000 4000 410 3 400 3 390 2 370 2 360 2 350 2 340 1 330 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 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...

Page 6: ... 4010677 Track Width Inches cm 15 38 Length Inches cm 121 307 Lug Height Inches cm 1 0 2 5 1 25 3 175 Option Track tension sag in cm with 10 lbs 4 54kg placed 16 in 40cm ahead of rear idler shaft 7 8 1 1 8 2 2 2 9cm Front Suspension Suspension Type IQ 42 5 Shocks Ryde FX HPG w IFP STD Rebuidlable Fox Compression Adj Remote Resevoir HPG OPT Rebuidable IFS Spring Rate lbs in N mm 100 17 5 Spring Ins...

Page 7: ... F to 50 F 1 C to 10 C 45 F to 65 F 7 C to 18 C 60 F 16 C 0 600 0 2000 440 3 430 3 420 2 400 2 390 2 380 2 370 2 360 1 600 1200 2000 4000 410 3 400 3 390 2 370 2 360 2 350 2 340 1 330 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 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...

Page 8: ...arking 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 lbs 4 54kg placed 16 in 40cm ahead of rear idler shaft 3 8 1 2 1 1 3cm Front Suspension Suspension Type IQ 42 5 Shocks Fox HPG w IFP STD Rebuidlable Fox Compression Adj Remote Resevoir HPG OPT Rebuidable IFS Spring Rate lbs in N mm 100 17 5 Spring Ins...

Page 9: ...50 F 1 C to 10 C 45 F to 65 F 7 C to 18 C 60 F 16 C 0 600 0 2000 440 3 430 3 420 2 400 2 390 2 380 2 370 2 360 1 600 1200 2000 4000 410 3 400 3 390 2 370 2 360 2 350 2 340 1 330 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 1 250 1 240 1 3000 3700 10000...

Page 10: ...7 Lug Height Inches cm 2 0 5 or 2 4 6 1 Track tension sag in cm with 10 lbs 4 54kg placed 16 in 40cm ahead of rear idler shaft 3 8 1 2 1 1 3cm Front Suspension Suspension Type IQ RMK Adjustable Shocks Ryde FX Compression Adjustable STD Walker Evans Air OPT Rebuidable IFS Spring Rate lbs in N mm 100 17 5 Spring Installed Length Inches cm 10 35 26 3 WE Air Oil Volume 95cc WE Air Nitrogen Charge Stoc...

Page 11: ... 1200 1800 4000 6000 10 58 22 40 76 1800 2400 6000 8000 10 56 2400 3000 8000 10000 10 54 20 41 76 3000 3600 10000 12000 10 AL Drive Clutch Bolt Torque 80 lb ft 108Nm General Width in cm 48 121 9 Length in cm 115 292 1 Height in cm 48 121 9 Estimated Dry Weight lb kg 485 220 2 Fuel Gallons Liters 11 7 44 3 Oil Quarts Liters 3 4 3 2 Cooling System Capacity Quarts Liters 6 3 6 Brake Fluid DOT 4 Drive...

Page 12: ...Distance Inches cm 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 Front Track Shock FTS Ryde FX HPG w IFP STD Rebuildable Fox HPG w IFP OPT Rebuildable FTS Spring Rate lbs in N mm 130 270 2 3 4 8 FTS Spring Installed Length Inches cm 7 97 20 2 Rear Track Shock RTS Fox PS5 w IFP STD Rebuildable Fox Compression Adjustable Remote Rese...

Page 13: ... 1200 1800 4000 6000 10 58 22 40 76 1800 2400 6000 8000 10 56 20 41 76 2400 3000 8000 10000 10 54 3000 3600 10000 12000 10 AL Drive Clutch Bolt Torque 80 lb ft 108Nm General Width in cm 48 121 9 Length in cm 125 317 5 Height in cm 48 121 9 Estimated Dry Weight lb kg 485 220 2 Fuel Gallons Liters 11 7 44 3 Oil Quarts Liters 3 4 3 2 Cooling System Capacity Quarts Liters 6 3 6 Brake Fluid DOT 4 Drive...

Page 14: ...tance Inches cm 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 144 Front Track Shock FTS Fox HPG w IFP Rebuildable FTS Spring Rate lbs in N mm 170 29 75 FTS Spring Installed Length Inches cm 7 25 18 4 Rear Track Shock RTS Fox Compression Adjustable Remote Resevoir HPG Rebuildable Torsion Springs 359 Square 77_ Stock 347 77_ Soft PN 704...

Page 15: ... 36 LW ER 1200 1800 4000 6000 10 58 22 40 76 1800 2400 6000 8000 10 56 2400 3000 8000 10000 10 54 20 41 76 3000 3600 10000 12000 10 AL Drive Clutch Bolt Torque 80 lb ft 108Nm General Width in cm 48 121 9 Length in cm 115 292 1 Height in cm 48 121 9 Estimated Dry Weight lb kg 505 229 3 Fuel Gallons Liters 11 7 44 3 Oil Quarts Liters 3 4 3 2 Cooling System Capacity Quarts Liters 6 3 6 Brake Fluid DO...

Page 16: ...ce Inches cm 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 FTS Spring Rate lbs in N mm 180 31 FTS Spring Installed Length Inches cm 8 5 21 6 Rear Track Shock RTS Fox HPG w IFP Rebuildable Lower Outer Spring Rate lbs in N mm 715 125 Lower Inner Spring Rate lbs in N mm 425 74 4 Upper Spri...

Page 17: ...60 56 42 36 LW ER 1200 1800 4000 6000 10 58 1800 2400 6000 8000 10 56 21 44 78 2400 3000 8000 10000 10 54 3000 3600 10000 12000 10 AL Drive Clutch Bolt Torque 80 lb ft 108Nm General Width in cm 48 121 9 Length in cm 129 327 7 Height in cm 53 134 6 Estimated Dry Weight lb kg 574 260 6 Fuel Gallons Liters 11 7 44 3 Oil Quarts Liters 3 4 3 2 Cooling System Capacity Quarts Liters 6 3 6 Brake Fluid DOT...

Page 18: ...Inches cm 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 FTS Spring Rate lbs in N mm 220 38 5 FTS Spring Installed Length Inches cm 8 5 21 6 Rear Track Shock RTS Fox HPG w IFP Rebuildable Lower Outer Spring Rate lbs in N mm 715 125 Lower Inner Spring Rate lbs in N mm 425 74 4 Upper Sprin...

Page 19: ...120 340 7042083 64 42 36 LW ER 1800 2400 6000 8000 10 60 22 39 76 2400 3000 8000 10000 10 58 56 42 36 LW ER 20 41 76 3000 3600 10000 12000 10 56 Drive Clutch Bolt Torque 80 lb ft 108Nm General Width in cm 48 121 9 Length in cm 115 292 1 Height in cm 47 119 4 Estimated Dry Weight lb kg 476 216 1 Fuel Gallons Liters 10 8 40 9 Oil Quarts Liters 3 4 3 2 Cooling System Capacity Quarts Liters 6 3 6 Brak...

Page 20: ... Center Distance Inches cm 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 Front Track Shock FTS Walker Evans w IFP Remote Resevoir Compression Adjustable Rebuildable FTS Spring Rate lbs in N mm 130 270 23 47 FTS Spring Installed Length Inches cm 7 97 20 2 Rear Track Shock RTS Walker Evans w IFP Remote Resevoir Compression Adjustabl...

Page 21: ...00 2000 4000 10 64 1200 1800 4000 6000 10 62 1800 2400 6000 8000 10 60 2400 3000 8000 10000 10 58 3000 3600 10000 12000 10 56 Drive Clutch Bolt Torque 80 lb ft 108Nm General Width in cm 46 5 118 1 Length in cm 130 330 2 Height in cm 49 124 5 Estimated Dry Weight lb kg 478 217 Fuel Gallons Liters 12 45 4 Oil Quarts Liters 3 4 3 2 Cooling System Capacity Quarts Liters 6 3 6 Brake Fluid DOT 4 Drive B...

Page 22: ... 104 1 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 RMK 155 Front Track Shock FTS Walker Evans Air Oil Volume 70cc FTS Nitrogen Charge Stock Optional 215 psi 210 220 psi Rear Track Shock RTS Walker Evans w IFP RTS Nitrogen Charge 200 psi Torsion Springs 359 Square 77_ Stock 347 77_ Soft PN 7041627 067 PN 7041628 067 375 77_ Firm P...

Page 23: ... 1 C to 10 C 45 F to 65 F 7 C to 18 C 60 F 16 C 0 600 0 2000 440 3 430 3 420 3 400 3 390 3 380 2 370 2 360 1 600 1200 2000 4000 410 3 400 3 390 3 370 3 360 2 350 2 340 1 330 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 2 280 1 270 1 260 1 2400 3000 8000 10 000 310 2 300 2 290 2 280 1 270 1 260 1 250 1 240 1 3000 3700 10 000 1...

Page 24: ... 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 lbs 4 54kg placed 16 in 40cm ahead of rear idler shaft 7 8 1 1 8 2 2 2 9cm Front Suspension Suspension Type IQ 42 5 Shocks Ryde FX MPV IFS Spring Rate lbs in N mm 100 17 5 Spring Installed Length Inches cm 10 5...

Page 25: ...9 C to 2 C 30 F to 50 F 1 C to 10 C 45 F to 65 F 7 C to 18 C 60 F 16 C 0 600 0 2000 440 3 430 3 420 2 400 2 390 2 380 2 370 2 360 1 600 1200 2000 4000 410 3 400 3 390 2 370 2 360 2 350 2 340 2 330 1 1200 1800 4000 6000 370 3 360 2 350 2 340 2 330 2 320 2 310 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 10 000 310 55Pj 2 300 55Pj 2 290 55Pj 2 280 55Pj 2...

Page 26: ...Gap in mm 027 70 Spark Plug Champion RN57YCC CDI Marking 4011033 Flywheel Marking 4010677 Track Width Inches cm 15 38 Length Inches cm 144 365 7 155 393 7 Lug Height Inches cm 2 0 5 08 144 2 4 6 155 Track tension sag in cm with 10 lbs 4 54kg placed 16 in 40cm ahead of rear idler shaft 3 8 1 2 1 1 3cm Front Suspension Suspension Type IQ RMK Shocks Ryde FX IFS Spring Rate lbs in N mm 100 17 5 Spring...

Page 27: ... 39 76 1200 1800 4000 6000 10 60 22 40 76 1800 2400 6000 8000 10 58 2400 3000 8000 10000 10 56 20 41 76 3000 3600 10000 12000 10 AL Drive Clutch Bolt Torque 80 lb ft 108Nm General Width in cm 48 121 9 Length in cm 115 292 1 Height in cm 48 5 123 2 Estimated Dry Weight lb kg 476 216 1 Fuel Gallons Liters 11 7 44 3 Oil qts l 3 2 8 Cooling System Capacity Quarts Liters 8 5 8 Brake Fluid DOT 4 Drive B...

Page 28: ... 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 lbs 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 35...

Page 29: ...200 2000 4000 10 62 1200 1800 4000 6000 10 60 22 40 76 1800 2400 6000 8000 10 58 2400 3000 8000 10000 10 56 20 41 76 3000 3600 10000 12000 10 AL Drive Clutch Bolt Torque 80 lb ft 108Nm General Width in cm 48 121 9 Length in cm 120 308 4 Height in cm 48 5 123 2 Estimated Dry Weight lb kg 490 222 5 494 224 3 Dragon Fuel Gallons Liters 11 7 44 3 Oil qts l 3 2 8 Cooling System Capacity Quarts Liters 9...

Page 30: ...p Width 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 lbs in N mm 130 270 23 47 FTS Spring Installed Length inches cm 7 97 Rear Track Shock RTS Base Dragon Fox PS5 Ryde FX Compression Adjustable w Remote Res Torsion Springs 347 Square 80_ Soft PN 7043070 067 ...

Page 31: ...200 1800 4000 6000 10 60 22 40 76 1800 2400 6000 8000 10 58 2400 3000 8000 10000 10 56 20 41 76 3000 3600 10000 12000 10 54 Drive Clutch Bolt Torque 80 lb ft 108Nm General Width in cm 48 121 9 Length in cm 115 292 1 Height in cm 48 5 129 5 Estimated Dry Weight lb kg 475 218 2 Fuel Gallons Liters 11 7 44 3 Oil qts l 3 2 8 Cooling System Capacity Quarts Liters 8 5 8 Brake Fluid DOT 4 Drive Belt Part...

Page 32: ...p Width 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 Fast M 10 128 Front Track Shock FTS Ryde FX MPV FTS Spring Rate lbs in N mm 160 28 FTS Spring Installed Length Inches cm 8 20 3 Rear Track Shock RTS Fox Zero Pro Lower Outer Spring Rate lbs in N mm 715 125 Lower Inner Spring Rate lbs in N mm 425 74 4 Upper Spring Rate lbs ...

Page 33: ... 4000 10 62 1200 1800 4000 6000 10 60 1800 2400 6000 8000 10 58 21 44 78 2400 3000 8000 10000 10 56 3000 3600 10000 12000 10 54 Drive Clutch Bolt Torque 80 lb ft 108Nm General Width in cm 48 121 9 Length in cm 129 327 7 Height in cm 53 134 6 Estimated Dry Weight lb kg 574 260 6 Fuel Gallons Liters 11 7 44 3 Oil qts l 3 2 8 Cooling System Capacity Quarts Liters TBD Brake Fluid DOT 4 Drive Belt Part...

Page 34: ...ches cm Setup Width 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 Comfort Front Track Shock FTS Ryde FX MPV FTS Spring Rate lbs in N mm 275 48 FTS Spring Installed Length inches cm 8 74 21 Rear Track Shock RTS Ryde FX MPV Torsion Springs 405 16 Stock PN 7043347 067 PN 7043346 067 421 18 Firm PN 7043369 067 PN 7043368 0...

Page 35: ...00 10 62 1200 1800 4000 6000 10 60 1800 2400 6000 8000 10 58 2400 3000 8000 10000 10 56 3000 3600 10000 12000 10 54 Drive Clutch Bolt Torque 80 lb ft 108Nm General Width in cm 46 5 118 1 Length in cm 129 327 7 Height in cm 48 121 9 Estimated Dry Weight lb kg 484 219 5 Fuel Gallons Liters 11 5 33 5 Oil qts l 3 2 8 Cooling System Capacity Quarts Liters 6 5 6 1 Brake Fluid DOT 4 Drive Belt Part Numbe...

Page 36: ...ce Inches cm Setup Width 39 40 41 99 1 101 6 104 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 Front Track Shock FTS Ryde FX FTS Spring Rate lbs in N mm 190 33 25 Rear Track Shock RTS Ryde AFX 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 Tra...

Page 37: ...64 1200 1800 4000 6000 10 62 23 39 76 1800 2400 6000 8000 10 60 2400 3000 8000 10 000 10 58 20 41 76 3000 3600 10 000 12 000 10 56 Drive Clutch Bolt Torque 80 lb ft 108Nm General Width in cm 48 121 9 Length in cm 115 292 1 Height in cm 48 5 123 2 Estimated Dry Weight lb kg Base Dragon 476 216 1 480 217 9 Fuel Gallons Liters 11 7 44 3 Oil qts l 3 2 8 Cooling System Capacity Quarts Liters 8 5 8 Brak...

Page 38: ... 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 lbs in N mm 130 270 23 47 FTS Spring Installed Length inches cm 7 97 Rear Track Shock RTS Base Dragon Fox PS5 Ryde FX Compression Adj w Remote Res Torsion Springs 347 Square 80_ Soft Dragon Stock IQ PN 7043070 067 PN 70430...

Page 39: ... 1200 2000 4000 10 64 1200 1800 4000 6000 10 62 1800 2400 6000 8000 10 60 2400 3000 8000 10 000 10 58 20 41 76 3000 3600 10 000 12 000 10 56 Drive Clutch Bolt Torque 80 lb ft 108Nm General Width in cm 48 121 9 Length in cm 120 308 4 Height in cm 48 5 123 2 Estimated Dry Weight lb kg Base Dragon 494 224 3 498 226 1 Fuel Gallons Liters 11 7 44 3 Oil qts l 3 2 8 Cooling System Capacity Quarts Liters ...

Page 40: ...8 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 lbs in N mm 130 270 23 47 FTS Spring Installed Length inches cm 7 97 Rear Track Shock RTS Base Dragon Fox PS5 Ryde FX Compression Adj w Remote Res Torsion Springs 347 Square 80_ Soft Dragon Stock IQ PN 7043070 067 PN ...

Page 41: ... 64 1200 1800 4000 6000 10 62 1800 2400 6000 8000 10 60 2400 3000 8000 10 000 10 58 3000 3600 10 000 12 000 10 56 Drive Clutch Bolt Torque 80 lb ft 108Nm General Width in cm 46 5 118 1 Length in cm 129 327 7 Height in cm 48 121 9 Estimated Dry Weight lb kg Base 155 Dragon 155 Dragon 163 489 221 8 484 219 5 489 221 8 Fuel Gallons Liters 11 5 43 5 Oil Quarts Liters 3 2 8 Cooling System Capacity Quar...

Page 42: ... 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 Dragon Ryde FX Walker Evans Air FTS Spring Rate lbs in N mm 190 33 25 WE Air Oil Volume 60cc WE Air Nitrogen Charge 217 5 psi Rear Track Shock RTS Base Dragon Ryde AFX Walker Evans w IFP Maximum Nitrogen Charge 200 psi Torsion Springs 359 Squ...

Page 43: ...0 10 66 1200 1800 4000 6000 10 64 1800 2400 6000 8000 10 62 2400 3000 8000 10 000 10 60 3000 3600 10 000 12 000 10 58 Drive Clutch Bolt Torque 80 lb ft 108 Nm General Width in cm 46 5 118 1 Length in cm 129 327 7 Height in cm 49 5 125 7 Estimated Dry Weight lb kg 155 163 487 220 9 487 220 9 Fuel Gallons Liters 11 5 43 5 Oil Quarts Liters 3 2 8 Cooling System Capacity Quarts Liters 155 6 5 6 1 163 ...

Page 44: ...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 77_ Soft PN 7041627 067 PN 7041628 067 375 77_ Firm PN 7041942 067 PN 7041943 067 Rear Tra...

Page 45: ...NOTES Model Specifications 1 42 ...

Page 46: ...ENGINE DATA FORMULAS 2 5 COMPRESSION RATIO 2 5 COMPRESSION RATIO EXAMPLE 2 6 HEAD CC REMOVAL EXAMPLE 2 6 PORT OPENING DURATION 2 6 TORQUE CONVERSION 2 7 US TO METRIC 2 7 GENERAL REFERENCE 2 8 STANDARD BOLT TORQUE SPECIFICATION 2 8 FUEL OIL PREMIX RATIOS 2 8 GASOLINE VOLATILITY 2 8 SAE TAP DRILL SIZES 2 9 METRIC TAP DRILL SIZES 2 9 DECIMAL EQUIVALENTS 2 9 MEASUREMENT CONVERSION CHART 2 10 PISTON WA...

Page 47: ...mance R Switchback S Switchback Prem T Touring U Utility X Race Y Touring LTD 1A 121 F C OHV 4 Cycle Fuji 3A 340 F C Piston Port 4B 488 L C Piston Port 5B 544 F C Cylinder Reed 6F 600 EV L C Case Reed 6H 600 EV L C Case Reed CFI 6J 600 EV L C Case Reed Race 7E 750 Four Stroke 7F 750 Four Stroke Turbo 7J 700 EV L C Case Reed CFI 8E 795 EV L C Case Reed CFI E Europe M Military R Rolling Chassis S St...

Page 48: ... 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 VIN Number Designation 1 2 3 World 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 ...

Page 49: ...49 700 IQ 9921065 9921071 9921070 700 Dragon IQ 700 Switchback 9921078 9921081 700 Dragon Switchback 700 RMK 155 9921102 9921104 9921549 700 Dragon RMK 155 163 9921104 9921106 800 Dragon RMK 155 163 9921301 9921107 9921114 MODEL OWNER S MANUAL SUPPLEMENT PARTS BOOK ONLINE PART MANUALS AVAILABLE ONLINE AT WWW POLARISINDUSTRIES COM 600 HO IQ 9920459 9920460 9920461 600 HO Switchback 9920597 9920598 ...

Page 50: ...ATA FORMULAS Compression Ratio R IHV DISP IHV I S DISP x 25 4 DISP PI x B x S 4 IHV INSTALLED HEAD VOLUME cc DISP CYLINDER DISPLACEMENT cc R COMPRESSION RATIO S FULL ENGINE STROKE cm I INCHES PER cc OF IHV B CYLINDER BORE cm PI 3 1416 2 ...

Page 51: ...acement IHV and you want to find out IHV Displacement 199 098cc and we want R to 13 6 so then IHV desired Displacement 199 098cc R 13 6 1 12 6 IHV desired 15 801cc desired IHV to have 13 6 1 Full Compression Ratio 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 0...

Page 52: ...5 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 ...

Page 53: ...gine 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 war...

Page 54: ... mm 9449 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 17 32 3 48 5 64 5 8 18 37 64 3 56 45 3 4 10 21 32 4 40 43 3 4 16 11 16 4 48 42 7 8 9 49 64 5 40 38 7 8 14 13 16 5 44 37 1 8 7 8 6 32 36 1 12 59 64 6 40 33 1 1 8 7 63 64 8 32 29 1 1 8 12 1 3 64...

Page 55: ...Then if 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 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 lb 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 oz x 28 35 grams g grams ...

Page 56: ...s 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 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 ...

Page 57: ...NOTES General Information 2 12 ...

Page 58: ... FUEL TANK VENT SYSTEM 3 13 AIR INTAKE BOX PRE FILTERS 3 13 CHASSIS LUBRICATION 3 14 REAR SUSPENSION 3 14 DRIVESHAFT BEARING 3 14 THROTTLE CABLE 3 15 CHOKE AND CHOKE CABLE 3 15 CHAINCASE OIL LEVEL CHECK 3 15 CHAINCASE OIL REPLACEMENT 3 15 DRIVE CHAIN TENSION ADJUSTMENT 3 15 BRAKE SYSTEM MAINTENANCE 3 16 BRAKE LEVER TRAVEL 3 16 BRAKE FLUID 3 16 THROTTLE AND CHOKE CABLE ADJUSTMENTS 3 16 THROTTLE LEV...

Page 59: ... Function I I I I Engine Torque Stop Engine Isolator I I I I Cylinder Head Bolts I I I I Cylinder Base Nuts I I I Ignition Timing I I Spark Plug Condition I I I R I Exhaust System Retaining Springs I I I I VES Valves Solenoid I C I C I C I C Cooling System Hoses Coolant Level Heat Exchangers I I Oil Filter I I Brake System Hose Condition Routing I I I I Fluid Level Leaks Fluid Condition I I I I Br...

Page 60: ...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 Ra...

Page 61: ...6 Gallon 55 Gallon 2876244 2876245 2876247 2876246 Synthetic Chaincase Lubricant Quart Gallon 2 5 Gallon 2873105 2873106 2872952 Antifreeze 60 40 Premix Quart Gallon 55 Gallon 2871534 2871323 2872278 Shock Oil 5W Walker Evans 2874522 Shock Oil Fox Quart Gallon 2870995 2872279 Shock Oil Ryde FX Arvin 2873716 Brake Fluid DOT 4 2872189 Fogging Oil Aerosol Quart 2870791 2871517 Premium All Season Grea...

Page 62: ...easurement should be 1 1 4 3 2cm 5 If 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 ...

Page 63: ...eft 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 i...

Page 64: ...m is COLD Recommended Coolant Use Polaris Premium 60 40 pre mix antifreeze This premium antifreeze is rated for temperatures down to 62 F 52 C Cooling System Bleeding 1 Allow the cooling system to cool completely 2 Verify the coolant level in the surge tank is at the COLD mark Fill the surge tank if required Loosely install the pressure cap 3 Open the thermostat housing bleed screw Wrap a clean sh...

Page 65: ...ually inspect the current oil pump setting 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 b...

Page 66: ...k to 1 full line width 050 above original oil pump boss index mark 2520831 600 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 2520622 700 33mm No Pointer Lever will not clear engine strap Pump used on all 2007 700 CFIs and some early build 2008 700 CFIs Set...

Page 67: ...al 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 Wh...

Page 68: ...inated material from the bowl Repeat for each carburetor 4 Wipe off the residue from the plug and reinstall the clamps Fuel Filter Carbureted Models All models feature a fuel pick with filter located inside the fuel tank To inspect and replace 1 Remove the gas cap 2 Use a coat hanger to carefully pickup the fuel hose inside the tank 3 Inspect and replace the pickup filter at the end of the hose WA...

Page 69: ... 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 ...

Page 70: ...inked Air Intake Box Pre Filters Inspect the inside of the air intake box and pre filters for foreign material and or damage 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 bo...

Page 71: ...remium All Season Grease Rear Suspension Lubricate grease zerks with Premium All Season Grease IQ 121 136 Coupled 136 Comfort M 10 128 M 10 136 IQ RMK Driveshaft Bearing Lubricate with Premium All Season Grease Polaris Premium All Season Grease Part Numbers 3oz Grease Gun Kit 2871312 14oz Tube 2871423 IQ Shift Shown ...

Page 72: ... Locate the chaincase drain plug on the bottom of the nosepan 2 Place an oil catch pan under the drain plug 3 Remove the drain plug and drain the oil into the catch pan 4 Clean the magnetic plug to remove metal shavings 5 Install drain plug and hand tighten Do not over tighten the drain plug 6 Fill chaincase with oil at the fill plug location Drive Chain Tension Adjustment 1 Rotate the driven clut...

Page 73: ... these steps 1 Check the idle RPM and verify it is within the specified range 2 Shut off engine 3 Locate the throttle cable that is attached to the carburetors and adjust the throttle free play by adjusting the barrel nut E and lock nuts F 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 ope...

Page 74: ...ne adjuster inwards clockwise will increase throttle lever free play Turning the in line adjuster outwards counter clockwise will decrease throttle lever free play After setting the throttle lever free play always verify the oil pump adjustment is set correctly Choke Adjustment 1 Flip the choke toggle to the OFF position 2 Loosen locknuts 1 on the carburetor 3 Turn sleeve adjusting nut 2 counter c...

Page 75: ...ver 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 5 If equipped reinstall the handlebar cover Rider Select Steering U Joint The rider select steering U joint should be lubricated with Polaris fogging oil P...

Page 76: ... let the engine turn the track over This will warm up the track for a correct measurement 3 Shut off the engine 4 Place a 10 lb 4 54kg 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 in the measurement range for the appropriate vehicle see chart o this page 6 If adjustment is neede...

Page 77: ...he engine and turn the ignition 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 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 engi...

Page 78: ...ventative measure must be cleaned off before installing belt for service and operating machine Controls And Linkage All bushings spindle shafts and tie rod ends should be coated with a light coat of oil or grease Throttle controls and cables should be lubricated Force a small amount of lubricant down cables Electrical Connections Separate electrical connector blocks and clean corrosive build up fr...

Page 79: ...NOTES Maintenance 3 22 ...

Page 80: ...R TBAP 4 25 CRANKSHAFT POSITION SENSORS CPS 4 25 STATOR ASSEMBLY 4 26 EXHAUST VALVE SOLENOID 4 27 CFI IGNITION COILS 4 27 REGULATOR RECTIFIER 4 27 CHASSIS POWER CAPACITOR 4 27 ENGINE COOLANT TEMPERATURE SENSOR 4 28 KNOCK SENSOR 4 28 FUEL INJECTORS 4 28 FUEL RAIL BLEEDING PRESSURE TESTING 4 29 DISCONNECT FITTINGS 4 29 FUEL TANK PRESSURE TEST 4 30 CFI FUEL RAIL INJECTOR S REMOVAL INSTALLATION 4 30 2...

Page 81: ... 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 change clothing CAUTION A main jet that is too small will cause a lean operating condition and may cause serious engine damage Jet accordin...

Page 82: ...60 3130139 530 N 3131402 125 3130108 210 3130124 370 3130290 540 N 3131408 130 3130109 220 3130125 380 3130140 550 N 3131409 135 3130110 230 3130126 390 3130480 560 N 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 31301...

Page 83: ...RT 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 AIR JET PART NUMBER 0 5 3131255 0 6 3131249 0 7 3131256 0 8 3131254 0 9 3131203 1 0 3131257 1 1 3131258 1 2 3131259 1 3 3131260 1 4 3131261 1 5 3131262 1 6 3131263 1 7 3131264 1 8 3131265 1 9 313126...

Page 84: ...4 5 Fuel Systems 4 Carbureted Fuel System Typical ...

Page 85: ...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 not enough fuel leaves the nozzle Therefore the predetermined fu...

Page 86: ...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...

Page 87: ... 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 gr...

Page 88: ...4 9 Fuel Systems 4 Throttle Opening Vs Fuel Flow VM only ...

Page 89: ...ors on the vacuum stroke or forced back into the fuel tank during the pressure stroke 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 engine idling at ...

Page 90: ...k 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 Inspect the needle 7 e clip 8 and plastic washer 9 for wear 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...

Page 91: ...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 starter jet 22 Clean them out 15 Remove the air jet screw if so equipped 16 Clean out all passages in carburetor body with carburetor cleaner Dry all passages and jets with compressed air 17 Replace gaskets...

Page 92: ...nstall 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...

Page 93: ...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 6 Once the PTO carburetor slide is flush loosen the Phillips head screw located under the top cover on the MAG carburetor 7 While holding the PTO carburetor slide flush to the top of the carburetor rotate the synchroniza...

Page 94: ...he 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 speeds...

Page 95: ...ection or faulty TBAP Intake Air Temperature Circuit Voltage Low P0112 Sensor signal is below 0 19 Vdc Can be caused by a faulty wire connection or faulty TBAP Barometric Pressure Sensor Voltage High P0108 4 Sensor signal is above 3 23 Vdc Can be caused by a faulty wire connection or faulty TBAP Barometric Pressure Sensor Voltage Low P0107 Sensor signal is below 1 25 Vdc Can be caused by a faulty ...

Page 96: ...tator wiring or ECU 5 Tooth CPS Signal Intermittent P0336 Steady LED 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 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 5 VDC Sensor Supp...

Page 97: ...gital 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 To access trouble codes click on the button If any codes are listed select a code to proceed ...

Page 98: ... Fuel Systems 4 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 Ft Lbs 10 Nm ...

Page 99: ...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 OVERHEAT DET LED 26 ORANGE GREEN ELECTRIC START CHARGE RELAY COIL GROUND 27 BLACK WHITE DIAGNO...

Page 100: ...ITE 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 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 BLA...

Page 101: ...4 22 Fuel Systems Chassis Relay ...

Page 102: ... 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 The second system is the hardware stop system The hardware stop system is a direct ignition kill system That is whenever the operator turns the key to off pulls the tether or pus...

Page 103: ...4 24 Fuel Systems Vehicle Speed Sensor ...

Page 104: ...e 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 detec...

Page 105: ...osition Sensor 5 Tooth Ignition timing GRN to WHT GRN 190Ω WHT to WHT RED Crank Position Sensor 2 Tooth Locates TDC and RPM WHT to WHT RED 190Ω COILS GRN RED Exciter Coil Powers the Ignition Coils ECU GRN RED to GRN YEL 15Ω GRN YEL GRN RED to BRN WHT 30Ω BRN WHT BRN WHT to Ground 0Ω INJECTOR POWER COIL BLU YEL TO BLU YEL Supplies power to fuel injectors BLU YEL to BLU YEL 2 4Ω ENGINE GROUND BROWN ...

Page 106: ...ial charge If the cap does not hold a charge or drains rapidly replace the component Specifications Coil Resistance WHT YEL to RED 15Ω 15 68 F 20 C Specifications Primary Coil Resistance Black to White 0 45Ω 15 68 F 20 C Secondary Coil Resistance Without Plug Cap Black to High Tension Lead 18 000Ω 15 68 F 20 C Plug Cap Resistance 4 000Ω 6 000Ω Regulator Rectifier Connections CONNECTOR WIRE COLORS ...

Page 107: ... must be replaced with the new color 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 Sensor Specifications Operating Temperature Range 22_F 248 _F 30_C 120_C Resistance 2 4 2 6KΩ 68_F 20_C Measure in stirred water Installation Torque 29 ft lbs 39 2Nm Specifications Resistan...

Page 108: ... cap Disconnect Fittings The fuel 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 1 To disconnect a fuel hose from the fuel pump or fuel rail insert the tapered end of either the 5 16 or 3 8 tool ...

Page 109: ... 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 CFI Fuel Rail Injector s Removal Installation NOTE Keep the red protective cap on the end of the ...

Page 110: ...re and splices 11 10 Apply 2 stroke oil to the fuel injector o rings seal and mating surfaces fuel rail 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 14 Replace the harness to the original routing and apply panduit straps back to the original locations m...

Page 111: ...llowing components Seat Assembly Console Loosen fasteners then lift console away from tank and set to the side Air box 3 If electric start is installed disconnect the negative cable the positive cable from the battery 4 Relieve the fuel pressure See Fuel Rail Bleeding Pressure Testing on page 4 29 5 Unplug the fuel pump electrical connector 6 Remove the fuel hoses from the fuel pump See Disconnect...

Page 112: ...e 15 Carefully slide the pump assembly into the fuel tank until the gasket rests on the tank 16 Using new screws supplied with the new gasket thread in one of the top two screws to locate the gasket and flange in the fuel tank A few turns of the screw is sufficient 17 Thread the remaining five screws in by hand 18 Using a nut driver or socket and following the specified torque sequence sequentiall...

Page 113: ...container 2 Remove the console and the seat assembly 3 Disconnect the positive battery cable from the battery if applicable 4 Remove the fasteners securing the fuel tank to the tunnel 5 Bleed the pressure from the fuel rail See Fuel Rail Bleeding Pressure Testing on page 4 29 6 Lift and move the tank back to gain access to the fuel lines Disconnect the fuel supply and return hoses from the pump fl...

Page 114: ...eeping the arrow between the PFA alignment marks 16 Using the PFA spanner wrench and nut socket PS48459 tighten the PFA to specification 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 1 Remove the air box 2 Remove the throttle body air box adapter 3 Pinch off the coolant lines with th...

Page 115: ...ssis 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 nosepan 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 R...

Page 116: ...te 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 knowledge base Search Website search engine Topics Vehicle specific Digital Wrench information 5 Locate the version of Digital Wrench currently running on the PC or laptop 6 Locate and click on the fileset ...

Page 117: ...ed 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 4 Click on the SPECIAL TESTS icon 5 Click on ENGINE CONTROLLER REPROGRAMMING 6 Select the engine model and color of ...

Page 118: ...ench Select the fuel injector color and model year engine from the drop down menu 13 The website willgenerate an authorization code Record the code 14 Enter the authorization number in the box on Digital Wrench Click on CONTINUE 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 so...

Page 119: ...NOTES Fuel Systems 4 40 ...

Page 120: ...2 EXHAUST VALVE ASSEMBLY 5 12 OPTIONAL EXHAUST VALVE SPRINGS 5 12 ENGINE MOUNTING SYSTEMS 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 ASSEMBLIES 5 17 600 HO CARBURETED CYLINDERS CYLINDER HEAD 5 17 600 HO CARBURETED RECOIL MAGNETO 5 18 600 HO CARBURETED PISTON...

Page 121: ...ts 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 Oil Pump 7 Ft Lbs 9 5 Nm Water Pump Cover 9 Ft Lbs 12 Nm 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 M...

Page 122: ...LUME CC HEAD SQUISH INCHES MM PISTON TO CYLINDER CLEARANCE INCHES MM PISTON RING END GAP INCHES MM TRIGGER TO FLYWHEEL GAP MM S3273 6044 PU6F S3274 6044 PU6F S3466 6044 PU6F S3467 6044 PU6F 27 6 28 9 050 060 1 283 1 544 004 006 105 159 014 020 356 508 4 8 S3206 6044 PU6H S3468 6044 PU6H S3469 6044 PU6H 26 65 28 15 045 058 1 143 1 482 36 1 34 S3305 7044 PF7J S3470 7044 PU7J S3471 7044 PU7J 29 3 30 ...

Page 123: ...rque Sequences Cylinder Head Torque Pattern All CFI Crankcase Torque Pattern Carbureted Crankcase Torque Pattern Cylinder Torque Pattern Except Monoblock Cylinder Torque Pattern Monoblock CFI Recoil Cover MAG PTO MAG PTO MAG PTO MAG PTO MAG PTO ...

Page 124: ... the measurements at the middle and bottom of the cylinder Use the chart below and record all measurements Crankshaft Runout Inspection 1 Support the crankshaft in a set of V blocks as shown 2 Use a dial indicator to measure the runout at the following locations PTO end First taper after bearing flat MAG end 1 2 from bearing flat 3 Runout deflection cannot exceed 0025 07mm 4 If the runout deflecti...

Page 125: ...ng new rings Piston rings are installed with marking or beveled side up Reed Valve Inspection 1 Loosen he hose clamps 2 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 b...

Page 126: ...ference between the two clearance measurements cannot exceed the maximum clearance differential specification 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 do...

Page 127: ...op speed Checking Crankshaft Index 1 Remove the drive belt and drive clutch 2 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 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 ind...

Page 128: ... may be wet or dry honed depending on the hone manufacturer s recommendations Wet honing removes more material faster and leaves a more distinct pattern in the bore Using a 50 13 mm drill motor rotating at a speed of 300 500 RPM run the hone in and out of the cylinder rapidly until cutting tension decreases Remember to keep the hone drive shaft centered to prevent edge loading and always bring the...

Page 129: ...r 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 If the crank rod pin location is 180 from the dial indicator opposite of above it will be necessary to ...

Page 130: ...ed from the housing reinstall it before attaching the rope handle 9 Slide the pulley down the center shaft and into the housing making sure the recoil spring re engages the pulley tab 10 Install the ratchet spring and ratchet into the pulley face The ratchet spring leg fits in the notch on the ratchet and holds the ratchet in retracted 11 Install friction spring with one leg inserted in the bottom...

Page 131: ...Torque the cap nut to specification 6 Lubricate the guillotine blade and shaft with engine oil 7 Actuate the guillotine to ensure full and free motion 8 Install the spring and cover 9 Torque the vertical cover fasteners to specification 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 sli...

Page 132: ... NOTE Use an engine mount socket PN 2871989 to remove the engine mounts from the bulkhead ENGINE ASSEMBLY TORQUE STOP SPACER CLINCH PLATE ENGINE MOUNT ISOLATOR ENGINE MOUNT ENGINE MOUNT ENGINE MOUNT BRACKET A A A A A A A A A A A B C C C C T A 28 Ft Lbs 38 Nm B 15 Ft Lbs 20 Nm C 45 Ft Lbs 61 Nm ...

Page 133: ...t socket PN 2871989 to remove the engine mounts from the bulkhead ISOLATOR TORQUE STOP ENGINE ASSEMBLY CLINCH PLATE ENGINE MOUNT ENGINE MOUNT ENGINE MOUNT RH ENGINE STRAP LH ENGINE STRAP ENGINE MOUNT BRACKET A A A A A A A A B C C C C T A 28 Ft Lbs 38 Nm B 15 Ft Lbs 20 Nm C 30 Ft Lbs 41 Nm ...

Page 134: ...mount socket PN 2871989 to remove the engine mounts from the bulkhead CLINCH PLATE ENGINE MOUNT RH ENGINE STRAP SPACER ENGINE MOUNT TORQUE STOP ENGINE MOUNT BRACKET LH ENGINE STRAP ENGINE MOUNT ENGINE ASSEMBLY A A A A A A B C C C C A T A 28 Ft Lbs 38 Nm B 15 Ft Lbs 20 Nm C 45 Ft Lbs 61 Nm ...

Page 135: ...N 2871989 to remove the engine mounts from the bulkhead CLINCH PLATE ENGINE MOUNT BOTTOM ENGINE MOUNT ENGINE MOUNT ENGINE MOUNT ENGINE MOUNT BRACKET TORQUE STOP ENGINE ASSEMBLY RH ENGINE STRAP LH ENGINE STRAP UPPER ENGINE MOUNT A A A A A A C C C C B A T A 28 Ft Lbs 38 Nm B 15 Ft Lbs 20 Nm C 30 Ft Lbs 41 Nm ...

Page 136: ...se gaskets Use a gasket scraper to clean the gasket residue from the crankcase and cylinder bases 11 Inspect the cylinder walls Nicasil cylinders can only be lightly honed Damage that cannot be removed with a light hone requires cylinder replacement or re lining 12 The assembly process is the reverse of disassembly 13 Always use new gaskets and o rings during assembly Liberally coat the inside of ...

Page 137: ...crews 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 8 Remove the magneto stator from the crankcase 9 Clean the crankshaft and flywheel tapers with a solvent such as clutch cleaner...

Page 138: ...o the piston making sure the open end is 180 opposite of the groove opening 7 Apply a liberal amount of Polaris two stroke engine oil to the needle bearings piston pin and piston assembly 8 Push the pin in to the piston then through the needle bearing Install the remaining c clip with the open end is 180 opposite of the groove opening NOTE Always use new cylinder base gaskets 9 Apply a liberal amo...

Page 139: ...t remover Flush out the crankcase 6 Reinstall the crankshaft backinto the lower crankcase using two new crankcase seals 7 Apply a thin bead of Three Bond 1215 to the lower crankcase mating surface Install the upper crankcase 8 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 INTAKE B...

Page 140: ...rankcase 6 Water pump assembly is the reverse of disassembly Always use new seals and gaskets during assembly 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 The 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 durin...

Page 141: ...R HEAD COVER TEMP SENSOR CYLINDER HEAD O RINGS KNOCK SENSOR O RINGS BASE GASKETS CYLINDERS PISTON RINGS PISTON PIN C CLIP PISTON BEARING T A 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 37 Ft Lbs 50 Nm Piston Matrix Engine Model Piston PN Piston ID S3206 6044 PF6G 2203319 EK 22202c S346...

Page 142: ...wards taking care not to drop the piston and rod abruptly against the crankcase 11 Remove the cylinder base gaskets Use a gasket scraper to clean the gasket residue from the crankcase and cylinder bases 12 Inspect the cylinder walls Nicasil cylinders can only be lightly honed Damage that cannot be removed with a light hone requires cylinder replacement or re chroming 13 The assembly process is the...

Page 143: ...PLUGS GASKET HEAD COVER TEMP SENSOR THROTTLE BODY HOSE PLUG BYPASS NOZZLE KNOCK SENSOR PISTON C CLIP PISTON RING PISTON PIN BASE GASKET CYLINDER CYLINDER HEAD O RINGS SEE NOTE O RINGS A B D E F T A 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 Engine Model Piston PN Pisto...

Page 144: ...he 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 ...

Page 145: ...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 8 Remove the magneto stator from the crankcase 9 Assembly is reverse of disassembly Reference the fastener ...

Page 146: ...arefully pry apart the crankcase halves Discard the PTO and MAG crankshaft seals 5 Remove the crankshaft Inspect as required 6 Thoroughly clean the two crankcase mating surfaces with carburetor cleaner and a gasket remover Flush out the crankcase galleries GEAR CLAMPS INTAKE BOOTS REED STUFFERS REED BLOCKS CYLINDER STUDS NEEDLE BEARINGS PTO SEAL MAG SEAL MAG BEARING PTO BEARINGS FLYWHEEL KEY CRANK...

Page 147: ...f 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 ...

Page 148: ...PTER PLATE REED STUFFERS REED BLOCKS SEAL GUARD PTO SEAL ALIGNMENT DOWELS MAG SEAL MAG BEARING FLYWHEEL KEY PTO BEARING WRIST PIN BEARINGS OIL INJECTION CHECK VALVE QTY 5 ALIGNMENT DOWELS A B C T A 9 Ft Lbs 12 Nm B 22 Ft Lbs 30 Nm Apply Loctite 242 C 10 Ft Lbs 13 Nm Apply Pipe Sealant ...

Page 149: ...s Discard the PTO and MAG crankshaft seals 5 Remove the crankshaft Inspect as required 6 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 a thin bead of Three Bond 1215 to the lower crankcase mating surface Install the upper...

Page 150: ... 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 Always use new seals and gaskets during assembly 7 To remove the oil pump remove the two fasteners then pull the pump cover out of the crankcase...

Page 151: ...e extracted from the water pump side of the crankcase 10 Assembly is the reverse of disassembly Always use new o rings seals and gaskets during assembly 11 Install a new seal onto the shaft from the water pump side 12 To install a new water pump seal use the seal installation tool PN 2872010 Verify the seal lips are facing the cross shaft gear 600 700 800 CFI Oil Hose Routing TEE FITTING ...

Page 152: ... 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 On CFI models disconnect the intake air sensor located on the MAG side of the airbox 7 On CFI models remove the return fuel line P holder located on the MAG side of the airbox 8 On CFI models separate the fuel filter from the filter clip that is on the MAG sid...

Page 153: ...the chassis brace and secure the recoil rope by tying a knot so that it does not go into the recoil housing 17 Drain the coolant from the engine into a suitable container 18 Remove all coolant hoses from the coolant bottle and secure the loose hoses out of the way for engine removal 19 Remove the four right hand chassis brace fasteners and remove the brace from the chassis 20 Drain the oil from oi...

Page 154: ...l line disconnection tool PN PS 47152 20 separate the fuel filter and the fuel return line 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 ...

Page 155: ...ure 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 Place the engine on the shock tower brace 6 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 ...

Page 156: ...re 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 15 Secure the oil bottle to the chassis by installing the two torx fasteners located at the top of the bottle 16 Connect the oil sender Yellow and Purple wires to t...

Page 157: ...st the rear torque stop so that you have 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 75mm long 25 Adjust the engine isolator limiter if equipped so the stop is bottomed out on the brace T Engine Mount Fasteners 28 ft lb 37 9 N m T Rear Torque Sto...

Page 158: ...odels connect he fuel filter and fuel return line by pushing them together until you hear a audible click 32 Secure the fuel return line P 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 connec...

Page 159: ...is 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 42 Replace the nosepan plugs were removed to access the front chassis brace fasteners 43 Route the recoil rope through the eyelet on the chassis brace and secure handle once past the console 44 Install the exhaust system 45 Add coolant and bleed syst...

Page 160: ...ons Center Thermostat Location Offset Thermostat Location 800 CFI Thermostats There are two different thermostats used depending on the engine model number The larger bleed hole thermostat is designed for cooling systems that do not feature a bypass circuit in the cooling system CAUTION Allow engine to cool completely before working with the engine cooling system Engine coolant can be under pressu...

Page 161: ...URGE TANK CFI ONLY REAR TUNNEL COOLER LH PERIMETER COOLER RH PERIMETER COOLER FRONT TUNNEL COOLER FOAM HOSE SURGE BOTTLE OUT TO ENGINE IN HOSE BYPASS OUT TO TUNNEL COOLING SYSTEM THERMOSTAT CLOSED OPEN HOSE ENGINE OUT TO FRONT COOLER THERMOSTAT OPEN HOSE FRT COOLER TO SURGE BOTTLE SURGE BOTTLE ...

Page 162: ...E THROTTLE BODY OUT TO SURGE TANK CFI ONLY RADIATOR SURGE BOTTLE HOSE BYPASS TO RADIATOR HOSE RADIATOR TO SURGE BOTTLE FOAM FRONT COOLER REAR COOLER REVERSED ON S B LH PERIMETER COOLER RH PERIMETER COOLER HOSE ENGINE OUT TO TUNNEL COOLING SYSTEM THERMOSTAT OPEN HOSE SURGE BOTTLE TO ENGINE IN ...

Page 163: ...H FOOTBOARD COOLER LH FOOTBOARD COOLER REAR COOLER RADIATOR SURGE TANK HOSE THROTTLE BODY OUT TO SURGE TANK CFI ONLY FRONT COOLER FOAM HOSE BYPASS TO RADIATOR HOSE RADIATOR TO SURGE TANK HOSE ENGINE OUT TO TUNNEL COOLING SYSTEM THERMOSTAT OPEN HOSE SURGE TANK TO ENGINE IN ...

Page 164: ...OLER TO SURGE TANK CAP SURGE TANK FRONT TUNNEL COOLER THERMOSTAT OPEN HOSE ENGINE OUT TO TUNNEL COOLER FOAM PAD GEAR CLAMP HOSE CYLINDER HEAD OUT TO FRONT COOLER HOSE FRONT COOLER OUT TO SURGE TANK HOSE SURGE TANK TO ENGINE IN SQUEEZE CLAMPS HOSE THROTTLE BODY OUT TO SURGE TANK CFI ONLY ...

Page 165: ...Cooling System SURGE TANK CAP HOSE SURGE TANK OUT TO ENGINE IN HOSE FRT COOLER OUT TO SURGE TANK RH PERIMETER COOLER LH PERIMETER COOLER CROSS OVER HOSE FRONT COOLER HOSE TUNNEL COOLERS OUT TO SURGE TANK THERMOSTAT OPEN HOSE ENGINE OUT TO TUNNEL COOLER HOSE BYPASS TO FRT COOLER ...

Page 166: ...MOSTAT OPEN FRONT TUNNEL COOLER SQUEEZE CLAMPS HOSE THROTTLE BODY OUT TO SURGE TANK FOAM PAD HOSE SURGE TANK TO ENGINE IN HOSE CYLINDER HEAD OUT TO FRONT COOLER HOSE FRONT COOLER OUT TO SURGE TANK HOSE SURGE TANK TO ENGINE IN FRONT TUNNEL CLOSEOFF PANEL HOSE ENGINE OUT TO TUNNEL COOLER THERMOSTAT OPEN HOSE TUNNEL COOLER TO SURGE TANK SURGE TANK HOSE THROTTLE BODY OUT TO SURGE TANK CAP GEAR CLAMP S...

Page 167: ...pipe to the exhaust manifold 600 700 SILENCER 600 700 MANIFOLD SNOW DEFLECTOR 800 SILENCER HEAT SHIELD EXHAUST PIPE EGT SENSOR ZINC PLATED YELLOW SPRINGS ZINC PLATED YELLOW SPRINGS ZINC PLATED YELLOW SPRINGS STAINLESS STEEL GRAY SPRINGS GASKET GASKETS 800 MANIFOLD A B T A EGT Sensor 32 Ft Lbs 44 Nm B Exhaust Manifold Fasteners 22 Ft Lbs 30 Nm ...

Page 168: ...TRAIN 6 7 SPEEDOMETER CABLE TYPE DRIVE TRAIN ASSEMBLY 6 7 ELECTRONIC SPEEDOMETER DRIVE TRAIN ASSEMBLY 6 8 DRIVESHAFT REMOVAL INSTALLATION 6 9 BRAKE SYSTEM 6 10 OVERVIEW 6 10 COMPENSATING PORT 6 10 GENERAL GUIDELINES 6 11 BRAKE FLUID REPLACEMENT BLEEDING 6 11 MASTER CYLINDER LEVER SERVICE 6 12 BRAKE LINE REPLACEMENT 6 13 BRAKE LIGHT SWITCH REPLACEMENT 6 14 CALIPER REMOVAL 6 14 CALIPER REPLACEMENT 6...

Page 169: ...5 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 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 ...

Page 170: ...10 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 CM 2900142 39T 3 4W 15 SPL HYVO Light Weight 3222099 40T 3 4W 15 SPL HYVO PM 2900141 40T 3 4W 15 SPL HYVO Light Weight 3222101 41T 3 4W 15 SPL HYVO PM 2900140 41T 3...

Page 171: ...ar Fastener 19 Ft Lbs 26 Nm C Upper Gear Castle Nut 50 Ft Lbs 62 Nm D Fill Plug 18 25 In Lbs E Tensioner Bolt Hand Tight F Tensioner Lock Nut 21 Ft Lbs 28 Nm G Drain Plug 8 Ft Lbs 11 Nm WARNING Incorrect chain tension may cause the chain to break which may result in the loss of braking control CAUTION Never re use Cotter pins Always replace with new parts Incorrect chain tension may cause the chai...

Page 172: ...ring from the backside of the case to remove each bearing 16 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 17 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 18 Inspect the jackshaft seal sleeve...

Page 173: ...ver seal is in good condition Install the cover and bracket Torque fasteners to specification using a criss cross pattern 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 shaft torque and PVT system assembly information T ...

Page 174: ...ten chaincase mounting nuts using a criss cross pattern Install jackshaft seal sleeve with beveled edge towards brake disc then install o ring inside sleeve A B C D E E T A Driven Clutch Fastener 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 38 Nm CAUTION Do not over t...

Page 175: ...all o ring inside sleeve DRIVEN CLUTCH BELT WASHERS WASHERS SPACER FLANGE FLANGE JACKSHAFT SNAP RING BRAKE DISC O RING SEAL SLEEVE SPEEDOMETER FLANGE SPEEDOMETER SENSOR DRIVESHAFT CHAINCASE A B C D E E F G T A Driven Clutch Fastener 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 ...

Page 176: ...o 8 ft lb 11 N m 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 left side and the rear skid removed remove the drive shaft 14 Assemble in reverse order T Drain ...

Page 177: ...es 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 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 syst...

Page 178: ...ver and diaphragm assembly from the reservoir 4 Under the cover inspect the vent slots under the bellows and remove any debris or blockage 5 Bleed or replace the fluid by attaching a clear hose from the caliper bleeder fitting to a clean container Be sure the hose fits tightly on the bleeder fitting 6 Pump the brake lever a few times and hold 7 Slowly open the bleeder fitting and let the old fluid...

Page 179: ...ck brake system for any fluid leaks Master Cylinder Lever Service 1 To remove the brake lever remove the E clip from the lever pin 2 Extract the pin from the housing then remove the lever 3 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 4 To remove the cartridge c...

Page 180: ...tch pack 8 Unplug the brake light switch harness from the master cylinder 9 Remove the brake line from the master cylinder 10 Install new brake line on caliper and orientate it as noted in step 4 11 Torque the caliper banjo bolt to 168 216 in lb 19 24 N m 12 Insert the new brake line and install into the master cylinder Torque the brake line to 144 192 in lb 16 21 N m 13 Tighten the brake line int...

Page 181: ... the top the longest one goes into the lower right side Caliper Removal 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 o...

Page 182: ...ding on page 6 11 8 On a liquid cooled caliper you will need to bleed the cooling system of any trapped air Brake Pad Replacement Brake pads need to be replaced if the total thickness of the pads and backing are less than 250 6 35mm 1 Remove brake pad retaining pin 3 2 Remove the brake pads 4 3 Inspect the brake disc 5 for any wear 4 Replace brake pads in reverse order of removal Brake Disc Replac...

Page 183: ...NOTES Final Drive and Brakes 6 16 ...

Page 184: ... FIN 7 7 TEAM RAMP ANGLES 7 7 TEAM DRIVEN SPRINGS 7 8 DRIVE BELTS 7 9 BELT INSPECTION 7 9 DRIVE CLUTCH BOLT TORQUE 7 9 BELT WEAR BURN DIAGNOSTICS 7 10 DRIVE BELT REMOVAL TEAM DRIVEN CLUTCH 7 11 DRIVE BELT INSTALLATION TEAM DRIVEN CLUTCH 7 11 ADJUSTING BELT DEFLECTION TEAM DRIVEN CLUTCH 7 11 PVT SYSTEM ADJUSTMENTS 7 12 CLUTCH ALIGNMENT OFFSET 7 12 OFFSET ADJUSTMENT 7 12 DRIVE CLUTCH 7 13 IDENTIFICA...

Page 185: ... 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 s...

Page 186: ...ded 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...

Page 187: ...pider Installation Tool 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...

Page 188: ...n 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 52 140 320 137 704...

Page 189: ...H 43 1321849 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 44 1321530 10M W 46 1321527 10M B 47 5 1321529 10M 5 48 8 1321528 10M 49 5 1321531 10A L 51 1321531 10 51 5 1321526 10A 53 1321589 10 54 54 1321685 10 56 56 1321684 10 58 58 1321588 10 60 60 1321587 10 62 62 1321586 10 62M 61 5 1321614 10 ...

Page 190: ...the starting and finish angles PART NUMBER DESCRIPTION 5135401 64 42 36 5135402 64 38 25 5135403 56 42 36 5135503 54 38 25 5136255 S42 5135504 S36 5135772 66 44 46 PART NUMBER DESCRIPTION 5135375 62 40 46 64 40 55 5135376 64 38 65 64 38 46 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 5135...

Page 191: ...w 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 1...

Page 192: ...circular wear in at least one spot an 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 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 Part Number Belt Widt...

Page 193: ...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...

Page 194: ...ectly 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 Adjusting Belt Deflection Team Driven Clutch 1 Loosen the jam nut 2 Using an 1 8 Allen head wrench turn the stud counter clockwise to decrease belt deflection and clockwise to increase belt deflec...

Page 195: ...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 exceed 025 Offset Adjustment 1 Determine direction driven clutch needs to be adjusted 2 Remove driven clutch retaining bolt and remove driven clutch 3 Add or remove washers from the jackshaft between the driven c...

Page 196: ...e 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 number of washers on retaining bolt 4 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 ...

Page 197: ... 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 ...

Page 198: ... 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 Install new buttons into the spider 4 Place roller in spider leg and center it on the pin 5 Place a second washer on the other side of the roller 6 Place the spider on a vise 7 Install pin centering tool ...

Page 199: ...ol PN 2870341 torque to the spider to specification 9 Install the spider jam nut onto the shaft and torque to specification 10 Place the drive spring on the shaft 11 Place the cover onto the clutch and torque the cover fasteners to specification NOTE Do not allow side loading or mis alignment of the cover or the bushing may become damaged T Weight Pin Torque 20 30 In Lbs 2 2 3 4 Nm T Spider Torque...

Page 200: ...51mm 5242981 025 63mm 5210753 032 81mm 5210754 050 1 27mm 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 Vary the amount and thickness of spacer washers washer thickness may var...

Page 201: ...clutch taper with lacquer thinner or isopropyl alcohol 5 Slide clutch onto crankshaft taper 6 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 Run engine then re torque the retaining bolt to specification DRIVEN CLUTCH Driven Clutch Removal 1 Remove the...

Page 202: ...ater 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 ...

Page 203: ...NOTES PVT System 7 20 ...

Page 204: ...CATIONS 8 10 CAMBER 8 10 ROD ENDS 8 11 ROD END ENGAGEMENT 8 11 CAMBER ADJUSTMENT 8 11 HANDLEBAR CENTERING 8 11 TOE ADJUSTMENT 8 11 DISASSEMBLY AND ASSEMBLY 8 12 SPINDLE REMOVAL 8 12 SPINDLE ASSEMBLY 8 12 SPHERICAL BEARING REPLACEMENT 8 12 UPPER LOWER CONTROL ARM REMOVAL 8 12 UPPER LOWER CONTROL ARM INSTALLATION 8 12 REAR SUSPENSION ASSEMBLY ILLUSTRATIONS 8 13 REAR SUSPENSION OPERATION 8 36 OPERATI...

Page 205: ...y on the center line of the carbide skags Width is measured from the center of the spindles 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 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 compress 4 5 inches A 15...

Page 206: ...n 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 Front Suspension Type by Model Rear Suspension Type by Model Suspension Mounting Fastener Torque NOTE FTA Front Torque Arm RTA Rear Torque Arm...

Page 207: ...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 RMK 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 RMK IQ Shift or against the FRSS IQ 121 IQ 136 Coupled IQ Comfort and not ...

Page 208: ...ener and pivot bushing on the rear lower control arm mount to allow sufficient clearance between nut and sway bar Orientate rod ends so they are parallel with mating component B B B B B B C A CAUTION Never re use lock nuts Always re assemble using new lock nuts 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 ...

Page 209: ...PPER POST BRACKET UPPER POST BRACKET BUSHINGS BUSHINGS LOWER POST BRACKET MOUNT SUPPORT BUSHING SUPPORT PLATE STEERING POST A A FASTENERS B Where Applicable CAUTION Never re use lock nuts Always re assemble using new lock nuts T A 16 Ft Lbs 22 Nm B 13 Ft Lbs 17 Nm ...

Page 210: ...t then torque the steering post mid bracket fasteners ADJUSTING LEVER NUTSERT ADJUSTER BLOCK STEERING BLOCK STEERING POST STEERING POST MID BRACKET BUSHING BUSHING BRACKET STEERING POST LOWER BRACKET BRACKET BUSHINGS A A FASTENER B B CAUTION Never re use lock nuts Always re assemble using new lock nuts T A 7 Ft Lbs 10 Nm B 11 Ft Lbs 15 Nm ...

Page 211: ...RING SPACER BUSHING BEARING BUSHING BEARING SPACER BEARING BUSHING A A A A A A A A A A B B TIE ROD JAM NUT TIE ROD CAUTION Never re use lock nuts Always re assemble using new lock nuts T A 29 Ft Lbs 40 Nm B 11 Ft Lbs 15 Nm Rod end jam nuts Linkage Assembly Measurements IQ 42 5 Tie Rod Length 15 06in 382 5mm IQ 42 5 Adjustable Steering Drag Link Length 14 78in 375 4mm IQ 42 5 Fixed Steering Drag Li...

Page 212: ...AKE ASSEMBLY GRIP HANDWARMER COVER BAR THROTTLE CABLE MOUNTAIN BAR HOOK THROTTLE BLOCK GRIP HANDWARMER RISER E CLIP SET SCREW ADAPTER COVER 16 Ft Lbs 21 Nm CLAMPS 16 Ft Lbs 21 Nm 16 Ft Lbs 21 Nm 16 Ft Lbs 21 Nm TIGHTEN FRONT SCREWS FIRST 25 30 In Lbs 2 9 3 4 Nm 25 30 In Lbs 2 9 3 4 Nm HAND TIGHT HAND TIGHT 40 In Lbs 4 5 Nm ...

Page 213: ...mine 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 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 existin...

Page 214: ...of the alignment bar to the top of the ski mount hole with the bushing s removed Record measurement 5 To adjust the camber unlock the lock nut and adjust the camber with the adjuster nut until alignment bar measurement is within the specified range for each spindle 6 Once the specification is achieved tighten all jam nut s and torque them Ft Lb 61 Nm 7 Re check the set up width and compare to spec...

Page 215: ...sion assembly illustration for fastener torque values Spherical Bearing Replacement 1 Remove the fastener securing the lower control arm LCA to the spindle 2 Remove the lower shock fastener 3 Remove the fasteners securing the LCA to the bulkhead 4 Remove the snap ring then using a press press the spherical bearing out of the LCA 5 Press in a new bearing then install the snap ring 6 Assemble the LC...

Page 216: ...ts 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 SHOCK PIVOT SHAFT SHAFT REAR PIVOT ARM IDLER WHEEL IDLER WHEEL WASHER SPACER A A B B B B B INNER SHAFT T A 45 Ft Lb 61 Nm B 35 Ft Lb 47 Nm ...

Page 217: ...s must rotate freely after tightening fasteners Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table H BRACKET SHOCK PIVOT SHAFT SHAFT REAR PIVOT ARM IDLER WHEEL IDLER WHEEL WASHER SPACER A A B B B B B WASHER SPACER SPACER WASHER INNER SHAFT IDLER SHAFT T A 45 Ft Lb 61 Nm B 35 Ft Lb 47 Nm ...

Page 218: ...ate freely after tightening fasteners Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table RAIL SLIDER BOGIE WHEEL X X X RAIL CAP BUMPER BUMPER FRSS RRSS SPRING ROLLER IDLER BOLT ADJUSTER WHEEL MOUNT CAMS A B C C C B D D 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 2 Nm ...

Page 219: ...st rotate freely after tightening fasteners Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table RAIL SLIDER BOGIE WHEEL X X X RAIL CAP BUMPER BUMPER RRSS SPRING ROLLER IDLER BOLT ADJUSTER WHEEL MOUNT CAM A B C C B D D 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 4 Nm ...

Page 220: ...TRAPS SHOCK ASSEMBLY FRONT TORQUE ARM O RING UPPER SHAFT BUSHING SHAFT SHAFT REAR TORQUE ARM REAR PIVOT SCISSOR REAR TRACK SHOCK SHOCK ROD CARRIER WHEEL SLEEVE TORSION SPRING MOUNTING ARM A A B B C B B B B B D D T 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 Never re...

Page 221: ...htening fasteners Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table FRA ADJUSTER FTA SHAFT SHOCK LIMITER STRAP SHAFT CENTERING SLEEVE O RINGS FRA SHAFT SLEEVES WASHERS BOGIE WHEEL RTA SHAFT IDLER SHAFT SPACER WASHER SUPPORT SHAFT A A C B B B B SPACER O RINGS T A 45 Ft Lb 61 Nm B 35 Ft Lb 47 Nm C 19 Ft Lb 26 Nm ...

Page 222: ...ots must rotate freely after tightening fasteners Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table RAIL TIP WHEEL MOUNTING BOGIE WHEEL BUMPER FRA BLOCK COUPLER BLOCK COUPLER IDLER ADJUSTER A C C B B B B D D T 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 ...

Page 223: ...c maintenance table FRONT TORQUE ARM FTA SHAFT UPPER SHAFT LIMITER STRAP SHOCK ASSEMBLY REAR TORQUE ARM UPPER SHAFT LOWER SHAFT SHOCK ASSEMBLY CARRIER WHEEL CARRIER WHEEL BRACKET A A B B B C C T A 12 Ft Lb 16 Nm B 35 Ft Lb 47 Nm C 70 Ft Lb 94 Nm 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 Al...

Page 224: ... after tightening fasteners Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table SHOCK LIMITER STRAP SHAFT FTA SHAFT SUPPORT SHAFT SHOCK FRA SHAFT RTA SHAFT SUPPORT SHAFT IDLER WHEEL IDLER SHAFT SPACER SPACER FRA ADJUSTER A A B A A B C B O RINGS O RINGS T A 45 Ft Lb 61 Nm B 35 Ft Lb 47 Nm C 19 Ft Lb 26 Nm ...

Page 225: ...te freely after tightening fasteners Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table SLIDER BOGGIE WHEEL WHEEL MOUNT BUMPER RAIL TIP IDLER WHEEL ADJUSTER COUPLER BLOCK COUPLER FRA BLOCK A C C B B B B B B B B D D 2006 T 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 ...

Page 226: ...le MID TRACK SHOCK CARRIER WHEEL REAR TORQUE ARM FRONT TORQUE ARM SHOCK ASSEMBLY SHOCK ASSEMBLY LIMITER STRAP SHAFTS SPACER SET SCREW UPPER SHAFT LOWER SHAFT A A B B B M 10 ACE ONLY B Fastener 35 Ft Lb 47 Nm C C T A 12 Ft Lb 16 Nm B 35 Ft Lb 47 Nm C 70 Ft Lb 94 Nm CAUTION The fasteners securing the rear suspension to the tunnel are pre coated with a locking agent when new Never re use these fasten...

Page 227: ...h 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 SHAFT CENTERING SLEEVES REAR PIVOT FRONT TORQUE ARM SHAFT SHOCK PIVOT IDLER WHEEL SPACER A A A A A A SHAFT SPACER WASHER INNER SHAFT T A 35 Ft Lb 47 Nm ...

Page 228: ...l pivots must rotate freely after tightening fasteners Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table RAIL SLIDER BOGGIE WHEEL X WHEEL MOUNT X X BUMPER BUMPER RAIL TIP IDLER WHEEL ADJUSTER B D C RIVETS A D C 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 4 Nm ...

Page 229: ...ARM SHOCK ASSEMBLY LIMITER STRAPS UPPER SHAFT SHOCK ASSEMBLY SHOCK ROD REAR TORQUE ARM REAR PIVOT SCISSOR SHAFT ADJUSTER SLEEVE SPRING CARRIER WHEEL SPACER SET SCREW LOWER SHAFT SHAFT B B B D D E B C C T A 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 CAUTION The fasteners securing the rear suspension to the tunnel are pre coated with a locking agent when new N...

Page 230: ...rts 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 IDLER WHEEL IDLER WHEEL SPACER INNER SHAFT SPACER BUSHING REAR PIVOT INNER SHAFT INNER SHAFT SHOCK PIVOT H BRACKET SHAFT A B B B B T A 45 Ft Lb 61 Nm B 35 Ft Lb 47 Nm ...

Page 231: ...r tightening fasteners Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table RRSS FRSS CAMS RAIL SLIDER BUMPER BUMPER RAIL TIP SUPPORT PLATE WHEEL MOUNT WHEEL MOUNT SPRING ROLLER BOGIE WHEEL WHEEL MOUNT IDLER WHEEL ADJUSTER A B B A B C D D D T A 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 ...

Page 232: ...e FRONT TORQUE ARM LIMITER STRAPS BUSHING BUSHING INNER SHAFT O RING BUSHING BUSHING BUSHING SHOCK ROD REAR SCISSOR SPRING ADJUSTER BUSHING REAR TORQUE ARM CARRIER WHEEL SLEEVE TORSION SPRING BUSHING A A B C C C B C C C T A 12 Ft Lb 16 Nm B 40 Ft Lb 54 Nm C 35 Ft Lb 47 Nm CAUTION The fasteners securing the rear suspension to the tunnel are pre coated with a locking agent when new Never re use thes...

Page 233: ...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 SHOCK PIVOT H BRACKET SHAFT INNER SHAFT INNER SHAFT SPACER INNER SHAFT IDLER WHEEL SPACER BLOCK REAR SCISSOR B B A A B A A A T A 35 Ft Lb 47 Nm B 45 Ft Lb 61 Nm ...

Page 234: ...st rotate freely after tightening fasteners Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table RAIL SLIDER RAIL TIP BUMPER BUMPER RRSS FRSS CAM BOGIE WHEEL WHEEL MOUNT IDLER WHEEL ADJUSTER SPRING ROLLER A B B B C D D D A T A 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 ...

Page 235: ...TRAPS SHOCK ASSEMBLY FRONT TORQUE ARM O RING UPPER SHAFT BUSHING SHAFT SHAFT REAR TORQUE ARM REAR PIVOT SCISSOR REAR TRACK SHOCK SHOCK ROD CARRIER WHEEL SLEEVE TORSION SPRING MOUNTING ARM A A B B C B B B B B D D T 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 Never re...

Page 236: ...ew 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 IDLER WHEEL 155 163 ONLY SHOCK PIVOT INNER SHAFT SHAFT INNER SHAFT SHAFT SPACER INNER SHAFT COLLAR WASHERS SPACER BLOCK A A A A A A A A A A A T A 35 Ft Lb 47 Nm ...

Page 237: ... pivots must rotate freely after tightening fasteners Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table RAIL SLIDER WHEEL MOUNT IDLER ADJUSTER BOLT BUMPER BUMPER RAIL TIP SPRING BLOCK BOGIE WHEEL A D D D C C B B 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 4 Nm ...

Page 238: ...ARM SHOCK ASSEMBLY LIMITER STRAPS UPPER SHAFT SHOCK ASSEMBLY SHOCK ROD REAR TORQUE ARM REAR PIVOT SCISSOR SHAFT ADJUSTER SLEEVE SPRING CARRIER WHEEL SPACER SET SCREW LOWER SHAFT SHAFT A B B B D D E B C C T A 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 CAUTION The fasteners securing the rear suspension to the tunnel are pre coated with a locking agent when new...

Page 239: ...e 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 ...

Page 240: ...ent 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 To determine the correct ride height subtract measurement X from measurement Y X Y ride heig...

Page 241: ...ustment 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 Limiter Strap Adjustment 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 Recomme...

Page 242: ...eds The issue that arises when installing the heavy spring on a Fusion sled is that the coil stack of the torsion spring is wide enough to interfere with the 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 ...

Page 243: ...he 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 primar...

Page 244: ...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 a rider prefers more ski pressure for improved steering performance adjustments can be made to the front limiter strap and front arm mount 1 Determine if the rider prefers comfort or control Lean toward the 4 setting for...

Page 245: ...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 4 Remove...

Page 246: ... VALVE SHIM STACK CONFIGURATIONS 9 13 OPTIONAL SHOCK SETTINGS 9 15 WALKER EVANS AIR SHOCK 9 15 RYDE FX AIR 2 0 SHOCK 9 15 SHOCK MAINTENANCE 9 16 RYDE FX AIR 2 0 SHOCK DISASSEMBLY 9 16 RYDE FX AIR 2 0 SHOCK ASSEMBLY 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 BAC...

Page 247: ...ols 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...

Page 248: ... 900 1700081 0 700 0 006 1700087 0 800 1700093 0 900 1700121 1 000 1700129 1 100 1700134 1 250 1700139 1 300 1700094 0 900 0 008 1700122 1 000 1700130 1 100 1700135 1 250 1700140 1 300 1700082 0 700 0 009 1700088 0 800 1700083 0 700 0 010 1700089 0 800 1700095 0 900 1700126 1 000 1700131 1 100 1700136 1 250 1700141 1 300 1700084 0 700 0 012 1700090 0 800 1700096 0 900 1700127 1 000 1700132 1 100 1...

Page 249: ...500028 0 800 1500033 0 900 1500032 1 000 1500031 1 100 1500051 1 250 1500030 1 300 1500044 0 700 0 010 1500047 0 800 1500046 0 900 1500045 1 000 1500027 1 100 1500026 1 250 1500062 1 300 1500056 0 700 0 012 1500057 0 800 1500058 0 900 1500059 1 000 1500060 1 100 1500078 1 250 1500079 1 300 1500081 0 700 0 015 1500082 0 800 1500083 0 900 1500084 1 000 1500085 1 100 1500086 1 250 1500087 1 300 ...

Page 250: ...100 1800086 1 200 1800087 1 250 1800088 1 300 1800052 700 010 1800053 800 1800054 900 1800055 1 000 1800056 1 100 1800057 1 200 1800058 1 300 1800059 700 012 1800060 800 1800061 900 1800062 1 000 1800063 1 100 1800064 1 200 1800089 1 250 1800072 1 300 1800066 700 015 1800067 800 1800068 900 1800069 1 000 1800070 1 100 1800071 1 250 1800072 1 300 1800090 1 000 025 1800091 1 100 1800092 1 200 180009...

Page 251: ...48 1 300 1800249 1 450 1800250 1 500 1800251 1 550 1800252 900 012 1800253 1 000 1800254 1 100 1800255 1 200 1800256 1 300 1800257 1 450 1800258 1 500 1800259 1 550 1800260 900 015 1800261 1 000 1800262 1 100 1800263 1 200 1800264 1 300 1800265 1 450 1800266 1 500 1800267 1 550 1800268 1 000 090 WASHERS 1800269 1 100 1800270 1 250 1800271 1 300 025 ...

Page 252: ...shock assembly is installed on the snowmobile Piston Orientation The face of the piston with the greater number of relief ports will always face the rebound valve stack NOTE On some Walker Evans shocks piston is color coded Blue COMPRESSION SIDE Red REBOUND SIDE PISTON COMPRESSION VALVE STACK REBOUND VALVE STACK SHOCK ROD FULLY EXTENDED FULLY COMPRESSED SHOCK ROD Relief Port Faces Rebound Stack Fa...

Page 253: ...25 Opt Front Track Shocks SHOCK PN MODEL EXTENDED LENGTH IN COLLAPSED LENGTH IN STROKE IN SHOCK ROD IN IFP DEPTH IN OIL VOLUME PSI 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 ...

Page 254: ...t Bleed 082 052 052 COMPRESSION 1 300 x 008 1 100 x 006 800 x 008 1 250 x 006 1 100 x 008 1 000 x 006 900 x 006 800 x 006 700 x 015 1 300 x 006 1 100 x 008 800 x 008 1 250 x 008 1 100 x 08 1 000 x 008 900 x 008 700 x 012 700 x 012 1 125 x 093 1 300 x 006 1 000 x 010 1 250 x 008 900 x 010 1 100 x 008 1 000 x 008 900 x 008 800 x 008 700 x 010 1 125 x 093 1 30 x 006 1 00 x 012 1 20 x 006 900 x 012 1 ...

Page 255: ...1 200 x 012 625 x 065 700 x 015 800 x 015 900 x 015 1 00 x 015 1 10 x 015 1 20 x 015 1 25 x 015 Piston Orifice 070 078 070 070 082 052 COMPRESSION 1 300 x 008 1 000 x 006 1 300 x 008 1 100 x 010 1 000 x 008 900 x 008 800 x 008 1 300 x 006 1 250 x 008 900 x 008 1 250 x 008 1 100 x 008 900 x 008 700 x 012 700 x 012 1 125 x 093 1 300 x 008 1 100 x 006 900 x 008 1 250 x 008 1 100 x 008 1 000 x 010 900...

Page 256: ...1 100 x 010 1 100 x 012 1 000 x 010 900 x 010 1 125 x 093 1 300 x 008 1 250 x 008 800 x 008 1 250 x 012 1 100 x 012 1 000 x 010 700 x 015 700 x 015 700 x 015 1 125 x 093 1 300 x 006 1 250 x 008 900 x 010 1 250 x 010 1 100 x 008 1 000 x 008 900 x 010 700 x 015 700 x 015 700 x 015 1 125 x 093 1 30 x 010 1 25 x 010 700 x 010 1 10 x 008 900 x 008 1 10 x 008 1 00 x 010 900 x 010 800 x 008 700 x 008 625...

Page 257: ... 95cc 220 2008 Front Track Shocks SHOCK PN MODEL EXTENDED LENGTH IN COLLAPSED LENGTH IN STROKE IN SHOCK ROD IN IFP DEPTH IN OIL VOLUME PSI 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 SHOCK PN MODEL EXTENDED LENGTH IN COLLAPSED LENGTH IN STROKE IN SHOCK ROD IN IFP DEPTH IN OIL VOLUME PSI 7043177 Fox 15 60 10 56 5 ...

Page 258: ...x 015 1 20 x 015 1 25 x 010 1 25 x 015 Piston Orifice 060 052 COMPRESSION 1 300 x 008 1 100 x 006 800 x 008 1 250 x 006 1 100 x 008 1 000 x 006 900 x 006 800 x 006 700 x 015 1 30 x 015 1 20 x 015 1 20 x 010 1 10 x 015 1 10 x 010 1 00 x 015 900 x 015 800 x 015 700 x 015 875 x 090 2008 Front Track Shocks SHOCK 7043244 7043365 REBOUND 700 x 010 800 x 012 900 x 010 1 000 x 010 1 100 x 010 1 250 x 010 ...

Page 259: ... 093 1 100 x 010 1 250 x 012 TBA 625 x 065 700 x 015 800 x 015 900 x 015 1 00 x 015 1 10 x 015 1 20 x 015 1 25 x 015 1 25 x 015 Piston Orifice 093 055 065 COMPRESSION 1 300 x 008 1 300 x 008 1 000 x 006 1 100 x 008 1 100 x 010 1 100 x 012 1 000 x 010 900 x 010 1 125 x 093 1 300 x 008 1 300 x 006 800 x 010 1 300 x 010 1 300 x 008 1 300 x 008 900 x 008 1 125 x 093 1 30 x 015 1 20 x 012 1 00 x 012 80...

Page 260: ...te 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 Air 2 0 Shock Notes All shock work must be performed when the shock assembly and nitrogen supply ta...

Page 261: ...ove 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 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 valv...

Page 262: ... 36mm piston shock rod upper mount in a soft jawed bench vise Remove the piston valve and valve shim assembly from the rod in the sequence of disassembly 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 r...

Page 263: ...lt to specification 7 Apply a light film of grease to the 36mm rod assembly pressure valve port counter bore where the pressure valve assembly o ring meets 8 Install pressure valve assembly and torque to specification 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 cylind...

Page 264: ...p Wrap the shock body with clean shop towels to catch any shock oil spillage 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 ente...

Page 265: ...shim service or adjustment is done torque the piston retaining bolt 6 to 25 30 ft lb 34 41 N m 8 If required 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 2 Insert and torque down the bearing cap 4 assembly into the shock body 9 3 Flip shock over in the vise so that the shock rod is facing downward 4 Pressurize...

Page 266: ... 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...

Page 267: ...ssion damping adjustment selector to position 1 7 Fill the shock body and remote reservoir 1 2 full of Walker Evans 5w shock oil PN 2874522 8 Apply a thin film of oil to the IFP o ring and floating wear band located on the shock rod piston 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 10 Screw the IFP tool PN PS 459...

Page 268: ...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 18 Set the IFP to specification then close the bleed screw 19 Pour out any remaining shock oil from the reservoir ...

Page 269: ...ck rod in a soft jawed bench vise Remove the valve shim stack and piston nut Remove the shims and piston as they are arranged on the shaft 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 ex...

Page 270: ...earing assembly back into the shock body Use a slight up and down movement to dispose of any air trapped below the piston assembly 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...

Page 271: ...ut of the shock body Discard old oil into an approved storage container and dispose appropriately Never reuse damper oil during shock rebuild 14 Using the I F P extraction tool thread the tool into the I 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 15 Clean the inside of the shock body using clean parts clean...

Page 272: ...t 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 shop cloth around shock body to catch possible oil overfl...

Page 273: ...ring the seal with the point of the scribe and pulling it out Use extreme caution 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 2 Use the scribe to remove the u cup wiper and o ri...

Page 274: ...EMBLY TYPICAL 10 4 IQ CONSOLE ASSEMBLY TYPICAL 10 4 RMK TUNNEL 10 5 FENDERS AND SIDE PANELS 10 6 SEAT ASSEMBLIES 10 7 IQ FIXED SEAT ASSEMBLY 10 7 IQ RAW SEAT ASSEMBLY 10 7 IQ REMOVABLE SEAT ASSEMBLY 10 7 2007 IQ TOURING SEAT ASSEMBLY 10 8 2008 IQ TOURING SEAT ASSEMBLY 10 9 SEAT COVER REPLACEMENT 10 10 DECALS 10 10 DECAL REMOVAL 10 10 DECAL INSTALLATION 10 11 ...

Page 275: ...10 2 Chassis IQ CHASSIS COMPONENTS Steering Hoop Assembly Typical STEERING HOOP RH UPPER BRACE LH UPPER BRACE CROSS MEMBER FUEL TANK BUMPER SPACER BRACKET A B B B T A 18 Ft Lb 24 Nm B 21 Ft Lbs 28 Nm ...

Page 276: ...laced For small cracks drill a small hole on both ends of the crack to limit spreading BRAKE DUCT NOT ALL MODELS INSTRUMENT POD INTAKE ACCESS COVER FRONT GRILLE HINGE MFD PRE FILTER HEADLIGHT SEALS ATTACH TO INSIDE OF HOOD AROUND HEADLIGHT OPENING AND WHERE POD MEETS WINDSHIELD FLARE HOOD CONSOLE SEAL NOTE TORQUE FASTENERS HAND TIGHT Crack Drill hole ...

Page 277: ...e Assembly Typical PANEL GRILLE W MESH NOSEPAN BUMPER HEAT FOIL FABRIC NOTE TORQUE FASTENERS HAND TIGHT FIXED STEERING COVER CONSOLE CONSOLE NUT O RING RIDER SELECT STEERING COVERS IGNITION SWITCH ROPE GUIDE STORAGE DOOR NOTE TORQUE FASTENERS HAND TIGHT ...

Page 278: ...10 5 Chassis 10 RMK Tunnel REAR BUMPER SNOW FLAP CLOSE OFF CONTROL ARM SUPPORT BULKHEAD TUNNEL ASSEMBLY 1 PIECE RIVETS RIVETS ...

Page 279: ...10 6 Chassis Fenders and Side Panels FOAM RH SIDE PANEL HEAT SHIELD LH FENDER FOAM LH SIDE PANEL TRIM RH FENDER EXHAUST SEAL PUSH RIVETS RIVETS ...

Page 280: ... IQ Fixed Seat Assembly IQ Raw Seat Assembly IQ Removable Seat Assembly T A 5 5 Ft Lbs 7 5 Nm SEAT SEAT BASE A 2007 VERSION 2007 TAILIGHT 2008 VERSION T A 5 5 Ft Lbs 7 5 Nm Plastic crushes at 10 Ft Lbs 13 Nm SEAT SEAT BASE LATCH A A ...

Page 281: ...10 8 Chassis 2007 IQ Touring Seat Assembly PASSENGER SEAT ASSEMBLY COVER SEAT ASSEMBLY LATCH BRACKETS SEAT LATCH HAND GUARD LUMBAR ADJUSTER A T A 5 5 Ft Lbs 7 5 Nm ...

Page 282: ...10 9 Chassis 10 2008 IQ Touring Seat Assembly HAND GUARD BACK REST MOUNT RIVETS A C C BACK REST ADJUSTER B D 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 ...

Page 283: ...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 DECALS Decal Removal Before beginning read these instructions and check to be sure all ...

Page 284: ... wipe the adhesive from the hood and deposit it in a paper shop towel You may have to repeat this process several times to remove all of the adhesive from the hood Use care not to get the cleaner on any other decals 5 When the bulk of the adhesive is removed from the hood by using the squeegee remove any left over residue with a clean non abrasive shop towel or cheese cloth that is wet with the 3M...

Page 285: ...ls 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 CAUTION ONCE THE ADHESIVE STICKS IT CAN BE VERY DIFFICULT TO PULL THE DECAL BACK OFF OF THE HOOD USE EXTREME CARE IF YOU ENCOUNTER AIR...

Page 286: ...OL 11 7 TPS ADJUSTMENT CARBURETED MODELS 11 8 TPS ADJUSTMENT CFI MODELS USING DIGITAL WRENCH 11 8 TPS BASELINE ADJUSTMENT CFI MODELS 11 8 TPS IDLE SPEED ADJUSTMENT CFI MODELS 11 10 THROTTLE PLATE SYNCHRONIZATION 11 10 ELECTRIC START IQ CARBURETED CFI 11 11 SYSTEM SCHEMATIC 600 CARBURETED 11 11 SYSTEM SCHEMATIC CFI 11 12 STARTER MOTOR FLEX DRIVE ASSEMBLY 11 13 IQ BATTERY BOX ASSEMBLY 11 14 CARBURET...

Page 287: ...t TPS ALL 600 700 800 CFI 18 Idle 1700 RPM 0 95Vdc TPS and 120 Engine Coolant Temperature 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 WIT...

Page 288: ...r 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 batteries require filling with electrolyte and a full charge prior to service 1 Fill battery with electrolyte to the upper level marks on the case 2 Set battery aside and allow it to cool and stabilize fo...

Page 289: ...d 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 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 Rin...

Page 290: ... 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 flywheel 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 cod...

Page 291: ...46 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...

Page 292: ...c 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 2 Verify the throttle cable is not kinked and the throttle flipper is closed Disconnect the throttle cable from the throttle flipper 3 Connect the test tool to the TPS 4 Insert the black ...

Page 293: ...e 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 CFI Models NOTE The TPS baseline and idle speed adjustments must be performed whenever the TPS is moved or replaced 1 Remove the drive belt driven clutch airbox and adapter plate 2 If the TPS require...

Page 294: ...s 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 Vdc 9 To adjust the TPS base line slightly loosen the screws then slowly turn the TPS clockwise or counter clockwise to adjust the voltage 10 Carefully tighten the screws to 31 In Lbs 3 5 Nm when the voltage is 0 70 0 01 Vdc 11 Open and close the throttle plate 2 3 times and verify th...

Page 295: ...ed 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 adjust...

Page 296: ...11 11 Battery and Electrical Systems 11 ELECTRIC START IQ CARBURETED CFI System Schematic 600 Carbureted ...

Page 297: ...11 12 Battery and Electrical Systems System Schematic CFI ...

Page 298: ...11 13 Battery and Electrical Systems 11 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 299: ...11 14 Battery and Electrical Systems IQ Battery Box Assembly MOUNTING BRACKET BATTERY BATTERY PAD BATTERY HOLD DOWN BRACKET CIRCUIT BREAKER SOLENOID GROUND CABLE ...

Page 300: ...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 YEL TO BRN 0 15Ω BRN TO ENGINE 0Ω BLK RED TO GRN 15Ω RED TO GRN 15Ω BLK or WHT TO ENGINE 0Ω WHT RED TO WHT 185Ω Specifications BLK TO WHT Primary 0 3Ω BLK or WHT TO...

Page 301: ...e RMK Shift regulator rectifier performs the same functions as the 2007 600 HO regulator rectifier Circuit Specifications PLUG PIN COLOR FUNCTION STATOR 2 BROWN GROUND STATOR 3 YELLOW AC POWER INPUT STATOR 4 BROWN GROUND STATOR 6 YELLOW AC POWER INPUT HARNESS A YELLOW REGULATED AC POWER HARNESS B ORG BLK DC BRAKE LAMP GROUND HARNESS C ORANGE AC BRAKE SIGNAL INPUT HARNESS D BRN WHT DC GROUND HARNES...

Page 302: ...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 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 ...

Page 303: ...ll 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 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 2 Ensure that the path behind you...

Page 304: ...the 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 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 into reverse 4000 RPM M...

Page 305: ...NOTES Battery and Electrical Systems 11 20 ...

Page 306: ...emoval 4 34 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 Sen...

Page 307: ... Compression Ratio Example 2 6 Head cc Removal Example 2 6 Port Opening Duration 2 6 Engine Inspections 5 5 Cylinder Head 5 5 Engine Installation 5 36 Engine Maintenance 3 7 Coolant Surge Tank 3 7 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 CF...

Page 308: ... 2 10 Publication Part Numbers 2 4 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 Helixes 7 7 Special Tools 7 4 Team Driven Springs 7 8 PVT System Adjustments 7 12 Clutch Alignment Offset 7 12 PVT System Overview 7 2 R Rail Sliders Break In 8 42 Removal and Installation 8 42 Wear Limit 8 42 Rear Suspen...

Page 309: ...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 T Team LWT Driven Clu...

Page 310: ...12 1 Wiring Diagrams 2007 600 HO Carbureted 1 of 2 ...

Page 311: ...12 2 Wiring Diagrams 2007 600 HO Carbureted 2 of 2 ...

Page 312: ...12 3 Wiring Diagrams 2007 600 HO Carbureted Hood Harness ...

Page 313: ...12 4 Wiring Diagrams 2007 600 700 CFI Chassis Harness 1 of 2 ...

Page 314: ...12 5 Wiring Diagrams 2007 600 700 CFI Chassis Harness 2 of 2 ...

Page 315: ...12 6 Wiring Diagrams 2007 600 700 CFI Hood Harness NOTE ALTIMETER AND AIR TEMP CONNECTORS WILL BE MALE AND FEMALE CONNECTOS NOT PLUGS ...

Page 316: ...12 7 Wiring Diagrams 2007 600 700 CFI Engine Harness ...

Page 317: ...12 8 Wiring Diagrams 2008 IQ Shift 1 of 2 ...

Page 318: ...12 9 Wiring Diagrams 2008 IQ Shift 2 of 2 ...

Page 319: ...12 10 Wiring Diagrams 2008 IQ Shift Hood Harness ...

Page 320: ...12 11 Wiring Diagrams 2008 IQ Shift RMK 1 of 2 ...

Page 321: ...12 12 Wiring Diagrams 2008 IQ Shift RMK 2 of 2 ...

Page 322: ...12 13 Wiring Diagrams 2008 IQ Shift RMK Hood Harness ...

Page 323: ...12 14 Wiring Diagrams 2008 IQ CFI Chassis Harness 1 of 2 ...

Page 324: ...12 15 Wiring Diagrams 2008 IQ CFI Chassis Harness 2 of 2 ...

Page 325: ...12 16 Wiring Diagrams 2008 IQ CFI Engine Harness ...

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