Polaris Supersport 2007 Service Manual Download Page 134 | Manualshive

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5.35

Engine Systems

5

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

©2011 Polaris Sales Inc.

Crankcase Assembly

Disassembly / Assembly Process

1.

Remove the recoil/waterpump housing assembly, oil
pump, flywheel, coils, and cylinder from the crankcase
assembly. Discard all gaskets and o rings.

2.

Remove engine mount plate fasteners from the lower
crankcase.

3.

Remove the crankcase fasteners. Thoroughly clean
the fasteners to remove any locking agents.

4.

Discard both crankshaft seals.

5.

Thoroughly clean the two crankcase mating surfaces
and the inner crankcases. Inspect for cracks. Verify
both crankcase drain screws are securely installed.

6.

Apply a thin bead of Three Bond 1215 to both
crankcase mating surfaces.

7.

Lubricate the oil pump drive gear with two-stroke
engine oil and install into crankcase.

8.

Install crankshaft and two new crankcase seals. Verify
seal lips face the inside of the engine. Ensure
crankshaft retaining ring and bearing locating pins are
seated correctly before installing upper crankcase.

9.

Torque crankcase fasteners to specified torque and
sequence outlined at beginning of chapter.

CRANKCASE SEAL

IMPULSE HOSE FITTING

CRANKCASE SEAL

UPPER CRANKCASE

LOWER CRANKCASE

CRANKCASE DRAIN SCREW

Fastener

Torque

Note

Crankcase

8mm
16 - 18 ft.lbs.
(23 - 25 Nm)
10mm
23 - 26 ft.lbs.
(32 - 35 Nm)

Apply Three Bond
1215 to
crankcase mating
surfaces.

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Summary of Contents for Supersport 2007

Page 1: ...s outlined in this service manual contact an authorized dealer for service We value your input and appreciate any assistance you can provide in helping make these publications more useful Please provide any feedback you may have regarding this manual Authorized dealers can submit feedback using Ask Polaris Click on Ask Polaris and then click on Publications Question Consumers please provide your f...

Page 2: ...operty damage NOTE NOTE provides key information by clarifying instructions IMPORTANT IMPORTANT provides key reminders during disassembly assembly and inspection of components 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 Trade...

Page 3: ...rvice Manual Chapters Model Specifications 1 General Information 2 Maintenance 3 Fuel Systems 4 Engine Systems 5 Final Drive Brake Systems 6 PVT System 7 Front Rear Suspensions 8 Chassis 9 Electrical Systems 10 Wiring Schematics 11 ...

Page 4: ...AIL TOURING DELUXE 1 8 2007 TRAIL RMK 1 10 2007 WIDETRAK LX 1 12 2007 500 XCSP 1 14 2008 340 1 16 2008 340 TRANSPORT 1 18 2008 SUPERSPORT 550 LX 1 20 2008 TRAIL TOURING DELUXE 1 22 2008 TRAIL RMK 1 24 2008 WIDETRAK LX 1 26 2009 550 TRANSPORT 1 28 2009 TRAIL TOURING 1 30 2009 TRAIL RMK 1 32 2009 WIDETRAK LX 1 34 2010 TRAIL RMK 1 36 2010 TRAIL TOURING 1 38 2010 WIDETRAK LX 1 40 2011 WIDETRAK LX 1 42...

Page 5: ... Non Oxygenated 89 Oxygenated Carburetor Jetting Altitude Meters feet Ambient Temperature 25 F 35 C 30 F to 10 F 34 C to 23 C 15 F to 5 F 26 C to 15 C 0 F to 20 F 18 C to 7 C 15 F to 35 F 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 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 400...

Page 6: ...PM Spark Plug Gap in mm 028 70 Spark Plug NGK BR8ES CDI Marking CU7245 Flywheel Marking FP9313 Track Width Inches cm 15 38 Length Inches cm 121 307 Lug Height Inches cm 66 1 7 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 EDGE 42 5 Shocks Arvin Nitrex Gas Bag IFS Spring Rate lbs in N mm 100 1 79 Spring Pre lo...

Page 7: ...n Oxygenated 89 Oxygenated Carburetor Jetting Altitude Meters feet Ambient Temperature 25 F 35 C 30 F to 10 F 34 C to 23 C 15 F to 5 F 26 C to 15 C 0 F to 20 F 18 C to 7 C 15 F to 35 F 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 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 6...

Page 8: ... Timing 26 5_ 3000 RPM Spark Plug Gap in mm 028 70 Spark Plug NGK BR8ES CDI Marking CU7245 Flywheel Marking FP9313 Track Width Inches cm 15 38 Length Inches cm 136 345 Lug Height Inches cm 1 2 5 Track tension sag in cm with 10 lbs 4 54kg placed 16 in 40cm ahead of rear idler shaft 1 1 8 1 3 8 2 9 3 5cm Front Suspension Suspension Type EDGE 42 5 Shocks Arvin Nitrex Gas Bag IFS Spring Rate lbs in N ...

Page 9: ...ygenated Carburetor Jetting Altitude Meters feet Ambient Temperature 25 F 35 C 30 F to 10 F 34 C to 23 C 15 F to 5 F 26 C to 15 C 0 F to 20 F 18 C to 7 C 15 F to 35 F 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 270 4 260 4 250 4 240 3 230 3 220 3 210 2 200 1 600 1200 2000 4000 260 4 250 4 240 3 230 3 220 3 220 2 210 2 200 1 1200 1800 4000 6000 250 4 240 3 23...

Page 10: ...lug NGK BR9ES CDI Marking EC55PM100 110 Flywheel Marking FP6318 Track Width Inches cm 15 38 Length Inches cm 121 307 Lug Height Inches cm 82 2 08 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 EDGE 42 5 Shocks Arvin Nitrex Gas Bag IFS Spring Rate lbs in N mm 100 1 79 Spring Pre load Inches cm 625 15 9 Front Ve...

Page 11: ...arburetor Jetting Altitude Meters feet Ambient Temperature 25 F 35 C 30 F to 10 F 34 C to 23 C 15 F to 5 F 26 C to 15 C 0 F to 20 F 18 C to 7 C 15 F to 35 F 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 270 4 260 4 250 4 240 3 230 3 220 3 210 2 200 1 600 1200 2000 4000 260 4 250 4 240 3 230 3 220 3 220 2 210 2 200 1 1200 1800 4000 6000 250 4 240 3 230 3 220 3 ...

Page 12: ...g Gap in mm 028 70 Spark Plug NGK BR9ES CDI Marking EC55PM100 110 Flywheel Marking FP6318 Track Width Inches cm 15 38 Length Inches cm 136 345 4 Lug Height Inches cm 1 0 2 5 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 EDGE 42 5 Shocks Arvin Nitrex Compression Adjustable IFS Spring Rate lbs in N mm 90 18...

Page 13: ...uretor Jetting Altitude Meters feet Ambient Temperature 25 F 35 C 30 F to 10 F 34 C to 23 C 15 F to 5 F 26 C to 15 C 0 F to 20 F 18 C to 7 C 15 F to 35 F 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 270 4 260 4 250 4 240 3 230 3 220 3 210 2 200 1 600 1200 2000 4000 260 4 250 4 240 3 230 3 220 3 220 2 210 2 200 1 1200 1800 4000 6000 250 4 240 3 230 3 220 3 210...

Page 14: ... NGK BR9ES CDI Marking EC55PM100 110 Flywheel Marking FP6318 Track Width Inches cm 15 38 Length Inches cm 136 345 Lug Height Inches cm 1 25 3 175 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 EDGE RMK 41 Shocks Arvin Nitrex Gas Bag IFS Spring Rate lbs in N mm 80 14 Spring Length Inches cm 9 75 24 8 Front Vert...

Page 15: ...ated Carburetor Jetting Altitude Meters feet Ambient Temperature 25 F 35 C 30 F to 10 F 34 C to 23 C 15 F to 5 F 26 C to 15 C 0 F to 20 F 18 C to 7 C 15 F to 35 F 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 210 2 200 2 195 2 190 2 185 2 175 2 170 2 170 1 600 1200 2000 4000 195 2 185 2 180 2 175 2 170 2 165 2 155 1 155 1 1200 1800 4000 6000 185 2 175 2 170 2 ...

Page 16: ...5 Vdc 200 Ignition Timing 28_ 3000 RPM Spark Plug Gap in mm 028 70 Spark Plug Champion RN3C CDI Marking IU2212 Flywheel Marking FP5536 Track Width Inches cm 20 51 Length Inches cm 156 396 Lug Height Inches cm 1 0 2 5 Track tension sag in cm with 10 lbs 4 54kg placed 16 in 40cm ahead of rear idler shaft 3 4 1 1 9 2 5cm Front Suspension Suspension Type Widetrak Shocks Arvin Nitrex Gas Bag IFS Spring...

Page 17: ... Oxygenated Carburetor Jetting Altitude Meters feet Ambient Temperature 25 F 35 C 30 F to 10 F 34 C to 23 C 15 F to 5 F 26 C to 15 C 0 F to 20 F 18 C to 7 C 15 F to 35 F 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 3 410 3 400 2 390 2 380 2 360 2 350 1 600 1200 2000 4000 420 3 400 2 390 2 370 2 360 2 350 2 330 1 320 1 1200 1800 4000 6000 390 2 380 2...

Page 18: ...ug Gap in mm 027 70 Spark Plug Champion RN57YCC CDI Marking 4010829 Flywheel Marking 4010677 Track Width Inches cm 15 38 Length Inches cm 121 307 Lug Height Inches cm 91 2 3 Euro 1 25 3 175 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 EDGE 42 5 Shocks Arvin Nitrex Gas Bag IFS Spring Rate lbs in N mm 68 160 1...

Page 19: ...enated 89 Oxygenated Carburetor Jetting Altitude Meters feet Ambient Temperature 25 F 35 C 30 F to 10 F 34 C to 23 C 15 F to 5 F 26 C to 15 C 0 F to 20 F 18 C to 7 C 15 F to 35 F 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 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 16...

Page 20: ...PM Spark Plug Gap in mm 028 70 Spark Plug NGK BR8ES CDI Marking CU7245 Flywheel Marking FP9313 Track Width Inches cm 15 38 Length Inches cm 121 307 Lug Height Inches cm 82 2 08 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 EDGE 42 5 Shocks Arvin Nitrex Gas Bag IFS Spring Rate lbs in N mm 100 1 79 Spring Pre l...

Page 21: ...d 87 Non Oxygenated 89 Oxygenated Carburetor Jetting Altitude Meters feet Ambient Temperature 25 F 35 C 30 F to 10 F 34 C to 23 C 15 F to 5 F 26 C to 15 C 0 F to 20 F 18 C to 7 C 15 F to 35 F 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 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...

Page 22: ...iming 26 5_ 3000 RPM Spark Plug Gap in mm 028 70 Spark Plug NGK BR8ES CDI Marking CU7245 Flywheel Marking FP9313 Track Width Inches cm 15 38 Length Inches cm 136 345 Lug Height Inches cm 1 25 3 175 Track tension sag in cm with 10 lbs 4 54kg placed 16 in 40cm ahead of rear idler shaft 1 1 8 1 3 8 2 9 3 5cm Front Suspension Suspension Type EDGE 42 5 Shocks Arvin Nitrex Gas Bag IFS Spring Rate lbs in...

Page 23: ...89 Oxygenated Carburetor Jetting Altitude Meters feet Ambient Temperature 25 F 35 C 30 F to 10 F 34 C to 23 C 15 F to 5 F 26 C to 15 C 0 F to 20 F 18 C to 7 C 15 F to 35 F 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 270 4 260 4 250 4 240 4 230 3 220 3 210 2 200 1 600 1200 2000 4000 260 4 250 4 240 3 230 3 220 3 220 2 210 2 200 1 1200 1800 4000 6000 250 4 240...

Page 24: ...lug NGK BR9ES CDI Marking EC55PM100 110 Flywheel Marking FP6318 Track Width Inches cm 15 38 Length Inches cm 121 307 Lug Height Inches cm 82 2 08 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 EDGE 42 5 Shocks Arvin Nitrex Gas Bag IFS Spring Rate lbs in N mm 100 1 79 Spring Pre load Inches cm 625 15 9 Front Ve...

Page 25: ...89 Oxygenated Carburetor Jetting Altitude Meters feet Ambient Temperature 25 F 35 C 30 F to 10 F 34 C to 23 C 15 F to 5 F 26 C to 15 C 0 F to 20 F 18 C to 7 C 15 F to 35 F 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 270 4 260 4 250 4 240 4 230 3 220 3 210 2 200 1 600 1200 2000 4000 260 4 250 4 240 3 230 3 220 3 220 2 210 2 200 1 1200 1800 4000 6000 250 4 240...

Page 26: ...Plug Gap in mm 028 70 Spark Plug NGK BR9ES CDI Marking EC55PM100 110 Flywheel Marking FP6318 Track Width Inches cm 15 38 Length Inches cm 136 345 4 Lug Height Inches cm 1 0 2 5 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 EDGE 42 5 Shocks Arvin Nitrex Compression Adjustable IFS Spring Rate lbs in N mm 10...

Page 27: ...89 Oxygenated Carburetor Jetting Altitude Meters feet Ambient Temperature 25 F 35 C 30 F to 10 F 34 C to 23 C 15 F to 5 F 26 C to 15 C 0 F to 20 F 18 C to 7 C 15 F to 35 F 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 270 4 260 4 250 4 240 4 230 3 220 3 210 2 200 1 600 1200 2000 4000 260 4 250 4 240 3 230 3 220 3 220 2 210 2 200 1 1200 1800 4000 6000 250 4 240...

Page 28: ...R9ES CDI Marking EC55PM100 110 Flywheel Marking FP6318 Track Width Inches cm 15 38 Length Inches cm 136 345 Lug Height Inches cm 1 25 3 175 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 EDGE RMK 41 Shocks Arvin Nitrex Gas Bag IFS Spring Rate lbs in N mm 100 1 79 Spring Pre load Inches cm 625 15 9 Front Vertic...

Page 29: ...ated Carburetor Jetting Altitude Meters feet Ambient Temperature 25 F 35 C 30 F to 10 F 34 C to 23 C 15 F to 5 F 26 C to 15 C 0 F to 20 F 18 C to 7 C 15 F to 35 F 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 210 2 200 2 195 2 190 2 185 2 175 2 170 2 170 1 600 1200 2000 4000 195 2 185 2 180 2 175 2 170 2 165 2 155 1 155 1 1200 1800 4000 6000 185 2 175 2 170 2 ...

Page 30: ...5 Vdc 200 Ignition Timing 27_ 3000 RPM Spark Plug Gap in mm 028 70 Spark Plug Champion RN3C CDI Marking IU2212 Flywheel Marking FP5536 Track Width Inches cm 20 51 Length Inches cm 156 396 Lug Height Inches cm 1 0 2 5 Track tension sag in cm with 10 lbs 4 54kg placed 16 in 40cm ahead of rear idler shaft 3 4 1 1 9 2 5cm Front Suspension Suspension Type Widetrak Shocks Arvin Nitrex Gas Bag IFS Spring...

Page 31: ...ng Altitude Meters feet Ambient Temperature 25 F 35 C 30 F to 10 F 34 C to 23 C 15 F to 5 F 26 C to 15 C 0 F to 20 F 18 C to 7 C 15 F to 35 F 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 270 4 260 4 250 4 240 4 230 3 220 3 210 2 200 1 600 1200 2000 4000 260 4 250 4 240 3 230 3 220 3 220 2 210 2 200 1 1200 1800 4000 6000 250 4 240 3 230 3 220 3 210 2 210 2 200...

Page 32: ...ug Gap in mm 028 70 Spark Plug NGK BR9ES CDI Marking EC55PM100 110 Flywheel Marking FP6318 Track Width Inches cm 15 38 Length Inches cm 136 345 4 Lug Height Inches cm 1 25 3 175 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 EDGE 42 5 Shocks Arvin Nitrex Compression Adjustable IFS Spring Rate lbs in N mm 1...

Page 33: ...Jetting Altitude Meters feet Ambient Temperature 25 F 35 C 30 F to 10 F 34 C to 23 C 15 F to 5 F 26 C to 15 C 0 F to 20 F 18 C to 7 C 15 F to 35 F 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 270 4 260 4 250 4 240 4 230 3 220 3 210 2 200 1 600 1200 2000 4000 260 4 250 4 240 3 230 3 220 3 220 2 210 2 200 1 1200 1800 4000 6000 250 4 240 3 230 3 220 3 210 2 210 ...

Page 34: ...Plug Gap in mm 028 70 Spark Plug NGK BR9ES CDI Marking EC55PM100 110 Flywheel Marking FP6318 Track Width Inches cm 15 38 Length Inches cm 136 345 4 Lug Height Inches cm 1 0 2 5 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 EDGE 42 5 Shocks Arvin Nitrex Compression Adjustable IFS Spring Rate lbs in N mm 10...

Page 35: ...rburetor Jetting Altitude Meters feet Ambient Temperature 25 F 35 C 30 F to 10 F 34 C to 23 C 15 F to 5 F 26 C to 15 C 0 F to 20 F 18 C to 7 C 15 F to 35 F 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 270 4 260 4 250 4 240 4 230 3 220 3 210 2 200 1 600 1200 2000 4000 260 4 250 4 240 3 230 3 220 3 220 2 210 2 200 1 1200 1800 4000 6000 250 4 240 3 230 3 220 3 2...

Page 36: ...9ES CDI Marking EC55PM100 110 Flywheel Marking FP6318 Track Width Inches cm 15 38 Length Inches cm 136 345 Lug Height Inches cm 1 25 3 175 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 EDGE RMK 41 Shocks Arvin Nitrex Gas Bag IFS Spring Rate lbs in N mm 100 1 79 Spring Pre load Inches cm 625 15 9 Front Vertica...

Page 37: ...ng Altitude Meters feet Ambient Temperature 25 F 35 C 30 F to 10 F 34 C to 23 C 15 F to 5 F 26 C to 15 C 0 F to 20 F 18 C to 7 C 15 F to 35 F 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 210 2 200 2 195 2 190 2 185 2 175 2 170 2 170 1 600 1200 2000 4000 195 2 185 2 180 2 175 2 170 2 165 2 155 1 155 1 1200 1800 4000 6000 185 2 175 2 170 2 165 2 160 2 155 1 145...

Page 38: ... 5 Vdc 200 Ignition Timing 27_ 3000 RPM Spark Plug Gap in mm 028 70 Spark Plug Champion RN3C CDI Marking IU2212 Flywheel Marking FP5536 Track Width Inches cm 20 51 Length Inches cm 156 396 Lug Height Inches cm 1 0 2 5 Track tension sag in cm with 10 lbs 4 54kg placed 16 in 40cm ahead of rear idler shaft 3 4 1 1 9 2 5cm Front Suspension Suspension Type Widetrak Shocks Arvin Nitrex Gas Bag IFS Sprin...

Page 39: ...Altitude Meters feet Ambient Temperature 25 F 35 C 30 F to 10 F 34 C to 23 C 15 F to 5 F 26 C to 15 C 0 F to 20 F 18 C to 7 C 15 F to 35 F 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 270 4 260 4 250 4 240 4 230 3 220 3 210 2 200 1 600 1200 2000 4000 260 4 250 4 240 3 230 3 220 3 220 2 210 2 200 1 1200 1800 4000 6000 250 4 240 3 230 3 220 3 210 2 210 2 200 2 ...

Page 40: ...9ES CDI Marking EC55PM100 110 Flywheel Marking FP6318 Track Width Inches cm 15 38 Length Inches cm 136 345 Lug Height Inches cm 1 25 3 175 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 EDGE RMK 41 Shocks Arvin Nitrex Gas Bag IFS Spring Rate lbs in N mm 100 1 79 Spring Pre load Inches cm 625 15 9 Front Vertica...

Page 41: ... Altitude Meters feet Ambient Temperature 25 F 35 C 30 F to 10 F 34 C to 23 C 15 F to 5 F 26 C to 15 C 0 F to 20 F 18 C to 7 C 15 F to 35 F 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 270 4 260 4 250 4 240 4 230 3 220 3 210 2 200 1 600 1200 2000 4000 260 4 250 4 240 3 230 3 220 3 220 2 210 2 200 1 1200 1800 4000 6000 250 4 240 3 230 3 220 3 210 2 210 2 200 2...

Page 42: ...Plug Gap in mm 028 70 Spark Plug NGK BR9ES CDI Marking EC55PM100 110 Flywheel Marking FP6318 Track Width Inches cm 15 38 Length Inches cm 136 345 4 Lug Height Inches cm 1 0 2 5 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 EDGE 42 5 Shocks Arvin Nitrex Compression Adjustable IFS Spring Rate lbs in N mm 10...

Page 43: ...ing Altitude Meters feet Ambient Temperature 25 F 35 C 30 F to 10 F 34 C to 23 C 15 F to 5 F 26 C to 15 C 0 F to 20 F 18 C to 7 C 15 F to 35 F 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 210 2 200 2 195 2 190 2 185 2 175 2 170 2 170 1 600 1200 2000 4000 195 2 185 2 180 2 175 2 170 2 165 2 155 1 155 1 1200 1800 4000 6000 185 2 175 2 170 2 165 2 160 2 155 1 14...

Page 44: ... 5 Vdc 200 Ignition Timing 28_ 3000 RPM Spark Plug Gap in mm 028 70 Spark Plug Champion RN3C CDI Marking IU2212 Flywheel Marking FP5536 Track Width Inches cm 20 51 Length Inches cm 156 396 Lug Height Inches cm 1 0 2 5 Track tension sag in cm with 10 lbs 4 54kg placed 16 in 40cm ahead of rear idler shaft 3 4 1 1 9 2 5cm Front Suspension Suspension Type Widetrak Shocks Arvin Nitrex Gas Bag IFS Sprin...

Page 45: ...de Meters feet Ambient Temperature 25 F 35 C 30 F to 10 F 34 C to 23 C 15 F to 5 F 26 C to 15 C 0 F to 20 F 18 C to 7 C 15 F to 35 F 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 210 2 200 2 195 2 190 2 185 2 175 2 170 2 170 1 600 1200 2000 4000 195 2 185 2 180 2 175 2 170 2 165 2 155 1 155 1 1200 1800 4000 6000 185 2 175 2 170 2 165 2 160 2 155 1 145 1 145 1 ...

Page 46: ... 5 Vdc 200 Ignition Timing 28_ 3000 RPM Spark Plug Gap in mm 028 70 Spark Plug Champion RN3C CDI Marking IU2212 Flywheel Marking FP5536 Track Width Inches cm 20 51 Length Inches cm 156 396 Lug Height Inches cm 1 0 2 5 Track tension sag in cm with 10 lbs 4 54kg placed 16 in 40cm ahead of rear idler shaft 3 4 1 1 9 2 5cm Front Suspension Suspension Type Widetrak Shocks Arvin Nitrex Gas Bag IFS Sprin...

Page 47: ...ters feet Ambient Temperature 25 F 35 C 30 F to 10 F 34 C to 23 C 15 F to 5 F 26 C to 15 C 0 F to 20 F 18 C to 7 C 15 F to 35 F 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 210 2 200 2 195 2 190 2 185 2 175 2 170 2 170 1 600 1200 2000 4000 195 2 185 2 180 2 175 2 170 2 165 2 155 1 155 1 1200 1800 4000 6000 185 2 175 2 170 2 165 2 160 2 155 1 145 1 145 1 1800 ...

Page 48: ... 5 Vdc 200 Ignition Timing 28_ 3000 RPM Spark Plug Gap in mm 028 70 Spark Plug Champion RN3C CDI Marking IU2212 Flywheel Marking FP5536 Track Width Inches cm 20 51 Length Inches cm 156 396 Lug Height Inches cm 1 0 2 5 Track tension sag in cm with 10 lbs 4 54kg placed 16 in 40cm ahead of rear idler shaft 3 4 1 1 9 2 5cm Front Suspension Suspension Type Widetrak Shocks Arvin Nitrex Gas Bag IFS Sprin...

Page 49: ...NOTES Model Specifications 1 46 9923396 2007 2012 EDGE Widetrak LX Service Manual 2011 Polaris Sales Inc ...

Page 50: ... 2 2 PUBLICATION PART NUMBERS 2 3 2007 PUBLICATIONS 2 3 2008 PUBLICATIONS 2 3 2009 PUBLICATIONS 2 3 2010 PUBLICATIONS 2 3 2011 PUBLICATIONS 2 3 2012 PUBLICATIONS 2 3 SERVICE SAFETY BULLETINS 2 4 GENERAL REFERENCE 2 5 STANDARD BOLT TORQUE SPECIFICATION 2 5 FUEL OIL PREMIX RATIOS 2 5 GASOLINE VOLATILITY 2 5 SAE TAP DRILL SIZES 2 6 METRIC TAP DRILL SIZES 2 6 DECIMAL EQUIVALENTS 2 6 MEASUREMENT CONVER...

Page 51: ...ently stamped into the tunnel The model number is embossed on the decal GROUP MODEL YEAR MODEL LINE MODEL TYPE ENGINE MODIFIER VIN IDENTIFIER OPTION IDENTIFIER 1st digit 2 3rd digit 4th digit 5th digit 6th digit 7th digit 8th digit 9th digit S 08 N D 5 B S digits that would transfer to 17 digit VIN and are used in digits 4 8 respectively 9th digit will be used on color featured versions of models ...

Page 52: ...EL OWNER S MANUAL SUPPLEMENT PARTS BOOK 340 9921041 9921045 9921046 340 Transport 9921056 9921061 9921058 Supersport 9921041 9921052 9921053 550 LX 9921041 9921050 9921051 Trail Touring 9921056 9921059 9921060 Trail RMK 9921054 N A 9921055 Widetrak LX 9921429 9921063 9921064 MODEL OWNER S MANUAL SUPPLEMENT PARTS BOOK 550 Transport 9921592 9921596 9921981 Trail Touring Deluxe 9921593 Trail RMK 9921...

Page 53: ...s Sales Inc Service Safety Bulletins BULLETIN MODEL YEAR DESCRIPTION S 07 14 A and B Widetrak LX 2007 Widetrak LX Fuel Tank Inspection Replacement Select Models Only S 08 03 550LX 2008 Trail Touring DLX 2008 550 Fan Electric Start Drive Clutch Ring Gear Replacement All w electric start ...

Page 54: ...d gasoline must be able to vaporize very quickly in order for an engine to start and warm up properly If summer blend fuel is being used in the winter little or no vaporization will occur Droplets will form causing flooding and very hard starting If winter blend fuel is being used during the summer months it may cause vapor lock boiling fuel inside the fuel lines fuel pump or carburetor This will ...

Page 55: ... 29 32 9063 59 64 9219 15 16 9375 24 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...

Page 56: ...EGT gauge for your baseline numbers Then if there is a rise or fall of 25 degrees you must jet accordingly to return your EGTs to the baseline numbers 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 m...

Page 57: ...al Bore Gauge A cylinder measuring instrument which uses a dial indicator Good for showing taper and out of round in the cylinder bore Electrical Open Open circuit An electrical circuit which isn t complete Electrical Short Short circuit An electrical circuit which is completed before the current reaches the intended load i e a bare wire touching the chassis End Seals Rubber seals at each end of t...

Page 58: ...tank in the liquid cooling system Resistance In the mechanical sense friction or load In the electrical sense ohms resulting in energy conversion to heat RPM Revolutions per minute Seized Piston Galling of the sides of a piston Usually there is a transfer of aluminum from the piston onto the cylinder wall Stator Plate The plate mounted under the flywheel supporting the battery charging coils TDC T...

Page 59: ...NOTES General Information 2 10 9923396 2007 2012 EDGE Widetrak LX Service Manual 2011 Polaris Sales Inc ...

Page 60: ...TANK 3 10 RECOMMENDED COOLANT 3 11 COOLING SYSTEM BLEEDING 3 11 WATER PUMP DRIVE BELT TENSION 3 11 OIL PUMP ADJUSTMENT 340 550 ENGINES 3 11 OIL PUMP ADJUSTMENT 488 LC ENGINE 3 11 OIL PUMP ADJUSTMENT 500 XCSP 3 12 OIL PUMP BLEEDING 3 12 OIL PUMP BLEEDING 550 ENGINES 3 12 OIL PUMP BLEEDING 550 ENGINES WITH AUTO BLEED 3 13 OIL FUEL FILTER 3 13 WATER SEDIMENT TRAP 3 14 CHASSIS LUBRICATION 3 14 BRAKE S...

Page 61: ... I Engine Engine Mounts I I I I Recoil Handle Rope Function I I I I Engine Torque Stop 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 Water Pump Drive Belt I I Liquid Cooling System I I Fan Cooling System I I Oil Filter I I VES Valves I C I C I C I C Brake System Hose Condition Routing I I I I...

Page 62: ...Throttle Safety Switch I I I I I Ignition Switch I I I I I Headlights Brake light Taillights I I I I I Hand Thumbwarmers I I I I I Perc Reverse System I I I I I Chassis Ski Toe Alignment I I I Suspension Mounting Bolts I I I I I Steering Fasteners Linkage Handlebars I I I I I Driveshaft Jackshaft Bearings L L L L Ski Fasteners I I I I Drive Chain Tension I I I I I Chaincase Gearcase Oil I I I R I ...

Page 63: ...2877889 2877890 PS 4 4 Cycle 2W 50 Oil Quart Gallon 16 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 5W Fox Quart Gallon 2870995 2872279 Shock Oil 5W Ryde FX Arvin 2873716 Brake Fluid DOT 4 2872189 Foggin...

Page 64: ...d Ratio 3 2oz for every 1 US gallon of fuel 10 US gallons of fuel requires 32oz of oil to achieve a 40 1 premix ratio Always mix fuel and oil 5 gallons at a time Never fill the tank with fuel and then add oil Drive Belt Break In Procedure The break in period for a new drive belt is 30 miles During this time vary the throttle position under 50 and limit full throttle use New drive belts that featur...

Page 65: ...am towards position 5 4 Torque cam fasteners to 10 ft lbs 12 Nm on the Polaris P 85 Torque P2 deflection cam screws to 12 ft lbs 16 Nm 5 Raise rear of snowmobile up off of the ground using a track stand to allow the track to spin 6 Start the engine and apply enough throttle to spin the track 7 Turn off the engine then re check the belt deflection NOTE Do not rotate the cam past positions 1 or 5 If...

Page 66: ...and to allow the track to spin 7 Start the engine and apply enough throttle to spin the track 8 Turn off then engine then re check the belt deflection NOTE Do not adjust the belt deflection to the point where the drive belt cord line is visible when the belt is seated in the driven clutch Torque Stop Adjustment Set torque stop bumper gap to specification after aligning drive and driven clutches Af...

Page 67: ...llotine and EV base 4 Inspect the guillotine for signs of damage Replace guillotine if damage is found and inspect the cylinder and piston for damage 5 Clean the guillotine with brake cleaner and a piece of fine steel wool Clean only to remove hardened carbon deposits 6 Once clean rinse blade with mild detergent and water Dry completely 7 Install a new gasket then reinstall the EV assembly Apply L...

Page 68: ...d and remove coolant from the fill tube The pressure cap maintains a system pressure of 19 20 psi 131 144 kPa The cap features a locking vent used to purge air from the cooling system without spilling coolant When operating the snowmobile the vent must be closed and locked to prevent engine overheating FRONT HEAT EXCHANGER LEFT HEAT EXCHANGER COOLANT HOSE FLOW TO ENGINE BRAKE CALIPER SURGE TANK FI...

Page 69: ...ng on the coolant temperature Always add coolant when the cooling system is COLD FRONT HEAT EXCHANGER LEFT HEAT EXCHANGER COOLANT HOSE FLOW TO ENGINE BRAKE CALIPER SURGE TANK COOLANT HOSE FLOW ENGINE OUT THERMOSTAT OPEN RIGHT HEAT EXCHANGER REAR HEAT EXCHANGER COOLANT HOSE FLOW ENGINE OUT BYPASS CIRCUIT CAUTION Never remove the fill tube pressure cap when the cooling system is warm Severe burns to...

Page 70: ...re cap Release the parking brake 11 Allow time for the coolant temperature to cool Re check the coolant level in the surge tank Add more coolant if required 12 Reset the engine idle RPM to specification Water Pump Drive Belt Tension 1 Slightly loosen the water pump mounting fasteners 2 Pull the intake nozzle side of the housing up to apply tension to the belt 3 Secure mounting fasteners when belt ...

Page 71: ...r make adjustments in small increments then re check the timing mark alignment 8 After setting the oil pump lever correctly apply a small drop of Loctite 242 to the cable barrel threads then secure the jam nuts 9 Re check the oil pump alignment marks after securing the jam nuts to verify the marks are set correctly 10 Re assemble the removed components in the reverse they were removed Reference th...

Page 72: ...all the auto bleed hose on the tank fitting 6 Pour the oil in the container into the storage tank Oil Fuel Filter EDGE Models The oil filter on EDGE models is incorporated within the oil level sender unit Filter replacement requires sender replacement Widetrak Models The oil filter on Widetrak models is an in line type The arrow on the filter body indicates the oil flow All models feature a fuel p...

Page 73: ...ediment tube and drain the contaminated material from the bowl Repeat for each carburetor 4 Wipe off the residue from the plug and reinstall the clamps CHASSIS LUBRICATION Most chassis suspension and mechanical grease points should be lubricated using Polaris Premium All Season Grease Front Suspension Lubricate grease zerks with Premium All Season Grease WARNING When draining the traps fuel spilla...

Page 74: ...3 15 Maintenance 3 9923396 2007 2012 EDGE Widetrak LX Service Manual 2011 Polaris Sales Inc Rear Suspension Lubricate grease zerks with Premium All Season Grease EDGE WIDETRAK ...

Page 75: ...Lubricate couplers with Premium All Season Grease Throttle Cable Lubricate the throttle cable lightly with fresh oil With the engine off turn the handlebars to the left and lubricate well as shown Choke And Choke Cable Lubricate the choke slide and cables lightly with oil or grease Before turning the engine off operate the choke intermittently to draw moisture out of the choke plunger area and red...

Page 76: ...on should be made with the lever firmly depressed If the lever has less than this amount you may need to bleed the brake system Brake Fluid Inspect the reservoir to be sure it contains the correct amount of fluid Use only Polaris DOT 4 high temperature brake fluid Change fluid every 2 years or whenever the fluid is dark or contamination is suspected NOTE A low brake fluid level can be indicated th...

Page 77: ...re the adjuster lock nut s 6 Slowly turn each idle speed screw inward until the tip begins to touch the throttle slide Remove the drill bit s 7 Set the throttle lever free play by loosening both carburetor adjuster lock nuts Turn each adjuster out equally until the throttle lever free play is set 8 Secure the adjuster lock nuts NOTE If the idle speed screw is adjusted inward and the cable sleeve i...

Page 78: ...ew is adjusted inward and the cable sleeve is not adjusted to take up the throttle lever clearance the engine may misfire or kill upon initial throttle opening Choke Lever Adjustment Mikuni VM 1 Flip the choke toggle to the OFF position 2 Loosen choke cable lock nut s 3 Turn cable sleeve adjuster counterclockwise on the carburetor until choke toggle has zero free play then rotate it clockwise unti...

Page 79: ...t locknut 2 STEERING SUSPENSION MAINTENANCE Handlebars Periodically inspect the torque of the handlebar clamp fasteners 1 To adjust the handlebar angle remove the handlebar cover to expose the clamp 2 Loosen the four clamp fasteners Slightly pry the upper clamp up with a flat blade screwdriver 3 Adjust handlebars to desired position Verify the wiring harness brake hose and throttle cable do not ki...

Page 80: ... is off of the ground 2 Start the engine and slowly let the engine turn the track over This will warm up the track for a correct measurement 3 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 veh...

Page 81: ...t least five complete revolutions 5 Stop the 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 ma...

Page 82: ...s panel Headlight Height Adjustment NOTE EDGE model shown Widetrak LX uses same procedure 1 Place the vehicle on a flat level surface with the headlight approximately 25 feet 7 6 meters from a wall 2 Measure the distance from the ground to the center of the headlight Mark this height on the wall in front of the vehicle 3 Start the engine and turn on the high beam lamps Observe the headlight aim Th...

Page 83: ...uld be coated with a light coat of oil or grease Throttle controls and cables should be lubricated Force a small amount of lubricant down cables Electrical Connections Separate electrical connector blocks and clean corrosive build up from connectors Lubricate or pack connector blocks with Nyogel grease and reconnect Replace worn or frayed electrical wire and connectors Carburetor Throttle Body Fog...

Page 84: ...SYSTEM 4 5 IDLE SPEED ADJUSTMENT 4 5 AIR SCREW 4 5 PILOT JET 4 5 MAIN JET 4 5 JETTING GUIDELINES 4 5 PISTON THROTTLE VALVE 4 6 JET NEEDLE NEEDLE JET 4 6 JET NEEDLE 4 6 NEEDLE JET 4 6 VM CARBURETOR DISASSEMBLY INSPECTION ASSEMBLY 4 7 VM CARBURETOR DISASSEMBLY 4 7 FLOAT ARM ADJUSTMENT 4 8 NEEDLE AND SEAT LEAK TESTING 4 8 MIKUNI TM CARBURETOR 4 9 DISASSEMBLY 4 9 ASSEMBLY 4 11 MIKUNI TM CARBURETOR ADJ...

Page 85: ... container Never ship a used fuel tank assembly Always follow local and federal regulations with regard to proper fuel handling and disposal guidelines CAUTION A main jet that is too small will cause a lean operating condition and may cause serious engine damage Jet according to the jetting charts provided for each snowmobile Never use fuel containing more than 10 ethanol or E85 fuels PILOT JET NU...

Page 86: ...y to efficient engine operation The engine is operated under a wide range of conditions from idling with the throttle valve almost closed to full load or maximum output with the throttle valve fully opened In order to meet the requirements for the proper mixture ratio under these varying conditions a low speed fuel system or pilot system and a main fuel system are provided in Mikuni type carbureto...

Page 87: ...l as the fuel flow characteristics when the jet needle e clip is moved from position 2 to position 4 This illustration can be helpful when trying to diagnose a fuel related problem when the throttle opening at which the rich or lean condition occurs is determined For example changing main jets to resolve an off idle hesitation or rich condition would do nothing as the main jet s effect on total fu...

Page 88: ... the screw in clockwise raises the throttle slide and raises engine RPM Turning the idle speed screw out counter clockwise lowers the throttle slide and lowers engine RPM Always set the idle speed after the engine reaches operating temperature Air Screw The air screw controls the amount of air that is mixed with the fuel drawn out of the float bowl The more air allowed to mix with the fuel the lea...

Page 89: ...complished by changing the location of the E clip on the needle Moving the clip down raises the needle in the jet passage and enriches the mixture Moving the clip up lowers the needle in the jet passage and leans the mixture Letter and number codes are stamped into the needle and the jet indicating sizes and tapers taper of needles only of each Jet Needle The jet needle tapers off at one end and t...

Page 90: ... and throttle cable plug 2 Remove the choke plunger Inspect the plunger for wear and replace if required Inspect the plunger seat for damage or foreign material 3 Check the choke plunger and cable movement Plunger must move up and down in bore without binding 4 Remove the float bowl Inspect the choke fuel supply passage 5 Remove the float pin then remove the inlet needle and seat assembly 6 Inspec...

Page 91: ...fully bend the float arm tang contacting the inlet needle so the float arm legs are parallel with the float bowl mating surface Needle and Seat Leak Testing A leaking needle and seat can cause hard starting and poor runability issues 1 Invert the carburetor assembly Verify the float arm is properly adjusted 2 Attach a Mity Vac pressure pump to the fuel inlet fitting 3 Apply approximately 5 PSI of ...

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

Page 93: ...d screw are removed 12 Remove the two 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 wi...

Page 94: ... gasket and replace if necessary 6 Install float bowl 16 on carburetor with water trap drain plug 15 and single screw 16 on the bottom of the carburetor 7 If throttle slide was removed install throttle slide 11 so that the wider face is facing the engine side of the carburetor 8 Install the funnel gasket 13 and funnel 12 onto the carburetor You will have to lift the throttle slide up and place the...

Page 95: ...flush with the top of the intake bores 5 If adjustment is required hold the PTO carburetor flush with the top of intake bore Turn the throttle stop screw in or out to set the PTO throttle slide flush with the intake bore 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...

Page 96: ...e fuel tank during this cycle When the piston in on the upward stroke negative pressure vacuum is applied to the diaphragm This draws fuel into the fuel pump from the fuel tank A check valve prevents fuel from being drawn out of the carburetors during this cycle To check the fuel pump operation disconnect one of the carburetor fuel supply hoses and place into an appropriate container A steady flow...

Page 97: ...14 Fuel System 9923396 2007 2012 EDGE Widetrak LX Service Manual 2011 Polaris Sales Inc FUEL TANK Widetrak Fuel Tank Assembly GAS CAP FUEL TANK FUEL SHUTOFF VALVE FUEL PUMP FUEL FILTER GASKET FITTING VENT ...

Page 98: ... tube The tube must be free of kinks and clear of pinch points Poor engine runability fuel starvation and possible engine damage may occur if the vent system becomes obstructed or pinched Additionally warm ambient temperatures may cause the fuel tank to expand if the fuel vapors are not allowed to vent into the atmosphere FUEL PUMP GAS CAP FUEL TANK FITTING FUEL FILTER GASKET FUEL SHUTOFF VALVE VE...

Page 99: ...NOTES Fuel System 4 16 9923396 2007 2012 EDGE Widetrak LX Service Manual 2011 Polaris Sales Inc ...

Page 100: ...ER ASSEMBLY 5 18 OIL PUMP ASSEMBLY 5 19 MAGNETO ASSEMBLY 5 20 CRANKCASE ASSEMBLY 5 21 PISTON AND CRANKSHAFT ASSEMBLY 5 22 550 FAN ENGINE 5 23 BLOWER HOUSING ASSEMBLY 5 23 CYLINDER ASSEMBLY 5 24 OIL PUMP ASSEMBLY 5 25 OIL PUMP ASSEMBLY FLEET MODELS 5 26 MAGNETO ASSEMBLY 5 27 CRANKCASE ASSEMBLY 5 28 PISTON AND CRANKSHAFT ASSEMBLY 5 29 488 LIQUID COOLED ENGINE 5 30 RECOIL WATERPUMP HOUSING ASSEMBLY 5...

Page 101: ... 550 Engine 488 Engine 500EV Engine Cylinder Torque Patterns 340 550 500EV Engines 488 Engine Cylinder Head Torque Patterns 340 Engine 550 Engine PTO MAG 1 2 3 4 5 6 7 8 9 10 11 12 PTO MAG 1 2 3 4 5 6 7 8 9 10 11 12 13 14 PTO MAG 1 2 3 4 5 6 7 8 9 10 11 12 MAG PTO PTO MAG 1 2 3 4 PTO MAG 4 2 2 5 6 1 7 PTO MAG 1 2 3 4 PTO MAG 1 2 3 4 5 6 7 8 9 10 11 12 ...

Page 102: ...measure the cylinder for taper and out of round with a telescoping gauge or a dial bore gauge Measure the bore 1 2 from the top of the cylinder in line with the piston pin and 90 to the pin to determine if the bore is out of round Repeat the measurements at the middle and bottom of the cylinder Use the chart below and record all measurements In mm Cylinder Head Warp Limit 003 08mm P M 2 3 4 6 8 12...

Page 103: ...rueing may correct the deflection Piston Inspection Check piston for scoring or cracks in piston crown or pin area Excessive carbon buildup below the ring lands is an indication of piston ring or cylinder wear On Fuji engines measure piston outside diameter at a point that is 1 2 12 7mm up form the bottom of the skirt at a 90 angle to the direction of the piston pin Subtract this measurement from ...

Page 104: ...surface is severely galled or damaged the crankcase assembly should be replaced Main Bearing Clean crankshaft thoroughly and oil main and connecting rod bearings with Polaris engine oil Carefully check each main bearing on the crankshaft Due to extremely close tolerances the bearings must be inspected visually and by feel Look for signs of discoloration scoring or galling Turn the outer race of ea...

Page 105: ...ing if there is any resistance to rotation or excessive axial or radial movement If play or roughness is evident with a new pin and bearing replace the connecting rod Crankshaft Index Polaris crankshafts are pressed together The connecting rod journal center lines are indexed 180 apart from each other It is sometimes necessary to check multi cylinder crankshafts to verify that one cylinder has not...

Page 106: ...ement note the Zero the dial indicator at this point 6 Continue to rotate the crankshaft in the normal direction of rotation until the dial indicator reads 100 2 54mm after top dead center ATDC 7 Bend the pointer or move the degree wheel until the pointer aligns with a 180 mark on the degree wheel 8 With the pointer aligned make sure the degree wheel and pointer are secured and will not move out o...

Page 107: ...ond the bore at the end of each stroke 6 Release the hone at regular intervals to inspect bore size and finish Honing To Oversize Iron Lined Cylinders If cylinder wear or damage is excessive it will be necessary to oversize the cylinder using a new oversize piston and rings This may be accomplished by either boring the cylinder and then finish honing to the final bore size or by rough honing follo...

Page 108: ...n relation to the dial indicator 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...

Page 109: ... Measure from the oil pump mounting surface to the top of the bushing Record measurement as MEASUREMENT A MEASUREMENT A _________________________ 3 Measure the distance between the oil pump mounting flange surface to end of seal flange as shown below Record measurement as MEASUREMENT B NOTE On 550 engines make sure the gasket is installed on the oil pump before taking measurement MEASUREMENT B ___...

Page 110: ...guillotine 5 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...

Page 111: ...uide was removed 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...

Page 112: ...s 28 ft lbs 38 Nm Engine Plate Left Front Mounting Bolt 28 ft lbs 38 Nm Engine Plate to Engine Bolts 45 ft lbs 61 Nm Vibration dampeners must be installed perpendicular to plate and centered in bushings and caps Exhaust Manifold Nuts 15 ft lbs 20 Nm EXHAUST MANIFOLD ENGINE PLATE ENGINE STRAP SPACER VIBRATION DAMPENERS DAMPENER CAPS BUSHINGS VIBRATION DAMPENERS DAMPENER CAPS ...

Page 113: ...ounting Nuts 28 ft lbs 38 Nm Rear Engine Mount Mounting Nuts 18 ft lbs 24 Nm Engine Strap Mounting Nuts 28 ft lbs 38 Nm Exhaust Manifold Screws 18 ft lbs 24 Nm Engine Strap to Crankcase Bolts 45 ft lbs 61 Nm ENGINE STRAP ENGINE STRAP BULKHEAD FRONT ENGINE MOUNT SPACER REAR ENGINE MOUNT BRACKETS REAR ENGINE MOUNT REAR ENGINE MOUNT SPACER EXHAUST MANIFOLD ...

Page 114: ...ice Manual 2011 Polaris Sales Inc 488 Engine Mounting Fastener Torque Note Engine Plate Mounting Nuts 28 ft lbs 38 Nm Engine Plate to Crankcase Bolts 45 ft lbs 61 Nm Apply Loctite 262 to threads Exhaust Manifold Nuts 18 ft lbs 24 Nm EXHAUST MANIFOLD ENGINE PLATE ...

Page 115: ...e Rear Rubber Mount to Bracket Nuts 18 ft lbs 24 Nm Mounting Strap to Crankcase Bolts 45 ft lbs 61 Nm Apply Loctite 262 to threads Mounting Strap to Rubber Mount Nuts 28 ft lbs 38 Nm Rear Engine Mount Bracket Bolts 28 ft lbs 38 Nm RH MOUNTING STRAP LH MOUNTING STRAP REAR ENGINE MOUNT BRACKETS FUEL PUMP MOUNT RUBBER MOUNT RUBBER MOUNT ...

Page 116: ...ylinder side covers Discard used intake and exhaust gaskets 4 Lock recoil hub with a large screwdriver Remove recoil hub fasteners 5 Reference RECOIL PULLEY section for recoil disassembly assembly information 6 Assembly is the reverse of disassembly CYLINDER COVER CYLINDER COVER CYLINDER COVER INTAKE GASKET RECOIL FAN HOUSING RECOIL HUB RATCHET RECOIL PULLEY RECOIL SPRING RETURN SPRING FRICTION SP...

Page 117: ...linder coat the piston and cylinder walls with Polaris Two Stroke engine oil 5 Verify the piston rings are centered around each piston ring locating pin before inserting the piston into the cylinder 6 Install cylinder base gaskets with adhesive strip facing upwards if applicable 7 Install head gasket with seal ring facing down towards cylinder 8 Assembly is the reverse of disassembly CYLINDER HEAD...

Page 118: ... abnormal wear and tear is found 4 Remove drive gear using a needle nose pliers 5 Lubricate all parts with Polaris Two Stroke engine oil during re assembly 6 Install the exact amount of shim s that were removed Verify return spring works and applies tension to the lever 7 Follow the oil pump bleed procedure outlined in the Maintenance chapter OIL PUMP DRIVE GEAR WASHER O RING SHIM WASHERS AS REQUI...

Page 119: ...he heavy duty flywheel puller PN 2871043 A NOTE Do not thread the flywheel puller bolts into the magneto stator located behind the flywheel 4 Thoroughly clean the crankshaft nose and flywheel nut threads Inspect the flywheel key for damage Replace if damage is found 5 Scribe a line in the magneto plate and crankcase to ensure alignment when re assembled 6 Assembly is the reverse of disassembly CDI...

Page 120: ... crankcase drain screws are securely installed 6 Apply a thin bead of Three Bond 1215 to both crankcase mating surfaces 7 Lubricate the oil pump drive gear with two stroke engine oil and install into crankcase 8 Install crankshaft and two new crankcase seals Verify seal lips face the inside of the engine Ensure crankshaft retaining ring and bearing locating pins are seated correctly before install...

Page 121: ...apter 5 Install the piston rings with the beveled edge facing upwards 6 The piston ring locator pins and ring open ends always face the intake side of the engine 7 Always lubricate the piston assembly and cylinder with two stroke engine oil when installing the cylinder over the piston PISTON RINGS PISTON C CLIP PISTON PIN NEEDLE BEARING NEEDLE BEARING ROD PIN CONNECTING ROD BEARING THRUST WASHER R...

Page 122: ...engine 3 Remove the recoil fan housing from the engine The recoil pulley is located inside the housing 4 Reference RECOIL PULLEY section for recoil disassembly assembly information 5 The fan flywheel and stator must be removed to remove the rear blower housing UPPER BLOWER HOUSING LOWER BLOWER HOUSING RECOIL FAN HOUSING BLOWER HOUSING RECOIL HUB FRICTION SPRING FRICTION PLATE RATCHET RATCHET SPRIN...

Page 123: ...eed pedal and or cage if damage or wear is found 5 During assembly the reed valve assembly is installed under the cylinder base gasket Install the base gasket with the sealing strip facing upwards 6 Lubricate cylinder walls and piston with two stroke engine oil when installing each cylinder 7 Install head gasket with EX on the exhaust side of the engine and UP on the intake side of the engine 8 Ve...

Page 124: ...ormal wear and tear is found 4 Remove drive gear using a needle nose pliers 5 Lubricate all parts with Polaris Two Stroke engine oil during re assembly 6 Install the exact amount of shim s that were removed Verify return spring works and applies tension to the lever 7 Follow the oil pump bleed procedure outlined in the Maintenance chapter GASKET AIR BLEED SCREW BUSHING O RING SHIM WASHERS AS REQUI...

Page 125: ...s found 4 Remove drive gear using a needle nose pliers 5 Lubricate all parts with Polaris Two Stroke engine oil during re assembly 6 Install the exact amount of shim s that were removed Verify return spring works and applies tension to the lever 7 Follow the oil pump bleed procedure outlined in the Maintenance chapter GASKET AIR BLEED HOSE BUSHING O RING SHIM WASHERS AS REQUIRED QTY OIL PUMP DRIVE...

Page 126: ... the heavy duty flywheel puller PN 2871043 A NOTE Do not thread the flywheel puller bolts into the magneto stator located behind the flywheel 4 Thoroughly clean the crankshaft nose and flywheel nut threads Inspect the flywheel key for damage Replace if damage is found 5 Scribe a line in the magneto plate and crankcase to ensure alignment when re assembled 6 Assembly is the reverse of disassembly I...

Page 127: ...cases Inspect for cracks Verify both crankcase drain screws are securely installed 6 Apply a thin bead of Three Bond 1215 to both crankcase mating surfaces 7 Lubricate the oil pump drive gear with two stroke engine oil and install into crankcase 8 Install crankshaft and two new crankcase seals Verify seal lips face the inside of the engine Ensure crankshaft retaining ring and bearing locating pins...

Page 128: ...Install the piston rings with the beveled edge facing upwards 6 The piston ring locator pins and ring open ends always face the intake side of the engine 7 Always lubricate the piston assembly and cylinder with two stroke engine oil when installing the cylinder over the piston PISTON RINGS PISTON C CLIP PISTON PIN NEEDLE BEARING NEEDLE BEARING CONNECTING ROD PIN THRUST WASHER THRUST WASHER THRUST ...

Page 129: ...s 2 Remove fasteners securing recoil waterpump housing to engine The recoil pulley mechanism is located inside the housing 3 Reference RECOIL PULLEY section for recoil disassembly assembly information 4 Lock the ratchet hub with a large screwdriver and remove the fasteners that secure the hub and waterpump pulley to the flywheel RATCHET HUB FRICTION PLATE FRICTION SPRING RATCHET RATCHET SPRING REC...

Page 130: ...r Pump Assembly Disassembly Assembly Process 1 Waterpump impeller seals and shaft are not serviceable 2 O ring belt cover castings cover gasket and belt pulley can be replaced with service parts 3 Set belt tension to 1 8 to 3 16 at the midpoint of the belt BELT BELT PULLEY WATER PUMP ASSEMBLY O RING ...

Page 131: ...all with sealing surface up 7 Apply a liberal amount of two stoke engine oil to each piston assembly and each cylinder bore Carefully install each piston while making sure each piston ring is centered at each piston ring locating pin 8 When installing a new head gasket install with UP located on the intake side of engine and readable when looking down at the engine 9 Use new exhaust gaskets and in...

Page 132: ...normal wear and tear is found 4 Remove the oil pump drive gear using a needle nose pliers 5 Lubricate all parts with Polaris Two Stroke engine oil during re assembly 6 Install the exact amount of shim s that were removed Verify return spring works and applies tension to the lever 7 Follow the oil pump bleed procedure outlined in the Maintenance chapter OIL PUMP DRIVE GEAR WASHER BUSHING SHIM WASHE...

Page 133: ...puller PN 2871043 A NOTE Do not thread the flywheel puller bolts into the coils located behind the flywheel 4 Thoroughly clean the crankshaft nose and flywheel nut threads Inspect the flywheel key for damage Replace if damage is found 5 Scribe a line in the magneto plate and crankcase to ensure alignment when re assembled 6 Assembly is the reverse of disassembly CDI IGNITION COIL PACK FLYWHEEL EXC...

Page 134: ...cks Verify both crankcase drain screws are securely installed 6 Apply a thin bead of Three Bond 1215 to both crankcase mating surfaces 7 Lubricate the oil pump drive gear with two stroke engine oil and install into crankcase 8 Install crankshaft and two new crankcase seals Verify seal lips face the inside of the engine Ensure crankshaft retaining ring and bearing locating pins are seated correctly...

Page 135: ... piston rings with the beveled edge facing upwards 6 The piston ring locator pins and ring open ends always face the intake side of the engine 7 Always lubricate the piston assembly and cylinder with two stroke engine oil when installing the cylinder over the piston PISTON RINGS PISTON C CLIP PISTON PIN NEEDLE BEARING THRUST WASHER THRUST WASHER THRUST WASHER NEEDLE BEARING CONNECTING ROD PISTON P...

Page 136: ...linder upwards taking care not to drop the piston and rod abruptly against the crankcase 10 Remove the cylinder base 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...

Page 137: ...ert 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 solven...

Page 138: ...lled as well 6 When installing a new piston insert one c clip into 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 openin...

Page 139: ...etor cleaner and a gasket remover Flush out the crankcase 6 Reinstall the crankshaft back into 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 tight...

Page 140: ...eal 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 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 ring...

Page 141: ...NOTES Engine Systems 5 42 9923396 2007 2012 EDGE Widetrak LX Service Manual 2011 Polaris Sales Inc ...

Page 142: ...9 SEAL SLEEVE O RING INSTALLATION 6 9 JACKSHAFT REMOVAL 6 10 JACKSHAFT INSTALLATION 6 10 DRIVESHAFT REMOVAL INSTALLATION 6 10 WIDETRAK GEARCASE 6 11 REMOVAL 6 11 INSPECTION 6 12 INPUT SHAFT INSPECTION 6 14 LOW REVERSE SHAFT INSPECTION 6 14 OUTPUT SHAFT INSPECTION 6 15 SHIFT DRUM INSPECTION 6 15 GEARCASE ASSEMBLY 6 16 GEARCASE INSTALLATION 6 16 HYDRAULIC BRAKE SYSTEM 6 18 OVERVIEW 6 18 COMPENSATING...

Page 143: ...72 74 74 76 Gear Ratio 1 48 1 52 1 60 1 64 1 54 1 58 1 63 1 71 1 75 1 65 1 70 1 83 1 87 1 68 1 77 1 82 1 95 Jackshaft RPM MPH 6000 87 85 81 79 84 81 79 75 74 78 76 71 69 77 73 71 66 6250 91 88 84 82 87 85 83 79 77 81 79 74 72 80 76 74 69 6500 94 92 87 85 91 88 86 82 80 84 82 76 75 83 79 77 71 6750 98 95 91 88 94 92 89 85 83 88 85 79 78 86 82 80 74 7000 102 99 94 92 98 95 93 88 86 91 89 82 80 89 85...

Page 144: ... 70 68 63 61 64 63 60 58 57 6250 76 70 69 66 73 71 65 64 67 65 62 61 59 6500 79 73 72 68 75 73 68 66 70 68 65 63 62 6750 82 76 74 71 78 76 71 69 72 71 67 66 64 7000 85 79 77 73 81 79 73 72 75 73 70 68 66 7250 88 82 80 76 84 82 76 74 78 76 72 70 69 7500 91 85 83 79 87 85 79 77 81 78 75 73 71 7750 94 87 85 81 90 88 81 79 83 81 77 75 74 8000 98 90 88 84 93 90 84 82 86 84 80 78 76 8250 101 93 91 87 96...

Page 145: ... 29 2 35 2 41 2 53 Jackshaft RPM MPH 6000 59 58 55 54 59 56 55 53 51 6250 62 60 58 56 62 59 57 56 53 6500 64 63 60 58 64 61 59 58 55 6750 67 65 62 61 67 63 62 60 57 7000 69 68 64 63 69 66 64 62 59 7250 72 70 67 65 72 68 66 65 62 7500 74 72 69 67 74 70 68 67 64 7750 77 75 71 70 76 73 71 69 66 8000 79 77 74 72 79 75 73 71 68 8250 82 80 76 74 81 77 75 73 70 8500 84 82 78 76 84 80 78 76 72 8750 87 85 ...

Page 146: ... 15 SPL HYVO PM 3221097 21T 3 4W 15 SPL HYVO PM 3221098 22T 3 4W 15 SPL HYVO PM 3221099 23T 3 4W 15 SPL HYVO PM 3221101 24T 3 4W 15 SPL HYVO PM 3221102 25T 3 4W 15 SPL HYVO PM 3222127 26T 3 4W 15 SPL HYVO PM 3222126 36T 3 4W 15 SPL HYVO PM 3222125 37T 3 4W 15 SPL HYVO PM 3222108 39T 3 4W 15 SPL HYVO PM 3222099 40T 3 4W 15 SPL HYVO PM 3222101 41T 3 4W 15 SPL HYVO PM 3221188 43T 3 4W 15 SPL HYVO PM ...

Page 147: ...8 ft lbs 11 Nm C 19 ft lbs 25 Nm D 62 ft lbs 84Nm 7 92 C D Assembly Notes Never re use cotter pins Always replace with new parts Install upper gear washer with dome raised side facing locknut COVER GASKET BRAKE DISC DRIVESHAFT JACKSHAFT DIPSTICK TENSIONER BOLT TENSIONER SNAP RING SNAP RING BEARING BEARING GEAR COTTER PIN SEAL SEAL MAGNETIC DRAIN PLUG GEAR CHAIN A B B B B B D C ...

Page 148: ... Loctite 680 to the bearing to case mating surface Always press on the outside bearing race 24 When installing new seals apply a light film of grease to the inner lip of the seal to aid in driveshaft jackshaft installation Chaincase Installation 1 Install new o rings on the jackshaft and driveshaft Install the seal sleeves so that the o rings fit inside each sleeve 2 Install jackshaft installation...

Page 149: ...ket retaining bolt 23 Release the parking brake 24 Adjust the chain tensioner by hand and back off 1 4 turn 25 Lock the adjuster lock nut 26 Install the chaincase cover and fasteners 27 Remove the fill cover and fill chaincase to the appropriate level 28 Check for leaks 29 Adjust track tension to the specified tension T Top Sprocket Nut 62 ft lb 84 N m T Bottom Sprocket Bolt 19 ft lb 26 N m T Chai...

Page 150: ...ing Fasteners Seal Sleeve O Ring Installation The o rings and seal sleeves must be installed as shown in the illustration below to prevent chaincase oil leaks Verify the o ring sits inside the sleeve DRIVEN CLUTCH GASKET LUBRICATION FLANGE BEARING FLANGE BEARING SPEEDOMETER FLANGE GASKET OFFSET FLANGE SPEEDOMETER DRIVE KEY DRIVESHAFT ASSEMBLY SEAL SLEEVE O RING BRAKE DISC SNAP RING JACKSHAFT KEY S...

Page 151: ...ft 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 ensure positive bearing and jackshaft seating to chaincase 6 If shaft is not centered tap shaft with a soft faced hammer until centered This will align the upper chaincase bearing in the chaincase bore 7 Once the correct jackshaft alignment ha...

Page 152: ...ome forward relieving track tension 10 Tighten idler wheel bolts so that spacers on shafts do not rotate and lose alignment 11 Remove carrier shaft bolts and front and rear suspension bolts from both sides 12 Place a protective mat on the floor Tip unit onto right side and remove suspension 13 Loosen and remove three bolts and nuts retaining angle drive housing and flangette 14 Remove angle drive ...

Page 153: ...soft faced hammer in the reinforced areas 7 Remove shaft and gear assembly from case by tapping with a soft faced hammer evenly on end of shafts 8 Remove output gear assembly and chain Mark chain direction for reference during reassembly Inspect gear teeth for damage Inspect chain for worn cracked or broken link plates 9 Remove shift fork shaft from gear cluster Inspect surface of fork for wear or...

Page 154: ...3396 2007 2012 EDGE Widetrak LX Service Manual 2011 Polaris Sales Inc 12 Gear shaft and chain cluster assembly shown Low gear output power flow High gear output power flow Reverse output power flow INPUT SHAFT LOW RVS SHAFT OUTPUT SHAFT ...

Page 155: ...a new bearing press on or support inner race while pressing bearing on to shaft 8 Lubricate needle bearings and splines with recommended gearcase engine oil lubricant Low Reverse Shaft Inspection 1 Press bearing from end of shaft using a press and bearing separator 2 Closely inspect drive dogs Replace gear and mating gear if rounded chipped or broken 3 Inspect needle bearings for wear or cracks on...

Page 156: ...nd of it s travel and aligning with the corresponding hole in the shift drum Press dowel pins into inner shift drum Discard pins and replace with new 4 Inspect shift forks for abnormal wear and tear Replace if unevenly worn 5 Inspect shift drum tracks for damage Replace drum if any damage is found 6 When installing shift forks press dowel pins up to 100 2 5mm below top of bore Verify pins do not b...

Page 157: ...damage coolant hoses Be sure transmission shift linkage is properly located 12 Install lower front mounting bolt 3 before coupling to shaft Once bolt is started into transmission housing align coupling with drive shaft and jack shaft splines Keep transmission flat and lower gradually to prevent binding of couplers 13 Install remaining transmission mounting bolts Reinstall shim washers in original ...

Page 158: ...1 Reinstall clutch offset washers on jackshaft and install driven clutch Using the clutch alignment tool adjust driven clutch to achieve proper offset 32 Widetrak models have no float on driven clutches Use shim washers PN 7555734 to create gap between shaft and cover washer only 33 Torque driven clutch retaining bolt to specification 34 Lift and support rear of unit and align track to specificati...

Page 159: ...s air to enter the system causing the brakes to feel spongy Compensating Port Located within the master cylinder is a small compensating port C which is opened and closed by the master cylinder piston assembly The port is open when the brake lever is released and the piston is outward As the temperature within the hydraulic system changes this port compensates for fluid expansion caused by heat or...

Page 160: ...luid is dark or contamination is suspected WARNING Contaminated brake discs or brake pads greatly reduce braking performance and increase stopping distance Do not attempt to clean contaminated pads Replace them Clean the brake disc with brake cleaner This brake system requires ethylene glycol based fluid DOT 4 Do not use or mix different types of fluid such as silicone based or petroleum based Do ...

Page 161: ...ut of the clear tube or all of the air bubbles disappear from the brake fluid 10 After removing the air or replenishing the brake fluid actuate the lever If the lever feels spongy further bleeding is required If the lever feels stiff the system is fully bled 11 Torque the bleed fitting when finished 12 When adding fluid add DOT 4 brake fluid to 1 4 6cm from the reservoir top 13 Install cover and d...

Page 162: ...lt to 168 216 in lb 19 24 N m 12 Insert the new brake hose and install into the master cylinder Torque the brake line to 144 192 in lb 16 21 N m 13 Tighten the brake line into the master cylinder in an orientation so that the line does not have any sharp bends when it is installed on the handlebar 14 Route the brake light switch in the harness correctly 15 Place the switch pack with the master cyl...

Page 163: ...install the master cylinder cover Clean the caliper assembly and master cylinder with a clean shop rag 11 Test the snowmobile at low speed to verify operation Caliper Removal Installation 1 Rotate and remove the brake pad retaining pin Remove both brake pads from the caliper 2 Remove the two bolts that secure the caliper to the chaincase 3 Remove the caliper from the brake disc 4 To install the ca...

Page 164: ...h in by hand carefully and slowly Push each piston down until bottomed out 14 Reinstall the brake caliper on to the chaincase Torque fasteners to specification 15 Inspect both brake pads prior to installation If they are within the pad wear specification reinstall into caliper 16 Install the brake hose using the same routing and orientation noted during removal Torque fitting to specification 17 I...

Page 165: ...NOTES Drive and Brake Systems 6 24 9923396 2007 2012 EDGE Widetrak LX Service Manual 2011 Polaris Sales Inc ...

Page 166: ...CLUTCH ALIGNMENT OFFSET 7 16 OFFSET FLOAT ADJUSTMENT 7 16 DRIVE CLUTCH 7 17 IDENTIFICATION 7 17 DRIVE CLUTCH REMOVAL 7 17 DRIVE CLUTCH DISASSEMBLY 7 18 ROLLER REMOVAL 7 19 ROLLER INSTALLATION 7 19 SPIDER BUTTON INSTALLATION 7 19 BUSHING REPLACEMENT 7 20 MOVEABLE SHEAVE BUSHING RETAINER 7 20 COVER BUSHING 7 20 CLUTCH ASSEMBLY 7 21 BELT TO SHEAVE CLEARANCE ADJUSTMENT 7 22 SPIDER INDEXING 7 22 DRIVE ...

Page 167: ...d will accelerate along the low ratio line until the drive clutch up shift force overcomes the opposing shift force generated by the driven clutch Shift Out Over Rev Engine RPM that spikes above the desired operating RPM speed The shift out RPM should come down to the desired operating RPM but never below after the driven clutch begins to open Shift Out RPM Engine RPM at which the up shift force g...

Page 168: ... top speed the snowmobile will ever achieve 1 1 Shift Ratio A 1 1 shift ratio occurs when the drive clutch and the driven clutch are rotating at the same RPM The mathematical vehicle speed for a given gear ratio at a 1 1 shift ratio is represented in the chaincase gearing charts located in the Final Drive Chapter Low High Ratio Low ratio is the mechanical position when the drive belt is all the wa...

Page 169: ...rench 9314177 A Strap Wrench PU 45419 Replacement Strap 305085 Drive Clutch Spider Nut Socket 2870338 Drive Clutch Spider Removal Installation Tool 2870341 Clutch Pin Punch 2870507 Tapered Reamer 29mm Short Drive All Fuji Snow Engines Excluding 700 800 XCR 2870576 Tapered Reamer 29mm Long Drive 755 866 w original crankshaft 700 800 XCR All Domestic Carbureted Excluding 600 IQ Racer PS 48587 Tapere...

Page 170: ...OAD RATE lbs inch 7041080 Blue 207 3 55 120 300 137 7041945 Almond 218 3 65 140 330 145 7041645 Almond Gold 207 4 00 150 290 107 7041818 Black White 218 3 52 140 320 137 7041816 Almond Black 200 3 75 165 310 111 7041922 Almond Blue 218 3 75 150 310 122 7041988 Almond Red 207 4 27 165 310 110 7042083 Black Green 218 3 38 120 340 168 7043681 Black 3681 225 3 327 120 310 145 7043342 Black 3342 218 3 ...

Page 171: ...tigue Replacement is required Drive Clutch Weights 10 Series Weights CAUTION Never shim a drive clutch spring to increase its compression rate This may result in complete stacking of the coils and subsequent clutch cover failure WEIGHT GRAMS 1gr PART NUMBER 10M R 44 1321530 10M W 46 1321527 10M B 47 5 1321529 10M 49 5 1321528 10 51 1321526 10A L 52 3 1321531 10 54 54 1321685 10A 55 1321589 10 56 5...

Page 172: ...and final angle is stamped on the back of the helix The first number A designates the starting angle of the ramp The second number B designates the finish angle The last number C is the transition distance in inches between the starting and finish angles WEIGHT GRAMS 8gr PART NUMBER 11 40 1322593 11 42 1322592 11 44 1322591 11 46 1322596 11 48 1322590 11 50 1322589 11 52 1322595 11 54 1322866 11 5...

Page 173: ...7043058 Red Black Subs to 7043149 P2 Non Tabbed 7043059 Red Green 4 767 12 1 120 220 90 7042066 Green Black 5 60 14 2 135 198 56 7043061 Red Silver 4 95 12 5 125 175 45 7043062 Red Yellow 4 40 11 2 100 150 45 7043057 Red Blue 4 767 12 1 140 200 54 7043063 Black Subs to 7043150 P2 Non Tabbed 7043064 Blue Black Subs to 7043152 P2 Non Tabbed 7043060 Red White 4 95 12 5 100 200 91 7043069 Red Pink 3 5...

Page 174: ...1 lbs Rate Lbs In TEAM EQUIVALENT COLOR 7043397 Black 4 4 11 2 100 150 45 RED YELLOW 7043398 4 95 12 6 125 175 45 RED SILVER 7043151 4 76 12 1 140 200 54 RED BLUE 7043150 4 2 10 6 140 220 65 BLACK 7043430 4 4 11 2 160 240 72 BLACK PURPLE 7043152 4 1 10 4 120 200 73 BLUE BLACK 7043149 4 7 11 9 140 240 90 RED BLACK PART NUMBER COLOR Free Length Inches cm LOAD 2 4 lbs LOAD 1 4 lbs Rate Lbs In 7043515...

Page 175: ...l Straight Angle Helix 48 40 40S Example 1st Angle 2nd Angle Vertical Distance to Transition Arc to Straight Angle Helix 56 42 45 Example 1st Angle at 100 from Horizontal 2nd Angle Vertical Distance to Transition PART NUMBER DESCRIPTION 5136975 38S 5137154 40S 5137155 42S 5137160 44S 5137142 58 40 35 5137150 40 38 45 5137157 44 38 45 5137176 58 42 45 5137153 60 40 45 ...

Page 176: ...ground before engaging throttle Belt Inspection 1 Measure the belt width and replace it if it is worn severely Generally a belt should be replaced if the clutches can no longer be adjusted to provide the proper belt deflection Project the side profiles and measure from corner to corner Place a straight edge on each side of the drive belt and measure the distance where the straight edges intersect ...

Page 177: ...cle speed and 60 m p h indicated on speedometer Lower the gear ratio Remove windage plates from driven clutch If possible move to better snow conditions and reduce RPM Avoid riding in very high ambient temperatures Ice and snow piled up between track and tunnel overnight or after stopping for a long period of time enough to re freeze the snow Break loose snow and ice under tunnel Allow longer than...

Page 178: ...tall belt so that the numbers can be read correctly on the left side of the machine or in the direction in which the belt was originally installed 2 Remove the wrench Wiggle the belt to remove slack while removing the wrench 3 Close the clutch guard Adjusting Belt Deflection Team P2 SPA 1 Loosen the jam nut 2 Using an 1 8 Allen head wrench turn the stud counter clockwise to decrease belt deflectio...

Page 179: ... can be read correctly on the left side of the machine or in the direction in which the belt was originally installed 2 Remove the wrench Wiggle the belt to remove slack while removing the wrench 3 Close the clutch guard Adjusting Belt Deflection P2 Cam Adjuster 1 Loosen but do not remove the three screws on the deflection cam 2 Rotate clockwise the deflection cam towards 1 in small increments to ...

Page 180: ...of the machine or in the direction in which the belt was originally installed 2 Wrap the belt around the top of the driven clutch A then pull it around the rear B 3 Firmly push on the moveable sheave while pulling the belt down into the sheaves from the rear 4 Close the clutch guard Adjusting Belt Deflection Widetrak 1 Loosen but do not remove the three screws on the deflection cam 2 Rotate counte...

Page 181: ...e front of the alignment bar does not touch the driven sheave the maximum clearance cannot exceed 025 Offset Float Adjustment 1 Determine direction driven clutch needs to be adjusted 2 Remove driven clutch retaining bolt and remove driven clutch 3 With one 16 GA bushing installed add or remove offset washers from behind the driven clutch to set the proper offset 4 After adjusting the offset add or...

Page 182: ...beginning of this chapter 1 Remove the belt 2 Place the clutch holding tool PN 9314177 A on the drive clutch 3 Remove the drive clutch retaining bolt Note the placement and 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 ...

Page 183: ...ge 12 Inspect the moveable sheave bushing for wear or damage 13 Remove all three drive clutch weights 14 Inspect each weight The roller 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 15 Inspect the rollers bushings and roller pins by pulling a flat metal rod across each roller 16 Ro...

Page 184: ...er 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 Place roller in spider leg and center it on the pin 4 Place a second washer on the other side of the roller 5 Place the spider on a vise 6 Install pin centering tool PN 2870910 A or 8700221 7 Drive the roller ...

Page 185: ...n slide the sheave onto the puller rod 12 Secure rod nut turn barrel to apply additional tension against sheave if required 13 Turn the sheave counterclockwise until bushing is fully seated 14 Remove the rod nut and installation tool and repeat steps 11 to 13 and install the new insert Cover Bushing NOTE A torch may be required to release the bushing retaining compound 1 On covers utilizing a reta...

Page 186: ...aft 7 Index the spider See Spider Indexing on page 7 22 8 Apply Loctite 243 to the spider threads Using the spider tool PN 2870341 torque to specification 9 Apply Loctite 243 to the spider jam nut threads Install the jam nut onto the shaft and torque it 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...

Page 187: ...d thickness of the washer s installed between the spider and clutch spacer To increase the clearance add or install thicker washer s To decrease the clearance remove or install thinner washer s Either way the belt to sheave clearance adjustment most often requires the spider to be re indexed Spider Indexing NOTE Spider indexing effects belt to sheave clearance and clutch balance Please read all pr...

Page 188: ...fore re installing clutch on engine 1 Place the specified clutch taper reamer in a vise and lubricate the cutting edges with cutting oil Clean the clutch taper by manually rotating the clutch clockwise on the reamer one or two revolutions Only use the weight of the clutch and do not push down on the clutch while turning 2 Check crankshaft taper for galling or scoring If necessary clean the taper e...

Page 189: ...tch bolt and washers A NOTE Count the number and location of the spacer washers located on the fastener and behind the clutch 4 Slide the driven clutch off the jackshaft 5 Inspect the splines and replace jackshaft if damage is found Driven Clutch Installation 1 Install the driven clutch bolt with the same amount of washers at removal 2 Torque the bolt to specification 3 Check for correct belt defl...

Page 190: ...ng cup spacer and rollers for wear and replace as required 7 To assemble the clutch slide the components back on to the stationary sheave shaft 8 Align the notch in the roller assembly with row of double splines on the shaft Slowly compress the spring and roller assembly down on to the shaft Install the snap ring making sure it is fully seated in the groove 9 Install the helix by aligning the roll...

Page 191: ...ill increase the amount of pre tension in the spring While this may prevent belt slippage belt burning or engine over revving may result 8 Align the helix and stationary keyway Compress the helix down onto the shaft enough to prevent the spring from dis lodging from the helix and sheave but do not engage the rollers 9 Hold the stationary sheave and rotate the moveable sheave 1 4 to 1 3 revolution ...

Page 192: ...rify the washer is not lodged inside the snap ring groove 4 Unscrew the compressor to remove the helix and spring Disassemble the clutch sheaves 5 Inspect the helix spring bushings rollers and clutch sheaves for damage 6 The cover and sheave bushings are not serviceable If bushings are severely worn or binding clutch assembly replacement is required 7 Clean the sheaves with a Scotch Brite pad and ...

Page 193: ...h tool 11 Align the helix alignment hole with the X on the moveable sheave 12 Align the wide gap in the helix splines with the skip tooth in the stationary sheave shaft 13 Visually verify the rollers are positioned underneath each corresponding helix ramp 14 Compress the helix down into the sheave Install the washer and snap ring Verify the snap ring is fully seated in the groove with the sharp ed...

Page 194: ...r damage 6 The cover and sheave bushings are not serviceable If bushings are severely worn or binding clutch assembly replacement is required 7 Clean the sheaves with a Scotch Brite pad and a solution of warm soapy water 8 Inspect the rollers for abnormal wear and replace as required Install new rollers with the ejector pin marks on the rollers facing center of sheave visible 9 Install the sheave ...

Page 195: ...ave shaft 14 Visually verify the rollers are positioned underneath each corresponding helix ramp 15 Compress the helix down into the sheave Install the washer and snap ring Verify the snap ring is fully seated in the groove with the sharp edge upward 16 Carefully release the clutch compressor 17 Align the two X marks and install the cover Torque fasteners to specification T P2 Cover Fastener Torqu...

Page 196: ...N SPRING TENSION ADJUSTMENT 8 11 REAR TRACK SHOCK CONTROL RODS 8 12 EDGE SHOCK RODS 8 12 REAR SUSPENSION ADJUSTMENTS 8 13 ADJUSTMENT PROCEDURES 8 13 SETTING THE REAR SUSPENSION RIDE HEIGHT 8 13 SCISSOR STOP ADJUSTMENTS 8 14 FRONT TORQUE ARM LIMITER STRAP ADJUSTMENT 8 14 TORSION SPRING ADJUSTMENT 8 14 WIDETRAK TORSION SPRING ADJUSTMENTS 8 15 WIDETRAK SKI PRESSURE ADJUSTER 8 15 REAR SUSPENSION ASSEM...

Page 197: ... 1 1 3 1 1 1 1 4 T Drag link fasteners Steering arm fasteners Tie rod fasteners 1 28 30 ft lb 38 41 N m Trailing arm fastener 2 35 40 ft lb 47 54N m Upper Radius Rod fasteners 3 55 60 ft lb 75 81 N m Lower Radius Rod fasteners 4 95 100 ft lb 129 136 N m Rod end jam nuts 8 14 ft lb 11 19 N m Specifications ITEM MEASUREMENT Camber 59 31 15 8mm Toe 12 25 3 6mm Width 40 44 102 7cm Drag Link Length 15 ...

Page 198: ... 1 1 1 T Draglinkfasteners Steeringarm fasteners Tie rod fasteners 1 28 30 ft lb 38 41 N m Trailing Arm fastener 2 35 40 ft lb 47 54N m Upper Radius Rod fasteners 3 60 ft lb 81 N m Lower Radius Rod fasteners 4 150 ft lb 203 N m Rod end jam nuts 8 14 ft lb 11 19 N m Specifications ITEM MEASUREMENT Camber 735 31 18 7 8mm Toe 12 25 3 6mm Width 41 104 cm Drag Link Length 15 07 38 2 cm Tie Rod Length 1...

Page 199: ...1 3 1 1 1 1 T Draglinkfasteners Steeringarm fasteners Tie rod fasteners 1 29 ft lb 39 N m Upper Radius Rod Inner 2 38 ft lb 52 N m Trailing arm fastener 3 43 ft lb 58 N m Lower Radius Rod Inner 4 48 ft lb 65 N m Center Steering Arm 5 58 ft lb 79 N m Rod end jam nuts 8 14 ft lb 11 19 N m Widetrak Specifications ITEM MEASUREMENT Camber 82 72 21 18mm Toe 0 12 3 mm Width 37 6 95 5 cm Drag Link Length ...

Page 200: ...t not full rebound Measure at a point 10 2 54cm forward of the ski mount bolt and 10 2 54cm behind the ski mount bolt preferably on the center line of the carbide skags Width is measured from the center of the spindles 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...

Page 201: ...n NOTE Install shock so the adjustment screw is facing inwards FRONT SUSPENSION STEERING Setup and Adjustments Spring preload is one of the adjustment options which affects ride Preload is the amount of pressure at which the spring is held The longer the installed length of the spring the less the amount of pre load the shorter the installed length of the spring the more the amount of pre load An ...

Page 202: ...to fabricate their own alignment bar must adhere to the following specifications DIAMETER 623 625 15 824 15 875mm LENGTH 45 114 3cm MATERIAL C 1018 Camber The following definitions of camber use automotive terminology to describe positive and negative positions 0 Neutral camber The spindle is 90 perpendicular to the ground Positive camber The bottom of the spindle is canted inward toward the chass...

Page 203: ...move the skis Remove the skis and pivot bushings 2 Loosen the tie rod end jam nuts then loosen the fasteners securing the tie rods to the spindles Insert the alignment bar through both spindles NOTE The upper radius rods may need to be removed from the trailing arms depending on the current camber setting 3 Visually center the handlebars then attempt to reinstall the tie rods Verify each tie rod i...

Page 204: ...e 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 2 Remove the alignment bar and install it to the opposite side 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 3 To adjust the camber change the lower ra...

Page 205: ...noted however that suspension adjustments involve a compromise or trade off A machine set up to perform well in the moguls would not suit the preference of a groomed trail rider Weight Transfer The shifting of weight from the skis to the track is called weight transfer As engine torque is applied to the drive axle the torque is transferred to the track pulling it forward This energy also tries to ...

Page 206: ...m and limits the amount of independence between the movement of the front torque arm and the rear torque arm When hitting a bump the front torque arm starts to compress The FRSS links that movement to the rear torque arm causing it to compress and raise the rear suspension up as one allowing the suspension to hit the bump only once and eliminating kickback The factory setting are usually adequate ...

Page 207: ... in the same orientation as set from the factory Any changes made to the shock rod orientation other than the factory setting may cause suspension damage 63 16 mm 45 11 4 mm Lower Upper Trail RMK lower end is smaller than the upper end 340 SuperSport both ends are the same size 475 12 mm 475 12 mm Facing Shock Facing Shock Shock Rod Assembly Example Trail RMK Shown Shock Lower Upper ...

Page 208: ...s it allows a lighter spring rate on the FTA because it can borrow spring rate from the rear torsion springs and it prepares the rear portion of the suspension for the bump reducing secondary kick back The FRSS is made of a resilient material allowing smooth action and preventing any suspension component damage Setting the Rear Suspension Ride Height 1 To set up the rear suspension torsion spring ...

Page 209: ...The dot is an indicator of the HIGH position The sides are the LOW position and the bottom is the MEDUIUM position Front Torque Arm Limiter Strap Adjustment One method of changing ski to snow pressure is to change the length of the front torque arm limiter straps The limiter strap is normally mounted in the fully extended position Both limiter straps must be adjusted evenly and remain equal in len...

Page 210: ...3 8 cm If the difference is greater than 1 1 2 the rear spring should be adjusted equally on both sides until the desired 1 1 2 drop is obtained Compensating adjustments for heavy or light drivers or cargo loads can be made by adjusting the rear spring eye bolt A length Adjust spring tension so there is equal tension on the long leg of each spring NOTE Rear spring settings will affect ski to groun...

Page 211: ...tate freely after tightening fasteners Apply Polaris Premium All Season Grease to all grease zerks as outlined in the maintenance table SHOCK PIVOT IDLER SHAFT SHAFT H BRACKET REAR PIVOT SHAFT SHAFT SPACER WASHER SPACER GREASE ZERK GREASE ZERK B A B C Both Sides B B A T A 45 Ft Lbs B 35 Ft Lbs C 36 Ft Lbs CAUTION Some rail shaft fasteners are pre coated with locking agent Never re use these fasten...

Page 212: ...ghtening fasteners Apply Polaris Premium All Season Grease to all grease zerks as outlined in the maintenance table RAIL TIP CARRIER WHEELS REAR REAR SCISSOR STOP FRONT REAR SCISSOR STOP IDLER ADJUSTMENT BOLT SLIDER SLIDER FASTENER A A A B B B C T A 19 Ft Lbs B 35 Ft Lbs C 3 6 Ft Lbs CAUTION Some rail shaft fasteners are pre coated with locking agent Never re use these fasteners once removed Alway...

Page 213: ...remium All Season Grease to all grease zerks as outlined in the maintenance table TORQUE ARM SHOCK ASSEMBLY GREASE ZERK SPACER GREASE ZERK LIMITER STRAP SHOCK ASSEMBLY SHOCK ROD SPACER TORSION SPRING MOUNTING ARM A A B B C B C C D C C T A 12 Ft Lbs B 45 Ft Lbs C 35 Ft Lbs D 25 Ft Lbs CAUTION The fasteners securing the rear suspension to the tunnel are pre coated with a locking agent when new Never...

Page 214: ...ate freely after tightening fasteners Apply Polaris Premium All Season Grease to all grease zerks as outlined in the maintenance table H BRACKET SHAFT SHOCK PIVOT REAR PIVOT SHAFT SPACER SHAFT SHAFT A B B A A C Shock Pivot Shaft B B T A 45 Ft Lbs B 35 Ft Lbs C 19 Ft Lbs CAUTION Some rail shaft fasteners are pre coated with locking agent Never re use these fasteners once removed Always use new pre ...

Page 215: ...Apply Polaris Premium All Season Grease to all grease zerks as outlined in the maintenance table SLIDER SLIDER FASTENER RAIL TIP REAR REAR SCISSOR STOP FRONT REAR SCISSOR STOP CARRIER WHEEL CARRIER WHEEL WHEEL MOUNT SPRING GUIDE IDLER ADJUSTMENT BOLT A A C C C A T A 3 6 Ft Lbs B 35 Ft Lbs C 19 Ft Lbs CAUTION Some rail shaft fasteners are pre coated with locking agent Never re use these fasteners o...

Page 216: ...Season Grease to all grease zerks as outlined in the maintenance table TORQUE ARM LIMITER STRAP SHAFT SHOCK ASSEMBLY GREASE ZERK GREASE ZERK SHAFT SHOCK ASSEMBLY TORQUE ARM SHOCK RODS SHAFT TORSION SPRING MOUNTING ARM SHAFT A A B B C C C D C C C T A 12 Ft Lbs B 40 Ft Lbs C 35 Ft Lbs D 25 Ft Lbs CAUTION The fasteners securing the rear suspension to the tunnel are pre coated with a locking agent whe...

Page 217: ...te freely after tightening fasteners Apply Polaris Premium All Season Grease to all grease zerks as outlined in the maintenance table SHAFT SHAFT SHAFT SPACER SHAFT SHAFT REAR PIVOT ARM SHOCK PIVOT ARM CENTERING SLEEVES A B A C A A T A 35 Ft Lbs B 45 Ft Lbs C 19 Ft Lbs CAUTION Some rail shaft fasteners are pre coated with locking agent Never re use these fasteners once removed Always use new pre c...

Page 218: ...ter tightening fasteners Apply Polaris Premium All Season Grease to all grease zerks as outlined in the maintenance table RAIL TIP SLIDER CARRIER WHEEL CARRIER WHEEL CARRIER WHEEL IDLER ADJUSTER BOLT SPRING GUIDE SLIDER FASTENER A B B B C B T A 3 6 Ft Lbs B 19 Ft Lbs C 35 Ft Lbs CAUTION Some rail shaft fasteners are pre coated with locking agent Never re use these fasteners once removed Always use...

Page 219: ...ris Premium All Season Grease to all grease zerks as outlined in the maintenance table TORQUE ARM SHOCK ASSEMBLY LIMITER STRAP SHAFT SHAFT TORQUE ARM TORSION SPRING SHAFT SCISSOR SHAFT SHOCK ROD SHOCK ASSEMBLY A A B C C D B D D D T A 40 Ft Lbs B 19 Ft Lbs C 12 Ft Lbs D 25 Ft Lbs CAUTION The fasteners securing the rear suspension to the tunnel are pre coated with a locking agent when new Never re u...

Page 220: ...ase zerks as outlined in the maintenance table Thoroughly grease all inner shafts prior to installing into outer shafts EXTENSION SPRING EXTENSION SPRING SPACER IDLER SHAFT SPACER SPACER CENTERING SLEEVES INNER SHAFT INNER OUTER SHAFTS INNER OUTER SHAFTS A A A B C D C A E E F T A 45 Ft Lbs B 50 Ft Lbs C 19 Ft Lbs D 55 65 Ft Lbs E 36 Ft Lbs F 3 6 Ft Lbs CAUTION Some rail shaft fasteners are pre coa...

Page 221: ...all grease zerks as outlined in the maintenance table Thoroughly grease all inner shafts prior to installing into torque arm assemblies TORSION SPRING INNER SHAFT REAR TORQUE ARM REAR SCISSOR INNER SHAFT TENSION ADJUSTER INNER SHAFT FRONT TORQUE ARM INNER SHAFT SPACER SPACER INNER SHAFT SHOCK ASSEMBLY A B B B A B A T A 40 Ft Lbs B 25 Ft Lbs C 45 Ft Lbs CAUTION Some rail shaft fasteners are pre coa...

Page 222: ...after tightening fasteners Apply Polaris Premium All Season Grease to all grease zerks as outlined in the maintenance table REAR EXTENSION SPACER INNER SHAFT SPACER CARRIER WHEEL TUNNEL MOUNTED CARRIER WHEELS IDLER SHAFT SPACER A A A C B B T A 40 Ft Lbs B 35 Ft Lbs C 3 6 Ft Lbs CAUTION Some rail shaft fasteners are pre coated with locking agent Never re use these fasteners once removed Always use ...

Page 223: ...ners Apply Polaris Premium All Season Grease to all grease zerks as outlined in the maintenance table ADJUSTMENT KNOB REAR TORQUE ARM COUPLER INNER SHAFT OUTER SHAFT CLEVIS INSIDE COUPLER LINK OUTER COUPLER RH INNER ADJUSTMENT ARM LH INNER ADJUSTMENT ARM ADJUSTER A B B B B B T A 45 Ft Lbs B 19 Ft Lbs CAUTION Some rail shaft fasteners are pre coated with locking agent Never re use these fasteners o...

Page 224: ...pivots must rotate freely after tightening fasteners Apply Polaris Premium All Season Grease to all grease zerks as outlined in the maintenance table T A 19 Ft Lbs CLEVIS COUPLER INSIDE COUPLER OUTER COUPLER A A KNOB RH INNER ADJUSTER LH INNER ADJUSTER ADJUSTER ASSEMBLY CAUTION Some rail shaft fasteners are pre coated with locking agent Never re use these fasteners once removed Always use new pre ...

Page 225: ...ck Special Tools PART NUMBER DESCRIPTION PS 45259 Gas Fill Tool and Gauge Incl 5 needles PS 45259 1 Gas Fill Needles replacement pack PS 45259 2 Gas Fill Gauge replacement PS 45260 Lower Retainer Wrench PS 45261 IFP Positioning Extraction tool PS 45262 Cylinder Head Wrench PS 45263 Wear Band Tool PS 45629 Arvin Shock Body Holder PS 45280 Shock Collar Tool PS 45821 Shock Reservoir Holder 2877143 Ai...

Page 226: ...121 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 1700137 1 250 1700142 1 300 1700085 0 700 0 015 1700091 0 ...

Page 227: ... shown in the illustration regardless of how the 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 COMPRE...

Page 228: ... would appear on the shaft when shock rod is locked in a table vise eyelet down threaded end up Rebuildable IFS Shocks SHOCK PN BRAND Extended Length in Collapsed Length in Stroke in Shock Rod in IFP Depth in Nitrogen PSI 7043082 Ryde FX 16 25 11 0 5 25 49 6 27 280 IFS Shocks SHOCK 7043082 REBOUND 8 x 010 9 x 010 1 0 x 010 1 1 x 010 1 25 x 006 Piston Orifice 093 COMPRESSION 1 3 x 008 1 25 x 008 9 ...

Page 229: ...ar on the shaft when shock rod is locked in a table vise eyelet down threaded end up Rebuildable Front Track Shocks SHOCK PN BRAND Extended Length in Collapsed Length in Stroke in Shock Rod in IFP Depth in PSI 7041975 Ryde FX 12 1 8 6 3 5 49 4 61 200 Front Track Shocks SHOCK 7041975 REBOUND 8 x 012 9 x 012 1 0 x 010 1 1 x 010 1 25 x 008 Piston Orifice 070 COMPRESSION 1 3 x 008 1 0 x 006 1 3 x 008 ...

Page 230: ...ssure valve assembly from the lower end mount Account for an O ring 12 Using an adjustable face spanner PN PS45262 fully loosen and remove cylinder head assembly 13 Pour the oil out of the shock body Discard old oil into an approved storage container and dispose appropriately Never reuse damper oil during shock rebuild 14 Using the I F P extraction tool thread the tool into the I F P and pull upwa...

Page 231: ...dicator knob comes in contact with the shock body The piston should now be located correctly 6 Screw the pressure valve assembly into the valve port by hand with a slotted head screwdriver and tighten to 100 110 in lb of torque 7 Fill the shock body with shock oil Internal Floating Piston Shocks Fill the shock body with shock oil to the bottom of the thread within the cylinder Emulsion Shocks Fill...

Page 232: ...rew clockwise Increase torsion spring preload Install stiffer torsion springs Rides too stiff in rear Check for binding suspension shafts and grease all pivot points Decrease torsion spring preload adjustments Decrease rear shock compression valving by turning screw counterclockwise Setting up for deep snow operation Change worn rail slides Increase front limiter strap length Based on rider prefer...

Page 233: ...NOTES Steering and Suspension Systems 8 38 9923396 2007 2012 EDGE Widetrak LX Service Manual 2011 Polaris Sales Inc ...

Page 234: ...MPER 9 2 EDGE FRONT BUMPER REMOVAL INSTALLATION 9 2 REAR BUMPER REMOVAL INSTALLATION 9 3 HEADLIGHT 9 3 EDGE HEADLIGHT REMOVAL INSTALLATION 9 3 SEATS 9 3 SEAT BASE REMOVAL INSTALLATION 9 3 SEAT AND FUEL TANK 9 3 EDGE FUEL TANK REMOVAL INSTALLATION 9 3 SEAT COVER REPLACEMENT 9 4 CONSOLE 9 4 CONSOLE REMOVAL INSTALLATION 9 4 TAIL LIGHT 9 4 EDGE TAIL LIGHT ASSEMBLY REPLACEMENT 9 4 TAIL LIGHT ASSEMBLY R...

Page 235: ...emoval Hood Repair Currently there is no procedures or materials recommended by Polaris for repairing hoods Hoods are made of Thermoplastic Olefin TPO and cannot be repaired If a hood is broken it must be replaced For small cracks you may drill a small hole on both ends of the crack to limit spreading This procedure is called stop drilling BUMPER Edge Front Bumper Removal Installation 1 Remove the...

Page 236: ...nstallation is the reverse of removal SEATS Seat Base Removal Installation 1 If unit is equipped with a seat latch 1 remove the seat or passenger seat if so equipped 2 Remove the fasteners 2 that hold the seat base onto the tunnel or rear seat brace 3 Unplug the tail light harness if applicable and remove the seat base SEAT AND FUEL TANK Edge Fuel Tank Removal Installation 1 Remove any fuel that m...

Page 237: ...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 12 Trim excess vinyl from the bottom around the back of the seat area only after a satisfactory fit is obtained CONSOLE Console Removal Installation 1 Place the adjustable steering in the center if equipped 2 Remove the two T25 Torx...

Page 238: ...INES 10 6 IGNITION TIMING CHART 10 7 THROTTLE POSITION SENSOR TPS 10 8 TPS TEST TOOL SETUP 10 8 USING THE TPS TEST TOOL 10 8 TPS ADJUSTMENT CARBURETED MODELS 10 9 ELECTRIC START GEN II EDGE 10 10 SYSTEM SCHEMATIC 10 10 STARTER MOTOR ASSEMBLY TYPICAL 10 11 BATTERY BOX 10 12 DYNAMIC TESTING 10 13 STATIC TESTING 10 13 STARTER HOUSING FIELD COIL TESTING 10 14 ARMATURE TESTING 10 14 CARBURETED ELECTRIC...

Page 239: ...Install vent covers Model Number Engine EC34 Fuji 340cc Fan Cooled EC50PL Fuji 488cc Liquid Cooled EC55PM Fuji 544cc Fan Cooled S3303 5044 PF5C Polaris 500cc Liquid Cooled Model Spark Plug Gap Inches mm EC34 NGK BR8ES 0 028 0 70 EC50PL Champion RN3C 0 028 0 70 EC55PM NGK BR9ES 0 028 0 70 S3303 5044 PF5C Champion RN57YCC 0 028 0 70 Model Stator Output of Pulses EC34 240W 6 EC50PL 200W 2 EC55PM 240W...

Page 240: ...ck specific gravity of each cell with a hydrometer to ensure each has a reading of 1 270 or higher 6 Install vent cover NOTE Once the vent cover is installed the battery is sealed Do not remove the cover Specifications BATTERY TESTING Testing Procedures Batteries should be kept at or as near full charge as possible If the battery is stored or used in a partially charged condition hard crystal sulf...

Page 241: ... to replace the battery Battery Conductance Analyzer Conductance describes the ability of a battery to conduct current A conductance tester functions by sending a low frequency AC signal through the battery and a portion of the current response is captured from this output a conductance measurement is calculated Conductance testing is more accurate than voltage specific gravity or load testing Aut...

Page 242: ...bles and terminals 3 Charge at a rate no greater than 1 10 of the battery s amp hr capacity 4 Store the battery in a cool dry place NOTE Stored batteries lose their charge at the rate of 1 per day They should be fully recharged every 30 to 60 days during a non use period If stored during winter months the electrolyte will freeze at higher temperatures as the battery discharges CAUTION DO NOT ALLOW...

Page 243: ... specified timing RPM 7 Point the timing light at the timing inspection hole 8 With your head positioned so there is a straight line between your eye the stationary pointer and the crankshaft center line note the relative position between the marked flywheel line and the pointer If the stationary pointer is aligned with the mark made in Step 3 or within the acceptable variance ignition timing is c...

Page 244: ...3 1 3624 0 0536 1 4678 0 0578 1 5938 0 0628 1 5439 0 0608 17 1 2106 0 0477 1 5359 0 0605 1 6548 0 0652 1 7969 0 0707 1 7406 0 0685 18 1 3552 0 0534 1 7195 0 0677 1 8526 0 0729 2 0117 0 0792 1 9487 0 0767 19 1 5077 0 0594 1 9130 0 0753 2 0611 0 0811 2 2380 0 0881 2 1681 0 0854 20 1 6679 0 0657 2 1163 0 0833 2 2802 0 0898 2 4759 0 0975 2 3986 0 0944 21 1 8358 0 0723 2 3294 0 0917 2 5098 0 0988 2 725...

Page 245: ... wire terminal and the red multimeter probe into the pink wire terminal Voltage should read 4 99 to 5 01 Vdc Use a new battery if voltage is below 4 99 Vdc 3 Connect the test tool to the TPS on the carburetor or 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 no...

Page 246: ...ngine operating temperature and the throttle cable free play is set to 0 10 0 30 1 Connect the TPS test tool to the TPS 2 Slightly loosen the screws securing the TPS to carburetor body 3 Have an assistant hold the throttle flipper in the WOT position 4 Turn the TPS clockwise to decrease voltage or counterclockwise to increase voltage 5 Carefully tighten the TPS screws when the WOT Vdc is 4 00Vdc ...

Page 247: ...10 10 Battery and Electrical Systems 9923396 2007 2012 EDGE Widetrak LX Service Manual 2011 Polaris Sales Inc ELECTRIC START GEN II EDGE System Schematic ...

Page 248: ... fasteners on 550 engines are treated with Loctite 262 Apply heat to each fastener to soften the threadlock prior to removing fastener Apply Loctite 262 to threads during assembly STARTER SOLENOID STARTER MOTOR MOTOR BRACKET MOTOR BRACKET GROUND CABLE 14 16 Ft Lbs 19 21 Nm 19 26 Ft Lbs 25 35 Nm 9 Ft Lbs 12 Nm COMMUTATOR CAP ARMATURE DRIVE CAP SCREW RETURN SPRING ASM PINION ...

Page 249: ... Battery and Electrical Systems 9923396 2007 2012 EDGE Widetrak LX Service Manual 2011 Polaris Sales Inc Battery Box BATTERY BOX SOLENOID CIRCUIT BREAKER RED LEAD TO STARTER RED LEAD FROM BATTERY GROUND WIRE ...

Page 250: ...hop battery to continue the test and continue with left column YES Disconnect two pin harness from starter solenoid Connect black multimeter probe to the engine or ground then the red probe to the red harness wire at solenoid Rotate ignition key to the start position Meter should read battery voltage Does it NO With black tester lead on ground check for voltage at large relay terminal circuit brea...

Page 251: ...pect insulated brush wire and field coil insulation for damage Repair or replace components as required Armature Testing 1 Using a digital multimeter measure resistance between each of the segments of the commutator The reading should indicate 3 ohms or less 2 Measure resistance between commutator and armature shaft Reading should be infinity 3 Place armature in a growler With the growler on posit...

Page 252: ...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 500 EV Coolant Temperature Sensor Specifications BRN WHT TO BLK RED 164 YELLOW TO YEL RED 0 2 0 5 YEL RED WHT BRN TO GROUND 0 Specifications YEL TO BRN 0 16 BRN TO ENGINE 0 BLK RED TO GRN 13 RED ...

Page 253: ...lace the coil Incorrect Timing Advanced Retard Follow the engine timing procedure for checking running timing at recommended RPM Is the timing within limits NO Adjust the ignition timing by rotating the stator plate to correct the timing After adjusting the recommended RPM timing continue with operating RPM timing if poor performance exists Continue on with left column YES Remove the ignition kill...

Page 254: ... of the reverse system To set the altitude settings 1 With the engine running push and hold the reverse button for 5 6 seconds and then release the button 2 The reverse light will flash rapidly on the instrument panel 3 To go back to the low elevation setting repeat step 1 The reverse light will flash slowly indicating the system is in the lower elevation setting NOTE The elevation setting will be...

Page 255: ...rmer on all Polaris snowmobiles is a thermistor type warming element pad This means its resistance will change based on temperature Thumb Warmer Resistance Checks CIRCUIT Wire Color RESISTANCE ROOM TEMP 68 F 20 C LOW ORANGE GRAY to GROUND BROWN 1 120 HIGH WHITE GRAY to GROUND BROWN 1 120 LOW or HIGH to CHASSIS SHORT O L OPEN CIRCUIT PACKARD CONNECTOR MOLEX CONNECTOR ...

Page 256: ...en between the left and right pads If the resistance of the left pad is significantly higher than that of the right more current will flow to the right side While more common reasons for this can be attributed to how the customer holds the bar in their hands fingers on brake lever and not wrapped around grip etc there may be instances where comparing the left and right hand warmer resistance value...

Page 257: ...wmobiles 3 Start the engine Set the multimeter to check for AC voltage carbureted DC CFI snowmobiles or DC voltage CFI snowmobiles 4 Observe the voltage reading The reading should be either 12 14 VAC or 12 14 VDC depending on the vehicle If no or low voltage is present there is a problem with the chassis electrical system If voltage is present continue with step 5 5 Reconnect the power harness bac...

Page 258: ...11 1 Wiring Diagrams 9923396 2007 2012 EDGE Widetrak LX Service Manual 2011 Polaris Sales Inc 2007 340 550 Models ...

Page 259: ...11 2 Wiring Diagrams 9923396 2007 2012 EDGE Widetrak LX Service Manual 2011 Polaris Sales Inc 2007 Widetrak ...

Page 260: ...11 3 Wiring Diagrams 9923396 2007 2012 EDGE Widetrak LX Service Manual 2011 Polaris Sales Inc 2007 500 XCSP ...

Page 261: ...11 4 Wiring Diagrams 9923396 2007 2012 EDGE Widetrak LX Service Manual 2011 Polaris Sales Inc 2008 340 2008 2010 550 Models ...

Page 262: ...11 5 Wiring Diagrams 9923396 2007 2012 EDGE Widetrak LX Service Manual 2011 Polaris Sales Inc 2008 2012 Widetrak ...

Page 263: ...Crankcase Torque Patterns 5 2 Crankshaft Runout Inspection 5 4 Truing 5 9 Crankshaft Indexing 5 6 Crankshaft Inspection Checking Crankshaft Indexing 5 7 Connecting Rod small end 5 6 Connecting rod bearing 5 5 Indexing 5 6 Main bearing 5 5 Crankshaft Truing 5 9 Cylinder Head Torque Patterns 5 2 Cylinder Honing 5 8 Cylinder Measurements 5 3 Cylinder Torque Patterns 5 2 D Drive Driven Clutches Belt D...

Page 264: ...tering 8 8 Maximum Width Setup 8 9 Overview and Specifications 8 5 Rod End Engagement 8 8 Setup and Adjustments 8 6 Toe Adjustment 8 10 Front Suspension Assembly Views EDGE 41 8 3 EDGE 42 5 8 2 Widetrak 8 4 Front Track Shock Specifications 8 34 Fuel Intake System Maintenance Water Sediment Trap 3 14 Fuel and Oil Premix Ratios 2 5 Fuel Filter 3 13 Fuel Pump Operation 4 13 Fuel System Overview Warni...

Page 265: ...le 3 2 Piston Inspection 5 4 Piston Ring Installed Gap 5 5 Piston Wash Reading 2 7 Publications 2007 2 3 2008 2 3 2009 2 3 2010 2 3 2011 2 3 2012 2 3 PVT System Adjusting Belt Deflection 7 13 Belt Deflection Widetrak Roller Driven 7 14 7 15 Drive Belt Installation Widetrak Roller Driven 7 15 Drive Belt Removal Widetrak Roller Driven 7 15 Drive Belts 7 11 Drive Clutch Springs 7 5 Non ER LW Driven H...

Page 266: ...Standard Bolt Torque Specification 2 5 Steering Inspection 8 5 T Taillights 9 4 Throttle Lever Freeplay 3 19 Throttle Position Sensor 10 8 Torque Stops Adjustment 3 7 Widetrak 3 7 Track Alignment 3 22 Track Tension 3 21 Troubleshooting Tables 10 16 V Vehicle Information Model Number 2 2 Tunnel Decal 2 2 VIN Number 2 2 VIN 2 2 W Wide Trak Driven Clutch Components 7 26 Widetrak Gearcase 6 11 Assembl...

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