2007 Polaris Two Stroke Snowmobile Workshop Repair manual
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2007 Polaris Two-Stroke Snowmobile Workshop Repair manual is a professional book.
Manual contains comprehensive instructions and maintenance, repair and procedures on how to fix problems.
Part Number: 9920463
Manuals chapters:
- Specifications
- General
- Maintenance
- Fuel delivery
- Engine
- Clutching
- Final drive and brakes
- Front suspension
- Rear suspension
- Chassis and hood
- Electrical
- Index
- Wiring diagram
Model covered by this manual:
340 LX
340 TOURING
WIDETRAK LX
500 XC SP
SUPER SPORT
550 LX
TRAIL RMK
TRAIL TOURING DELUXE
600 HO IQ
600 HO IQ CLEANFIRE
600 HO IQ LX CLEANFIRE
600 HO SWITCHBACK
600 HO SWITCHBACK CLEANFIRE
600 HO RMK 144/155 (F/O)
600 HO IQ TOURING CLEANFIRE
DRAGON
DRAGON RMK
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Full list of manual chapters:
2007 TWO stroke SNOWMOBILE SERVICE MANUAL
FOREWORD
understanding manual safety labels and directions
TRADEMARKS
CHAPTER 1 SPECIFICATIONS
340 LX
MODEL S07ND3AS
340 TOURING
MODEL S07NT3A(E,S)
WIDETRAK LX
MODEL S07SU4BS
500 XC SP
MODEL S07NP5CS(E)
SUPER SPORT
MODEL S07NP5B(E,S)
550 LX
MODEL S07ND5BS
TRAIL RMK
MODEL S07NJ5B(E,S)
TRAIL TOURING DELUXE
MODEL S07NT5B(E,S)(A)
600 HO IQ
MODEL S07PP6FS(A,B)
600 HO IQ CLEANFIRE
MODEL S07PP6HS(A,B)
600 HO IQ LX CLEANFIRE
MODEL S07PD6HS
600 HO SWITCHBACK
MODEL S07PS6FS(A)
600 HO SWITCHBACK CLEANFIRE
MODEL S07PS6HS(A,B)
600 HO RMK 144/155 (F/O)
MODEL S07(P,M)(M,K)6FS(A)
600 HO IQ TOURING CLEANFIRE
MODEL S07PT6HS
DRAGON
MODEL NUMBER: S07PC7J(E,S)
DRAGON RMK
MODEL NUMBER: S07PL7JS
CHAPTER 2 GENERAL
HOW TO USE THIS MANUAL
Gearing
Jetting
Clutch Springs
Suspension Spring Pre-Load/Installed Length
SNOWMOBILE NUMBER DESIGNATIONS
Model Number Designation
VEHICLE IDENTIFICATION NUMBER (VIN)
Tunnel Decal
VIN Number Designation
PUBLICATION PART NUMBERS
Misc. Publications
2007 Service Publications
GENERAL REFERENCE
Standard Bolt Torque Specification
2 Stroke Gasoline / Oil Pre Mix
Gasoline Volatility
SAE Tap Drill Sizes
Metric Tap Drill Sizes
Decimal Equivalents
Measurement Conversion Chart
Piston Wash / Spark Plug Reading
Glossary Of Terms
SPECIAL TOOLS
Special Tools
CHAPTER 3 MAINTENANCE
MAINTENANCE PROGRAM
Polaris Recommended Program
INSPECTONS
Cylinder Head Inspection
Cylinder Measurement
Cylinder Honing
Honing Procedure
Honing To Over Size (340/500 Fuji Engines Only)
Cleaning The Cylinder After Honing
Piston Inspection
Piston Ring Installed Gap
Coolant Level
Recommended Coolant
Cooling System Bleeding
Bearing Fit
Main Bearing
Connecting Rod (Big End) Bearing
Wrist Pin Bearing
Crankshaft Indexing
Checking Crankshaft Index
Crankshaft Trueing
Crankshaft Runout Inspection
Oil Pump Bleeding
Oil / Fuel Filter
Brake Lever Travel
Brake Fluid
Exhaust System Removal/Installation
Manifold Installation
Belt Deflection Inspection
Measuring Belt Deflection
LUBRICATION
Rear Suspension
Front Suspension
Steering
Jackshaft Bearing
Driveshaft Bearing
Throttle Cable
Choke And Choke Cable
Chaincase Oil
ADJUSTMENTs
Choke Adjustment
Throttle Lever Free Play - Non CFI
Throttle Lever Free-Play - CFI Models
Oil Pump Adjustment
Track Alignment
Track Tension
Rear Engine Torque Stop Adjustment
Engine Isolator Limiter Setting
CLEANING
Air Filter
Water Sediment Trap
Nosepan Care
STORAGE
Chassis And Hood
Clutch And Drive System
Controls And Linkage
Electrical Connections
Carburetor/Throttle Body
Fuel System
Corrosion
Shocks
Battery
REPLACEMENT
Headlight Bulb Replacement
Edge Headlight Bulb Replacement
IQ Headlight Bulb Replacement
IQ Snow Beam Bulb Replacement
Coolant Draining
CHAPTER 4 FUEL DELIVERY
WARNINGS
GENERAL INFORMATION
Service Precautions
FUEL DELIVERY SYSTEM (Carbureted)
Carbureted System Overview
FUEL PUMP (Carbureted units)
Fuel Pump Overview
Maintenance
MIKUNI JET NEEDLE
Overview
MIKUNI TM 38
Carburetor Overview
MIKUNI 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
Jet Needle
Needle Jet
Throttle Opening Vs. Fuel Flow
MIKUNI TM38 FLAT SLIDE SERVICE
Disassembly
Assembly
CARBURETOR SYNCRONIZATION
Throttle Valve Synchronization
CARBURETOR COMPONENT PART NUMBERS
Mikuni Pilot Jets
Mikuni Main Jets
Mikuni Jet Needles
Mikuni Starter Jets
Mikuni (Short) Pilot Air Jets
Mikuni (Long) Pilot Air Jets
Mikuni Piston Valves
Mikuni (Notched) Piston Valves
Cleanfire Injection (CFI)
Injector Replacement
600/700 CFI Injector Replacement
600/700 CFI Fuel Rail/Injector(s) Removal/ Installation
Cleanfire System Overview
Fuel Pump (700)
Fuel Level Indicator
2007 Fuel Supply / Return Fittings
Fuel Rail Bleeding
600 CFI Fuel Tank / Fuel Supply
600 CFI Pump / Sender Specifications
600 CFI Fuel Pump Replacement
Fuel Tank Pressure Test
Throttle Body Removal
Fuel Filter Removal
Fuel Filter Installation
CHAPTER 5 ENGINE
GENERAL ENGINE INFORMATION
Exhaust Valve Exploded View
Exhaust Valve Disassembly
Exhaust Valve Assembly
Optional Exhaust Valve Springs
Reed Valve Disassembly
Reed Valve Assembly
Thermostat Replacement
Water Temperature Sensor Replacement
Engine Mount Replacement
Cylinder Stud Installation
500/600/700 Water/Oil Pump Cross Shaft Disassembly
500/600/700 Water/Oil Pump Cross Shaft Assembly
Cylinder Head / Head Components
Cylinder Head Disassembly
Cylinder Head Assembly
Recoil/Stator Removal
Recoil/Stator Assembly
COOLING SYSTEMS
500/600/700 121/Switchback/RMK/DRAGON
500/600 Touring / WideTrak LX
340/550 FUJI ENGINE
340/550 Fuji/500 Liberty Engine Removal/installation
340/550 Engine Disassembly (550 shown)
Engine Assembly
500 FUJI ENGINE
Disassembly
Assembly
500/600 HO ENGINE
Engine Removal
500/600 (Carbureted) Engine Disassembly
500/600 (Carbureted) Torques
500/600 (Carbureted) Cylinder Head Torque Pattern
500/600 (Carbureted) Cylinder Base
500/600 (Carbureted) Crankcase Torque Pattern
500/600 (Carbureted) Engine Assembly
500/600 (Carbureted) Recoil/Stator Removal
500/600 (Carbureted) Recoil/Stator Installation
500/600 (Carbureted) Engine Installation
Torque Specifications
600 / 700 HO CFI ENGINE
600/700 CFI Engine Removal
600/700 CFI Engine Disassembly
Engine Assembly
600/700 CFI Cylinder Head Torque Pattern
600/700 CFI Cylinder Base
600/700 CFI Crankcase Torque Pattern
600/700 CFI Engine Installation
Torque Specifications
Specifications
Fastener Torque Specifications
CHAPTER 6 CLUTCHING
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
Non-ER LWT Driven Helixes
Team Helix Options with PERC
Team Ramp Angles
Team Driven Springs
Belt Inspection
Belt Wear / Burn Diagnostics
Drive Belt Removal
Drive Belt Installation
Adjusting Belt Deflection
Drive Belts
Belt PN 3211115 Break -In Procedure
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
Components
Driven Clutch Removal
Driven Clutch Installation
Driven Clutch Disassembly
Driven Clutch Assembly
Belt to Sheave Clearance Inspection
Belt to Sheave Clearance Adjustment
Belt Deflection Inspection
CHAPTER 7 FINAL DRIVE and BRAKES
GEARING CHARTS
Chaincase Speed Charts
GEARS AND CHAINS
Gears
Drive Chain
CHAIN CASE
Exploded View
Chaincase Removal
Chaincase Installation
Chaincase Seal and Bearing Replacement
DRIVE TRAIN
Jackshaft Exploded View
Jackshaft Removal
Jackshaft Installation
ADJUSTMENTS
Chaincase Drive Tension
DRIVESHAFT
Driveshaft Removal/Installation
WIDETRAK TRANSMISSION
Removal
Inspection
Low/Reverse Shaft Disassembly
Shift Fork Disassembly
Transmission Assembly
Transmission Installation
HYDRAULIC BRAKE SYSTEM
Overview
Compensating Port
General Guidelines
Brake Fluid Replacement and Bleeding
Brake Line Replacement
Brake Light Switch Replacement
CALIPER
Caliper Removal
Caliper Replacement
Caliper Assembly
Brake Pad Replacement
Brake Disc Replacement
WIDETRAK BRAKE CALIPER
Removal
Assembly
Installation
CHAPTER 8 FRONT SUSPENSION and STEERING
Model Front suspension type
Front Suspension Type by Model
Front Suspension Torque and Specifications
IQ/IQ LX/IQ RMK/Switchback
Edge/Edge LX
Edge RMK
Widetrack LX
FRONT SUSPENSION ADJUSTMENT PROCEDURES
SET UP AND ADJUSTMENTS
IFS SHOCK SPRINGS
SPRINGS
COMPRESSION DAMPING ADJUSTABLE SHOCKS
SHOCK INFORMATION
IFS Shock Fastener Torques
IFS SHOCK SPECIFICATIONS
IFS SHOCK PRODUCTION VALVING
IQ FRONT SUSPENSION
Spindle Removal
Spindle Assembly
Lower Spherical Bearing Replacement
UPPER / LOWER CONTROL ARM REMOVAL
Upper / Lower Control Arm Installation
STEERING
INSPECTION
Alignment Bar Specifications
Camber Definition
Rod End
Rod End Engagement
Front Suspension Measuring
Maximum Width
Toe Alignment
Camber
ALIGNMENT ADJUSTMENTS
Edge/Edge LX/Edge RMK Set Up Width
Edge/Edge LX/Edge RMK Camber Adjustment
IQ/IQ LX/Switchback Camber Adjustment
Handlebar Centering
Toe Adjustment
SKI STANCE
Adjustment (IQ RMK Only)
HANDLEBAR
RMK Handlebar Position
RMK Handlebar Angle
CHAPTER 9 REAR SUSPENSION
Rear Suspension Type per Model
SPECIAL TOOLS
Shock Rebuilding Tools
REAR SUSPENSION TORQUE SPECIFICATIONS
Shock Mounting Fasteners Specification
Suspension to Chassis Fasteners Specification
SHOCK CONTROL RODS
Edge Shock Rods
IQ Shock Rod
REAR SUSPENSION OPERATION
Operation
Weight Transfer
Suspension Coupling
Rear Torsion Spring Tension Adjustment
REAR SUSPENSION ADJUSTMENTS AND SETTINGS
Rear Suspension Adjustment Procedures
Setting the Rear Suspension Ride Height
Scissor Stop Adjustments
Front Torque Arm Limiter Strap Adjustment
Torsion Spring Adjustment
Torsion Spring Detail
Installing Heaviest Springs On A IQ 121" Suspension
Widetrak Torsion Spring Adjustments
M-10 SUSPENSION
M-10 Overview
M-10 RTS Adjustments
M-10 Terminology
M-10 Adjustments
M-10 FRA Initial Set Up Reference
M-10 Rear Spring Preload
M-10 Ski Pressure
RAIL SLIDER
Rail Slide Wear Limit
Rail Slide Removal
Rail Slider Break In
REAR SUSPENSION REMOVAL / INSTALLATION
Rear Suspension Removal
Rear Suspension Installation
SHOCK INFORMATION
Serviceable Shocks
Rear Suspension Front Track Shock (FTS) Stock Valving
Rear Suspension Rear Track Shock (RTS) Stock Valving
SHOCK VALVE PART NUMBERS
Ryde FX Shock Valve Part Numbers
Fox Shock Valve Part Numbers
Walker Evans Shock Valve Part Numbers
Shock Valving Arrangement
REAR SHOCK specifications
Walker Evans FTS 7043204
Fox FTS 7043267
Walker Evans FTS 7043234
Ryde FX FTS 7043244
Fox FTS 7043142
Ryde FX FTS 7041975
Walker Evans RTS 7043205
Fox RTS 7043246
Fox RTS 7043266
Fox RTS 7043177
Walker Evans RTS 7043235
Fox RTS (M-10) 7043216
SHOCK MAINTENANCE
Shock Maintenance
Walker Evans Shocks (7043234, 7043233)
Ryde Fx Mono-tube Shock Disassembly
Ryde Fx Mono-tube Shock Assembly
Fox Monotube Disassembly
Fox Monotube Assembly
REAR SUSPENSION TROUBLESHOOTING
CHAPTER 10 CHASSIS and HOOD
SIDE PANELS
Side Panel Removal
Side Panel Installation
HOOD ASSEMBLY
Hood Removal/Installation
Edge Instrument Removal/Installation
IQ MFD Removal/Installation
Hood Repair
BUMPER
Edge Front Bumper Removal/Installation
IQ Front Bumper Removal/Installation
Rear Bumper Removal/Installation
HEADLIGHT
IQ Headlight Removal/Installation
Edge Headlight Removal/Installation
COOLANT/OIL TANK
Coolant Tank Removal
Coolant Tank Installation
OIL TANK
Oil Tank Removal
Oil Tank Installation
SEAT INformation
Seat and Base Removal/Installation
SEAT and FUEL TANK
IQ Fuel Tank Removal
IQ Fuel Tank Installation
Edge Fuel Tank Removal/Installation
Seat Cover Replacement
CONSOLE
Console Removal/Installation
TAIL LIGHT
Edge Tail Light Assembly Replacement
Tail Light Assembly Replacement
HANDLEBAR COVER
HANDLE BAR COVER REMOVAL/ INSTALTION
SKIS
SKI REMOVAL
SKI INSTALLATION
NOSEPAN
REPLACEMENT
DECALS
DECAL REMOVAL
DECAL INSTALLATION
CHAPTER 11 ELECTRICAL
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
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 - Gen II / EDGE
System Schematic
Starter Motor Assembly (Typical)
Battery Box
Dynamic Testing
Static Testing
Starter Housing / Field Coil Testing
Armature Testing
Electric Start - IQ Carbureted / CFI
System Schematic - 600 HO Carbureted
System Schematic - 600 / 700 CFI
Starter Motor / Flex Drive Assembly
IQ Battery Box Assembly
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
CFI Power System
CFI Ignition / Injection Power
CFI Crank Position System
CFI Safety Stop System
CFI Full Load Fuel Injectors
CFI Part Load Fuel Injectors
CFI Chassis Power
CFI Ignition Coils
CFI TBAP Sensor
CFI TPS / Engine Temp. Sensors
CFI Exhaust Solenoid
CFI Knock Sensor
CFI Fuel Pump
CFI Diagnostic Connections
CFI MFD Circuits
CFI MFD Power Circuits
CFI Fuel Level Circuit
CFI Vehicle Speed Circuit
CFI Mode Set Switch
CFI PERC Switch
Digital Wrench Diagnostic Software
Overview
Digital Wrench Connections
Updating Digital Wrench
Version / Fileset Identification
Engine Controller Reprogramming (Reflash)
Carbureted Electrical Systems
EC50PL Stator Specifications
EC34 / EC55 Stator Specifications
500cc EV / 600 HO Stator Specifications
Ignition Coil Packs
Exhaust Valve Solenoid
Knock Sensor
600HO Coolant Temperature Sensor
500 EV Coolant Temperature Sensor
Oil Level Sender
600 HO Regulator / Rectifier
Troubleshooting Tables
NO SPARK
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
INDEX
WIRE DIAGRAMS