Polaris SUPERSPORT 2006 Manual Download Page 141 | Manualshive

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6.29

ENGINE

17. Torque the cylinder base nuts to:

•340 = 17-18 ft-lb (23-25Nm)

•550 = 25-30 ft-lb (34-40Nm)

18. Install a new head gasket with the “EX” facing the exhaust

side. Also make sure that the “UP” is facing the intake side
of the engine.

19. Insert the head bolts and torque to:

•340 = 18-21 ft-lb (25-28 Nm)

•550 = 17-21 ft-lb (23-28 Nm)

20. Insert the dowels on the stator housing that match up with

the crankcase.

21. Route the stator wires harness correctly.

22. Install the flywheel, lock washer, woodruff key, and

flywheel nut onto the shaft.

23. Torque the flywheel nut to:

• 340 = 61-70 ft-lb (83-90Nm)

• 550 = 58-72 ft-lb (79-98Nm)

24. Install the recoil cup onto the flywheel.

25. Install the recoil cover.

26. Install the CDI box on the flywheel cover.

27. Insert the vibration dampener in between the cooling fins

that are located between the two cylinders on the intake
side.

28. Install the two fan deflectors.

NOTE: Make sure that the fan deflectors interlock
before tightening down.

29. Install the oil pump onto the lower case half.

NOTE: Install all oil pump shims.

30. Apply Blue Loctite 243 to the oil pump mounting screw

threads and torque to 48-72 in-lb (5.5-8.3Nm).

31. Route each oil line on the oil pump in the correct positions.

32. Install intake boots.

33. Install the boot clamps onto the boots.

34. Install the carburetors onto the boots.

35. Tighten the boot clamps.

36. Insert engine into the chassis.

500 FUJI

DISASSEMBLY

NOTE: Inspect all parts for wear or damage during
disassembly. Replace all seals, O-rings, and gaskets
with Genuine Polaris parts during assembly. Refer to
General Section for Inspection Procedures.

1.

Remove carburetors, recoil housing and exhaust manifold.

2.

Remove water pump, and starter recoil cup with water
pump drive pulley and flywheel nut.

3.

Install flywheel puller PN 2871043. Use all flywheel bolt
holes. Do no install puller bolts more than 5/16, (7mm)
into flywheel or stator damage may result.

CYLINDER BASE TORQUE PATTERN-FUJI

1

3

4

2

CYLINDER HEAD TORQUE PATTERN-FUJI

5

3

2

1

4

6

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Summary of Contents for SUPERSPORT 2006

Page 1: ...500 INDY 1 12 SUPERSPORT 1 14 340 INDY TOURING 1 16 TRAIL TOURING 1 18 600 EDGE TOURING 1 20 700 TOURING 1 22 WIDETRAK LX 1 24 500 XC SP 1 26 600 HO STANDARD FUSION 1 28 600 HO DRAGON FUSION 1 30 700...

Page 2: ...F 16_C 0 600 0 2000 185 4 180 3 170 3 170 3 165 3 160 3 155 3 150 3 600 1200 2000 4000 175 3 170 3 160 3 160 3 155 3 150 3 140 2 140 2 1200 1800 4000 6000 165 3 160 3 155 3 150 3 145 3 140 2 130 2 130...

Page 3: ...distance in cm 42 5 108 Camber in mm 59 31 15 0 7 9 Toe in mm 12 25 3 0 6 35 Table 1 10 Rear Suspension Suspension type Edge Front track shock FTS Arvin 7041939 FTS Spring Rate lbs in kg mm 200 3 58...

Page 4: ...0_C 0 600 0 2000 390 4 370 3 360 3 360 2 340 2 320 2 600 1200 2000 4000 370 3 350 3 340 2 320 2 310 2 300 2 1200 1800 4000 6000 350 3 330 3 320 2 300 2 290 2 270 1 1800 2400 6000 8000 320 3 310 3 300...

Page 5: ...center distance in cm 42 5 108 Camber in mm 59 31 15 0 7 9 Toe in mm 12 25 3 0 6 35 Table 1 23 Rear Suspension Suspension type Edge M 10 Front track shock FTS Fox 7042224 FTS spring rate lbs in kg mm...

Page 6: ...50 240 2 600 1200 2000 4000 290 280 3 270 260 3 260 250 3 250 240 3 240 230 3 230 220 2 1200 1800 4000 6000 270 260 3 260 250 3 250 240 3 240 230 2 230 220 2 220 210 2 1800 2400 6000 8000 250 240 3 24...

Page 7: ...er distance in cm 42 5 108 Camber in mm 59 31 15 0 7 9 Toe in mm 12 25 3 0 6 35 Table 1 35 Rear Suspension Suspension type Edge Front track shock FTS Arvin 7041939 FTS Spring rate lbs in kg mm 100 1 7...

Page 8: ...0 3 400 3 390 2 380 2 600 1200 2000 4000 450 4 430 4 420 4 410 3 400 3 380 2 360 2 350 2 1200 1800 4000 6000 420 4 400 4 390 3 380 3 370 2 350 2 330 2 320 2 1800 2400 6000 8000 400 4 380 3 360 2 350 2...

Page 9: ...ront vertical travel in cm 10 25 4 Ski center distance in cm 42 5 108 Camber in mm 59 31 15 0 7 9 Toe in mm 12 25 3 0 6 35 Table 1 48 Rear Suspension Suspension type Edge M 10 Front track shock FTS Fo...

Page 10: ...6 ER 23 39 76 600 1200 2000 4000 10 72 Dark Blue White Red Black 62 42 46 ER 23 39 76 1200 1800 4000 6000 10 70 Dark Blue White Red Black 62 42 46 ER 23 39 76 1800 2400 6000 8000 10 68 Black Green Red...

Page 11: ...hock FTS Fox 7043123 FTS spring rate lbs in kg mm 160 2 9 FTS spring installed length in cm 8 20 3 Rear track shock Fox 7043190 Lower outer spring lbs in kg mm 715 12 8 Lower inner spring lbs in kg mm...

Page 12: ...to 10_C 50_F 10_C 0 600 0 2000 390 4 370 3 360 3 360 2 340 2 320 2 600 1200 2000 4000 370 3 350 3 340 2 320 2 310 2 300 2 1200 1800 4000 6000 350 3 330 3 320 2 300 2 290 2 270 1 1800 2400 6000 8000 3...

Page 13: ...r distance in cm 42 5 108 Camber in mm 59 31 15 0 7 9 Toe in mm 12 25 3 0 6 35 Table 1 72 Rear Suspension Suspension type Edge Front track shock FTS Arvin 7041939 FTS spring rate lbs in kg mm 200 3 58...

Page 14: ...250 3 250 240 2 600 1200 2000 4000 290 280 3 270 260 3 260 250 3 250 240 3 240 230 2 230 220 2 1200 1800 4000 6000 270 260 3 260 250 3 250 240 3 240 230 2 230 220 2 220 210 2 1800 2400 6000 8000 250...

Page 15: ...59 31 15 0 7 9 Toe in mm 12 25 3 0 6 35 Table 1 86 Edge Rear Suspension Front track shock FTS Arvin 7041939 FTS spring rate lbs in kg mm 200 Var 3 6Var FTS spring installed length in cm 7 5 19 1 Rear...

Page 16: ...0 0 2000 185 4 180 3 170 3 170 3 165 3 160 3 155 3 150 3 600 1200 2000 4000 175 3 170 3 160 3 160 3 155 3 150 3 140 2 140 2 1200 1800 4000 6000 165 3 160 3 155 3 150 3 145 3 140 2 130 2 130 2 1800 240...

Page 17: ...n cm 42 5 108 Camber in mm 59 31 15 0 7 9 Toe in mm 12 25 3 0 6 35 Table 1 99 Rear Suspension Suspension type Edge Front track shock FTS Arvin 7041939 FTS spring rate lbs in kg mm 200 Var 3 6 FTS spri...

Page 18: ...40 2 600 1200 2000 4000 290 280 3 270 260 3 260 250 3 250 240 3 240 230 2 230 220 2 1200 1800 4000 6000 270 260 3 260 250 3 250 240 3 240 230 2 230 220 2 220 210 2 1800 2400 6000 8000 250 240 3 240 23...

Page 19: ...9 Toe in mm 12 25 3 0 6 35 Table 1 112 Rear Suspension Suspension type Edge Touring Front track shock FTS Arvin 7041486 FTS spring rate 90 150 1 6 2 7 FTS spring installed length 10 375 26 4 Rear tra...

Page 20: ...4 370 4 360 4 340 4 330 3 320 3 1200 1800 4000 6000 380 4 360 4 350 4 340 4 330 4 320 3 300 3 290 3 1800 2400 6000 8000 360 4 340 4 330 4 320 3 300 3 290 3 280 3 270 3 2400 3000 8000 10000 340 4 320 4...

Page 21: ...cm 10 25 4 Ski center distance in cm 42 5 108 Camber in mm 59 31 15 0 7 9 Toe in mm 12 25 3 0 6 35 Table 1 125 Rear Suspension Suspension type Edge Touring Front track shock FTS Arvin 7041486 FTS spr...

Page 22: ...tch Spring Clutch Spring Driven Helix Gearing 0 600 0 2000 10 72 Dark Blue White Red Black 62 42 46 ER 23 39 76 600 1200 2000 4000 10 72 Dark Blue White Red Black 62 42 46 ER 23 39 76 1200 1800 4000 6...

Page 23: ...in mm 0 12 0 3 0 Table 1 138 M 10 Rear Suspension Suspension type M 10 136 Front track shock Fox 7043123 Front track shock spring rate lbs in kg mm 220 3 9 Spring installed length in cm 8 5 21 6 Rear...

Page 24: ...2_C to 1_C 30_F to 50_F 1_C to 10_C 50_F 10_C 0 600 0 2000 210 2 200 2 195 2 185 2 175 2 170 2 600 1200 2000 4000 195 2 185 2 180 2 170 2 165 2 155 2 1200 1800 4000 6000 185 2 175 2 170 2 160 2 155 1...

Page 25: ...in cm 38 96 5 Camber in mm 82 72 20 8 18 3 Toe in mm 0 12 0 3 Table 1 150 Rear Suspension Suspension type Slide Rail Coupled Front track shock FTS Arvin 7041742 FTS spring rate lbs in kg mm 181 3 2 F...

Page 26: ...0_C 50_F 10_C 0 600 0 2000 440 3 430 3 410 2 390 2 380 2 360 2 600 1200 2000 4000 420 3 400 2 390 2 370 2 350 2 340 1 1200 1800 4000 6000 390 2 380 2 360 2 340 2 330 1 310 1 1800 2400 6000 8000 370 2...

Page 27: ...Ski center distance in cm 42 5 108 Camber in mm 59 31 15 0 7 9 Toe in mm 12 25 3 0 6 35 Table 1 163 Rear Suspension Front track shock Arvin 7041975 FTS Spring rate lbs in kg mm 160 Var 2 86 Var FTS Sp...

Page 28: ...0 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 1 300...

Page 29: ...5 7 79 Toe in mm 0 12 0 3 0 Table 1 177 M 10 Rear Suspension Suspension type M 10 128 Front track shock Fox 7043123 Front track shock spring rate lbs in kg mm 180 3 2 Spring installed length in cm 8 7...

Page 30: ...000 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 3...

Page 31: ...avel in cm 10 25 4 Ski center distance in cm 42 5 108 Camber in cm 2 25 31 5 7 79 Toe in mm 0 12 0 3 0 Table 1 191 Rear Suspension Suspension type IQ 121 Front track shock Walker 7043096 FTS spring ra...

Page 32: ...ght Clutch Spring Clutch Spring Driven Helix Gearing 0 600 0 2000 10 72 Dark Blue White Red Black 62 42 46 ER 26 40 78 600 1200 2000 4000 10 72 Dark Blue White Red Black 62 42 46 ER 26 40 78 1200 1800...

Page 33: ...7043178 FTS spring rate lbs in kg mm 130 270 2 3 4 8 FTS spring installed length in cm 7 97 20 2 Rear track shock Fox 7043177 Rear vertical travel in cm 13 9 35 3 notes that shock is rebuildable Tabl...

Page 34: ...H TEAM Shift Weight Clutch Spring Clutch Spring Driven Helix Gearing 0 600 0 2000 10 74 Dark Blue White Red Black 62 42 46 ER 25 37 76 600 1200 2000 4000 10 72 Dark Blue White Red Black 62 42 46 ER 25...

Page 35: ...pring rate lbs in kg mm 130 270 2 3 4 8 Spring installed length in cm 7 97 20 2 Rear track shock Fox 7043177 Rear travel in cm 13 9 35 3 notes that shock is rebuildable Table 1 221 M 10 Rear Suspensio...

Page 36: ...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 2...

Page 37: ...el in cm 10 25 4 Ski center distance in cm 42 5 108 Camber in cm 2 25 31 5 7 79 Toe in mm 0 12 0 3 0 Table 1 234 Rear Suspension Suspension type IQ RMK 144 Front track shock FTS Arvin 7043142 FTS spri...

Page 38: ...H TEAM Shift Weight Clutch Spring Clutch Spring Driven Helix Gearing 0 600 0 2000 10 74 Dark Blue White Red Black 64 42 46 ER 25 40 78 600 1200 2000 4000 10 72 Dark Blue White Red Black 64 42 46 ER 25...

Page 39: ...Table 1 247 IQ Rear Suspension Suspension type IQ RMK 144 Front track shock Fox 7043142 Front track shock spring rate lbs in kg mm 170 3 2 Spring installed length in cm 7 25 18 4 Rear track shock Fox...

Page 40: ...0 3 280 270 3 270 260 3 260 250 3 250 240 3 240 230 3 600 1200 2000 4000 290 280 3 280 270 3 270 260 3 260 250 3 250 240 3 240 230 3 1200 1800 4000 6000 290 280 3 280 270 3 270 260 3 260 250 3 250 240...

Page 41: ...avel in cm 7 6 19 3 Ski center distance in cm 41 104 Camber in mm 735 31 18 7 7 9 Toe in mm 0 12 Table 1 260 Rear Suspension Suspension type Edge RMK Front track shock Arvin 7042085 FTS spring rate lb...

Page 42: ...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 2...

Page 43: ...31 5 5 79 Toe in mm 0 12 0 3 0 Table 1 273 Rear Suspension Suspension type IQ RMK 144 Front track shock FTS Arvin 7043048 FTS spring rate lbs in kg mm 170 3 0 FTS spring installed length in cm 7 4 18...

Page 44: ...LUTCH TEAM Shift Weight Clutch Spring Clutch Spring Driven Helix Gearing 0 600 0 2000 10 74 Black Green Red Black 64 36 25 ER 20 41 76 600 1200 2000 4000 10 72 Black Green Red Black 64 36 25 ER 20 41...

Page 45: ...nsion type IQ RMK Front track shock Arvin 7043048 Front track shock FTS spring rate lbs in kg mm 170 3 0 FTS spring installed length in cm 7 40 18 8 FTS option Arvin 7042335 FTS option spring rate lbs...

Page 46: ...LUTCH TEAM Shift Weight Clutch Spring Clutch Spring Driven Helix Gearing 0 600 0 2000 10 78CS Black Green Red Black 64 38 25ER 20 41 76 600 1200 2000 4000 10 76CS Black Green Red Black 64 38 25ER 20 4...

Page 47: ...track shock FTS 7043048 FTS spring rate lbs in kg mm 170 3 0 FTS spring installed length in cm Fixed Front track shock FTS option Arvin 7042335 FTS option spring rate lbs in kg mm 170 3 0 FTS option s...

Page 48: ...NOTES SPECIFICATIONS 1 48...

Page 49: ...RT NUMBERS 2 4 2006 PART NUMBERS 2 4 GENERAL REFERENCE 2 6 STANDARD BOLT SPECIFICATIONS 2 6 SAE TAP DRILL SIZES 2 7 METRIC TAP DRILL SIZES 2 7 DECMIAL EQUIVALENTS 2 7 MESUREMENT CONVERSION CHART 2 8 P...

Page 50: ...mbers are listed as chapter number and page number Chapter number is separated by a period Example of this is 3 12 The first number 3 designates the chapter the second number 12 is the page number The...

Page 51: ...l Number Designation Identifier Model Year Model Line Model Type Engine Modifier VIN Identifier Option Identifier S 06 P S 8 D S A S Snow 06 2006 05 2005 04 2004 M IQ N Edge P IQ RMK S GenII W Mini In...

Page 52: ...V 4 Cycle Fuji 3A 340 F C Piston Port 4B 488 L C Piston Port 4C 440 EV L C Piston Port 5B 544 F C Cylinder Reed 6E 600 EV L C Case Reed 2 Cyl Dom 6F 600 EV L C Case Reed HP 2 Cyl Dom 7E 750 NA 7F 750...

Page 53: ...27 9919728 9919882 9919763 120 S06WB1AS 9919675 9919757 9919758 9916891 9919766 500 Indy S06NB4BS 9919667 9919935 9919936 9919937 9916508 9919763 500 XC SP Edge M 10 S06NE P 5CS A B 9919667 9919686 99...

Page 54: ...cific manual section for torque values of fasteners Table 2 5 Standard Bolt Specifications Bolt Size Threads In Grade 2 ft lb Nm Grade 5 ft lb Nm Grade 8 ft lb Nm 1 4 20 5 7 8 11 12 16 1 4 28 6 8 10 1...

Page 55: ...2 7 GENERAL SAE TAP DRILL SIZES METRIC TAP DRILL SIZES DECMIAL EQUIVALENTS...

Page 56: ...rams g x 035 Ounces oz cc s x 03381 Fluid Ounces oz lbs x 454 kg kg x 2 2046 lbs Cubic Inches x 16 387 Cubic Centermeters Cubic Centimeters x 061 Cubic Inches Imperial pints x 568 liters l liters l x...

Page 57: ...of gasoline is its volatility or ability to vaporize at different ambient temperatures and altitudes during the year When gasoline is blended it is given a Reid Vapor Pressure RVP number which reflect...

Page 58: ...at you are looking for 20 this will give you the amount of oil that you need 6 4 oz to add to the fuel in the mixing container 1 gallon has 128oz 20 6 4 oz of oil needed to mix to each 1 gallon of gas...

Page 59: ...2 11 GENERAL SPECIAL TOOLS Fuel Pressure Gauge PV 43506 A Throttle Position Sensor Tester Kit 2201519 Fuel Line Disconnection Tool PS 47152 Mity Vac Pressure Test Kit 2870975...

Page 60: ...2 12 GENERAL SPECIAL TOOLS...

Page 61: ...2 13 GENERAL...

Page 62: ...2 14 GENERAL...

Page 63: ...TRUING 3 11 CRANKSHAFT RUNOUT INSPECTION 3 12 OIL PUMP BLEEDING 3 12 FITTING TYPES 3 13 VERIFYING CHECK VALVE OPERATION 3 13 OIL FUEL FILTER 3 13 BRAKE LEVER TRAVEL 3 14 BRAKE FLUID 3 14 BRAKE FLUID B...

Page 64: ...ND DRIVE SYSTEM 3 24 CONTROLS AND LINKAGE 3 24 ELECTRICAL CONNECTIONS 3 24 CARBURETOR THROTTLE BODY 3 24 FUEL SYSTEM 3 24 CORROSION 3 24 SHOCKS 3 25 BATTERY 3 25 REPLACEMENT 3 25 HEADLIGHT BULB REPLAC...

Page 65: ...ent procedures and the use of tools or if you don t feel comfortable performing these tasks yourself contact an authorized Polaris dealer for service The following chart is a guide based on average ri...

Page 66: ...I I I I I I Ignition Switch I I I I I I Taillight I I I I I I Brakelight I I I I I I Headlight I I I I I I Tether Switch and Strap I I I I I I CHASSIS Ski Toe Alignment I I I Suspension Mounting Bolts...

Page 67: ...003 08mm Seat Latches I Rear Wheel Idler Bolts I I I I I I Idler Bolt Jam Nut I I I I I Rear Suspension Pivot Shafts L L L Handle Bar U Joint L L L Camber Alignment I I I Handlebar Centering I Track...

Page 68: ...fine stones removes only a very small amount of material A proper crosshatch pattern is important to provide a surface that will hold oil and allow the rings to seat properly If the crosshatch is too...

Page 69: ...r oversizing cylinders cylinder boring and finish honing The use of an arbor type honing machine is recommended Always check piston to cylinder clearance and piston ring installed gap after boring hon...

Page 70: ...is not add coolant to the FULL COLD mark on the bottle If you have coolant over the FULL COLD level you may have air in the system and need to bleed the air out of the system RECOMMENDED COOLANT Pola...

Page 71: ...t the machine slightly on its left side so that the coolant bottle is the highest point in the cooling system and cycle the RPM from idle to enough RPM 4000 to get coolant to flow but not enough RPM t...

Page 72: ...m and be equal on all rods within 002 05mm 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 alterna...

Page 73: ...ee wheel until the pointer aligns with a 180_ mark on the degree wheel 9 With the pointer aligned make sure the degree wheel and pointer are secured and will not move out of position Re check accuracy...

Page 74: ...ft 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 locat...

Page 75: ...t always be bled following any service to the oil injection system or engine FITTING TYPES VERIFYING CHECK VALVE OPERATION 1 To check the operation of the fittings fill the oil reservoir bleed the pum...

Page 76: ...ction should be made with the lever firmly depressed If the lever has less than this amount you may need to bleed the brake system see BRAKE FLUID REPLACEMENT BLEEDING on page 8 3 BRAKE FLUID Inspect...

Page 77: ...A low brake fluid level can be indicated through the sight glass on the cover If the fluid is low this sight glass will glow a brighter color BRAKE FLUID BLEEDING see BRAKE FLUID REPLACEMENT BLEEDING...

Page 78: ...higher temperature ranges then the other springs 3 Disconnect the exhaust temperature sensor if equipped 4 Remove the exhaust pipe C resonator seal D and manifold seal E 5 Remove the resonator F Some...

Page 79: ...ion 2 Place a straight edge across the tow clutches on top the belt 3 Apply downward pressure to the belt and measure the distance at point D 4 The measurement should be 1 1 4 3 2cm 5 If the measureme...

Page 80: ...a dip stick the correct level will be indicated between the SAFE markings To add fluid to this style chaincase you can add it through the dipstick hole The dip stick also has safety magnetic tip that...

Page 81: ...ve all the chain slack to the tensioner side 3 Lock the parking brake 4 Loosen the adjuster bolt jam nut B 5 Finger tighten the adjuster bolt A 6 Back off the adjuster bolt 1 4 turn out counterclockwi...

Page 82: ...t D If the track runs to the right loosen the right locknut and tighten the right adjusting bolt It may be necessary to check this with the engine rotating the track Be sure to SHUT THE MACNINE OFF be...

Page 83: ...re the distance D between the rail slider and the track This measurement should fall with in the measurement range for the appropriate vehicle 6 If adjustment is needed loosen up the lock nuts B on ea...

Page 84: ...ors air box and plug in the CDI and coils if they were taken off in step 1 9 Check idle to specification and adjust if needed NOTE A mirror may aid in checking the oil line markings HEADLIGHT ADJUSTME...

Page 85: ...ver slides and dart clips HANDLEBAR RIDING POSITION ADJUSTMENT Rider Select only On the IQ vehicles you have the option of seven 7 different riding positions 1 While sitting in the riding position on...

Page 86: ...rottle lever clearance the engine may misfire or kill upon initial throttle opening TORQUE STOP After aligning clutches adjust torque stop A by loosening the lock nut and rotating the stop so that the...

Page 87: ...Remove drive belt and store in a cool dry location Lubricate sheave faces and ramps of drive and driven clutches with light oil or rust inhibitor All lubrication applied as a rust preventative measure...

Page 88: ...3 Squeeze and move the bulb clip up 4 Replace the bulb clip and access panel IQ HEADLIGHT BULB REPLACEMENT 1 Unplug the headlight harness 1 form the bulb 2 Remove the rubber boot 2 from the housing 3...

Page 89: ...FUEL DELIVERY 4 8 PILOT JET 4 8 PILOT AIR SCREW 4 8 MAIN JET 4 8 JETTING GUIDELINES 4 9 PISTON VALVE OR THROTTLE VALVE 4 9 JET NEEDLE NEEDLE JET 4 9 JET NEEDLE 4 9 NEEDLE JET 4 10 THROTTLE OPENING VS...

Page 90: ...out 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 If a torquing sequence is indicated for nut...

Page 91: ...ted fuel system contains many components which directly affect fuel mixture and drive ability When performing diagnosis or carburetor maintenance the entire fuel delivery system should be inspected Th...

Page 92: ...acing or if carbs carburetor racks or fuel pumps are removed from chassis FUEL PUMP non injected units FUEL PUMP OVERVIEW The fuel pumps 340 550 style shown The differences are in the size and locatio...

Page 93: ...imately 2000 RPM a steady flow of fuel should be visible CLEANING The pump and impulse line must be disassembled and cleaned of foreign material in the event of piston or other internal engine part fa...

Page 94: ...interchangeable with VM needles To raise or lower the needle remove the top cap D and loosen the 2 5mm Allen screw holding the needle in place Reach inside with a long nose pliers and pull the needle...

Page 95: ...o efficient engine operation The engine of a vehicle is operated under a wide range of conditions from idling with the throttle valve remaining almost closed to full load or maximum output with the th...

Page 96: ...edle jet and main jet The main system begins to take effect as soon as there is enough air flow into the carburetor venturi to draw fuel up through the main jet and needle jet assembly This system wor...

Page 97: ...ontrols the rate of engine air intake by moving up and down inside the main bore At small throttle openings air flow control is performed chiefly by the cutaway By controlling air flow the negative pr...

Page 98: ...the jet needle to regulate fuel flow rate An air bleed opening in the side of the needle jet brings in air measured by the air jet This air initiates the mixing and atomizing process inside the needl...

Page 99: ...plastic washer from the throttle slide NOTE Keep track of the plastic washer G 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 I...

Page 100: ...an 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 and any par...

Page 101: ...gine running The MAG side carburetor is the adjusting carburetor the PTO side carburetor has a non adjustable set screw on the throttle shaft The PTO carburetor is considered the base carburetor All a...

Page 102: ...he black probe lead to the black terminal 7 Place the red probe lead to the Pink terminal 8 Turn your meter to the VDC setting 9 Your voltage reading on your meter should read 4 99 5 01 VDC If not rep...

Page 103: ...great there will be excessive toggle free play resulting in hard starting Also the half on position used for intermittent applications will not function 1 Flip the choke toggle to the full off positio...

Page 104: ...3130123 360 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...

Page 105: ...30782 1 5 3130783 1 6 3130784 1 7 3130785 1 8 3130786 1 9 3130787 2 0 3130788 Table 4 7 Mikuni Pilot Air Jets LONG AIR JET PART NUMBER 0 5 3131255 0 6 3131249 0 7 3131256 0 8 3131254 0 9 3131203 1 0 3...

Page 106: ...4 18 CARBURETION...

Page 107: ...ERY SYSTEM CLEANFIRET 5 2 CLEANFIRE SYSTEM OVERVIEW 5 2 PUMP FLANGE ASSEMBLY 5 3 FUEL PUMP 5 3 FUEL LEVEL 5 3 FUEL RAIL 5 3 FUEL RAIL INJECTOR REMOVAL 5 3 FUEL RAIL INJECTOR INSTALLATION 5 3 FUEL RAIL...

Page 108: ...hould be inspected for cracks or leaks Do not use pliers or other tools that may damage fuel lines when installing or removing fuel rail Fuel travels from the fuel pump through the fuel filter and to...

Page 109: ...lure you can check the continuity from the fuel sender to the gauge The given resistance below is from the Violet White 2 wire to the Brown 4 wire located at the front of the fuel pump FUEL RAIL FUEL...

Page 110: ...rst find out what injector color is on the unit You can do this by checking the decal that is located on the top portion of the ECU or looking at the color wiring cover is on the injectors 1 Remove th...

Page 111: ...tle lever Make sure that both throttle plates are full closed 9 Connect the TPS tool Make sure it is set up correctly before it is connected See TPS SET UP on page 13 16 NOTE Note the voltage at this...

Page 112: ...tle cable lock nut and remove cable from throttle body 5 Loosen the oil cable lock nut and remove the cable from the throttle body 6 Remove the coolant lines from the throttle body 7 Disconnect the TP...

Page 113: ...00 RECOIL STATOR DISASSEMBLY 6 14 700 900 RECOIL STATOR ASSEMBLY 6 14 500 600 HO ENGINE 6 15 500 600 HO TORQUE SPECIFICATIONS 6 15 600 HO IQ ENGINE REMOVAL 6 15 600 IQ ENGINE INSTALLATION 6 19 500 600...

Page 114: ...emove the four fasteners 3 holding on the exhaust valve base 7 Remove the base and base gasket 8 Remove the exhaust valve guillotine 4 9 Clean base and the guillotine with carbon clean WARNING Exhaust...

Page 115: ...e bellows nut to 144in lb 16Nm 8 Insert spring 8 onto the bellows nut 9 9 Place cover and hardware on to the base and torque the fasteners to 108 in lb 12Nm REED VALVE DISASSEMBLY NOTE Reeds should be...

Page 116: ...ace cover onto the thermostat and install the longer cover fastener on the intake side of the engine Place the shorter fastener on the exhaust side of the cover 5 Torque the fasteners to 9 ft lb 12Nm...

Page 117: ...18 ft lb 24Nm CYLINDER HEAD 27ft lb 37Nm 1 3 BLEEDER SCREW 48 in lb 4 5Nm THERMOSTAT HOUSING 108 in lb 12Nm WATER TEMPERATURE SENSOR 216 in lb 24Nm 2 WATER INLET PIPE N A DETIONATION SENSOR 168 in lb...

Page 118: ...cement of all fasteners and cable ties 11 Remove the left hand side brace and fuel filter 12 Remove the right hand brace The middle front fastener has the hose guide 13 Remove the two fasteners that h...

Page 119: ...ector 30 Disconnect the Stator Coil connector 7 31 Disconnect the Crank Position Sensor connector 8 32 Disconnect the DET sensor harness 9 33 Route these connections through the chassis so that they c...

Page 120: ...chassis next to the ECU 7 Route the DET connection through the chassis next to the ECU 8 First route the Mag side injector connectors through the chassis next to the ECU then the PTO end injector con...

Page 121: ...T TANK INSTALLATION on page 12 3 26 Hook up the exhaust valve lines back onto the base of the exhaust valve 27 Orientate the center crankshaft supply line 6 so that it is closer to the engine and the...

Page 122: ...ust gaskets and header Torque the header fasteners to 22 ft lb 30Nm 43 Install the boost box to the throttle body 44 Tighten the boot clamps 45 Hook up the intake air sensor 46 Install the fuel tank a...

Page 123: ...7 Remove the head 2 and o rings 3 8 Remove the cylinder bolts 4 9 Remove the cylinders 5 10 Remove the MAG side piston c clips from the pistons 11 Remove the piston pins using the piston pin removal i...

Page 124: ...nstall the piston rings onto the piston with the bevel side up and the gap facing the piston ring locating pin 10 If old base gaskets are damaged install new ones NOTE New base gaskets have a rib that...

Page 125: ...by lifting up on the seal flange This will crush the flange upward 6 Pry the mechanical seal out of the case NOTE You will destroy the oil seal when you remove it from the case You will also mar up t...

Page 126: ...Remove the recoil basket fasteners 3 and remove the recoil basket from the flywheel 4 Remove the flywheel nut 4 5 Hold the flywheel 5 with holding tool PN 8700229 6 Place the flywheel puller tool PN...

Page 127: ...move the air box 9 Remove the recoil handle and secure the recoil rope 2 10 Remove the drive belt driven clutch and drive clutch DRIVE CLUTCH REMOVAL on page 7 10 and DRIVEN CLUTCH REMOVAL on page 7 2...

Page 128: ...6 and the Stator connections 7 These are located behind the brake disc area 17 Loosen up the boot clamps that hold the carburetor onto the intake 18 Separate the carburetors from the engine 19 Disconn...

Page 129: ...ine 24 Remove the rear 10 and left 11 motor mounts located on the right hand side of the engine 25 Remove the left hand rear torque stop fasteners 12 26 Remove the inside motor mount fastener 13 locat...

Page 130: ...ough the guide 18 32 Lift the front of the engine up and then tilt the rear so that the engine straps clear the motor mount studs 33 Carefully place the engine on top of the shock tower brace 34 Remov...

Page 131: ...ply line through the guide 2 on the MAG intake 5 Place the engine into the bulk head and make sure that it is lined up with the motor mounts 6 Insert the LH rear torque stop plate 3 between the motor...

Page 132: ...or 13 connections 14 Connect the thermostat cooling hose and secure it with the clamp 14 15 Connect the cooling hose going to the water pump front of engine to the water bottle and secure it with the...

Page 133: ...E Install the long bolts and the spacer on the front portion of the bar before inserting it into the mounting area 25 Replace the nosepan plugs 26 Install the air box See IQ CARBURETED AIR INTAKE REMO...

Page 134: ...e wrist pin into the piston 9 8 Using the piston pin puller PN 2870386 remove the piston pins and the piston from the crankshaft 15 9 Remove the water pump cover 10 Remove the water oil pump assembly...

Page 135: ...ts 17 18 14 Turn the crankcase assembly back over and remove the top of the crankcase 12 15 Remove the crankshaft and refer to the General chapter for general engine component inspections and measurem...

Page 136: ...down 6 00 position Make sure that the c clip is fully seated in the piston groove Use c clip installation tool PN 2872622 10 Install the piston rings onto the piston with the bevel side up and the gap...

Page 137: ...shers 5 7 into the case from the intake side 3 Install the flanged pump bearing 3 with the o ring 4 on to the cross shaft 4 Install the water pump mechanical seal 9 Use water pump seal installation to...

Page 138: ...e flywheel 7 so that it matches up with the index of the woodruff key 4 Apply Loctite 242 to the threads of the flywheel nut 5 and place the washer 6 and nut onto the end of the crankshaft 5 Holding t...

Page 139: ...6 27 ENGINE 340 550 ENGINE REBUILDING 10 11 3 4 12 13 5 2 14 1 16 15 16 9 17 6 7 8...

Page 140: ...ins from the pistons 22 Turn the crankcase over and remove the crankcase bolts 15 23 Carefully turn the case back over and separate the case halves 24 Remove the crankcase seals 16 25 Remove the oil p...

Page 141: ...sure that the fan deflectors interlock before tightening down 29 Install the oil pump onto the lower case half NOTE Install all oil pump shims 30 Apply Blue Loctite 243 to the oil pump mounting screw...

Page 142: ...pin from piston 12 Remove crankcase bolts 13 Refer to INSPECTONS on page 3 5 for engine component inspection i e crankshaft and crankcase inspection piston clearance oil pump drive gear end play etc...

Page 143: ...eled side facing upward 9 Lubricate rings and cylinder with Premium 2 Cycle Lubricant and compress rings with fingers aligning end gaps with locating pins Install cylinder with a gentle front to back...

Page 144: ...e flywheel nut to 60 65 ft lb 83 90Nm using the flywheel holding tool PN 8700229 19 Install water pump and recoil starter cup make sure that the thicker end of the drive pulley is towards the flywheel...

Page 145: ...MP 7 7 CENTRIFUGAL DRIVE SYSTEM 7 8 THEORY OF OPERATION 7 8 DRIVE CLUTCH 7 8 OPERATION 7 8 DRIVE CLUTCH IDENTIFICATION 7 9 DRIVE CLUTCH REMOVAL 7 9 DRIVE CLUTCH COMPONENTS 7 10 DRIVE CLUTCH DISASSEMBL...

Page 146: ...7 2 CLUTCHING POLARIS BELT DEFLECTION 7 26 TEAM BELT DEFLECTION 7 26 DRIVE BELT 7 27 DATA 7 27 GENERAL BELT SELECTION GUIDELINES 7 28 CVT 7 28 STANDARD COMPOUND 7 28...

Page 147: ...0 550 Fuji Engine Drive Clutch Puller 2872084 1999 Current 600 700 800 Domestic Engine Clutch Puller 2871855 1999 2001 700 800 XCR Triple Fuji Engine Clutch Puller 2872085 Replacement Handle for ALL C...

Page 148: ...the snow Engage throttle aggressively for short durations for initial cold drive away Towing another machine at or about engagement RPM When possible do not go in deep snow when towing another machine...

Page 149: ...uard retaining pin and open the clutch guard 2 Apply and lock the parking brake 3 Insert the L wrench A into the threaded hole B located on the driven clutch and turn it clockwise until the clutch she...

Page 150: ...y between clutches and pull upward and rearward to open the driven clutch sheaves A Remove the belt from the driven clutch and then from the drive clutch B C 4 Release the parking brake BELT INSTALLAT...

Page 151: ...sing shift force generated by the driven clutch SHIFT OUT OVERREV Engine RPM that spikes above the desired operating RPM speed The shift out RPM should come down to the desired operating RPM but never...

Page 152: ...wmobile too low for extended high speed runs may cause damage to the drive belt and drive system while gearing a snowmobile too high for deep snow mountain use may cause premature belt and clutch wear...

Page 153: ...s an RPM sensing device The main functions of the drive clutch is to control the neutral RPM speed initial engagement RPM and desired engine operating RPM The drive clutch works by using the principle...

Page 154: ...clutch holding tool PN 9314177 A on the drive clutch 8 Remove the drive clutch retaining bolt Note the placement and number of washers that are on retaining bolt 9 Place the correct clutch puller for...

Page 155: ...HING DRIVE CLUTCH COMPONENTS NOTE Replacement clutches come complete and balanced without clutch weights and clutch spring The clutch cover spider and sheaves cannot be purchased separately as replace...

Page 156: ...7 12 CLUTCHING 1 1 2 3 4 5 6 7 18 17 10 8 9 13 12 11 15 16 14...

Page 157: ...or wear by rocking the weight back and forth 17 Inspect all the rollers 15 bushings 16 and roller pins 14 by pulling a flat metal rod across the roller 18 Roller can also be inspected by rolling with...

Page 158: ...jam nut 6 onto the shaft and torque it to 235 ft lb 324 Nm 10 Place the drive spring on the shaft 11 Place the cover 3 onto the clutch and torque the cover fasteners 2 to 90 in lb 10Nm NOTE DO not al...

Page 159: ...Specification for the width of the spider with buttons installed is 1 496 37 99mm 12 Measure the width of the moveable sheave towers 10 and record the measurement Specification for the width of the o...

Page 160: ...stress the spring is subject to during operation it should always be inspected and checked for tolerance limits during any clutch operation diagnosis or repair With the spring resting on a flat surfa...

Page 161: ...3 65 140 330 145 7041645 Almond Gold 207 4 00 150 290 107 7041818 Black White 218 3 52 140 320 137 7041816 Almond Black 200 3 75 165 310 111 7041922 Almond Blue 218 3 75 150 310 122 7041988 Almond Red...

Page 162: ...29 10M Bushed 49 5 1321531 10 Bushed 51 1321531 10 AL Bushed 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 64 64 1321585 10 64M...

Page 163: ...uld be clean and dry Do not use harsh cleaners which may cause clutch taper to corrode or damage to the crank seal This may cause difficulty when removing clutch in the future 4 Clean clutch taper wit...

Page 164: ...tch will open or upshift when the shift force generated by the drive clutch is greater than the shift force generated by the driven clutch The driven clutch will close or backshift whenever the driven...

Page 165: ...p The second number B designates the lowest angle that it progresses to The last number C is the measurement length at which the transition takes place Electric reverse ramps have only one set of angl...

Page 166: ...48 46 74 40 46 5133493 72 44 46 72 40 46 5133494 70 44 46 70 40 46 5133495 68 44 46 68 40 46 5133496 66 48 46 66 40 46 5133497 64 44 46 64 40 46 5133498 62 44 46 62 40 46 5133499 58 44 46 58 40 46 51...

Page 167: ...the inner hub at full shift which can cause belt failure Wide belt models use only the existing washer under the snap ring Table 7 10 Team Driven Ramps for Electric Reverse PART NUMBER DESCRIPTION PAR...

Page 168: ...ver 207 125 175 45 7043062 Red Yellow 207 100 150 45 7043057 Red Blue 218 140 200 54 7043063 Black Red 218 155 222 65 7043064 Blue Black 218 123 203 73 7043060 Red White 218 100 200 91 7043069 Red Pin...

Page 169: ...ine mounts securely 4 Re check both clutch offset and clutch alignment 5 Verify proper torque stop adjustment See TORQUE STOP on page 3 24 CLUTCH OFFSET Clutch off set is a combination of engine mount...

Page 170: ...he clutch pin D to open or close the clutch sheaves Do not rotate past the 1 position 6 Torque the adjustment cam bolts to 48 72 in lbs 5 8Nm TEAM BELT DEFLECTION 1 Loosen the jam nut E by turning it...

Page 171: ...4 6 Longer P 90 belt 3211061 1 375 34 9 32_ 12 30 47 188 119 9 CVT version of 3211045 3211065 1 438 36 5 28_ 12 5 31 75 48 375 122 9 CVT Double Cog Storm belt 3211066 1 375 34 9 28_ 12 30 47 25 120 Do...

Page 172: ...for specific application CVT Increased service life for high horsepower and extended high speed running Need 1 2 grams heavier drive clutch weight Good for prolonged high speed running Good for aggre...

Page 173: ...ION 7 9 7 92 CHAINCASE REMOVAL 7 9 7 92 CHAINCASE ASSEMBLY 7 9 CHAINCASE SEAL BEARING REPLACEMENT 7 10 DRIVE TRAIN 7 11 JACKSHAFT EXPLODED VIEW 7 11 JACKSHAFT REMOVAL 7 12 JACKSHAFT INSTALLATION 7 12...

Page 174: ...6 84 82 94 92 89 87 85 7000 112 109 100 98 104 102 99 96 94 92 89 87 85 98 95 93 90 88 7250 116 112 104 101 108 105 102 100 97 95 93 91 88 101 98 96 93 91 7500 120 116 107 105 112 109 106 103 101 98 9...

Page 175: ...83 81 79 78 72 86 84 82 80 78 76 74 69 7000 86 84 93 91 89 86 84 82 80 75 89 87 85 83 81 79 77 72 7250 89 87 97 94 92 90 87 85 83 78 93 90 88 86 84 82 80 74 7500 92 90 100 97 95 93 90 88 86 81 96 93 9...

Page 176: ...8 66 65 62 6750 82 80 78 76 74 72 71 69 66 65 78 76 74 72 71 69 67 64 7000 85 83 81 79 77 75 73 72 69 67 81 79 77 75 73 72 70 67 7250 88 86 84 82 80 78 76 74 71 70 84 82 80 78 76 74 72 69 7500 91 89 8...

Page 177: ...61 59 58 57 55 6750 74 72 71 69 67 66 64 60 71 69 67 65 64 62 61 67 65 63 62 60 59 57 7000 77 75 73 71 70 68 66 62 73 71 69 68 66 64 63 69 67 66 64 62 61 59 7250 80 78 76 74 72 70 69 64 76 74 72 70 68...

Page 178: ...M 3222126 36T 3 4W 15 SPL HYVO PM 7 92 8 37 11 35 2900010 37T 3 4W 15 SPL HYVO CM 3222125 37T 3 4W 15 SPL HYVO PM 2900011 38T 3 4W 15 SPL HYVO CM 3222108 39T 3 4W 15 SPL HYVO PM 3222099 40T 3 4W 15 SP...

Page 179: ...221115 70P 3 4W HYVO CHAIN 3221110 72P 3 4W HYVO CHAIN 3221109 74P 3 4W HYVO CHAIN 3221108 76P 3 4W HYVO CHAIN 3221158 90P 3 4W HYVO CHAIN 11 35 3221157 92P 3 4W HYVO CHAIN 3221156 94P 3 4W HYVO CHAIN...

Page 180: ...per out of the way of the chaincase 23 Remove the rear suspension 24 Carefully slide the driveshaft down so that it clears the chaincase and remove the driveshaft 25 Remove the track from the chassis...

Page 181: ...Torque to 19 21 ft lb 26 28 Nm 26 Release the parking brake 27 Adjust the chain tensioner by hand and back off 1 4 turn 28 Lock the adjuster lock nut 29 Install the chaincase cover and torque the cov...

Page 182: ...rque to 50 ft lb 22 Install cotter pin and bent the ends around the jackshaft end 23 Install the lower sprocket retaining bolt Torque to 19 ft lb 26Nm 24 Release the parking brake 25 Adjust the chain...

Page 183: ...ing B first then seal sleeve C on jackshaft C Seal D Brake Disk Minimum thickness 193 4 9mm E Retaining Ring included on jackshaft F Jackshaft G Bulkhead area H Bearing I Flangette J Belt K Spacer L W...

Page 184: ...t installation tool 4 With the jackshaft through the chaincase install the jackshaft alignment tool PN 2871535 and secure with the flat washer and castle nut 5 Tighten the castle nut securely to ensur...

Page 185: ...chaincase cover 2 6 Loosen the tensioner 3 7 Remove the lower sprocket bolt and washer 4 8 Shut off the fuel valve if so equipped 9 Remove the exhaust system See EXHAUST REMOVAL on page 3 16 10 Remove...

Page 186: ...dler wheels and bolts 13 Loosen jam nuts on adjustment bolts on both sides Back out adjustment bolts to allow rear idler assembly to come forward relieving track tension 14 Tighten idler wheel bolts s...

Page 187: ...d tip unit onto right side Notice direction of track rotation for reassembly The arrow in the photo at right indicates track bottom rear of unit 30 Remove front and rear carrier shafts 31 Remove suspe...

Page 188: ...ain from input and reverse shaft Inspect gear teeth for damage Inspect chain for worn cracked or broken link plates 11 Inspect dog gears and slots in mating gears closely Rounded edges will cause gear...

Page 189: ...gs Replace gear and mating gear if rounded chipped or broken 6 Inspect needle bearings for wear or cracks on cage Shiny spots on cage indicate wear and the bearing should be replaced Inspect shaft and...

Page 190: ...ive 8 Install nuts and finger tighten 9 Tip machine onto its left side 10 Replace O rings on input and output shafts Apply Polaris All Season Grease to drive shaft coupler splines 11 Reinstall transmi...

Page 191: ...nd tighten 26 Reinstall bumper plug 27 Reinstall and secure muffler 28 Install battery air box oil tank and coolant recovery bottle 29 Loosen rear idler bolts 30 Reinstall driven clutch and spacers on...

Page 192: ...8 20 FINAL DRIVE...

Page 193: ...INES 8 2 BRAKE FLUID REPLACEMENT BLEEDING 8 3 BRAKE LINE REPLACEMENT 8 3 BRAKE LIGHT SWITCH REPLACEMENT 8 4 CALIPER 8 4 CALIPER REMOVAL 8 4 CALIPER REPLACEMENT 8 5 CALIPER ASSEMBLY 8 5 BRAKE PAD REPLA...

Page 194: ...d allowed to function If the reservoir is overfilled or the diaphragm vent is plugged the expanding fluid may build pressure in the brake system and lead to brake failure GENERAL GUIDELINES Keep these...

Page 195: ...lockage 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 t...

Page 196: ...es not have any sharp bends when it is installed on the handlebar 14 Route the brake light switch in the harness correctly 15 Place the switch pack with the master cylinder onto the handle bar Two sma...

Page 197: ...D REPLACEMENT BLEEDING on page 9 3 7 On a liquid cooled caliper you will need to bleed the cooling system of any trapped air See COOLING SYSTEM BLEEDING on page 3 8 BRAKE PAD REPLACEMENT Brake pads ne...

Page 198: ...aliper housing 2 Install lifter ramp NOTE Ramp may be installed in any position 3 Install spring and arm with arm located in 2 00 position 4 Install lower guide bushing and both spring clips Place pad...

Page 199: ...IQ FRONT SUSPENSION 10 12 SPINDLE REMOVAL 10 14 SPINDLE ASSEMBLY 10 14 LOWER SPHERICAL BEARING REPLACEMENT 10 14 UPPER LOWER CONTROL ARM REMOVAL 10 14 UPPER LOWER CONTROL ARM INSTALLATION 10 14 STEERI...

Page 200: ...10 2 FRONT SUSPENSION STEERING FUSION IQ RMK 600 RMK Fusion 14 78...

Page 201: ...10 3 FRONT SUSPENSION STEERING EDGE RMK Apply Polaris All Season Grease to all zerks...

Page 202: ...10 4 FRONT SUSPENSION STEERING 42 5 EDGE Apply Polaris All Season Grease to all zerks...

Page 203: ...10 5 FRONT SUSPENSION STEERING WIDETRAK Apply Polaris All Season Grease to all zerks...

Page 204: ...stment For the best ride the spring preload should be as low as possible Set the preload to use the full travel of the ski shock with occasional light bottoming For the best ride the spring preload sh...

Page 205: ...2 75 Yes 7041552 9 09 80 10 75 283 1 89 2 75 Yes 7041553 11 46 60 11 33 283 1 89 2 75 Yes 7041554 9 09 80 10 75 283 1 89 2 75 Yes 7041571 10 40 70 10 50 263 1 89 2 53 No 7041573 9 28 160 10 331 1 89...

Page 206: ...n had 4 inches of spring travel the 100 in spring would bottom out while the 150 in spring would have one inch of travel remaining COMPRESSION DAMPING ADJUSTABLE SHOCKS Snowmobiles equipped with the I...

Page 207: ...nt screw should be located toward the inside of the suspension Access to the adjuster is not possible if installed differently SHOCK INFORMATION IFS SHOCK SPECIFICATIONS Rebuildable shock b IFP depth...

Page 208: ...41 COMPRESSION 1 125x 093 700x 012 700x 012 900x 008 1 000x 008 1 100x 008 1 250x 008 800x 008 1 100x 008 1 300x 006 Piston orifice 078 REBOUND 1 250x 008 700x 008 1 100x 010 1 000x 010 900x 012 800x...

Page 209: ...ION STEERING Table 10 7 IFS 7043082 COMPRESSION 800x 012 900x 012 1 000x 012 1 100x 010 1 250x 008 1 300x 010 900x 006 1 250x 008 1 300x 008 Piston orifice 093 REBOUND 1 250x 006 1 100x 010 1 000x 010...

Page 210: ...10 12 FRONT SUSPENSION STEERING IQ FRONT SUSPENSION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30...

Page 211: ...t Bushing 6 Upper A Arm pivot bolt 7 Pivot shaft 8 Flanged nut 40 ft lb 54Nm 9 Pivot Bushing 10 Upper control arm 11 Camber lock nut 12 Rod end bolt 13 Rod end 14 Flanged nut 35 ft lb 47Nm 15 Screw 16...

Page 212: ...s 5 9 in the control arm s 2 Replace the upper or lower control arm s into the bulkhead 3 Replace the upper or lower control arm bolts 1 6 Torque to 40 ft lb 54Nm NOTE The washer 2 is only located on...

Page 213: ...rod should rotate freely approximately 1 8 turn ROD END ENGAGEMENT Rod ends must engage the rod a minimum of 2x the thread diameter when adjustment is complete Example 4375 11mm rod end A X 2 minimum...

Page 214: ...ar through one spindle to the other spindle Measure the distance 2 from the top of the alignment bar to the top of the ski mount hole with the bushing s removed Record measurement 4 Remove the alignme...

Page 215: ...n HANDLEBAR CENTERING 1 Raise the front of the machine off the floor so that the spindles are off the floor 3 7 62cm 2 Insert the alignment bar through both ski bolt holes in each spindles 3 Adjust To...

Page 216: ...SKI STANCE ADJUSTMENT RMK ONLY WIDE SKI STANCE For maximum stability install both of the spacers to the outside of the spindle NARROW SKI STANCE For maximum maneurverability install both of the space...

Page 217: ...ADJUSTMENTS 11 11 M 10 FRA INITIAL SET UP REFERENCE 11 11 M 10 REAR SPRING PRELOAD 11 12 M 10 SKI PRESSURE 11 12 RAIL SLIDER 11 13 RAIL SLIDE WEAR LIMIT 11 13 RAIL SLIDE REMOVAL 11 13 RAIL SLIDER BRE...

Page 218: ...ent has a great affect on weight transfer Limiter straps only affect acceleration It is important to check track tension whenever limiter strap length is changed Front track shock spring preload also...

Page 219: ...by the free opening angle see TORSION SPRING ADJUSTMENT on page 11 5 REAR SUSPENSION ADJUSTMENTS AND SETTINGS REAR SUSPENSION ADJUSTMENT PROCEDURES It is a good idea to have customers break the suspen...

Page 220: ...E RMK EDGE 4 10cm EDGE M 10 3 5 8 13cm Widetrak 1 5 4cm 5 Adjust for the desired ride height by rotating the torsion spring cams located on the rear of the torsion spring If the rear suspension ride h...

Page 221: ...o avoid improper Hi Fax and track wear Lengthening the straps decreases ski pressure under acceleration Shortening the straps increases ski pressure under acceleration RMK Set up Recommendations for O...

Page 222: ...ches D COIL ID inches E OF COILS inches F DEGREES OPEN ANGLE G SPRING WIDTH inches H 7042068 LH 7042069 RH 359 16 5 4 5 1 95 2 01 8 64 47 3 75 7041911 LH 7041912 RH 347 16 5 4 5 1 82 1 88 7 75 90 3 49...

Page 223: ...8 RH 405 16 5 4 5 2 225 6 75 90 3 55 7041940 LH 7041941 RH 405 16 5 4 5 2 232 6 71 77 3 55 7043070 LH 7043071 RH 347 14 75 4 5 1 80 1 84 6 72 80 3 20 7042157 LH 7042158 RH 359 15 625 3 75 1 82 1 84 6...

Page 224: ...5 6 72 80 3 40 7043130 RH 7043131 LH 359 14 75 4 5 2 5 5 72 80 3 75 Table 11 1 Square Torsion Springs SPRING PN last 3 digits A WIRE DIAMETER inches B LEG 1 inches C LEG 2 inches D COIL ID inches E OF...

Page 225: ...sleds 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...

Page 226: ...er X Over Tube Length Adjustment IMPORTANT The M 10 rear suspension has been designed to be very sensitive to rider weight Changes in rider weight of 25 lbs or more may require appropriate changes in...

Page 227: ...adjust loosen the hex bolts A attaching the rear lower shock cross shaft to the rail beam 3 Using a 9 16 wrench loosen the jam nuts B on the preload bolts 4 Adjust the preload bolts C to the desired F...

Page 228: ...an removed for half step adjustments Re tighten the pinch bolts 4 There are also two front arm mounting holes in the slide rail that can adjust ski pressure The lower hole A increases ski pressure whi...

Page 229: ...BREAK IN After installing new rail sliders they must be broke in for longer life and better wear patterns When performing the breaking in procedure ride the sled on a surface that has adequate snow c...

Page 230: ...3 34 49 1 250 b 1500736 300 7042335 Arvin 12 51 8 92 3 59 49 4 77 t 1700182 200 7043048 Arvin 12 49 8 92 3 58 43 N A N A N A 7043142 Fox 12 51 8 92 3 59 49 840 b 1500713 200 Table 11 6 Rear Track Shoc...

Page 231: ...x 010 900x 010 800x 010 700x 010 625x 065 ADJUSTER 1 10x 010 1 00x 012 1 00x 012 700x 010 875x 090 Table 11 8 FTS 7041975 COMPRESSION 800x 008 900x 008 1 000x 008 1 100x 010 1 300x 008 1 000x 006 1 30...

Page 232: ...015 1 300x 015 1 300x 015 Piston orifice 093 REBOUND 1 250x 010 1 100x 008 900x 008 800x 008 620x 093 Table 11 12 FTS 7043123 COMPRESSION 1 125x 093 1 100x 006 1 300x 015 1 000x 004 1 300x 015 1 300x...

Page 233: ...800x 015 700x 015 620x 093 Table 11 15 RTS 7042129 COMPRESSION 1 125x 093 900x 010 1 000x 010 1 100x 010 1 250x 012 1 000x 006 1 300x 010 Piston orifice 063 REBOUND 1 250x 015 1 250x 012 1 100x 012 1...

Page 234: ...x 008 1 100x 010 1 000x 010 900x 010 800x 010 700x 010 625x 065 ADJUSTER 1 100x 025 1 000x 015 1 000x 015 700x 010 875x 090 Table 11 18 RTS 7042216 COMPRESSION 1 125x 093 900x 008 1 300x 012 1 300x 01...

Page 235: ...300x 006 1 300x 008 Piston orifice 055 REBOUND 1 250x 012 1 100x 010 1 125x 093 620x 093 Table 11 20 RTS 7043177 COMPRESSION 1 125x 093 900x 010 1 000x 010 1 100x 012 1 100x 010 1 100x 008 1 000x 006...

Page 236: ...unt of fluid that is forced by as the piston travels through its motion Below is a chart that has the part numbers of these valves proceeding the part number is the size of the washer out side diamete...

Page 237: ...1700141 1 300 1700084 0 700 0 012 1700090 0 800 1700096 0 900 1700127 1 000 1700132 1 100 1700137 1 250 1700142 1 300 1700085 0 700 0 015 1700091 0 800 1700120 0 900 1700128 1 000 1700133 1 100 17001...

Page 238: ...the shaft Table 11 23 PART NUMBER SIZE THICKNESS 1800051 700 006 1800075 800 1800076 900 1800077 1 000 1800078 1 100 1800079 1 200 1800080 1 300 1800081 700 008 1800082 800 1800083 900 1800084 1 000 1...

Page 239: ...echarging Kit 2201639 Shock Shaft Seal Protector 1 2 Diameter 2201640 Shock Shaft Seal Protector 5 8 Diameter 2870623 Shock Absorber Spring Compression Tool 2870803 Shock Spring Pre Load Adjustment To...

Page 240: ...urized gas and shock oil could eject the valve assembly from the cylinder resulting in bodily injury 11 Using a slotted screwdriver remove the pressure valve assembly from the lower end mount Account...

Page 241: ...e floating wear band and O ring and install the floating piston into the top of the shock body positioning it below the counterbore 5 Using the tool as a handle push the floating piston down into the...

Page 242: ...a clean lint free towel There are many pieces to the piston assembly and the assembly order of these pieces is critical to the proper performance of your shock This step ensures that the proper order...

Page 243: ...n the IFP bleed screw REAR SUSPENSION TROUBLESHOOTING Table 11 27 PROBLEM SOLUTION Rear suspension bottoms too easily Increase rear shock compression valving by turning screw clockwise if equipped wit...

Page 244: ...11 28 REAR SUSPENSION...

Page 245: ...E REMOVAL INSTALLATION 12 4 IQ RMK SEAT REMOVAL INSTALLATION 12 4 IQ RMK SEAT BASE REMOVAL INSTALLATION 12 5 IQ FUEL TANK REMOVAL 12 5 IQ FUEL TANK INSTALLATION 12 5 EDGE SEAT REMOVAL INSTALLATION 12...

Page 246: ...STALLATION 1 Remove the intake from the under side of the hood C 2 Disconnect the MFD harness from the gauge 3 Remove the MFD screws D 4 Remove the MFD E 5 Installation is the reverse of removal BUMPE...

Page 247: ...supply fitting at the bottom of the oil tank 2 Attach the cross shaft supply line to the fitting on the right hand side 3 Line up the centering shafts with the chassis centering bracket 4 Install the...

Page 248: ...hold the seat base on the tunnel 2 Remove the seat B 3 Installation is reverse order of removal Torque the seat fasteners to 8 12 ft lb 11 16Nm IQ RMK SEAT REMOVAL INSTALLATION 1 RMK seats have a sma...

Page 249: ...that hold the seat base on the tunnel 7 Remove the console see page See IQ CONSOLE REMOVAL INSTALLATION on page 6 8 Remove the fuel line clips See FUEL CLIP REMOVAL on page 3 9 Remove the fuel lines f...

Page 250: ...he back of the seat area only after a satisfactory fit is obtained IQ SEAT COVER REPLACEMENT CONSOLE IQ CONSOLE REMOVAL INSTALLATION 1 Place the adjustable steering in the center 2 Remove the two T25...

Page 251: ...5 Loosen the narrow clamps E 6 Pull the boost box C forward from the boots F and remove it from the machine IQ 700 900 AIR INTAKE INSTALLATION 1 If the boost box was removed install the intake air sen...

Page 252: ...everse order of removal SKIS SKI REMOVAL 1 Securely lift the front of the machine off the ground 2 Remove the ski to spindle bolt and washers 3 Remove ski bushing and ski bumper SKI INSTALLATION 1 Pla...

Page 253: ...ad these instructions and check to be sure all parts and tools are accounted for You will need the following items Squeegee Cheese Cloth or a non abrasive cloth Paper Shop Towels Hair Drier or Heat Gu...

Page 254: ...ety glasses Spray the cleaner on the adhesive and let set for 15 20 seconds Using a squeegee wipe the adhesive from the hood and deposit it in a paper shop towel You may have to repeat this process se...

Page 255: ...ith the chrome exposed the chrome will be damaged 5 When finished installing the decal carefully remove the decal mask at a 180_ angle 6 Peel the backing off and install the urocals in the appropriate...

Page 256: ...12 12 CHASSIS HOOD...

Page 257: ...13 8 VOLTAGE 13 8 UNREGULATED VOLTAGE 13 8 REGULATED VOLTAGE 13 9 SHORT CIRCUIT CURRENT AC AMP TEST 13 9 ALTERNATORS 13 9 ELECTRICAL TESTING 13 10 HEADLIGHT BULB FILIMENT CONTINUITY TEST 13 10 HI LOW...

Page 258: ...3 22 STATOR 13 23 IGNITION COIL 13 24 EXHAUST VALVE SOLINOID 13 24 REGULATOR RECTIFIER 13 26 CAPACITOR 13 27 CHASSIS RELAY 13 27 CHASSIS GROUND 13 27 MAIN HARNESS CALLOUTS 13 28 GENERAL ELECTRICAL ITE...

Page 259: ...g position and mark the flywheel at this point follow procedure outlined in this chapter 3 Connect an accurate tachometer and a good quality timing light to the engine according to manufacturer s inst...

Page 260: ...2 1 7969 0 0707 1 7406 0 0685 2 1984 0 0866 18 1 3552 0 0534 1 7195 0 0677 1 8526 0 0729 2 0117 0 0792 1 9487 0 0767 2 4612 0 0969 19 1 5077 0 0594 1 9130 0 0753 2 0611 0 0811 2 2380 0 0881 2 1681 0 0...

Page 261: ...ty As the battery goes through the charge discharge cycle the electrolyte goes from a heavy more acidic state at full charge to a light more water state when discharged The hydrometer can measure stat...

Page 262: ...arger no larger than 1 10 of the battery s amp hr rating and for as many hours as needed to raise the specific gravity to 1 270 per cell or greater STARTER SYSTEM DYNAMIC TESTING OF THE ELECTRIC START...

Page 263: ...ed white of the ignition switch with switch on start Repair or replace any defective parts YES Reconnect solenoid connect tester black lead to battery positive terminal and red tester lead to solenoid...

Page 264: ...tact cleaner and or a non metallic grit sandpaper Replace brush assembly when worn to 5 16 8 cm or less STARTER HOUSING AND FIELD COIL INSPECTION 1 Using a digital multitester measure resistance betwe...

Page 265: ...pinion spring stopper and snap ring STARTER SOLINOID BENCH TEST The only test which can be done on the bench is the pull in coil resistance which should be 3 4 ohms STARTER INSTALLATION 1 Position st...

Page 266: ...ow wire from the regulator Carefully observe the voltage reading Do not allow voltage to increase above 14 0 volts 5 Slowly increase RPM Voltage above 12 volts at 2500 3000 and a bright headlight indi...

Page 267: ...SS TROUBLESHOOTING 1 Remove the taillight lens 2 Remove the two taillight bulbs and the brake light bulb 3 Separate the seat harness from the main harness by unplugging the connector at the right rear...

Page 268: ...e engine fail safe is turned on at high TPS input and high temperatures At room temperature 68_ F 20_ C the thermistor should read 2189 to 2675 ohms See chart below for other temperature resistances S...

Page 269: ...ce is adjusted properly the switch assembly must be replaced TEST 2 CLOSED CIRCUIT OFF The two speed control switches must make a complete circuit to kill the engine To check the switches pull the thr...

Page 270: ...ator Recheck the resistances look for pinched or bare harness wires or replace the coil Table 13 8 Incorrect Timing Advanced Retard Follow the engine timing procedure for checking running timing at re...

Page 271: ...e 13 9 IQ Blink Codes SENSOR LED EXPLINATION Throttle Sensor 1 Sensor signal is below 0 7 volts or above 4 39 volts Water Temperature Sensor 2 Sensor signal is below 0 1 volts or above 4 8 volts Air T...

Page 272: ...attery 3 Remove the connector from the TPS 4 Install test harness connector on TPS 5 Insert red voltmeter lead into yellow terminal and black lead to black terminal Slowly open throttle and check for...

Page 273: ...example the TEMP light will come on at idle under 2000 RPM 0 throttle and coolant temperature of 230_F 110_C Timing retard initiates at 176_F and a TPS of over 80 100 For more severe conditions the en...

Page 274: ...detonation by compensation of timing and fuel This results in decreased engine RPM and performance This sensor detects engine knock by converting pressure pulses from the engine and converting the pul...

Page 275: ...ct detonation DET failure will add 10 injector duration and the ECU will use other sensors The rider will experience a loss in power The sensor will need to be reconnected or repaired to once again ac...

Page 276: ...ion sensor A picks up all 5 flywheel teeth C The 2 tooth crank position sensor B picks up 2 off set flywheel teeth D Both crank position sensors will have a gap E to the flywheel pick up of 035 90mm T...

Page 277: ...ures the speed of the drive shaft to give you the speed of the track Table 13 15 Speed Sensor Testing PIN COLOR ITEM VALUE A Red Gauge Power 5 volts powered bu gauge B White Speed Signal to Gauge Chec...

Page 278: ...Temp 7 Green White PTO Injector part load ground 24 White Black Exhaust temp sensor 8 Yellow MAG Injector full load ground 25 Green Blue EV Solenoid ground 9 Yellow White MAG Injector part load groun...

Page 279: ...External power ground 6 23 Black PTO Ignition coil ground 7 Pink Digital Wrench 24 Black MAG Ignition coil ground 8 Orange External Power 25 Brown Exciter Coil ground 9 White PTO Ignition coil 26 Red...

Page 280: ...Charge coil YELLOW Charge coil CRANK POSITION SENSOR CPS GRN GRN WHITE Crank Position Sensor 5 Tooth Ignition timing machine will not run with out Resistance between and Green Green White 190 W 15 RE...

Page 281: ...e solenoid Fail safe mode will keep the valves closed and the unit will have no top end This solenoid valve type a 2 way and is normally closed Ignition Coil Table 13 19 Ignition Coils PRIMARY COIL 1...

Page 282: ...13 26 ELECTRICAL...

Page 283: ...tor charge coils to the Reg Rec for converting it to DC voltage ECU ORANGE Provides DC power to ECU for low voltage situations CHASSIS BROWN Provides DC power to the chassis RED From To To Stator ECU...

Page 284: ...close at a set RPM when the system can support the chassis load and open when engine RPM drops past a calibrated histories or 700 RPM Voltage Boost kicks in at 700 RPM the relay opens the stator power...

Page 285: ...er shaft B and ECU sends a signal to the MFD when the level get to the point where you need to add more oil The oil level signal is measured in resistance FULL is open and 10 at lower level Table 13 2...

Page 286: ...ne will now automatically change direction form reverse to forward and the reverse light on the instrument panel will stop flashing NOTE When servicing clutches ensure that the vehicle is in forward g...

Page 287: ...ehicle is in the forward gear DIGITAL WRENCH CONNECTIONS DIAGNOSTIC PORT The diagnostic port is used with the Digital Wrench diagnostic program The communication cable hooks to this port to communicat...

Page 288: ...13 32 ELECTRICAL...

Page 289: ...14 1 WIRE DIAGRAM 2006 600 FUSION HO HOOD...

Page 290: ...14 2 WIRE DIAGRAM 2006 HO RMK HOOD...

Page 291: ...14 3 WIRE DIAGRAM 600 HO FUSION RMK CHASSIS...

Page 292: ...14 4 WIRE DIAGRAM 600 HO FUSION RMK CHASSIS CALL OUTS...

Page 293: ...14 5 WIRE DIAGRAM 700 900 ENGINE...

Page 294: ...14 6 WIRE DIAGRAM 700 900 ENGINE AND ENGINE CALL OUTS...

Page 295: ...14 7 WIRE DIAGRAM 700 900 CHASSIS...

Page 296: ...MP 20 BRN R W BRN SPLICE SAVER IGNITION 65 R REGULATOR CHASSIS RELAY 21 BRN REGULATOR POWER POINT 66 R REGULATOR FUEL PUMP 22 BRN R W BRN SPLICE SAVER LEFT HANDLEBAR 67 23 R REGULATOR CHASSIS RELAY 68...

Page 297: ...14 9 WIRE DIAGRAM 340 550 FUJI FAN ENGINE CHASSIS...

Page 298: ...14 10 WIRE DIAGRAM 500 FUJI ENGINE CHASSIS...

Page 299: ...14 11 WIRE DIAGRAM 500 600 IBERTY ENGINE CHASSIS...

Page 300: ...14 12 WIRE DIAGRAM WIDETRAK ENGINE CHASSIS...

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