2007-2008 Polaris IQ Snowmobiles Service Manual
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Polaris Snowmobiles - Factory Service / Repair/ Workshop Manual Download.
Factory repair manual for 2007-2008 Polaris IQ Snowmobiles.
Manual covers complete tear down and rebuild, pictures and parts diagrams, torque specs, maintenance, troubleshooting, etc.
Yamaha Snowmobiles models covered in this manual:
- 2007 600 HO IQ
- 2007 600 HO SWITCHBACK
- 2007 600 HO RMK
- 2007 600 HO IQ CFI
- 2007 600 HO SWITCHBACK CFI
- 2007 600 HO IQ LX CFI
- 2007 600 HO IQ TOURING CFI
- 2007 700 HO IQ DRAGON
- 2007 700 HO RMK DRAGON
- 2008 IQ SHIFT
- 2008 600 RMK 144 / 600 RMK SHIFT 155
- 2008 600 DRAGON IQ
- 2008 600 SWITCHBACK / 600 DRAGON SWITCHBACK
- 2008 600 IQ LX
- 2008 600 IQ TOURING
- 2008 600 RMK 155
- 2008 700 IQ / 700 DRAGON IQ
- 2008 700 SWITCHBACK / 700 DRAGON SWITCHBACK
- 2008 700 RMK 155 / 700 DRAGON RMK 155 / 163
- 2008 800 DRAGON RMK 155 / 163
Manual PN 9921044
Some Manual Chapters:
- Model Specifications
- General Information
- Maintenance
- Fuel Systems
- Engine and Cooling Systems
- Final Drive and Brakes
- PVT System
- Steering and Suspensions
- Shocks
- Chassis
- Electrical Systems
- Wiring Diagrams
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Full list of manual chapters:
2007 - 2008 IQ SNOWMOBILE SERVICE MANUAL
Foreword
Understanding Manual Safety Labels and Directions
TRADEMARKS
Chapter 1 - Model Specifications
Specifications
2007 600 HO IQ
2007 600 HO Switchback
2007 600 HO RMK
2007 600 HO IQ CFI
2007 600 HO Switchback CFI
2007 600 HO IQ LX CFI
2007 600 HO IQ Touring CFI
2007 700 HO IQ Dragon
2007 700 HO RMK Dragon
2008 IQ Shift
2008 600 RMK 144 / 600 RMK Shift 155
2008 600 Dragon IQ
2008 600 Switchback 600 Dragon Switchback
2008 600 IQ LX
2008 600 IQ Touring
2008 600 RMK 155
2008 700 IQ / 700 Dragon IQ
2008 700 Switchback 700 Dragon Switchback
2008 700 RMK 155 700 Dragon RMK 155 / 163
2008 800 Dragon RMK 155 / 163
Chapter 2 - General Information
Snowmobile Number Designations
Model Number Designation
Vehicle Identification Number (VIN)
Tunnel Decal
VIN Number Designation
Publication Part Numbers
2008 Publications
2007 Publications
Engine Data Formulas
Compression Ratio
Compression Ratio Example
Head cc Removal Example
Port Opening Duration
Torque Conversion
US to Metric
General Reference
Standard Bolt Torque Specification
Fuel / Oil Premix Ratios
Gasoline Volatility
SAE Tap Drill Sizes
Metric Tap Drill Sizes
Decimal Equivalents
Measurement Conversion Chart
Piston Wash / Spark Plug Reading
Service Precautions
GENERAL PRECAUTIONS
Chapter 3 - Maintenance
Periodic Maintenance
Periodic Maintenance Schedule
Maintenance Products
Engine Oils / Lubricants / Misc.
Drive / Driven Clutches
Belt Deflection Inspection
Deflection Adjustment - Team Driven
Torque Stop Adjustment
Engine Isolator Limiter Setting
Engine Maintenance
Exhaust Valve Cleaning
Surge Tank
Recommended Coolant
Cooling System Bleeding
Oil Pump Adjustment - Carbureted Models
Oil Pump Adjustment - CFI Models
Oil Pump Bleeding
Fuel / Intake System
Water Sediment Trap
Fuel Filter - Carbureted Models
Fuel Filter - CFI Models
Oil Filter
Fuel Tank Vent System
Air Intake Box / Pre-Filters
Chassis Lubrication
Rear Suspension
Driveshaft Bearing
Throttle Cable
Choke And Choke Cable
Chaincase Oil Level Check
Chaincase Oil Replacement
Drive Chain Tension Adjustment
Brake System Maintenance
Brake Lever Travel
Brake Fluid
Throttle and Choke Cable Adjustments
Throttle Lever Free Play - Non CFI
Throttle Lever Free-Play - CFI Models
Choke Adjustment
Steering / Suspension Maintenance
Handlebars
Rider Select Steering U-Joint
Ski / Ski Skag Fasteners
Track Tension
Track Alignment
Electrical Systems
Headlight Bulb Replacement
Off-Season Storage
Chassis And Hood
Clutch And Drive System
Controls And Linkage
Electrical Connections
Carburetor/Throttle Body
Fuel System
Corrosion
Shocks
Battery
Chapter 4 - Fuel Systems
Service Warnings and Precautions
Service Warnings
Carburetor Fuel Systems
Mikuni Main Jets
Mikuni Pilot Jets
Mikuni Starter Jets
Mikuni Jet Needles
Mikuni (Short) Pilot Air Jets
Mikuni (Long) Pilot Air Jets
Mikuni TM Piston Valves
Mikuni TM (Notched) Piston Valves
Carbureted Fuel System (Typical)
Mikuni TM Carburetor
Function
Float System
Fuel Metering
Fuel Delivery
Pilot Jet
Fuel Screw
Main Jet
Jetting Guidelines
Piston Valve Or Throttle Valve
Jet Needle
Needle Jet
Throttle Opening Vs. Fuel Flow
Fuel pump
Fuel Pump Overview
Maintenance
Carburetor Service
Disassembly
Assembly
Carburetor Adjustment
Throttle Valve Synchronization
Cleanfire Fuel Injection
System Overview
Diagnostic Trouble Codes (DTCs)
MFD Blink Codes
DTC Troubleshooting
CFI Clutch Guard Electrical Center
34 Pin CNA ECU Connector
26 Pin CNB ECU Connector
Chassis Relay
Throttle / Ignition Kill System
Vehicle Speed Sensor
Exhaust Temperature Sensor
Temperature / Air Pressure Sensor (TBAP)
Crankshaft Position Sensors (CPS)
Stator Assembly
Exhaust Valve Solenoid
CFI Ignition Coils
Regulator / Rectifier
Chassis Power Capacitor
Engine Coolant Temperature Sensor
Knock Sensor
Fuel Injectors
Fuel Rail Bleeding / Pressure Testing
Disconnect Fittings
Fuel Tank Pressure Test
CFI Fuel Rail/Injector(s) Removal/Installation
2007 700 CFI Fuel System
2007 700 CFI Fuel Pump Service
CFI "Drop In Pump" Fuel Supply (Typical)
Drop In Fuel Pump Service
Drop In Fuel Pump Replacement
Throttle Body Removal
Digital Wrench Diagnostic Software
Overview
Digital Wrench Connections
Updating Digital Wrench
Version / Fileset Identification
Engine Controller Reprogramming (Reflash)
Chapter 5 - Engine and Cooling Systems
Engine Specifications
Fastener Torque Guide
Engine Specifications
Engine Service Specifications - All Engines
Component Torque Sequences
Engine Inspections
Cylinder Head Inspection
Cylinder Measurement
Crankshaft Runout Inspection
Piston Inspection
Piston Ring Installed Gap
Reed Valve Inspection
Bearing Fit
Main Bearing
Connecting Rod Lower Bearing
Piston Needle Bearing
Crankshaft Index
Checking Crankshaft Index
Cylinder Honing
Honing Procedure
Cleaning The Cylinder After Honing
Crankshaft Truing
Recoil Assembly
Rope Removal and Installation
Exhaust Valve Maintenance
Exhaust Valve Assembly
Exhaust Valve Disassembly
Exhaust Valve Assembly
Optional Exhaust Valve Springs
Engine Mounting Systems
2007 IQ Carbureted Engine Mounting
2007 IQ 600 CFI Engine Mounting
2008 IQ Carbureted Engine Mounting
2007 700 CFI / 2008 IQ CFI Engine Mounting
Engine Component Assemblies
600 HO Carbureted Cylinders / Cylinder Head
600 HO Carbureted Recoil / Magneto
600 HO Carbureted Pistons / Crankshaft
600 HO Carbureted Crankcase
600 HO Carbureted Water / Oil Pump
2007 - 2008 600 / 700 CFI Cylinder Head / Cylinders / Pistons
2008 800 CFI Cylinder Head / Cylinder / Pistons
2007 - 2008 600 / 700 / 800 CFI Recoil / Stator Assembly
2007 - 2008 600 / 700 CFI Crankcase / Crankshaft Assembly
2008 800 CFI Crankcase / Crankshaft
2007 - 2008 600 / 700 / 800 CFI Water / Oil Pump Assembly
600 / 700 / 800 CFI Oil Hose Routing
Engine Removal (Typical)
Engine Installation (Typical)
Cooling Systems
Thermostat Replacement
Thermostat Orientation
800 CFI Thermostats
2007 700 Dragon IQ Cooling System
2007 600 IQ / Switchback / LX - 2008 CFI LX Cooling System
2007 - 2008 CFI Touring Cooling System
2007 - 2008 600 / 700 RMK Cooling System
2008 IQ Shift - CFI 600 / 700 121 and Switchback Cooling System
2008 800 CFI RMK 155 Cooling System
2008 800 CFI RMK 163 (No Bypass) Cooling System
Exhaust Systems
Assembly View (Typical)
Chapter 6 - Final Drive and Brakes
Gear Ratio Speed Charts
8.373 CD Chaincase Speed Charts
Drive Gears and Chains
Drive Gears
Drive Chains
8.373 Chaincase
Assembly View
Chaincase Disassembly
Chaincase Assembly
Drive Train
Speedometer Cable Type Drive Train Assembly
Electronic Speedometer Drive Train Assembly
Driveshaft Removal/Installation
Brake System
Overview
Compensating Port
General Guidelines
Brake Fluid Replacement and Bleeding
Master Cylinder / Lever Service
Brake Line Replacement
Brake Light Switch Replacement
Caliper Removal
Caliper Replacement
Caliper Assembly
Brake Pad Replacement
Brake Disc Replacement
Chapter 7 - PVT System
PVT System
Overview
Drive Spring
Clutch Weight
Neutral Speed
Engagement RPM
Shift Out Over-Rev
Shift Out RPM
Driven Spring
Back-Shifting
Final Gearing
1:1 Shift Ratio
Low / High Ratio
Driven Helix / Ramp
General Information
Special Tools
Drive Clutch Springs
Spring Free Length
Drive Clutch Weights
PERC Team LWT Driven Helixes (24 Fin)
Non-PERC Team LWT Driven Helixes (24 Fin)
Team Ramp Angles
Team Driven Springs
Drive Belts
Belt Inspection
Drive Clutch Bolt Torque
Belt Wear / Burn Diagnostics
Drive Belt Removal - Team Driven Clutch
Drive Belt Installation - Team Driven Clutch
Adjusting Belt Deflection - Team Driven Clutch
PVT System Adjustments
Clutch Alignment / Offset
Offset Adjustment
Drive Clutch
Identification
Drive Clutch Removal
Drive Clutch Disassembly
Roller Removal
Roller Installation
Clutch Assembly
Spider Indexing
Drive Clutch Installation
Driven Clutch
Driven Clutch Removal
Driven Clutch Installation
Team LWT Components
Chapter 8 - Steering and Suspensions
Overview / Specifications
Inspection
Camber / Toe Specifications
Springs
Adjustable Shocks
Front Suspension Type by Model
Rear Suspension Type by Model
Suspension Mounting Fastener Torque
IQ Rear Suspension Shock Rod
IQ Rear Track Shock Pivot Orientation
Front Suspension Assembly Illustrations
IQ Front Suspension
IQ Fixed Steering Post Assembly
IQ Rider Select Steering Post Assembly
IQ Steering Linkage
Handlebar Assemblies
Adjustment Procedures
Setup and Adjustments
Alignment Bar Specifications
Camber
Rod Ends
Rod End Engagement
Camber Adjustment
Handlebar Centering
Toe Adjustment
Disassembly and Assembly
Spindle Removal
Spindle Assembly
Spherical Bearing Replacement
Upper / Lower Control Arm Removal
Upper / Lower Control Arm Installation
Rear Suspension Assembly Illustrations
IQ 121 Pivots / Rear Idler
IQ 121 Shift Pivots / Rear Idler
IQ 121 Rail Assembly
IQ 121 Shift Rail Assembly
IQ 121 / Shift Front / Rear Torque Arms
M-10 128 Pivots / Rear Idler
M-10 128 Rail Assembly
M-10 128 Front / Rear Torque Arms
M-10 136 Pivots / Rear Idler
M-10 136 Rail Assembly
M-10 136 Front / Rear Torque Arms
IQ Switchback 144 Pivots / Rear Idler
IQ Switchback 144 Rail Assembly
IQ Switchback 144 Front / Rear Torque Arms
IQ 136 Comfort Pivots / Rear Idler
IQ 136 Comfort Rail Assembly
IQ 136 Comfort Front / Rear Torque Arms
IQ 136 Coupled Pivots / Rear Idler
IQ 136 Coupled Rail Assembly
IQ 136 Coupled Front / Rear Torque Arms
IQ RMK 144 / 155 / 163 Pivots / Rear Idler
IQ RMK 144 / 155 / 163 Rail Assembly
IQ RMK 144 / 155 / 163 Front / Rear Torque Arms
Rear Suspension Operation
Operation
Weight Transfer
Coupling
Rear Suspension Adjustments
Adjustment Procedures
Rear Suspension Ride Height
Scissor Stop Adjustment
Limiter Strap Adjustment
Torsion Spring Adjustment
IQ 121 Heavy Torsion Spring Installation
M-10 Suspension
M-10 OVERVIEW
M-10 ADJUSTMENTS
M-10 TERMINOLOGY
M-10 ADJUSTMENTS
M-10 FRA INITIAL SET UP REFERENCE
M-10 REAR SPRING PRELOAD
M-10 SKI PRESSURE
Rail Sliders
Wear Limit
Removal
Break-In
Rear Suspension Removal and installation
Removal
Installation
Chapter 9 - Shocks
Special Tools
Shock Rebuilding Tools
Valve Shims
Ryde FX Shock Valve Part Numbers
Fox Shock Valve Part Numbers
Walker Evans Shock Valve Part Numbers
Walker Evans Shock Valve Part Numbers - 7/16² I.D.
Valve Shim Arrangement
Piston Orientation
Specifications
2007 Shock Specifications
2007 Shock Valve Shim Stack Configurations
2008 Shock Specifications
2008 Shock Valve Shim Stack Configurations
Optional Shock Settings
Walker Evans Air Shock
Ryde FX Air 2.0 Shock
Shock Maintenance
Ryde FX Air 2.0 Shock Disassembly
Ryde FX Air 2.0 Shock Assembly
Walker Evans Air Shock Disassembly
Walker Evans Air Shock Assembly
Walker Evans Remote Reservoir / Piggy Back Shock Disassembly
Walker Evans Remote Reservoir / Piggy Back Shock Assembly
Ryde FX Remote Reservoir Shock Disassembly
Ryde FX Remote Reservoir Shock Assembly
RYDE FX MONO-TUBE SHOCK DISASSEMBLY
RYDE FX MONO-TUBE SHOCK ASSEMBLY
FOX PS-5 DISASSEMBLY
FOX PS-5 ASSEMBLY
Chapter 10 - Chassis
IQ Chassis Components
Steering Hoop Assembly (Typical)
Hood Assembly
Hood / Plastic Repair
Front Bumper Assembly (Typical)
IQ Console Assembly (Typical)
RMK Tunnel
Fenders and Side Panels
Seat Assemblies
IQ Fixed Seat Assembly
IQ Raw Seat Assembly
IQ Removable Seat Assembly
2007 IQ Touring Seat Assembly
2008 IQ Touring Seat Assembly
Seat Cover Replacement
Decals
Decal Removal
Decal Installation
Chapter 11 - Electrical Systems
Specifications
Engine Models
Spark Plugs
Charging System
Ignition Timing
Conventional Battery
Battery Preparation
Specifications
Refilling a Conventional Battery
Fresh Pack Battery
Battery Preparation
Specifications
Battery Testing
Testing Procedures
Open Circuit Voltage Test (OCV)
Load Test
Specific Gravity Test (Conventional Battery)
Off Season Storage
Ignition Timing
Timing Procedure - Carbureted Engines
Timing Procedure - CFI Engines
Ignition Timing Chart
Throttle Position Sensor (TPS)
TPS Test Tool Setup
Using the TPS Test Tool
TPS Adjustment - Carbureted Models
TPS Adjustment - CFI Models - Using Digital Wrench
TPS Baseline Adjustment - CFI Models
TPS Idle Speed Adjustment - CFI Models
Throttle Plate Synchronization
Electric Start - IQ Carbureted / CFI
System Schematic - 600 Carbureted
System Schematic - CFI
Starter Motor / Flex Drive Assembly
IQ Battery Box Assembly
Carbureted Electrical Systems
600 HO Stator Specifications
Ignition Coil Packs
Exhaust Valve Solenoid
Knock Sensor
600HO Coolant Temperature Sensor
Oil Level Sender
2007 600 HO Regulator / Rectifier
2008 RMK Shift 155 Regulator / Rectifier
2008 IQ Shift Regulator / Rectifier
Detonation Control (DET)
Overview
Variable Exhaust System (VES)
Overview
Diagnostic Plugs
IQ Chassis Power Plug
IQ CFI Fuel Pump Prime Plug
Electronic Reverse (PERC)
Overview
Operation
FORWARD OPERATION
Altitude Setting
Important Notes
Chapter 12 - Wiring Diagrams
2007 600 HO Carbureted 1 of 2
2007 600 HO Carbureted 1 of 2
2007 600 HO Carbureted 2 of 2
2007 600 HO Carbureted Hood Harness
2007 600 / 700 CFI Chassis Harness 1 of 2
2007 600 / 700 CFI Chassis Harness 2 of 2
2007 600 / 700 CFI Hood Harness
2007 600 / 700 CFI Engine Harness
2008 IQ Shift 1 of 2
2008 IQ Shift 2 of 2
2008 IQ Shift Hood Harness
2008 IQ Shift RMK 1 of 2
2008 IQ Shift RMK 2 of 2
2008 IQ Shift RMK Hood Harness
2008 IQ CFI Chassis Harness 1 of 2
2008 IQ CFI Chassis Harness 2 of 2
2008 IQ CFI Engine Harness
