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11.2

BATTERY & ELECTRICAL SYSTEMS

CRANKSHAFT POSITION SENSORS (CPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.29
STATOR ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.30
EXHAUST VALVE SOLENOID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.31
CFI IGNITION COILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.31
REGULATOR / RECTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.31
CHASSIS POWER CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.31
ENGINE COOLANT TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.32
KNOCK SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.32
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.32
CFI POWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.33
CFI IGNITION / INJECTION POWER  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.33
CFI CRANK POSITION SYSTEM  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.34
CFI SAFETY STOP SYSTEM  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.34
CFI FULL LOAD FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.35
CFI PART LOAD FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.35
CFI CHASSIS POWER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.36
CFI IGNITION COILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.36
CFI TBAP SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.37
CFI TPS / ENGINE TEMP. SENSORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.37
CFI EXHAUST SOLENOID  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.38
CFI KNOCK SENSOR  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.38
CFI FUEL PUMP  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.39
CFI DIAGNOSTIC CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.39
CFI MFD CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.40
CFI MFD POWER CIRCUITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.40
CFI FUEL LEVEL CIRCUIT  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.41
CFI VEHICLE SPEED CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.41
CFI MODE SET SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.42
CFI PERC SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.42

DIGITAL WRENCH DIAGNOSTIC SOFTWARE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  11.43

OVERVIEW  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.43
DIGITAL WRENCH CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.43
UPDATING DIGITAL WRENCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.44
VERSION / FILESET IDENTIFICATION  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.45
ENGINE CONTROLLER REPROGRAMMING (REFLASH)  . . . . . . . . . . . . . . . . . . . . 11.45

CARBURETED ELECTRICAL SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  11.47

EC50PL STATOR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.47
EC34 / EC55 STATOR SPECIFICATIONS  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.47
500CC EV / 600 HO STATOR SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.47
IGNITION COIL PACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.47
EXHAUST VALVE SOLENOID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.47
KNOCK SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.47
600HO COOLANT TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.48
500 EV COOLANT TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.48
OIL LEVEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.48
600 HO REGULATOR / RECTIFIER  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.48

TROUBLESHOOTING TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  11.49

NO SPARK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.49

DETONATION CONTROL (DET)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  11.50

OVERVIEW  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.50

VARIABLE EXHAUST VALVES (VES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  11.50

OVERVIEW  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.50

DIAGNOSTIC PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  11.51

IQ CHASSIS POWER PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.51
IQ CFI FUEL PUMP PRIME PLUG  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.51

ELECTRONIC REVERSE (PERC)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  11.51

OVERVIEW  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.51
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.51
FORWARD OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.52
ALTITUDE SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.52
IMPORTANT NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.52

Содержание 340 LX 2007

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

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

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

Страница 4: ......

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 47: ...ce stations selling a large volume of fuel will normally have the correct blend to work well at all times throughout the year in their local area When the weather is very cold gasoline must be able to...

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

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

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

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

Страница 52: ...2 12 GENERAL...

Страница 53: ...2 13 GENERAL 2...

Страница 54: ...2 14 GENERAL...

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

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

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

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

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

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

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

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

Страница 63: ...ng Polaris uses crankshafts that are pressed together The connecting rod journal center lines are indexed 180 apart from each other It is sometimes necessary to check multi cylinder crankshafts to ver...

Страница 64: ...54mm ATDC NOTE Do not move the crankshaft degree wheel or pointer after the initial setting on the MAG end cylinder simply read the wheel and dial indicator 10 Remove the dial indicator and install in...

Страница 65: ...s you what action is required to straighten the shaft Truing Examples To correct a situation like this Strike the shaft at point A with a brass hammer To correct a situation like the one shown in this...

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

Страница 67: ...e Brake Fluid Replacement Bleeding on page 7 20 NOTE A low brake fluid level can be indicated through the sight glass on the cover If the fluid is low this sight glass will glow a brighter color Exhau...

Страница 68: ...belt deflection B is when the belt is too short or the center distance is too long The initial starting ratio will be too low In addition the machine may creep when the engine idles causing damage to...

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

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

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

Страница 72: ...e slack that occurs if the cable has stretched over time NOTE Never use the in line adjuster to adjust engine idle speed and never adjust the cable so that the throttle plate cam on the throttle body...

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

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

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

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

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

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

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

Страница 80: ...NOTES MAINTENANCE 3 26...

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

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

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

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

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

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

Страница 87: ...ng sure gaskets are properly positioned MIKUNI CARBURETOR Function The function of a carburetor is to produce a combustible air fuel mixture by breaking fuel into tiny particles in the form of vapor t...

Страница 88: ...en starting the engine Fuel Delivery The pilot system s main function is to meter fuel at idle and low speed driving Though its main function is to supply fuel at low speed it does feed fuel continuou...

Страница 89: ...et installed in production is not correct for all altitudes and or temperatures Refer to the jetting cart in the Specifications Chapter of this manual for correct jetting for altitude temperature rang...

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

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

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

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

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

Страница 95: ...ER MAIN JET PART NUMBER MAIN JET PART NUMBER 95 3130102 175 3130118 310 3130134 470 3130147 100 3130103 180 3130119 320 3130135 490 3130148 105 3130104 185 3130120 330 3130136 500 3130149 110 3130105...

Страница 96: ...3130778 1 1 3130799 1 2 3130780 1 3 3130781 1 4 3130782 1 5 3130783 1 6 3130784 1 7 3130785 1 8 3130786 1 9 3130787 2 0 3130788 AIR JET PART NUMBER 0 5 3131255 0 6 3131249 0 7 3131256 0 8 3131254 0 9...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 136: ...enter of the throttle bodies 31 Remove the oil cable lock nut from the threads on the cable housing 32 Remove the throttle cable from the oil pump bracket 33 Remove the oil cable 23 from the oil pump...

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

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

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

Страница 140: ...ot pinched or interfere with installation 13 Route the oil supply line from the engine through the hose guide 14 Install the oil bottle and hook up the supply line 3 Open and slide the hose clamp onto...

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

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

Страница 143: ...d install the braces NOTE Install the long bolts and the spacer on the front portion of the bar before inserting it into the mounting area 42 Replace the nosepan plugs were removed to access the front...

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

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

Страница 146: ...NOTES ENGINE 5 42...

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

Страница 148: ...red operating RPM but never below after the driven clutch begins to open Shift Out RPM Engine RPM at which the up shift force generated by the drive clutch overcomes the shift force within the driven...

Страница 149: ...ed to gear the snowmobile with a slightly higher ratio than the actual top speed the snowmobile will ever achieve 1 1 Shift Ratio A 1 1 shift ratio occurs when the drive clutch and the driven clutch a...

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

Страница 151: ...041168 Green 177 3 05 42 142 76 7041148 Gold 207 3 25 100 275 133 7041150 Red White 192 3 59 100 220 91 7041286 Silver Gold 218 3 05 77 240 163 7041080 Blue 207 3 55 120 300 137 7041781 Dark Blue Whit...

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

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

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

Страница 155: ...p h indicated on speedometer Lower the gear ratio Remove windage plates from driven clutch If possible move to better snow conditions and reduce RPM Avoid riding in very high ambient temperatures Ice...

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

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

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

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

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

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

Страница 162: ...for wear or damage 15 Remove all three drive clutch weights 16 Inspect each weight The surface should be smooth with no waves or galling Place bolt inside weight to check flyweight bushing and pin sur...

Страница 163: ...roller failure 1 Drive pin into the spider leg 100 125 0 25 0 32cm beyond the first land of the spider leg 2 Install one washer on the portion of the pin that is protruding from the spider leg 3 Insta...

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

Страница 165: ...der has little effect on overall clutch balance Re indexing the spider 1 3 turn clockwise or 1 leg will allow the realignment of the moveable and stationary sheaves as previously marked D For EXAMPLE...

Страница 166: ...taper should be clean and dry Do not use harsh cleaners which may cause clutch taper to corrode or damage the crank seal 4 Clean clutch taper with lacquer thinner or isopropyl alcohol C 5 Slide clutc...

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

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

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

Страница 170: ...NOTES CLUTCHING 6 24...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 189: ...e the fluid to equalize pressure as the fluid expands or contracts Be sure the vent is open and allowed to function If the reservoir is overfilled or the diaphragm vent is plugged the expanding fluid...

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

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

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

Страница 193: ...on the caliper in the same orientation as it was before it was removed 4 Clean the threads of the banjo bolt and the threads in the caliper 5 Follow Brake Line Replacement See Brake Line Replacement...

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

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

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

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

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

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

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

Страница 201: ...ustment For the best ride the spring preload should be as low as possible Set the preload to use the full travel of the ski shock with occasional light bottoming For the best ride the spring preload s...

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

Страница 203: ...mpress 4 5 inches A 150 in spring would only compress 3 inches If the suspension had 4 inches of spring travel the 100 in spring would bottom out while the 150 in spring would have one inch of travel...

Страница 204: ...inues after the screw is turned in full clockwise the compression spring should be adjusted with the threaded adjustment collar Back the screw out to the original starting position after the compressi...

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

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

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

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

Страница 209: ...n do the steering arms go on weld up or weld down etc Some of the fasteners used in the IFS are special and cannot be purchased at a hardware store Always use genuine Polaris parts and hardware when r...

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

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

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

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

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

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

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

Страница 217: ...l Tools PART NUMBER DESCRIPTION PS 45259 Gas Fill Tool and Gauge Incl 5 needles PS 45259 1 Gas Fill Needles replacement pack PS 45259 2 Gas Fill Gauge replacement PS 45260 Lower Retainer Wrench PS 452...

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

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

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

Страница 221: ...effect rear spring and spring preload also have some effect on weight transfer Softer rear springs or less preload allow more weight transfer to the track and reduce ski pressure Stiffer rear springs...

Страница 222: ...eload measure the distance between the ground and rear bumper with out the rider on the seat and the suspension at full extension This can be achieved by lifting the rear of the machine so that the su...

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

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

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

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

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

Страница 228: ...The suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions It should be noted however that suspension adjustments involve a compromise or t...

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

Страница 230: ...iners listed in the chart always order the retainer insert as well The insert is not removable once installed so a new insert is needed when installing a new retainer M 10 Ski Pressure Ski pressure is...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 248: ...a tool is required to aid in proper seating of o ring use the non writing end of a pen or a similar soft blunt object to push it in 7 Install the new U cup seal into bearing U cup should be installed...

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

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

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

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

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

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

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

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

Страница 257: ...il the decal is warm to touch DO NOT OVER HEAT Overheating may cause damage to the paint and to the integrity of the hood Polaris is not responsible for any hood damage resulting from this decal repla...

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

Страница 259: ...10 11 CHASSIS HOOD 10...

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

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

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

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

Страница 264: ...eater FRESH PACK BATTERY NOTE Do not service the battery unless it will be put into regular service within 30 days Battery Preparation Some models are equipped with a fresh pack battery These batterie...

Страница 265: ...be observed in a fully charged battery Differences of more than 0 025 between the lowest and highest cell readings indicate a need to replace the battery Off Season Storage To prevent battery damage d...

Страница 266: ...tain specified timing RPM 7 Point the timing light at the timing inspection hole 8 With your head positioned so there is a straight line between your eye the stationary pointer and the crankshaft cent...

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

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

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

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

Страница 271: ...elieved the plates are out of sync To adjust throttle plate synchronization follow these steps 1 Perform the TPS Baseline Adjustment The TPS must be set to specification 2 Carefully back the synchroni...

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

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

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

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

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

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

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

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

Страница 280: ...egulator rectifier RED circuit is used to power the ECU and fuel pump Ignition Coils Provide ignition energy to each spark plug Both coils are fired at the same time Fuel Injectors CFI uses one set of...

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

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

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

Страница 284: ...CE ECU GROUND 14 RED BLUE CHASSIS HOOD 2 WATER TEMP SIGNAL 16 YELLOW RED CHASSIS HOOD 1 TACHOMETER SIGNAL 17 ORANGE REGULATOR RECTIFIER VOLTAGE BOOST POWER 21 PINK DIAGNOSTIC K LINE 22 GRAY GRAY SPLIC...

Страница 285: ...REEN WHITE PTO PART LOAD INJECTOR INJECTOR CONTROL GROUND 10 RED WHITE TPS 5 VDC POWER SUPPLY 13 WHITE YELLOW EV SOLENOID SOLENOID CONTROL GROUND 14 BROWN MAG IGNITION COIL STATOR STATOR GROUND 15 GRE...

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

Страница 287: ...tivated when the throttle flipper switch is closed closed throttle but the TPS throttle plate position is still above idle When this occurs the ECU software will determine the throttle cable is stuck...

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

Страница 289: ...ll cause the engine to not start or kill if running The 2 tooth pick up detects the crank angle and obtains minimal information of the crank angle when control enters into limp home mode 5 tooth picku...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 312: ...instrument panel 3 You have now set the PERC system to the higher elevation setting 4 To go back to the low elevation setting repeat step 1 The reverse light will flash slowly indicating that the syst...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 327: ...12 10 Wiring Diagrams...

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