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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

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