2007 TWO STROKE SNOWMOBILE
SERVICE MANUAL
FOREWORD
This service manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with service
procedures before starting the work. Certain procedures require the use of special tools. Use only the proper tools as
specified.
Comments or suggestions about this manual may mailed to: Service Publications Dept. @ Polaris 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
Polaris Manual Correction Feedback link.
© Copyright 2006 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting
or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.
area click on Service & Warranty link and the feedback link is at the bottom of the page named
2007 Two Stroke Snowmobile Service Manual PN 9920463
UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS
Throughout this manual, important information is brought to your attention by the following symbols:
WARN IN G
SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or
person(s) inspecting or servicing the vehicle.
CAU TION
SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.
CAU TI ON
CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage.
NOTE:
NOTE provides key information by clarifying instructions.
IMPORTANT:
IMPORTANT provides key reminders during disassembly, assembly and inspection of components.
= In. / mm.
MEASUREMENT provides a key for a determined measurement specification.
= T
TORQUE provides a key for a required torque value.
TRADEMARKS
POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL:
Loctite, Registered Trademark of the Loctite Corporation
Nyogel, Trademark of Wm. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity-Vac, Registered Trademark of Neward Enterprises, Inc.
Torx, Registered Trademark of Textron
M-10, Registerd Trademark of FAST, Inc
Some Polaris factory publications can be downloaded from www.polarisindustires.com, purchased from www.purepolaris.com or
by contacting the nearest Polaris dealer.
SPECIFICATIONS
1
GENERAL
MAINTENANCE
FUEL DELIVERY
ENGINE
CLUTCHING
ENGINE AND DRIVE TRAINCHASSIS AND ELECTRICAL
FINAL DRIVE
2
3
4
5
6
7
FRONT SUSPENSION
REAR SUSPENSION
CHASSIS/HOOD
ELECTRICAL
8
9
10
11
MODEL SPECIFICATIONS
CHAPTER 1
MODEL SPECIFICATIONS
340 LX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
340 TOURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
WIDETRAK LX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
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 CLEANFIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.26
600 HO RMK 144/155 (F/O) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.28
600 HO IQ TOURING CLEANFIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.30
DRAGON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.32
DRAGON RMK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.34
1
1.1
MODEL SPECIFICATIONS
340 LX
MODEL S07ND3AS
Body
Body Style EDGE
Engine
Engine type Fuji
Engine displacement 339cc
Bore (in/mm) 2.45/62.3
Stroke (in/mm) 2.19/55.6
Piston to cylinder clearance (in/mm) .003-.005/.080-.130
Piston ring end gap
(in/mm)
Operating RPM±200 7000
Idle RPM±200 1600
Clutch engagement RPM ±200 4100
Fuel Delivery
Type VM30SS
Main Jet 170
Pilot Jet 35
Jet Needle/Clip position 5DP13/3
Needle Jet O-6 (169)
Throttle gap under cutaway (in/mm) .240/6.1
Throttle slide cutaway 2.5AL
Valve seat 1.5Viton
Starter jet 1.5
Pilot air jet 2.5
Fuel screw setting N/A
Air screw setting 1.5
Recommended fuel octane (R+M/2) 87 NonOxy Minimum
.008-.014/.20-.41
Altitude
meters (feet)
0-600
(0-2000)
600-1200
(2000-4000)
1200-1800
(4000-6000)
1800-2400
(6000-8000)
2400-3000
(8000-10000)
3000-3700
(10000-12000)
Altitude meters
(feet)
0-900
(0-3000)
900-1800
(3000-6000)
1800-2700 (6000-
9000)
2700-3700 (9000-
12000)
Drive clutch bolt torque 50 ft-lbs (69 N-m)
Jetting
Ambient Temperature
< -25°F/<-35°C
0°F to +20°F/-18°C to -7°C
-15°F to +5°F/-26°C to -15°C
-30°F to -10°F/-34°C to -23°C
185#4180#3170#3170#3165#3160#3155#3150
175#3170#3160#3160#3155#3150#3140#2140
165#3160#3155#3150#3145#3140#2130#2130
155#3150#3140#3135#3135#2130#2120#1120
145#3140#3130#2130#2125#2120#1110#1110
135#3130#2120#2115#2115#1110#1100#1100
+15°F to +35°F/-9°C to +2°C
+30°F to +50°F/-1°C to +10°C
+45°F to +65°F/+7°C to +18°C
#3
#2
#2
#1
#1
#1
Clutching
Drive Clutch (P-85) Driven Clutch (TEAM)
Shift
Weight
10-M
Blue
10MW
10MR
Clutch
Spring
110/290
10
(Black-
2287)
110/290
(Black-
2287)
110/290
(Black-
2287)
110/290
(Black-
2287)
Clutch
Spring
Red/
Black
Red/
Black
Red/
Black
Red/
Black
Driven
Helix
S36 LW
ER
S36 LW
ER
S36 LW
ER
S36 LW
ER
Gearing
16:41-72
16:41-72
16:41-72
16:41-72
Belt
>+60°F/>+16°C
1.2
Belt part number 3211078
Belt width (in/cm) 1.438/3.65
Belt side angle 28°
Outside diameter (in/cm) 46.625/118.4
Clutch center distance (in/cm) 11.5/29.2
Chaincase
Center distance (in/cm) 7.92/20.1
Reverse type PERC
MODEL SPECIFICATIONS
Fluids and Capacities
Fuel (gal/l) 11.8/44.7
Oil (qts/l) 3.25/3.1
Coolant (qts/l) N/A
Chaincase (oz/ml) 9/266.2
Brake fluid type DOT4
Track
Width (in/cm) 15/38
Length (in/cm) 121/307
Lug height (in/cm) .66/1.7
Manufacture Camoplast
Track tension sag (in/cm) with 10 lbs/
4.54kg placed 16 in/40.6cm ahead of
rear idler shaft
.375-.5/1-1.3
Front Suspension
Suspension type Edge LX
IFS shocks Arvin/7041932
IFS Spring PN 7041551
IFS Spring Pre-Load (in/mm) .625/15.9
IFS spring rate (lb/in - kg/mm) 100/1.79
IFS Spring free length (in/cm) 10.75/27.3
Front vertical travel (in/cm) 10/25.4
Ski center distance (in/cm) 42.5/108
Camber (in/mm) .59±.31/15.0±7.9
Toe (in/mm) .12-.25/3.0-6.35
Dimensions
Width (in/cm) 48/122
Length (in/cm) 113/287
Height (in/cm) 46/117
Est dry weight (lb/kg) 457/207.7
Electrical
Ignition timing 26.5°@3000RPM
Spark plug gap (in/mm) .0275/.70
Spark plug NGK BR8ES
Voltage regulator/output 240watt
CDI marking CU7245
Flywheel Markings FP9313
Features
Electric Fuel Gauge Accessory
Electric Start Standard
Low Oil Light Standard
Parking Brake Standard
Speedometer Standard 5 inch
Tachometer Accessory
1
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) 200-240/3.6-4.3
FTS pre-load Fixed
Rear track shock Arvin MPV/7043239
Rear travel (in/cm) 13.9/35.3
Torsion Spring
Torsion spring PNs (LH/RH) 7041629/7041630
Torsion spring diameter (in/mm) .359/9.12
Torsion spring tail angle 77°
1.3
MODEL SPECIFICATIONS
340 TOURING
MODEL S07NT3A(E,S)
Body
Body Style EDGE
Engine
Engine type Fuji
Engine displacement 339cc
Bore (in/mm) 2.45/62.3
Stroke (in/mm) 2.19/55.6
Piston to cylinder clearance (in/mm) .003-.005/.080-.130
Piston ring end gap
(in/mm)
Operating RPM±200 7000
Idle RPM±200 1600
Clutch engagement RPM ±200 3700
Fuel Delivery
Type VM30SS
Main Jet 170
Pilot Jet 35
Jet Needle/Clip position 5DP13/3
Needle Jet O-6(169)
Throttle gap under cutaway (in/mm) .240/6.1
Throttle slide cutaway 2.5AL
Valve seat 1.5 Viton
Starter jet 1.5
Pilot air jet 2.5
Fuel screw setting N/A
Air screw setting 1.5
Recommended fuel octane (R+M/2) 87 non Oxy/Minimum
.008-.014/.20-.41
Altitude
meters (feet)
0-600
(0-2000)
600-1200
(2000-4000)
1200-1800 (4000-
6000)
1800-2400 (6000-
8000)
2400-3000
(8000-10000)
3000-3700
(10000-12000)
Altitude meters
(feet)
0-900
(0-3000)
900-1800
(3000-6000)
1800-2700 (6000-
9000)
2700-3700 (9000-
12000)
Drive clutch bolt torque 50 ft-lbs(69 N-m)
Jetting
Ambient Temperature
< -25°F/<-35°C
0°F to +20°F/-18°C to -7°C
-15°F to +5°F/-26°C to -15°C
-30°F to -10°F/-34°C to -23°C
185#4180#3170#3170#3165#3160#3155#3150
175#3170#3160#3160#3155#3150#3140#2140
165#3160#3155#3150#3145#3140#2130#2130
155#3150#3140#3135#3135#2130#2120#1120
145#3140#3130#2130#2125#2120#1110#1110
135#3130#2120#2115#2115#1110#1100#1100
+15°F to +35°F/-9°C to +2°C
+30°F to +50°F/-1°C to +10°C
+45°F to +65°F/+7°C to +18°C
#3
#2
#2
#1
#1
#1
Clutching
Drive Clutch (P-85) Driven Clutch (TEAM)
Shift
Weight
10-M
Blue
10 MW
10 MR
Clutch
Spring
(110/290)
10
Black-
2287
(110-290)
Black-
2287
(110-290)
Black-
2287
(110-290)
Black-
2287
Clutch
Spring
Blue/
Black
Blue/
Black
Blue/
Black
Blue/
Black
Driven
Helix
54/38-25
LW E R
54/38-25
LW E R
54/38-25
LW E R
54/38-25
LW E R
Gearing
17:41-72
17:41-72
17:41-72
17:41-72
Belt
>+60°F/>+16°C
1.4
Belt part number 3211078
Belt width (in/cm) 1.438/3.65
Belt side angle
28°
Outside diameter (in/cm) 46.625/118.4
Clutch center distance (in/cm) 11.5/29.2
Chaincase
Center distance (in/cm) 7.92/20.1
Reverse type PERC
MODEL SPECIFICATIONS
Fluids and Capacities
Fuel (gal/l) 12.25/46.4
Oil (qts/l) 3.25/3.1
Coolant (qts/l) N/A
Chaincase (oz/ml) 9/266.2
Brake fluid type DOT 4
Track
Width (in/cm) 15/38
Length (in/cm) 136/345
Lug height (in/cm) 1/2.5
Manufacture Soucy
Track tension sag (in/cm) with 10 lbs/
4.54kg placed 16 in/40.6cm ahead of
rear idler shaft
1.125 - 1.375 / 2.9 - 3.5
Front Suspension
Suspension type Edge LX
IFS shocks Arvin/7041932
IFS Spring PN 7041551
IFS Spring Pre-Load (in/mm) .625/15.9
IFS spring rate (lb/in - kg/mm) 100/1.79
IFS Spring free length (in/cm) 10.75/27.3
Front vertical travel (in/cm) 10/25.4
Ski center distance (in/cm) 42.5/108
Camber (in/mm) .59±.31/15.0±7.9
Toe (in/mm) .12-.25/3.0-6.35
Dimensions
Width (in/cm) 47.25/120
Length (in/cm) 128/325.1
Height (in/cm) 49.5/125.7
Est dry weight lb/kg 517/234.7
Electrical
Ignition timing 26.5°@3000RPM
Spark plug gap (in/mm) .028/.70
Spark plug NGK BR8ES
Voltage regulator/output 240watt
CDI marking CU7245
Flywheel Marking FP9319
Features
Electric Fuel Gauge Accessory
Electric Start Standard
Low Oil Light Standard
Parking Brake Standard
Speedometer Standard 5 inch
Tachometer Accessory
1
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/cm) Fixed
Rear track shock Arvin/7042138
Rear travel (in/cm) 13.9/35.3
Torsion Spring
Torsion spring PNs
(LH/RH)
Torsion spring diameter (in/mm)
Torsion spring tail angle
7041940/7041941
.405/10.3
77°
1.5
MODEL SPECIFICATIONS
WIDETRAK LX
MODEL S07SU4BS
Body
Body Style GENII
Engine
Engine type Fuji
Engine displacement 488cc
Engine model number EC50PL237
Bore (in/mm) 2.83/72
Stroke (in/mm) 2.36/60
Piston to cylinder clearance (in/mm) .0035-.0049/.090-.125
Piston ring end gap (in/mm) .0070-.016/.20-.47
Operating RPM±200 7000
Idle RPM±200 1600
Clutch engagement RPM ±200 3800
Fuel Delivery
Type VM34SS
Main Jet 195
Pilot Jet 35
Jet Needle/Clip position 6EJ26/2
Needle Jet P-6 (166)
Throttle gap under cutaway (in/mm) .240/6.1
Throttle slide cutaway 3
Valve seat 1.5 Viton
Starter jet 1.5
Pilot air jet N/A
Fuel screw setting N/A
Air screw setting .5
Recommended fuel octane (R+M/2) 87 NonOxy/Minimum
Jetting
Ambient Temperature
Altitude
meters (feet)
< -25°F/<-35°C
0°F to +20°F/-18°C to -7°C
+15°F to +35°F/-9°C to +2°C
+30°F to +50°F/-1°C to +10°C
+45°F to +65°F/+7°C to +18°C
#1
#1
#1
#1
#1
#1
0-600
(0-2000)
600-1200
(2000-4000)
1200-1800
(4000-6000)
1800-2400
(6000-8000)
2400-3000
(8000-10000)
3000-3700
(10000-12000)
-15°F to +5°F/-26°C to -15°C
-30°F to -10°F/-34°C to -23°C
210#2200
195#2190#2185#2175#2170#2170
#2
195#2185#2180#2175#2170#2165#2155#1155
185#2175#2170#2165#2160#1155#1145#1145
170#2165#2155#2155#1150#1140#1135#1135
160#2155#2145#1145#1140#1130#1120#1120
150#2140#1135#1130#1125#1120#1110#1110
When using non oxygenated fuel with an octane number
greater than 93, decrease the main jet number in the above
chart by 5
Clutching
Altitude meters
(feet)
0-900
(0-3000)
900-1800
(3000-6000)
1800-2700
(6000-9000)
2700-3700
(9000-12000)
Drive Clutch (P-85) Driven Clutch (P-85)
Shift
Weight
10-M
Blue
10 MW
Clutch
Spring
10 Brown Silver 36D #2 19:41-66
10
Red/
White
Red/
White
Red/
White
Clutch
Spring
Silver 36D #2 19:41-66
Silver 36D #2 19:41-66
Silver 36D #2 19:41-66
Driven
Helix
Drive clutch bolt torque 50 ft-lbs (69 N-m)
Gearing
>+60°F/>+16°C
1.6
Belt
Belt part number 3211070
Belt width (in/cm) 1.375/3.49
Belt side angle 28°
Outside diameter (in/cm) 47.25/120
Clutch center distance (in/cm) 12/30.5
Chaincase
Center distance (in/cm)
Reverse type
N/A
Hi/Low/Reverse
MODEL SPECIFICATIONS
Fluids and Capacities
Fuel (gal/l) 11/41.6
Oil (qts/l) 2/1.9
Coolant (qts/l) 3.4/3.2
Gearcase (oz/ml) 20/591.5
Brake fluid type DOT4
Track
Width (in/cm) 20/51
Length (in/cm) 156/396
Lug height (in/cm) 1/2.5
Manufacture Camoplast
Track tension sag (in/cm) with 10 lbs/
4.54kg placed 16 in/40.6cm ahead of
rear idler shaft
.75-1.0/1.9-2.5
Front Suspension
Suspension type WideTrak GenII
IFS shocks Arvin/7041535
IFS spring rate (lb/in - kg/mm) 105/1.9
Spring installed length (in/cm) Fixed
Front vertical travel (in/cm) 7.25/18.4
Ski center distance (in/cm) 38/96.5
Camber (in/mm) .82±.72/20.8±18.3
Toe (in/mm) 0-.12/0-3
Dimensions
Width (in/cm) 43.5/110
Length (in/cm) 128/325
Height (in/cm) 51/130
Est dry weight lb/kg 643/291.9
Electrical
Ignition timing 28°@3000
Spark plug gap (in/mm) .028/.71
Spark plug Champion RN3C
Voltage regulator/output 200watt
CDI marking IU2212
Flywheel Marking FP5536
Features
Electric Fuel Gauge N/A
Electric Start Standard
Low Oil Light Standard
Parking Brake N/A
Speedometer Standard 5 inch
Tachometer Accessory
1
Rear Suspension
Suspension type WideTrak
Front track shock (FTS) Arvin 7041742
FTS spring rate
lbs-in/kg-mm
FTS spring installed length (in/cm) Fixed
Rear track shock Arvin/7042309
Rear travel (in/cm) 9/22.9
181/3.2
Torsion Spring
Torsion spring PNs
(LH/RH)
Torsion spring diameter (in/mm) .468/11.9
Torsion spring tail angle
7041239/7041240
74°
1.7
MODEL SPECIFICATIONS
500 XC SP
MODEL S07NP5CS(E)
Body
Body Style EDGE
Engine
Engine type Liberty
Engine displacement 500
Engine model number S3033-5044-PF5F
Bore (in/mm) 2.78/70.5
Stroke (in/mm) 2.52/64
Piston to cylinder clearance (in/mm) .0045-.0059/.11-.15
Piston ring end gap (in/mm)
Operating RPM±200 8500
Idle RPM 1500
Clutch engagement RPM +/- 200 4200
Exhaust valve spring Pink/Yellow
Fuel Delivery
Type TM38
Main Jet 410
Pilot Jet 45
Jet Needle/Clip position 6BGY41/4
Needle Jet P-8
Throttle gap under cutaway (in/mm) .079/2
Throttle slide cutaway 2
Valve seat 1.5
Starter jet 145
Pilot air jet N/A
Fuel screw setting 3
Air screw setting 1.25
Recommended fuel octane (R+M/2) 87 Min NonOxy
.014-.020/.40-.61
Jetting
Ambient Temperature
Altitude
meters (feet)
< -25°F/<-35°C
0°F to +20°F/-18°C to -7°C
+15°F to +35°F/-9°C to +2°C
+30°F to +50°F/-1°C to +10°C
+45°F to +65°F/+7°C to +18°C
#1
#1
#1
#1
#1
#1
0-600
(0-2000)
600-1200
(2000-4000)
1200-1800 (4000-
6000)
1800-2400 (6000-
8000)
2400-3000
(8000-10000)
3000-3700
(10000-12000)
-15°F to +5°F/-26°C to -15°C
-30°F to -10°F/-34°C to -23°C
440#3430
410#2400#2390#2380#2360#2350
#3
420#3400#2390#2370#2360#2250#2330#1320
390#2380#2360#2350#2340#2330#1310#1300
370#2350#2340#2320#2310#1300#1290#1270
340#2330#2310#1300#1290#1280#1260#1250
320#1300#1290#1270#1260#1250#1240#1230
When using non oxygenated fuel with an octane number
greater than 93, decrease the main jet number in the above
chart by 20.
Clutching
Altitude meters
(feet)
0-900
(0-3000)
900-1800
(3000-6000)
1800-2700 (6000-
9000)
2700-3700 (9000-
12000)
Drive Clutch (P-85) Driven Clutch (TEAM)
Shift
Weight
10-56
10-54
10M Blue
Clutch
Spring
Black/
Green
Black/
Green
Black/
10
Green
Black/
Green
Clutch
Spring
Red/
Black
Red/
Black
Red/
Black
Red/
Black
Driven
Helix
56/42-36
LW E R
56/42-36
LW E R
56/42-36
LW E R
56/42-36
LW E R
Drive clutch bolt torque 50 ft-lbs (69 N-m)
Gearing
22:40-74
22:40-74
21:40-74
21:40-74
>+60°F/>+16°C
1.8
Belt
Belt part number 3211080
Belt width (in/cm) 1.438/3.65
Belt side angle 28°
Outside diameter (in/cm) 46.625/118.4
Clutch center distance (in/cm) 11.5/29.2
Chaincase
Center distance (in/cm) 7.92/20.1
Reverse type PERC
MODEL SPECIFICATIONS
Fluids and Capacities
Fuel (gal/l) 11.8/44.7
Oil (qts/l) 3.25/3.1
Coolant (qts/l) 5.6/5.3
Chaincase (oz/ml) 9/266.2
Brake fluid type DOT4
Track
Width (in/cm) 15/38
Length (in/cm) 121/307
Lug height (in/cm) [Euro] .91/2.3 [1.25/31.75]
Manufacture Camoplast
Track tension sag (in/cm) with 10 lbs/
4.54kg placed 16 in/40.6cm ahead of
rear idler shaft
.375-.5/1-1.3
Front Suspension
Suspension type Edge
IFS shocks Arvin/7043082
IFS spring rate (lb/in - kg/mm) 68-160/1.22-2.9
IFS Spring installed length (in/cm) 10.5/26.7
Front vertical travel (in/cm) 10.3/26.2
Ski center distance (in/cm) 42.5/108
Camber (in/mm) .59±.31/15.0±7.9
Toe (in/mm) .12-.25/3.0-6.35
Dimensions
Width (in/cm) 48/122
Length (in/cm) 113/287
Height (in/cm) 46/117
Est dry weight lb/kg 481/218.4
Electrical
Ignition timing 25°@2500RPM
Spark plug gap (in/mm) .027/.70
Spark plug Champion RN57YCC
Voltage regulator/output 280watt
CDI marking 4010829
Flywheel Marking 4010677
Features
Electric Fuel Gauge Accessory
Electric Start Accessory
Low Oil Light Standard
Parking Brake Standard
Speedometer Standard 5 inch
Tachometer Standard 5 inch
1
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 shock Arvin MPV/7043239
Rear travel (in/cm) 13.9/35.3
Torsion Spring
Torsion spring PNs
(LH/RH)
Torsion spring diameter (in/mm) .375/9.5
Torsion spring tail angle 77°
7041942/7041943
1.9
MODEL SPECIFICATIONS
SUPER SPORT
MODEL S07NP5B(E,S)
Body
Body Style EDGE
Engine
Engine type Fuji
Engine Model EC550PM100
Engine Displacement 544cc
Bore (in/mm) 2.87/73
Stroke (in/mm) 2.56/65
Piston to cylinder clearance (in/mm) .0039-.0053/.10-.135
Piston ring end gap
(in/mm)
Operating RPM±200 7000
Idle RPM±200 1600
Clutch engagement RPM ±200 3800
Exhaust valve spring N/A
Fuel Delivery
.016-.022/.40-.55
Altitude
meters (feet)
0-600
(0-2000)
600-1200
(2000-4000)
1200-1800
(4000-6000)
1800-2400
(6000-8000)
2400-3000
(8000-10000)
3000-3700
(10000-12000)
Jetting
Ambient Temperature
< -25°F/<-35°C
0°F to +20°F/-18°C to -7°C
-15°F to +5°F/-26°C to -15°C
-30°F to -10°F/-34°C to -23°C
270#4260
250#4240#3230#3220#3210#2200
#4
260#4250#4240#3230#3220#3220#2210#2200
250#4240#3230#3220#3210#2210#2200#1190
230#3220#3220#3210#2210#2200#1190#1180
220#3210#3210#2200#2190#1190#1180#1170
210#3200#2190#2190#1180#1180#1170#1160
+15°F to +35°F/-9°C to +2°C
+30°F to +50°F/-1°C to +10°C
+45°F to +65°F/+7°C to +18°C
#1
#1
#1
#1
#1
#1
>+60°F/>+16°C
Type VM34
Main Jet 250
Pilot Jet 35
Jet Needle/Clip position 6DEH11/3
Needle Jet Q-0 (480)
Throttle gap under cutaway (in/mm) .256/6.5
Throttle slide cutaway 3
Valve seat 1.5 Viton
Starter jet 1.5
Pilot air jet 2.5
Fuel screw setting N/A
Air screw setting 1.0
Recommended fuel octane (R+M/2) 87 NonOxy/Min.
Clutching
Altitude meters
(feet)
0-600
(0-2000)
600-1200
(2000-4000)
1200-1800
(4000-6000)
1800-2400
(6000-8000)
2400-3000
8000-10000)
3000-3600
(10000-12000)
Drive Clutch (P-85) Driven Clutch (TEAM)
Shift
Weight
10-62
10-60
10-60
10-58
10-56
10-56
Clutch
Spring
Dark Blue/
White
Dark Blue/
White
Dark Blue/
White
Dark Blue/
White
Dark Blue/
White
Dark Blue/
White
Clutch
Spring
Red/Blue
Red/Blue
Red/Blue
Red/Blue
Red/Blue
Red/Blue
Driven
Helix
(56/42-.36)
LW E R
(56/42-.36)
LW E R
(56/42-.36)
LW E R
(56/42-.36)
LW E R
(56/42-.36)
LW E R
(56/42-.36)
LW E R
Drive clutch bolt torque 50 ft-lbs (69 N-m)
Gearing
19:39- 72
19:39- 72
19:39- 72
18:39- 72
18:39- 72
18:39- 72
Belt
Belt part number 3211078
Belt width (in/cm) 1.438/3.65
Belt side angle 28°
Outside diameter (in/cm) 46.625/118.4
Clutch center distance (in/cm) 11.5/29.2
Chaincase
1.10
Center distance (in/cm) 7.92/18.52
Reverse type PERC
MODEL SPECIFICATIONS
Fluids and Capacities
Fuel (gal/l) 11.8/44.7
Oil (qts/l) 3.25/3.1
Coolant (qts/l) N/A
Chaincase (oz/ml) 9/266.2
Brake fluid type DOT4
Track
Width (in/cm) 15/38
Length (in/cm) 121/307
Lug height (in/cm) .82/2.1
Manufacturer Camoplast
Track tension sag (in/cm) with 10 lbs/
4.54kg placed 16 in/40.6cm ahead of
rear idler shaft
.375-.5/1-1.3
Front Suspension
Suspension type Edge
IFS shocks Arvin/7041932
IFS spring rate (lb/in - kg/mm) 100/1.79
Spring preload (in/cm) .625/15.875
Front vertical travel (in/cm) 10/25.4
Ski center distance (in/cm) 42.5/108
Camber (in/mm) .59±.31/15.0±7.9
Toe (in/mm) .12-.25/3.0-6.35
Dimensions
Est dry weight lb/kg 460/208.7
Electrical
Ignition timing 27°@3000
Spark plug gap (in/mm) .028/.70
Spark plug NGK BR9ES
Voltage regulator/output 280watt
CDI marking EC55PM 100/110
Flywheel Marking FP6318
Features
Electric Fuel Gauge Accessory
Electric Start Accessory
Low Oil Light Standard
Parking Brake Standard
Speedometer Standard 5 inch
Tachometer Accessory
1
Rear Suspension
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 travel (in/cm) 13.9/35.3
* notes that shock is serviceable
Torsion Spring
Torsion spring PNs
(LH/RH)
Torsion spring diameter (in/mm) .375/9.5
Torsion spring tail angle 77°
7041942/7041943
Dimensions
Width (in/cm) 48/122
Length (in/cm) 113/287
Height (in/cm) 45/114
1.11
MODEL SPECIFICATIONS
550 LX
MODEL S07ND5BS
Body
Body Style EDGE
Engine
Engine type Fuji
Engine Model EC550PM110
Engine Displacement 544cc
Bore (in/mm) 2.87/73
Stroke (in/mm) 2.56/65
Piston to cylinder clearance (in/mm) .0039-.0053/.10-.135
Piston ring end gap
(in/mm)
Operating RPM±200 7000
Idle RPM±200 1600
Clutch engagement RPM ±200 3800
Exhaust valve spring N/A
Fuel Delivery
.016-.022/.40-.61
Altitude
meters (feet)
0-600
(0-2000)
600-1200
(2000-4000)
1200-1800
(4000-6000)
1800-2400
(6000-8000)
2400-3000
(8000-10000)
3000-3700
(10000-12000)
Jetting
Ambient Temperature
< -25°F/<-35°C
0°F to +20°F/-18°C to -7°C
-15°F to +5°F/-26°C to -15°C
-30°F to -10°F/-34°C to -23°C
270#4260
250#4240#3230#3220#3210#2200
#4
260#4250#4240#3230#3220#3220#2210#2200
250#4240#3230#3220#3210#2210#2200#1190
230#3220#3220#3210#2210#2200#1190#1180
220#3210#3210#2200#2190#1190#1180#1170
210#3200#2190#2190#1180#1180#1170#1160
+15°F to +35°F/-9°C to +2°C
+30°F to +50°F/-1°C to +10°C
+45°F to +65°F/+7°C to +18°C
#1
#1
#1
#1
#1
#1
>+60°F/>+16°C
Type VM34
Main Jet 250
Pilot Jet 35
Jet Needle/Clip position 6BGY41/4
Needle Jet Q-0 (480)
Throttle gap under cutaway (in/mm) .256/6.5
Throttle slide cutaway 3
Valve seat 1.5 Viton
Starter jet 1.5
Pilot air jet 2.5
Fuel screw setting N/A
Air screw setting 1.0
Recommended fuel octane (R+M/2) 87 NonOxy/Min.
Clutching
Altitude meters
(feet)
0-600
(0-2000)
600-1200
(2000-4000)
1200-1800
(4000-6000)
1800-2400
(6000-8000)
2400-3000
8000-10000)
3000-3600
(10000-12000)
Drive Clutch (P-85) Driven Clutch (TEAM)
Shift
Weight
10-62
10-60
10-60
10-58
10-56
10-56
Clutch
Spring
Dark Blue/
White
Dark Blue/
White
Dark Blue/
White
Dark Blue/
White
Dark Blue/
White
Dark Blue/
White
Clutch
Spring
Red/Blue
Red/Blue
Red/Blue
Red/Blue
Red/Blue
Red/Blue
Driven
Helix
(56/42-.36)
LW E R
(56/42-.36)
LW E R
(56/42-.36)
LW E R
(56/42-.36)
LW E R
(56/42-.36)
LW E R
(56/42-.36)
LW E R
Drive clutch bolt torque 50 ft-lbs (69 N-m)
19:39- 72
19:39- 72
19:39- 72
18:39- 72
18:39- 72
18:39- 72
Belt
Belt part number 3211078
Belt width (in/cm) 1.438/3.65
Belt side angle 28°
Outside diameter (in/cm) 46.625/118.4
Clutch center distance (in/cm) 11.5/29.2
Chaincase
Gearing
1.12
Center distance (in/cm) 7.92/18.52
Reverse type PERC
MODEL SPECIFICATIONS
Fluids and Capacities
Fuel (gal/l) 11.8/44.7
Oil (qts/l) 3.25/3.1
Coolant (qts/l) N/A
Chaincase (oz/ml) 9/266.2
Brake fluid type DOT4
Track
Width (in/cm) 15/38
Length (in/cm) 121/307
Lug height (in/cm) .82/2.1
Manufacturer Camoplast
Track tension sag (in/cm) with 10 lbs/
4.54kg placed 16 in/40.6cm ahead of
rear idler shaft
.375-.5/1-1.3
Front Suspension
Suspension type Edge
IFS shocks Arvin/7041932
IFS spring rate (lb/in - kg/mm) 100/1.79
Spring preload (in/cm) .625/15.875
Front vertical travel (in/cm) 10/25.4
Ski center distance (in/cm) 42.5/108
Camber (in/mm) .59±.31/15.0±7.9
Toe (in/mm) .12-.25/3.0-6.35
Dimensions
Est dry weight lb/kg 460/208.7
Electrical
Ignition timing 27°@3000
Spark plug gap (in/mm) .028/.70
Spark plug NGK BR9ES
Voltage regulator/output 280watt
CDI marking EC55PM 100/110
Flywheel Marking FP6318
Features
Electric Fuel Gauge Accessory
Electric Start Standard
Low Oil Light Standard
Parking Brake Standard
Speedometer Standard 5 inch
Tachometer Accessory
1
Rear Suspension
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 travel (in/cm) 13.9/35.3
* notes that shock is serviceable
Torsion Spring
Torsion spring PNs
(LH/RH)
Torsion spring diameter (in/mm) .375/9.5
Torsion spring tail angle 77°
7041629/7041630
Dimensions
Width (in/cm) 48/122
Length (in/cm) 113/287
Height (in/cm) 45/114
1.13
MODEL SPECIFICATIONS
TRAIL RMK
MODEL S07NJ5B(E,S)
Body
Body Style EDGE
Engine
Engine type Fuji
Engine Model EC550PM110
Engine displacement 544cc
Bore (in/mm) 2.87/73
Stroke (in/mm) 2.56/65
Piston to cylinder clearance (in/mm) .0039-.005/.10-.135
Piston ring end gap (in/mm) .016-.022/.4-.61
Operating RPM±200 7000
Idle RPM 1600
Clutch engagement RPM ±200 3800
Fuel Delivery
Type VM34
Main Jet 210
Pilot Jet 35
Jet Needle/Clip position 6BGY41/4
Needle Jet Q-0 (480)
Throttle gap under cutaway (in/mm) .264/6.71
Throttle slide cutaway 3
Valve seat 1.5 Viton
Starter jet 1.5
Pilot air jet 2.5
Fuel screw setting N/A
Air screw setting .75
Recommended fuel octane (R+M/2) 87 NonOxy/Min.
Altitude
meters (feet)
0-600
(0-2000)
600-1200
(2000-4000)
1200-1800
(4000-6000)
1800-2400
(6000-8000)
2400-3000
(8000-10000)
3000-3700
(10000-12000)
Altitude meters
(feet)
0-600
(0-2000)
600-1200
(2000-4000)
1200-1800
(4000-6000)
1800-2400
(6000-8000)
2400-3000
8000-10000)
3000-3600
(10000-12000)
Drive clutch bolt torque 50 ft-lbs (69 N-m)
Jetting
Ambient Temperature
< -25°F/<-35°C
0°F to +20°F/-18°C to -7°C
-30°F to -10°F/-34°C to -23°C
-15°F to +5°F/-26°C to -15°C
+15°F to +35°F/-9°C to +2°C
+30°F to +50°F/-1°C to +10°C
+45°F to +65°F/+7°C to +18°C
270#4260#4250#4240#3230#3220#3210#2200
#1
260#4250#4240#3230#3220#3220#3210#2200
#1
250#4240#3230#3220#3210#2210#2200#1190
#1
230#3220#3220#3210
210#2200#1190#1180
#2
#1
220#3210#3210#2200#2190#1190#1180#1170
#1
210#3200#2190#2190#1180#1180#1170#1160
#1
Clutching
Drive Clutch (P-85) Driven Clutch (TEAM)
Shift
Weight
10-64
10-62
10-60
10-60
10-58
10-56
Clutch
Spring
Dark Blue/
White
Dark Blue/
White
Dark Blue/
White
Dark Blue/
White
Dark Blue/
White
Dark Blue/
White
Clutch
Spring
Red/Blue
Red/Blue
Red/Blue
Red/Blue
Red/Blue
Red/Blue
Driven
Helix
(56/42-.36)
LW E R
(56/42-.36)
LW E R
(56/42-.36)
LW E R
(56/42-.36)
LW E R
(56/42-.36)
LW E R
(56/42-.36)
LW E R
Gearing
19:43- 74
19:43- 74
19:43- 74
19:43- 74
19:43- 74
19:43- 74
>+60°F/>+16°C
1.14
Belt
Belt part number 3211078
Belt width (in/cm) 1.438/3.65
Belt side angle 28°
Outside diameter (in/cm) 46.625/118.4
Clutch center distance (in/cm) 11.5/29.2
MODEL SPECIFICATIONS
Chaincase
Center distance (in/cm) 7.92/20.1
Reverse type PERC
Fluids and Capacities
Fuel (gal/l) 11.8/44.7
Oil (qts/l) 3.25/3.1
Coolant (qts/l) Air
Chaincase (oz/ml) 9/266.2
Brake fluid type DOT 4
Track
Width (in/cm) 15/38
Length (in/cm) 136/345
Lug height (in/cm) 1.25/3.2
Manufacturer Camoplast
Track tension sag (in/cm) with 10 lbs/
4.54kg placed 16 in/40.6cm ahead of
rear idler shaft
.375-.50/1-1.3
Front Suspension
Torsion Spring
Torsion spring PNs
(LH/RH)
Torsion spring diameter (in/mm)
Torsion spring tail angle
7041627/7041628
.347/8.8
77°
Dimensions
Width (in/cm) 45.5/115.6
Length (in/cm) 124/315
Height (in/cm) 48/123
Est dry weight lb/kg 475/215.7
Electrical
Ignition timing
Spark plug gap (in/mm) .028/.70
Spark plug NGK BR9ES
Voltage regulator/output 280 watts
CDI marking EC55PM100/110
Flywheel marking FP6318
27°@3000 RPM
14°@6500RPM
1
Suspension type Edge RMK
IFS shocks Arvin/7042107
IFS spring rate (lb/in - kg/mm) 80/1.4
Spring installed length (in/cm) 9.75/24.8
Front vertical travel (in/cm) 7.6/19.3
Ski center distance (in/cm) 41/104
Camber (in/mm) .735±.31/18.7±7.9
Toe (in/mm) 0-.12
Rear Suspension
Suspension type
Front track shock
FTS spring rate (lb/in - kg/mm)
FTS spring installed length (in/cm)
Rear track shock
Rear travel (in/cm) 13.8/35.1
Edge RMK 136
Arvin/7042085
170/3.0
Fixed
7042058
Features
Electric Fuel Gauge Accessory
Electric Start Standard
Low Oil Light Standard
Parking Brake Standard
Speedometer Standard 5 inch
Tachometer Accessory
1.15
MODEL SPECIFICATIONS
TRAIL TOURING DELUXE
MODEL S07NT5B(E,S)(A)
Body
Body Style EDGE
Engine
Engine type Fuji
Engine Model EC550PM100
Engine displacement 544cc
Bore (in/mm) 2.87/73
Stroke (in/mm) 2.56/65
Piston to cylinder clearance (in/mm) .0039-.005/.10-.135
Piston ring end gap
(in/mm)
Operating RPM±200 7000
Idle RPM 1600
Clutch engagement RPM ±200 3800
Fuel Delivery
Type VM34
Main Jet 250
Pilot Jet 35
Jet Needle/Clip position 6BGY41/4
Needle Jet Q-0 (480)
Throttle gap under cutaway (in/mm) .256/6.5
Throttle slide cutaway 3
Valve seat 1.5 Viton
Starter jet 1.5
Pilot air jet 2.5
Fuel screw setting N/A
Air screw setting 1.0
Recommended fuel octane (R+M/2) 87 NonOxy/Min.
.016-.022/.4-.61
Altitude
meters (feet)
0-600
(0-2000)
600-1200
(2000-4000)
1200-1800
(4000-6000)
1800-2400
(6000-8000)
2400-3000
(8000-10000)
3000-3700
(10000-12000)
Altitude meters
(feet)
0-600
(0-2000)
600-1200
(2000-4000)
1200-1800
(4000-6000)
1800-2400
(6000-8000)
2400-3000
8000-10000)
3000-3600
(10000-12000)
Drive clutch bolt torque 50 ft-lbs (69 N-m)
Jetting
Ambient Temperature
< -25°F/<-35°C
0°F to +20°F/-18°C to -7°C
+15°F to +35°F/-9°C to +2°C
+30°F to +50°F/-1°C to +10°C
+45°F to +65°F/+7°C to +18°C
#1
270#4260
#4
-15°F to +5°F/-26°C to -15°C
-30°F to -10°F/-34°C to -23°C
250#4240#3230#3220#3210#2200
260#4250#4240#3230#3220#3220#3210#2200
#1
250#4240#3230#3220#3210#2210#2200#1190
#1
230#3220#3220#3210#2210#2200#1190#1180
#1
220#3210#3210#2200#2190#1190#1180#1170
#1
210#3200#2190#2190#1180#1180#1170#1160
#1
Clutching
Drive Clutch (P-85) Driven Clutch (TEAM)
Shift
Weight
10-62
10-60
10-60
10-58
10-56
10-56
Clutch
Spring
Dark Blue/
White
Dark Blue/
White
Dark Blue/
White
Dark Blue/
White
Dark Blue/
White
Dark Blue/
White
Clutch
Spring
Red/Blue
Red/Blue
Red/Blue
Red/Blue
Red/Blue
Red/Blue
Driven
Helix
(56/42-.36)
LW E R
(56/42-.36)
LW E R
(56/42-.36)
LW E R
(56/42-.36)
LW E R
(56/42-.36)
LW E R
(56/42-.36)
LW E R
Gearing
21:41-74
21:41-74
21:41-74
20:41-74
20:41-74
20:41-74
>+60°F/>+16°C
1.16
Belt
Belt part number 3211078
Belt width (in/cm) 1.438/3.65
Belt side angle 28°
Outside diameter (in/cm) 46.625/118.4
Clutch center distance (in/cm) 11.5/29.2
Chaincase
Center distance (in/cm) 7.92/20.1
Reverse type PERC
MODEL SPECIFICATIONS
Fluids and Capacities
Fuel (gal/l) 12.25/46.4
Oil (qts/l) 3.25/3.1
Coolant (qts/l) N/A
Chaincase (oz/ml) 9/266.2
Brake fluid type DOT4
Track
Width (in/cm) 15/38
Length (in/cm) 136/345
Lug height (in/cm) 1/2.5
Manufacturer Soucy
Track tension sag (in/cm) with 10 lbs/
4.54kg placed 16 in/40.6cm ahead of
rear idler shaft
1.125 - 1.375 / 2.9 - 3.5
Front Suspension
Suspension type Edge
IFS shocks Arvin/7041918
IFS spring rate (lb/in - kg/mm) 90-180/1.6-3.2
IFS Spring Pre-Load (in/cm) 1/2.54
Front vertical travel (in/cm) 10/25.4
Ski center distance (in/cm) 42.5/108
Camber (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 200-240 / 3.6 - 4.4Var
FTS spring installed length Fixed
Rear track shock (RTS) Arvin/7042138
Rear travel (in/cm) 13.9/33.5
Torsion Spring
Torsion spring PNs
(LH/RH)
Torsion spring diameter (in/mm) .405/10.3
Torsion spring tail angle 77°
7042240/7042241
Dimensions
Width (in/cm) 48/122
Length (in/cm) 128/325
Height (in/cm) 49.5/126
Est dry weight lb/kg 570/258.8
Electrical
Ignition timing
Spark plug gap (in/mm) .028/.70
Spark plug NGK BR9ES
Voltage regulator/output 280watt
CDI marking EC55PM 100/110
Flywheel Marking FP6318
27°@3000
14°@6500
Features
Electric Fuel Gauge Accessory
Electric Start Standard
Low Oil Light Standard
Parking Brake Standard
Speedometer Standard 5 inch
Tachometer Accessory
1
1.17
MODEL SPECIFICATIONS
600 HO IQ
MODEL S07PP6FS(A,B)
Body
Body Style IQ
Engine
Engine type Liberty
Engine Model S3273-6044-PF6F
Engine displacement 599
Bore (in/mm) 3.04/77.25
Stroke (in/mm) 2.52/64
Piston to cylinder clearance (in/mm) .0045-.0059/.115-.149
Piston ring end gap
(in/mm)
Operating RPM±200 8100
Idle RPM 1500
Clutch engagement RPM ±200 3800
Exhaust valve spring Pink
Fuel Delivery
Type TM38
Main Jet 420
Pilot Jet 50
Jet Needle/Clip position 9DGN6-57/2
Needle Jet P-8
Throttle gap under cutaway (in/mm) 0.08/2.1
Throttle slide cutaway 1.5 Notch
Valve seat 1.5
Starter jet 145
Pilot air jet .6
Fuel screw setting 1.25
Air screw setting N/A
Recommended fuel octane (R+M/2) 91 Min. NonOxy
.014-.020/.0356-.508
Jetting
Ambient Temperature
Altitude
meters (feet)
< -25°F/<-35°C
0°F to +20°F/-18°C to -7°C
+15°F to +35°F/-9°C to +2°C
+30°F to +50°F/-1°C to +10°C
+45°F to +65°F/+7°C to +18°C
0-600
(0-2000)
600-1200
(2000-4000)
1200-1800 (4000-
6000)
1800-2400 (6000-
8000)
2400-3000
(8000-10000)
3000-3700
(10000-12000)
-15°F to +5°F/-26°C to -15°C
-30°F to -10°F/-34°C to -23°C
440#3430
420#2400#2390#2380#2370#2360
#3
410#3400#3390#2370#2360#2350#2340#1330
370#3360#2350#2340#2330#2320#1310#1300
340#3320#2310#2300#2280#2280#1270#1260
310#2300#2290#2280#1270#1260#1250#1240
290#2280#2270#1250#1240#1230#1220#1210
When using non oxygenated fuel with a research octane
Number (RON) greater than 93, decrease the main jet
number in the above chart by 10 and raise the E-clip one
position. If the above chart recommends clip #1, install
washer on top when using the above fuel.
Clutching
Altitude meters
(feet)
0-600
(0-2000)
600-1200
(2000-4000)
1200-1800
(4000-6000)
1800-2400
(6000-8000)
2400-3000
8000-10000)
3000-3600
(10000-12000)
Drive Clutch (P-85) Driven Clutch (TEAM)
Shift Weight
10-62 Black/Green Red/Black
10-60 Black/Green Red/Black
10-58 Black/Green Red/Black
10-56 Black/Green Red/Black
10-54 Black/Green Red/Black
10 AL Black/Green Red/Black
Clutch
Spring
Clutch
Spring
Driven Helix Gearing
(64/42-.36)
LW E R
(56/42-.36)
LW E R
(56/42-.36)
LW E R
(56/42-.36)
LW E R
(56/42-.36)
LW E R
(56/42-.36)
LW E R
Drive clutch bolt torque 50 ft-lbs (69 N-m)
>+60°F/>+16°C
#1
#1
#1
#1
#1
#1
23:39-76
22:39-76
22:40-76
22:40-76
20:41-76
20:41-76
1.18
Belt
Belt part number 3211080
Belt width (in/cm) 1.438/3.65
Belt side angle 28°
Outside diameter (in/cm) 46.625/118.4
Clutch center distance (in/cm) 11.5/29.2
MODEL SPECIFICATIONS
Chaincase
Center distance (in/cm) 8.373/21.3
Reverse type PERC
Fluids and Capacities
Fuel (gal/l) 10.8/40.9
Oil (qts/l) 3.4/3.2
Coolant (qts/l) 6.3/6.0
Chaincase (oz/ml) 11/325.3
Brake fluid type DOT4
Track
Width (in/cm) 15/38
Length (in/cm) 121/307
Lug height (in/cm)
1/2.5(std)
1.25/3.175(opt)
Manufacturer Camoplast
Track tension sag (in/cm) with 10 lbs/
4.54kg placed 16 in/40.6cm ahead of
rear idler shaft
.875-1.125/2.2-2.9
Front Suspension
Suspension type IQ
Arvin/7043245*(Std.)
IFS shocks
IFS spring rate (lb/in - kg/mm) 100/1.79 (Std & Opt)
IFS Spring installed length (in/cm) 10.55/26.8 (Std & Opt)
Front vertical travel (in/cm) 10.25.4
Ski center distance (in/cm) 42.5/108
Camber (in/mm) 2.25±.31/5.7±.79
Toe (in/mm) 0-.12/0-3.0
* notes that shock is serviceable
Fox/7043268* LH,
7043269 *RH (Opt)
Rear Suspension
Suspension type IQ 121
Front track shock (FTS)
FTS spring rate (lb/in - kg/mm)
FTS installed length (in/mm) 7.97/20.2 (Std & Opt)
Rear track shock (RTS)
Rear Suspension Travel (in/cm) 13.9/35.3
* notes that shock is serviceable
Arvin/7043244* (Std)
Fox/7043267* (Opt)
130-270/2.3-4.8
(Std & Opt)
Fox/7043177*(Std)
Fox/7043266*(Opt)
Torsion Spring
Torsion spring PN (LH/RH) 7043070/7043071
Torsion spring diameter (in/mm) .374/9.5
Torsion spring tail angle 80°
Dimensions
Width (in/cm) 47.25/120
Length (in/cm) 115/292
Height (in/cm) 48/122
Est dry weight lb/kg 497/255.6
Electrical
Ignition timing
Spark plug gap (in/mm) .027/.70
Spark plug Champion RN57YCC
Voltage regulator/output 280watt
CDI marking 4011033
Flywheel marking 4010677
26°@3500RPM
(TPS Unplugged)
Features
1
Electric Fuel Gauge N/A
Electric Start Optional
Low Oil Light Standard
Parking Brake Standard
Speedometer Standard
Tachometer Standard
1.19
MODEL SPECIFICATIONS
600 HO IQ CLEANFIRE
MODEL S07PP6HS(A,B)
Body
Body Style IQ
Engine
Engine type Liberty
Engine Model S3206-6044-PF6H
Engine displacement 599
Bore (in/mm) 3.04/77.25
Stroke (in/mm) 2.52/64
Piston to cylinder clearance (in/mm) .0045-.0059/.115-.149
Piston ring end gap (in/mm) .014-.020/.0356-.508
Operating RPM±200 8250
Idle RPM 1700
Clutch engagement RPM ±200 3800
Exhaust valve spring Purple
Fuel Delivery
Type Injected
Throttle Body Manufacturer Mikuni
Throttle Body Bore Size (in/mm) 1.81/46
Fuel Injection Type Kokusan
Regulator Pressure (psi/Bar) 58/4
TPS Voltage at Idle .95 ±.01v
Throttle Gap @ Idle 0
Recommended fuel octane (R+M/2) 91 Min. NonOxy
Clutching
Altitude meters
(feet)
0-600
(0-2000)
600-1200
(2000-4000)
1200-1800
(4000-6000)
1800-2400
(6000-8000)
2400-3000
8000-10000)
3000-3600
(10000-12000)
Drive Clutch (P-85) Driven Clutch (TEAM)
Shift Weight
10-62 Black/Green Red/Black
10-60 Black/Green Red/Black
10-58 Black/Green Red/Black
10-56 Black/Green Red/Black
10-54 Black/Green Red/Black
10 AL Black/Green Red/Black
Clutch
Spring
Clutch
Spring
Driven Helix Gearing
(64/42-.36)
LW E R
(56/42-.36)
LW E R
(56/42-.36)
LW E R
(56/42-.36)
LW E R
(56/42-.36)
LW E R
(56/42-.36)
LW E R
Drive clutch bolt torque 80 ft-lbs (108Nm)
Belt
Belt part number 3211080
Belt width (in/cm) 1.438/3.65
Belt side angle 28°
Outside diameter (in/cm) 46.625/118.4
Clutch center distance (in/cm) 11.5/29.2
Chaincase
Center distance (in/cm) 8.373/21.3
Reverse type PERC
Fluids and Capacities
Fuel (gal/l) 11.7/44.3
Oil (qts/l) 3.4/3.2
Coolant (qts/l) 6.3/6
Chaincase (oz/ml) 11/325.3
Brake fluid type DOT4
23:39-76
22:39-76
22:40-76
22:40-76
20:41-76
20:41-76
1.20
Track
Width (in/cm) 15/38
Length (in/cm) 121/307
Lug height (in/cm)
Manufacturer Camoplast
Track tension sag (in/cm) with 10 lbs/
4.54kg placed 16 in/40.6cm ahead of
rear idler shaft
1/2.5(std)
1.25/3.175(opt)
.875-1.125/2.2-2.9
MODEL SPECIFICATIONS
Front Suspension
Suspension type IQ
Arvin/7043245*(Std.)
IFS shocks
Fox/7043268* LH,
7043269* RH (Opt)
IFS spring rate (lb/in - kg/mm) 100/1.79 (Std & Opt)
IFS Spring installed length (in/cm) 10.55/26.8 (Std & Opt)
Front vertical travel (in/cm) 10.25.4
Ski center distance (in/cm) 42.5/108
Camber (in/mm) 2.25±.31/5.7±.79
Toe (in/mm) 0-.12/0-3.0
* notes that shock is serviceable
Rear Suspension
Suspension type IQ 121
Front track shock (FTS)
FTS spring rate (lb/in - kg/mm)
FTS installed length (in/mm) 7.97/20.2 (Std & Opt)
Rear track shock (RTS)
Rear Suspension Travel (in/cm) 13.9/35.3
* notes that shock is serviceable
Arvin/7043244* (Std)
Fox/7043267* (Opt)
130-270/2.3-4.8
(Std & Opt)
Fox/7043177*(Std)
Fox/7043266*(Opt)
Torsion Spring
Torsion spring PN (LH/RH) 7043070/7043071
Torsion spring diameter (in/mm) .374/9.5
Torsion spring tail angle 80°
Dimensions
Width (in/cm) 47.25/120
Length (in/cm) 115/292
Height (in/cm) 48/122
Est dry weight lb/kg 497/255.6
Electrical
18° @ 1700 RPM (±200
Ignition timing
Spark plug gap (in/mm) .027/.70
Spark plug Champion RN57YCC
Voltage regulator/output 400watt
RPM) & 120° F (±10° F)
49 ° C (±12° C) water
temp
Features
Electric Fuel Gauge Standard
Electric Start Optional
Low Oil Light Standard
Parking Brake Standard
Speedometer Standard
Tachometer Standard
1
1.21
MODEL SPECIFICATIONS
600 HO IQ LX CLEANFIRE
MODEL S07PD6HS
Body
Body Style IQ Luxury
Engine
Engine type Liberty
Engine displacement 599
Engine model number S3206-6044-PF6H
Bore (in/mm) 3.04/77.25
Stroke (in/mm) 2.52/64
Piston to cylinder clearance (in/mm) .0045-.0059/.115-.149
Piston to cylinder service limit
(in/mm)
Piston ring end gap (in/mm)
Operating RPM±200 8250
Idle RPM 1700
Clutch engagement RPM ±200 3800
Exhaust valve spring Purple
.0059/.149
.014-.020/.0356-.508
Clutching
Altitude meters
(feet)
0-600
(0-2000)
600-1200
(2000-4000)
1200-1800
(4000-6000)
1800-2400
(6000-8000)
2400-3000
8000-10000)
3000-3600
(10000-12000)
Drive Clutch (P-85) Driven Clutch (TEAM)
Shift Weight
10-62 Black/Green Red/Black
10-60 Black/Green Red/Black
10-58 Black/Green Red/Black
10-56 Black/Green Red/Black
10-54 Black/Green Red/Black
10 AL Black/Green Red/Black
Clutch
Spring
Clutch
Spring
Driven Helix Gearing
(64/42-.36)
LW E R
(56/42-.36)
LW E R
(56/42-.36)
LW E R
(56/42-.36)
LW E R
(56/42-.36)
LW E R
(56/42-.36)
LW E R
Drive clutch bolt torque 80 ft-lbs (108Nm)
Belt
Belt part number 3211080
Belt width (in/cm) 1.438/3.65
Belt side angle 28°
Outside diameter (in/cm) 46.625/118.4
Clutch center distance (in/cm) 11.5/29.2
Chaincase
22:39-76
22:39-76
22:40-76
22:40-76
20:41-76
20:41-76
Fuel Delivery
Type Injected
Throttle Body Manufacturer Mikuni
Throttle Body Bore Size (in/mm) 1.81/46
Fuel Injection Type Kokusan
Regulator Pressure (psi/Bar) 58/4
TPS Voltage at Idle .95
Throttle Gap @ Idle 0
Recommended fuel octane (R+M/2) 91 Min. NonOxy
±.01v
Center distance (in/cm) 7.92/20.1
Reverse type PERC
Fluids and Capacities
Fuel (gal/l) 11.7/44.3
Oil (qts/l) 3.4/3.2
Coolant (qts/l) 7/6.6
Chaincase (oz/ml) 9/266.2
Brake fluid type DOT4
Track
Width (in/cm) 15/38
Length (in/cm) 128/325
Lug height (in/cm) 1/2.5
Manufacturer Camoplast
Track tension sag (in/cm) with 10 lbs/
4.54kg placed 16 in/40.6cm ahead of
rear idler shaft
.875-1.13/2.2-2.9
1.22
Front Suspension
Suspension type IQ
IFS shocks Arvin /7043054
IFS spring rate (lb/in - kg/mm) 120/2.1
IFS Spring installed length (in/cm) 9.95/25.3
Front vertical travel (in/cm) 10/25.4
Ski center distance (in/cm)
Camber (in/mm)
Toe (in/mm)
* notes that shock is serviceable
41.16"
104.5
2.25" ±.31"
5.7 ±.79
0-.12"
0-3
Rear Suspension
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) 13/33
* notes that shock is serviceable
MODEL SPECIFICATIONS
1
Dimensions
Width (in/cm) 47.25/120
Length (in/cm) 116/295
Height (in/cm) 51/130
Est dry weight lb/kg 505/229.3
Electrical
18° @ 1700 RPM (±200
Ignition timing
Spark plug gap (in/mm) .027/.70
Spark plug Champion RN57YCC
Voltage regulator/output 400watt
Base ECU 4011518
RPM) & 120° F (±10° F)
49 ° C (±12° C) water
temp
1.23
MODEL SPECIFICATIONS
600 HO SWITCHBACK
MODEL S07PS6FS(A)
Engine
Engine type Liberty
Engine displacement 599cc
Engine model number S3273-6044-PF6F
Bore (in/mm) 3.04/77.25
Stroke (in/mm) 2.52/64
Piston to cylinder clearance (in/mm) .0045-.0059/.114-.150
Piston ring end gap (in/mm)
Operating RPM±200 8100
Idle RPM±200 1500
Clutch engagement RPM ±200 3800
Exhaust valve spring Pink
Fuel Delivery
Type TM38
Main Jet 420
Pilot Jet 50
Jet Needle/Clip position 9DGN6-57/2
Needle Jet P-8
Throttle gap under cutaway (in/mm) 0.08/2.1
Throttle slide cutaway 1.5 Notch
Valve seat 1.5
Starter jet 145
Pilot air jet .6
Fuel screw setting 1.25
Air screw setting N/A
Recommended fuel octane (R+M/2) 91
.014-.020/.36-.51
Jetting
Ambient Temperature
Altitude
meters (feet)
< -25°F/<-35°C
0°F to +20°F/-18°C to -7°C
+15°F to +35°F/-9°C to +2°C
+30°F to +50°F/-1°C to +10°C
+45°F to +65°F/+7°C to +18°C
#1
#1
#1
#1
#1
#1
0-600
(0-2000)
600-1200
(2000-4000)
1200-1800 (4000-
6000)
1800-2400 (6000-
8000)
2400-3000
(8000-10000)
3000-3700
(10000-12000)
-15°F to +5°F/-26°C to -15°C
-30°F to -10°F/-34°C to -23°C
440#3430#3420#2400#2390#2380#2370#2360
410#3400#3390#2370#2360#2350#2340#1330
370#3360#2350#2340#2330#2320#1310#1300
340#3320#2310#2300#2280#1280#1270#1260
310#2300#2290#2280#1270#1260#1250#1240
290#2280#2270#1250#1240#1230#1220#1210
When using non oxygenated fuel with an octane number
greater than 93, decrease the main jet number in the above
chart by 10 and raise the E-clip one position. If already in
position #1 install washer on top when using the above fuel.
Clutching
Altitude meters
(feet)
0-600
(0-2000)
600-1200
(2000-4000)
1200-1800 (4000-
6000)
1800-2400 (6000-
8000)
2400-3000
(8000-10000)
3000-3700
(10000-12000)
Drive Clutch (P-85) Driven Clutch (TEAM)
Shift
Weight
10-62
10-60
10-58
10-56
10-54
10AL
Clutch
Spring
Black/
Green
Black/
Green
Black/
Green
Black/
Green
Black/
Green
Black/
Green
Clutch
Spring
Red/
Black
Red/
Black
Red/
Black
Red/
Black
Red/
Black
Red/
Black
Driven
Helix
64/42-36
ER
56/42-36
ER
56/42-36
ER
56/42-36
ER
56/42-36
ER
56/42-36
ER
Drive clutch bolt torque 50 ft-lbs (69 N-m)
Gearing
22:39-76
22:39-76
22:39-76
20:41-76
20:41-76
20:41-76
>+60°F/>+16°C
1.24
Belt
Belt part number 3211080
Belt width (in/cm) 1.438/3.65
Belt side angle 28°
Outside diameter (in/cm) 46.625/118.4
Clutch center distance (in/cm) 11.5/29.2
MODEL SPECIFICATIONS
Chaincase
Center distance (in/cm) 8.373/21.27
Reverse type PERC
Fluids and Capacities
Fuel (gal/l) 10.8/40.9
Oil (qts/l) 3.4/3.2
Coolant (qts/l) 6...3/6
Chaincase (oz/ml) 11/325.3
Brake fluid type DOT 4
Track
Width (in/cm) 15/38
Length (in/cm) 144/366
Lug height (in/cm)
Manufacturer Camoplast
Track tension sag (in/cm) with 10 lbs/
4.54kg placed 16 in/40.6cm ahead of
rear idler shaft
1.25/3.2 (Std)
1.50/3.8(Opt)
.375-.50/1-1.3
Torsion Spring
Torsion spring PNs
(LH/RH)
Torsion spring diameter (in/mm) .359/9.12
Torsion spring tail angle 77°
7041629/7041630
Dimensions
Width (in/cm) 47.25/120
Length (in/cm) 126/320
Height (in/cm) 48/122
Est dry weight lb/kg 483/219
Electrical
Ignition timing
Spark plug gap (in/mm) .027/.70
Spark plug Champion RN57YCC
Voltage regulator/output 280w
CDI marking 4011033
Flywheel marking 4010677
26°@3500 w/TPS
unplugged
1
Front Suspension
Suspension type IQ 42.5
Fox/7043141* (Std)
IFS shocks
7043268*,7043269*
Fox/
(Option)
IFS spring rate (lb/in - kg/mm) 100/1.79 (Std & Opt)
Spring installed length (in/cm) 10.55/26.8 (Std & 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 Switchback
Front track shock (FTS) Fox/7043142*
FTS spring rate
lbs-in/kg-mm
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
170/3.0
1.25
MODEL SPECIFICATIONS
600 HO SWITCHBACK CLEANFIRE
MODEL S07PS6HS(A,B)
Engine
Engine type Liberty
Engine displacement 599cc
Engine model number S3206-6044-PF6H
Bore (in/mm) 3.04/77.25
Stroke (in/mm) 2.52/64
Piston to cylinder clearance (in/mm) .0045-.0059/.115-.149
Piston ring end gap (in/mm)
Operating RPM±200 8250
Idle RPM±200 1700
Clutch engagement RPM ±200 3800
Exhaust valve spring Purple
Fuel Delivery
Type Injected
Throttle Body Manufacturer Mikuni
Throttle Body Bore Size (in/mm) 1.81/46
Fuel Injection Type Kokusan
Regulator Pressure (psi/Bar) 58/4
TPS Voltage at Idle .95
Throttle Gap @ Idle 0
Recommended fuel octane (R+M/2) 91 Min. NonOxy
Clutching
.014-.020/.36-.51
±.01v
Belt
Belt part number 3211080
Belt width (in/cm) 1.438/3.65
Belt side angle 28°
Outside diameter (in/cm) 46.625/118.4
Clutch center distance (in/cm) 11.5/29.2
Chaincase
Center distance (in/cm) 8.373/21.27
Reverse type PERC
Fluids and capacities
Fuel (gal/l) 11.7/44.3
Oil (qts/l) 3.4/3.2
Coolant (qts/l) 6.3/6
Chaincase (oz/ml) 11/325.3
Brake fluid type DOT 4
Track
Width (in/cm) 15/38
Length (in/cm) 144/366
Lug height (in/cm)
Manufacturer Camoplast
Track tension sag (in/cm) with 10 lbs/
4.54kg placed 16 in/40.6cm ahead of
rear idler shaft
1.25/3.2 (Std)
1.50/3.8 (Option)
.375-.50/1-1.3
Altitude meters
(feet)
0-600
(0-2000)
600-1200
(2000-4000)
1200-1800 (4000-
6000)
1800-2400 (6000-
8000)
2400-3000
(8000-10000)
3000-3700
(10000-12000)
1.26
Drive Clutch (P-85) Driven Clutch (TEAM)
Shift
Wei gh t
10-62
10-60
10-58
10-56
10-54
10AL
Clutch
Spring
Black/
Green
Black/
Green
Black/
Green
Black/
Green
Black/
Green
Black/
Green
Clutch
Spring
Red/
Black
Red/
Black
Red/
Black
Red/
Black
Red/
Black
Red/
Black
Driven
Helix
64/42-36
ER
56/42-36
ER
56/42-36
ER
56/42-36
ER
56/42-36
ER
56/42-36
ER
Drive clutch bolt torque 80 ft-lbs (108Nm)
Gearing
22:39-76
22:39-76
22:40-76
20:41-76
20:41-76
20:41-76
MODEL SPECIFICATIONS
Front Suspension
Suspension type IQ 42.5
Fox/7043141* (Std)
IFS shocks
Fox/7043268*,
7043269*(Option)
IFS spring rate
lbs-in/kg-mm
Spring installed length (in/cm) 10.55/26.8 (Std & 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
100/1.79 (Std & Opt)
Rear Suspension
Suspension type IQ Switchback
Front track shock (FTS) Fox/7043142*
FTS spring rate (lb/in - kg/mm) 170/3.0
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
Features
Electric Fuel Gauge Standard
Electric Start Optional
Low Oil Light Standard
Parking Brake Standard
Speedometer Standard
Tachometer Standard
1
Torsion Spring
Torsion spring PNs
(LH/RH)
Torsion spring diameter (in/mm) .359/9.12
Torsion spring tail angle 77°
7041629/7041630
Dimensions
Width (in/cm) 46.5/118
Length (in/cm) 128/325
Height (in/cm) 46.5/118
Est dry weight lb/kg 489/222
Electrical
18° @ 1700 RPM (±200
Ignition timing
Spark plug gap (in/mm) .027/.70
Spark plug Champion RN57YCC
Voltage regulator/output 400w@4000RPM
RPM) & 120° F (±10° F)
49 ° C (±12° C) water
temp
1.27
MODEL SPECIFICATIONS
600 HO RMK 144/155 (F/O)
MODEL S07(P,M)(M,K)6FS(A)
Body
Body Style IQ
Engine
Engine type Liberty
Engine displacement 599cc
Engine model number S3274-6044-PF6F
Bore (in/mm) 3.04/77.25
Stroke (in/mm) 2.52/64
Piston to cylinder clearance (in/mm) .0045-.0059/.114-.150
Piston ring end gap (in/mm)
Operating RPM±200 8100
Idle RPM 1500
Clutch engagement RPM±200 3800
Exhaust valve spring Pink
Fuel Delivery
Type TM38
Main Jet 280
Pilot Jet 50
Jet Needle/Clip position 9DGN6-57/1
Needle Jet P-8
Throttle gap under cutaway (in/mm) 0.13/3.2
Throttle slide cutaway 2.5
Valve seat 1.5
Starter jet 145
Pilot air jet .6
Fuel screw setting 1
Air screw setting N/A
Recommended fuel octane (R+M/2) 91
.014-.020/.36-.51
Jetting
Ambient Temperature
Altitude
meters (feet)
< -25°F/<-35°C
0°F to +20°F/-18°C to -7°C
+15°F to +35°F/-9°C to +2°C
280#1280#1270#1260
#2
+30°F to +50°F/-1°C to +10°C
+45°F to +65°F/+7°C to +18°C
#1
#1
#1
#1
#1
**
0-600
(0-2000)
600-1200 (2000-
4000)
1200-1800 (4000-
6000)
1800-2400 (6000-
8000)
2400-3000
(8000-10000)
3000-3700
(10000-12000)
-15°F to +5°F/-26°C to -15°C
-30°F to -10°F/-34°C to -23°C
440#3430#3420#2400#2390#2380#2370#2360
410#3400#3390#2370#2360#2350#2340#1330
370#3360#2350#2340#2330#2320#1310#1300
340#3320#2310#2300
310#2300#2290#2280#1270#1260#1250#1240
290#2280#2270#1250#1240**230**220**210
** Denotes clip in position #1 with the washer on top.
When using non oxygenated fuel with an octane number
greater than 93, decrease the main jet number in the above
chart by 10 and raise the E-clip one position to **. If already
in position ** no adjustment is needed.
Clutching
Altitude meters
(feet)
0-600
(0-2000)
600-1200
(2000-4000)
1200-1800
(4000-6000)
1800-2400
(6000-8000)
2400-3000
(8000-10000)
3000-3700
(10000-12000)
Drive Clutch (P-85) Driven Clutch (TEAM)
Shift
Weight
10-62
10-60
10-58
10-56
10-54
10AL
Clutch
Spring
Black/
Green
Black/
Green
Black/
Green
Black/
Green
Black/
Green
Black/
Green
Clutch
Spring
Red/
Black
Red/
Black
Red/
Black
Red/
Black
Red/
Black
Red/
Black
Driven
Helix
56/42-36 19:41-76
56/42-36 19:41-76
56/42-36 19:41-76
56/42-36 19:41-76
56/42-36 19:41-76
56/42-36 19:41-76
Drive clutch bolt torque 50 ft-lbs (69 N-m)
Gearing
>+60°F/>+16°C
1.28
Belt
Belt part number 3211115
Belt width (in/cm) 1.460/3.7
Belt side angle 26°
Outside diameter (in/cm) 46.77/118.8
Clutch center distance (in/cm) 11.5/29.2
MODEL SPECIFICATIONS
Chaincase
Center distance (in/cm) 8.373/21.27
Reverse type PERC
Fluids and Capacities
Fuel (gal/l) 12.1/45.8
Oil (qts/l) 3/2.8
Coolant (qts/l) 6.3/6
Chaincase (oz/ml) 11/325.3
Brake fluid type DOT 4
Track
Width (in/cm) 15/38
Length (in/cm)
Lug height (in/cm)
144/366
151/384
144=2/5
151=2.4/6.1
Manufacturer Camoplast
Track tension sag (in/cm) with 10 lbs/
4.54kg placed 16 in/40.6cm ahead of
rear idler shaft
.375-.50/1-1.3
Front Suspension
Suspension type IQ RMK
IFS shocks (Std) Arvin/7043222
IFS spring rate (lb/in - kg/mm) 100/1.8
IFS shocks (Premium) WE Air/7043233*
IFS nitrogen charge
IFS spring installed length (in/cm) 10.35/26.3
Front vertical travel (in/cm) 9/22.9
Ski center distance (in/cm) 38.67/98.2
Camber (in/cm) 2.17±.31/5.5±.79
Toe (in/mm) 0-.12/0-3.0
* notes that shock is serviceable
215 psi/14.8 bar
nitrogen
Rear Suspension
Suspension type IQ RMK 144/155
Std. Front track shock (FTS)
Arvin/7043048 (Std)
Rear Suspension
FTS spring installed length (in/cm)
Rear track shock Arvin/7043047
Rear track shock Premium WE/7043235*
Rear travel (in/cm)
* notes that shock is serviceable
7.4/18.8 (Std)
No Spring (Premium)
144=14.5/36.8
155=15.5/39.4
Torsion Spring
Torsion spring PNs
(LH/RH)
Torsion spring diameter (in/mm) .359/9.12
Torsion spring tail angle 77°
7041629/7041630
Dimensions
Width (in/cm) 46.5/118
Length (in/cm)
Height (in/cm) 46.5/118
Est dry weight lb/kg
144=125/318
155=130.5/331
144=472/214.3
155=478/217
Electrical
Ignition timing
Spark plug gap (in/mm) .027/.70
Spark plug Champion RN57YCC
Voltage regulator/output 280w
CDI marking 4011033
Flywheel marking 4010677
26°@3500 w/TPS
unplugged
Features
Electric Fuel Gauge N/A
Electric Start
Low Oil Light Standard
Parking Brake Standard
Speedometer Standard
Tachometer Standard
(144) Accessory
(155) Optional
1
FTS spring rate (lb/in - kg/mm)
Prem. Front track shock (FTS)
FTS nitrogen charge
190/3.4 (Std)
WE Air/7043234*
(Premium)
215 psi / 14.8 bar
nitrogen (Premium)
1.29
MODEL SPECIFICATIONS
600 HO IQ TOURING CLEANFIRE
MODEL S07PT6HS
Body
Body Style IQ Touring
Engine
Engine type Liberty
Engine displacement 599
Engine model number S3206-6044-PF6H
Bore (in/mm) 3.04/77.25
Stroke (in/mm) 2.52/64
Piston to cylinder clearance (in/mm) .0045-.0059/.115-.149
Piston ring end gap
(in/mm)
Operating RPM±200 8250
Idle RPM 1700
Clutch engagement RPM ±200 3800
Exhaust valve spring Purple
Fuel Delivery
Type Injected
Throttle Body Manufacturer Mikuni
Throttle Body Bore Size (in/mm) 1.81/46
Fuel Injection Type Kokusan
Regulator Pressure (psi/Bar) 58/4
TPS Voltage at Idle .95 ±.01v
Throttle Gap @ Idle 0
Recommended fuel octane (R+M/2) 91 Min. NonOxy
.014-.020/.356-.508
Belt
Belt part number 3211080
Belt width (in/cm) 1.438/3.65
Belt side angle 28°
Outside diameter (in/cm) 46.625/118.4
Clutch center distance (in/cm) 11.5/29.2
Chaincase
Center distance (in/cm) 7.92/20.1
Reverse type PERC
Fluids and Capacities
Fuel (gal/l) 11.7/44.3
Oil (qts/l) 3.4/3.2
Coolant (qts/l) 7/6.6
Chaincase (oz/ml) 9/266.2
Brake fluid type DOT 4
Track
Width (in/cm) 15/38
Length (in/cm) 136/345
Lug height (in/cm) 1/2.5
Manufacturer Camoplast
Track tension sag (in/cm) with 10 lbs/
4.54kg placed 16 in/40.6cm ahead of
rear idler shaft
.75-1.0/1.9-2.5
Altitude meters
(0-3000)
900-1500
(3000-5000)
1500-2100
(5000-7000)
2100-2700
(7000-9000)
2700-3350
(9000-11000)
3350-4000
(11000-13000)
1.30
Clutching
Drive Clutch (P-85) Driven Clutch (TEAM)
(feet)
0-900
Shift
Wei gh t
10-62
10-60
10-58
10-56
10-54
10AL
Drive clutch bolt torque 80 ft-lbs (108Nm)
Clutch
Spring
Black/
Green
Black/
Green
Black/
Green
Black/
Green
Black/
Green
Black/
Green
Clutch
Spring
Red/
Black
Red/
Black
Red/
Black
Red/
Black
Red/
Black
Red/
Black
Driven
Helix
64/42-36
LW E R
56/42-36
LW E R
56/42-36
LW E R
56/42-36
LW E R
56/42-36
LW E R
56/42-36
LW E R
Gearing
22:43-78
22:43-78
22:43-78
21:44-78
21:44-78
21:44-78
Front Suspension
Suspension type IQ
IFS shocks Arvin/7043054
IFS spring rate
(lb/in - kg/mm)
Spring installed length (in/cm) 9.95/25.3
Front vertical travel (in/cm) 10/25.4
Ski center distance (in/cm)
Camber (in/mm)
Toe (in/mm)
* notes that shock is serviceable
122-2.1
41.16"
104.5
2.25" ±.31"
5.7 ±.79
0-.12"
0-3
Rear Suspension
Suspension type M-10 136
Front track shock (FTS) Arvin /7043207
FTS spring rate
lbs-in/kg-mm
FTS spring installed length (in/cm) 8.5/21.6
Rear track shock Fox /7043216*
Rear travel (in/cm) 14/35.6
* notes that shock is serviceable
220/3.9
MODEL SPECIFICATIONS
1
Dimensions
Width (in/cm) 48/121.9
Length (in/cm) 129/327.7
Height (in/cm) 53/134.6
Est dry weight lb/kg 574/260.6
Electrical
18° @ 1700 RPM (±200
Ignition timing
Spark plug gap (in/mm) .027/.70
Spark plug Champion RN57YCC
Voltage regulator/output 280watt
Base ECU 4011518
RPM) & 120° F (±10° F)
49 ° C (±12° C) water
temp
1.31
MODEL SPECIFICATIONS
DRAGON
MODEL NUMBER: S07PC7J(E,S)
Engine
Engine type Liberty
Engine displacement 700cc
Engine model number S3305-7044-PF7J
Bore (in/mm) 3.19/81
Stroke (in/mm) 2.68/68
Piston to cylinder clearance (in/mm) .0045-.0059/.115-.149
Piston ring end gap (in/mm) .014-.020/.356-.508
Operating RPM ±200 8250
Idle RPM 1700
Clutch engagement RPM ±200 3800
Exhaust valve spring Purple
Fuel Delivery
Type Injected
Throttle Body Manufacturer Mikuni
Throttle Body Bore Size (in/mm) 1.81/46
Fuel Injection Type Kokusan
Regulator Pressure (psi/Bar) 58/4
TPS Voltage at Idle .95 ±.01v
Throttle Gap @ Idle 0
Recommended fuel octane (R+M/2) 91 Min. NonOxy
Clutching
ALTITUDE
meters
(feet)
0-600
(0-2000)
600-1200
(2000-4000)
1200-1800
(4000-6000)
1800-2400
(6000-8000)
2400-3000
(8000-10000)
3000-3600
(10000-12000)
DRIVE CLUTCH (P-85) DRIVEN CLUTCH (TEAM)
Shift
Weight
10-64
10-62
10-62
10-60
10-58
10-56
Clutch
Spring
Dark Blue /
White
Dark Blue /
White
Black /
Green
Black /
Green
Black /
Green
Black /
Green
Clutch
Spring
Red/Black
Red/Black
Red/Black
Red/Black
Red/Black
Red/Black
Driven
Helix
66/44-46
LW E R
66/44-46
LW E R
64/42-36
LW E R
64/42-36
LW E R
56/42-36
LW E R
56/42-36
LW E R
Drive clutch bolt torque 80 ft-lb (108Nm)
Belt
Belt part number 3211115
Belt width (in/cm) 1.460/3.7
Belt side angle 26°
Outside diameter (in/cm) 46.77/118.8
Clutch center distance (in/cm) 11.5/29.2
Chaincase
Center distance (in/cm) 8.373/21.27
Reverse type PERC
Fluids and Capacities
Gearing
23:39-76
23:39-76
23:39-76
22:39-76
20:41-76
20:41-76
1.32
Fuel (gal/l) 10.8/40.9
Oil (qts/l) 3.4/3.2
Coolant (qts/l) N/A
Chaincase (oz/ml) 11/325.3
Brake fluid type DOT 4
MODEL SPECIFICATIONS
Track
Width (in/cm) 15/38
Length (in/cm) 121/307
Lug height (in/cm) 1.25/3.2
Manufacturer Camoplast
Track tension sag (in/cm) with 10 lbs/
4.54kg placed 16 in/40.6cm ahead of
rear idler shaft
.875-1.125/2.2-.9
Front Suspension
Suspension type IQ 121 Dragon
IFS shocks Walker/7043206*
IFS spring rate lbs-in/kg-mm 100/1.79
Spring installed length (in/cm) 11.17/28.4
Front vertical travel (in/cm) 10.55/26.8
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
Electrical
Stator output 400w
18° @ 1700 RPM (±200
Ignition timing BTDC @ RPM
Spark plug gap (in/mm) .027/.70
Spark plug Champion RN57YCC
Base ECU 4011518
RPM) & 120° F (±10° F)
49 ° C (±12° C) water
temp
Features
Electric Fuel Gauge N/A
Electric Start Accessory
Low Oil Light Standard
Parking Brake Standard
Speedometer Standard
Tachometer Standard
1
Suspension type IQ 121
Front 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 that shock is serviceable
Torsion Spring
Torsion spring PNs
(LH/RH)
Torsion spring diameter (in/mm)
Torsion spring tail angle
7043070/7043071
.347
80°
Dimensions
Width (in/cm) 47.25/120
Length (in/cm) 115/292
Height (in/cm) 47/119
Est dry weight lb/kg 476/216.4
1.33
MODEL SPECIFICATIONS
DRAGON RMK
MODEL NUMBER: S07PL7JS
Engine
Engine type Liberty
Engine displacement 700cc
Bore (in/mm) 3.19/81
Stroke (in/mm) 2.68/68
Piston to cylinder clearance
(in/mm)
Piston ring end gap (in/mm)
Operating RPM ±200 8250
Idle RPM ±200 1700
Clutch engagement RPM ±200 3800
Exhaust valve spring
Fuel Delivery
Type Injected
Throttle Body Manufacturer Mikuni
Throttle Body Bore Size (in/mm) 1.81/46
Fuel Injection Type Kokusan
Regulator Pressure (psi/Bar) 58/4
TPS Voltage at Idle .95 ±.01v
Throttle Gap @ Idle 0
Recommended fuel octane (R+M/2) 91 Min. NonOxy
.0045-.0059/.115-.149
.014-.020/.35-.50
Purple
Clutching
ALTITUDE
meters
(feet)
0-600
(0-2000)
600-1200
(2000-4000)
1200-1800
(4000-6000)
1800-2400
(6000-8000)
2400-3000
(8000-10000)
3000-3600
(10000-12000)
DRIVE CLUTCH (P-85) DRIVEN CLUTCH (TEAM)
Shift
Weight
10-66
10-64
10-62
10-60
10-58
10-56
Clutch
Spring
Black/
Green
Black/
Green
Black/
Green
Black/
Green
Black/
Green
Black/
Green
Clutch
Spring
Black
Black
Black
Black
Black
Black
Driven
Helix
56/42-36
LW E R
56/42-36
LW E R
56/42-36
LW E R
56/42-36
LW E R
56/42-36
LW E R
56/42-36
LW E R
Drive clutch bolt torque 80 ft-lbs (108Nm)
Belt
Belt part number 3211115
Belt width (in/cm) 1.460/3.7
Belt side angle 26°
Outside diameter (in/cm) 46.77/118.8
Clutch center distance (in/cm) 11.5/29.2
Chaincase
Center distance (in/cm) 8.373/21.27
Reverse type PERC
Fluids and Capacities
Gearing
20:41-76
20:41-76
20:41-76
20:41-76
20:41-76
20:41-76
1.34
Fuel (gal/l) 12.1/45.8
Oil (qts/l) 3/2.8
Coolant (qts/l) 6.7/6.3
Chaincase (oz/ml) 11/325.3
Brake fluid type DOT 4
MODEL SPECIFICATIONS
Track
Width (in/cm) 15/38
Length (in/cm) 155/393.7
Lug height (in/cm) 2.4/6.1
Manufacturer Camoplast
Track tension sag (in/cm) with 10 lbs/
4.54kg placed 16 in/40.6cm ahead of
rear idler shaft
.375-.50/1-1.3
Front Suspension
Suspension type IQ RMK
IFS shocks Walker/7043233*
IFS nitrogen charge
Spring installed length (in/cm) N/A
Front vertical travel (in/cm) 9/22.9
Ski center distance (in/cm) 38.67/98.2
Camber (in/cm) 2.17±.31/5.5±.79
Toe (in/mm) 0-.12/0-3.0
* notes that shock is serviceable
215 psi/14.8 bar
nitrogen
Torsion Spring
Torsion spring PNs
(LH/RH)
Torsion spring diameter (in/mm) .359/9.12
Torsion spring tail angle 77°
7041629/7041630
Dimensions
Width (in/cm) 46.5/118
Length (in/cm) 130.5/331
Height (in/cm) 49/124
Est dry weight lb/kg 484/219.7
Electrical
Stator output 400w@4000RPM
18° @ 1700 RPM (±200
Ignition timing
Spark plug gap (in/mm) .027/.70
Spark plug Champion RN57YCC
RPM) & 120° F (±10° F)
49 ° C (±12° C) water
temp
1
Rear Suspension
Suspension type IQ RMK 155
Front track shock Walker/7043234*
IFS nitrogen charge
FTS spring installed length (in/cm) N/A
Rear track shock (RTS) Walker/7043235*
Rear travel (in/cm) 15.5/39.4
* notes that shock is serviceable
215 psi/14.8 bar
nitrogen
Features
Electric Fuel Gauge N/A
Electric Start Accessory
Low Oil Light Standard
Parking Brake Standard
Speedometer Standard
Tachometer Standard
1.35
MODEL SPECIFICATIONS
NOTES
1.36
GENERAL
CHAPTER 2
GENERAL
HOW TO USE THIS MANUAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
GEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2
JETTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
CLUTCH SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
SUSPENSION SPRING PRE-LOAD/INSTALLED LENGTH . . . . . . . . . . . . . . . . . . . . . . 2.3
SNOWMOBILE NUMBER DESIGNATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
MODEL NUMBER DESIGNATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
VEHICLE IDENTIFICATION NUMBER (VIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
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 GASOLINE / OIL PRE MIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
GASOLINE VOLATILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.8
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.8
MEASUREMENT CONVERSION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
PISTON WASH / SPARK PLUG READING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
2
2.1
GENERAL
HOW TO USE THIS MANUAL
Gearing
Gearing that is called out in the clutching table is stated as TOP GEAR
teeth) - CHAIN PITCH (total number of links)
Example 22:39-76
• Top Gear = 22 tooth
• Bottom Gear = 39 tooth
• Drive Chain = 76 pitch (links)
Production setting is designated in the shaded areas
(total number of teeth): BOTTOM GEAR (total number of
Jetting
Jetting chart is called out in the Jetting table and is stated as MAIN JET on top and the e-clip position on the bottom.
Example:
Example
260
#3
260 = Main Jet
#3 = The E-clip setting from the top down
Production setting is designated in the shaded areas. If 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 designated by color. For example part number 7041781 is a Dark Blue/White spring. The color means that the main color
of the spring is Dark Blue and it will have a White stripe down the center of the spring. This color designation represents the
compression weight of the spring. The spring force is 120-310.
Any new springs that are released will now be all Black in color and will have the last four digits of the part number with the spring
force printed on the main body of the spring. Example: Part Number 7042287 would have “2287 110/290” printed in white ink on
the spring.
2.2
GENERAL
Suspension Spring Pre-Load/Installed Length
When installing springs on shocks the specifications will call out “Installed Length” or “Pre-Load”.
Installed 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 length.
Pre-Load is the amount of space that you have from the bottom of the spring preload adjuster to the top of the spring retainer.
Preload
Installed Length
2
2.3
GENERAL
SNOWMOBILE NUMBER DESIGNATIONS
Model Number Designation
S07PP6FSA (600 HO IQ STOCK A)
IDENTIFIER
1st digit 2/3rd digit 4th digit 5th digit 6th digit* 7th digit* 8th digit 9th digit**
MODEL
YEAR
MODEL LINE MODEL TYPE ENGINE MODIFIER
VIN
IDENTIFIER
OPTION
IDENTIFIER
S 06 P S 8 D S A
S=Snow
C=Dragon 121
D=Classic
F=Classic LTD
J=136 RMK
07=2007
06=2006
05=2005
04=2004
M=Race IQ
N=Edge
P= IQ
S=GenII
W=Mini Indy
*=digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively
**=9th digit will be used on color/featured versions of models (not including the base)
First 3 digits and 9th digit are sued in model number only. They are not used with the 17 digit VIN.
K=144 RMK
L=155 Assult
M=155 RMK
N=166 RMK
P=Performance
S=Switchback
T=Touring
U=Utility
Y=Touring
Limited
1A=121 F/C OHV 4 Cycle 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 Reed SDI 2 Cyl Liberty
7E=750 2 Cyl FS Webber
7F=750 Turbo2 Cyl FS Webber
7H=755 EV SDI Case Reed Liberty
7J=700 EV L/C Case Reed SDI 2 Cyl Liberty
8D=866 EV SDI Case Reed Liberty
E=Europe
Unit
M=Military
R=Rolling
Chassis
S=Standard
Production
Unit
V=
Validation
Option
Identifier
2.4
GENERAL
VEHICLE IDENTIFICATION NUMBER (VIN)
Tunnel Decal
The Tunnel Decal has the Model Number (1), V.I.N. Number (2), and the Manufactured Date (3).These numbers should be referred
to in any correspondence regarding warranty, service or replacement parts.The machine model and V.I.N. number identification
decal is located on the right front side of the tunnel. The V.I.N (2) number is permanently stamped into the tunnel. The model number
is embossed on the decal.
1
VIN Number Designation
Vehicle Descriptors Vehicle Identifiers
2
3
2
World Mfg. ID
Body Style
Type
Engine Size
Engine Modifier
Series
Check Digit
Model Year
Mfg. Location
1234567891011121314151617
SN1SB5BS022000000
Individual Serial No.
PUBLICATION PART NUMBERS
Misc. Publications
YEAR PUBLICATION PART NUMBER
2007 2007 Specification/Quick Reference Manual 9920653
2007 2007 Wiring Diagram Packet (all models) 9920688
2006-2007 2006-2007 FS/FST Pages 9920472
2006-2007 2006-2007 FS/FST Binder 9921004
ALL Track Diagnosis Poster 9918459
ALL Belt Failure Poster 9920936
2006 2006 Specification/Quick Reference Manual 9920147
2006 2006 Wiring Diagram packet (all models) 9920672
ALL Monotube Shock Rebuilding Video 9917736
ALL Remote Reservoir Shock Rebuilding 9917737
2.5
GENERAL
2007 Service Publications
2007 MODEL
440 IQ S07MX4CS
340 Edge LX S07ND3AS
550 Edge LX S07ND5BS
Trail RMK S07NJ5B(E,S)
SuperSport S07NP5BS
500 XCSP S07NP5C(E,S)
Indy 340 Touring S07NT3A(E,S)
Trail Touring Deluxe S07NT5B(E,S)(A)
Dragon S07PC7J(E,S)
600 CFI IQ LX S07PD6HS
FST IQ LX S07PD7FS
600 RMK 144 S07PK6FS
Dragon RMK S07PL7JS
600 RMK 155 S07PM6FS(A)
600 HO IQ S07PP6FS(A,B)
600 CFI IQ S07PP6HS(A,B)
FST IQ S07PP7F(E,S)
600 HO IQ Switchback F/O S07PS6FS(A)
600 SDI IQ Switchback F/O S07PS6HS(A)
FST IQ Switchback S07PS7F(E,S)
600 CFI IQ Touring S07PT6H(E,S)
FS IQ Touring S07PT7E(E,S)
FST IQ Touring S07PT7F(E,S)
FST IQ Cruiser S07PY7F(E,S)
Widetrak LX S07SU4B(E,S)
120 S07WB1AS
MODEL
NUMBER
OWNER'S
MANUAL
9920432 9920433 9920434 9919882 9920436
9920437 9920438 9920442 9916508 9920444
9920437 9920439 9920445 9916508 9920444
9920449 9920450 9920451 9919882 9920444
9920437 9920440 9920445 9916508 9920444
9920437 9920441 9920447 9916508 9920444
9920449 9920453 9920454 9916508 9920444
9920449 9920456 9920457 9916508 9920444
9920648 9920460 9920461 9919882 9920463
9920464 9920465 9920466 9916508 9920463
9920468 9920473 9920474 9916508 9920472
9920476 9920477 9920478 9919882 9920463
9920911 N/A 9920912 9920606 9920463
9920476 9920483 9920478 9919882 9920463
9920459 9920460 9920461 9919882 9920463
9920464 9920487 9920466 9919882 9920463
9920468 9920488 9920474 9919882 9920472
9920459 9920597 9920598 9916508 9920463
9920464 9920495 9920496 9916508 9920463
9920468 9920498 9920499 9916508 9920463
9920464 9920501 9920502 9916508 9920463
9920468 9920504 9920505 9916508 9920472
9920468 9920507 9920508 9916508 9920472
9920468 9920507 9920508 9916508 9920472
9920449 9920510 9920511 9916508 9920444
9920513 no suppl. 9920515 9916891 9920517
OWNER'S
MANUAL
PARTS
BOOK
ASSEMBLY
INSTRUCTIONS
SERVICE
MANUAL
2.6
GENERAL
GENERAL REFERENCE
Standard Bolt Torque Specification
Grade 2
BOLT SIZE
1/4 20 5 (7) 8 (11) 12 (16)
1/4 28 6 (8) 10 (14) 14 (19)
5/16 18 11 (15) 17 (23) 25 (35)
5/16 24 12 (16) 19 (26) 29 (40)
3/8 16 20 (27) 30 (40) 45 (62)
3/8 24 23 (32) 35 (48) 50 (69)
7/16 14 30 (40) 50 (69) 70 (97)
7/16 20 35 (48) 55 (76) 80 (110)
1/2 13 50 (69) 75 (104) 110 (152)
1/2 20 55 (76) 90 (124) 120 (166)
THREADS/IN
FT-LB X 1.356 = N-M
N-M X.7376 = FT-LB
Grade 5
GRADE 2
FT-LB(N-M)
GRADE 5
FT-LB(N-M)
2 Stroke Gasoline / Oil Pre Mix
OZ OF OIL
GALLONS OF
FUEL
164
2138
31912
42616
53220
63824
To figure out the correct fuel to oil ratio per gallon, you will need
to use different formulas for the ratio that you are looking for.
Example of a fuel/oil ratio of 20:1 is figured out by taking the
gallons of the fuel mixing container (1 gallon) and converting it
to ounces (128 oz.) divided by the ratio that you are looking for
(20), this will give you the amount of oil that you need (6.4 oz.)
to add to the fuel in the mixing container.
NEEDED TO
ACHIEVE A
20:1 RATIO
OZ OF OIL
NEEDED TO
ACHIEVE A
32:1 RATIO
Grade 8
GRADE 8
FT-LB(N-M)
1 gallon has 128oz. / 20 = 6.4 oz. of oil needed to mix to each
1 gallon of gasoline. For a 5 gallon mixture, you would need add
32 oz. of oil to the gasoline.
Gasoline Volatility
MAXIMUM REID VAPOR
CLASS PRESSURE LOW HIGH
A 7.0 psi (0.5 bar)
B 9.0 psi (0.6 bar)
C 10.5psi (0.7 bar)
D 12.0psi (0.8 bar)
E 13.5psi (0.9 bar)
Add 2.45°F for each 1000 ft (305m) above sea level
One of the misunderstood properties of gasoline is its volatility,
or ability to vaporize at different ambient temperatures and
altitudes during the year.
When gasoline is blended, it is given a Reid Vapor Pressure
(RVP) number which reflects its ability to vaporize or mix with
air at a given temperature range. Gasoline vapor pressure is
measured by putting a sample of fuel inside a closed container
and applying a specified amount of heat to the container for a
certain amount of time. RVP will vary from about 7.0 PSI during
the summer to approximately 13.5 PSI during the colder
months. Service 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 vaporize
very quickly in order for an engine to start and warm up
properly. If summer blend fuel is being used in the winter, little
or no vaporization will occur. Droplets will form causing
flooding and very hard starting.
If winter blend fuel is being used during the summer months, it
may cause vapor lock (boiling fuel) inside the fuel lines, fuel
pump, or carburetor. This will cause warm engine drive ability
problems and hard starting when warm.
AMBIENT AIR TEMP
RANGE
60°F
(16°C)
50°F
(10°C)
40°F
(4°C)
30°F
(-1°C)
20°F
(-7°C)
110°F+
(43°C+)
110°F
(43°C)
97°F (36°C)
85°F (29°C)
69°F (21°C)
2
2.7
GENERAL
SAE Tap Drill Sizes
Thread Size/ Drill Size Thread Size / Drill Size
#0-80 3/64 1/2-13 27/64
#1-64 53 1/2-20 29/64
#1-72 53 9/16-12 31/64
#2-56 51 9/16-18 33/64
#2-64 50 5/8-11 17/32
#3-48 5/64 5/8-18 37/64
#3-56 45 3/4-10 21/32
#4-40 43 3/4-16 11/16
#4-48 42 7/8-9 49/64
#5-40 38 7/8-14 13/16
#5-44 37 1-8 7/8
#6-32 36 1-12 59/64
#6-40 33 1 1/8-7 63/64
#8-32 29 1 1/8-12 1 3/64
#8-36 29 1 1/4-7 1 7/64
#10-24 24 1 1/4-12 1 11/64
#10-32 21 1 1/2-6 1 11/32
#12-24 17 1 1/2-12 1 27/64
#12-28 4.6mm 1 3/4-5 1 9/16
1/4-20 7 1 3/4-12 1 43/64
1/4-28 3 2-4 1/2 1 25/32
5/16-18 F 2-12 1 59/64
5/16-24 I 2 1/4-4 1/2 2 1/32
3/8-16 O 2 1/2-4 2 1/4
3/8-24 Q 2 3/4-4 2 1/2
7/16-14 U 3-4 2 3/4
7/16-20 25/64
Metric Tap Drill Sizes
Tap Size Drill Size
3x.50 #39 0.0995 3/32
3x.60 3/32 0.0937 3/32
4x.70 #30 0.1285 1/8
4x.75 1/8 0.125 1/8
5x.80 #19 0.166 11/64
5x.90 #20 0.161 5/32
6x1.00 #9 0.196 13/64
7x1.00 16/64 0.234 15/64
8x1.00 J 0.277 9/32
8x1.25 17/64 0.265 17/64
9x1.00 5/16 0.3125 5/16
9x1.25 5/16 0.3125 5/16
10x1.25 11/32 0.3437 11/32
10x1.50 R 0.339 11/32
11x1.50 3/8 0.375 3/8
12x1.50 13/32 0.406 13/32
12x1.75 13/32 0.406 13/32
Decimal
Equivalent
Nearest
Fraction
Decimal Equivalents
1/64 . . . . . . . . . . . . . . . . . .0156
1/32 . . . . . . . . . . . . . .0312 . . . 1 mm= .0394"
3/64 . . . . . . . . . . . . . . . . . .0469
1/16 . . . . . . . . . . . . . .0625
5/64 . . . . . . . . . . . . . . . . . .0781. . . 2 mm = .0787"
3/32 . . . . . . . . . . . . . .0938
7/64 . . . . . . . . . . . . . . . . . .1094. . . 3 mm =.1181"
1/8 . . . . . . . .1250
9/64 . . . . . . . . . . . . . . . . . .1406
5/32 . . . . . . . . . . . . . .1563 . . . 4 mm = .1575"
11/64 . . . . . . . . . . . . . . . . . .1719
3/16 . . . . . . . . . . . . . .1875 . . . 5mm= .1969"
13/64 . . . . . . . . . . . . . . . . . .2031
7/32 . . . . . . . . . . . . . .2188
15/64 . . . . . . . . . . . . . . . . . .2344. . . 6 mm = .2362"
1/4 . . . . . . . .25
17/64 . . . . . . . . . . . . . . . . . .2656. . . 7 mm = .2756"
9/32 . . . . . . . . . . . . . .2813
19/64 . . . . . . . . . . . . . . . . . .2969
5/16 . . . . . . . . . . . . . .3125 . . . 8mm= .3150"
21/64 . . . . . . . . . . . . . . . . . .3281
11/32 . . . . . . . . . . . . .3438. . . 9 mm = .3543"
23/64 . . . . . . . . . . . . . . . . . .3594
3/8 . . . . . . . .375
25/64 . . . . . . . . . . . . . . . . . .3906. . . 10 mm = .3937"
13/32 . . . . . . . . . . . . .4063
27/64 . . . . . . . . . . . . . . . . . .4219. . . 11 mm =.4331"
7/16 . . . . . . . . . . . . . .4375
29/64 . . . . . . . . . . . . . . . . . .4531
15/32 . . . . . . . . . . . . .4688 . . . 12 mm = .4724"
31/64 . . . . . . . . . . . . . . . . . .4844
1/2 . . . . . . . .5. . . . . . . . . . . . 13mm = .5118"
33/64 . . . . . . . . . . . . . . . . . .5156
17/32 . . . . . . . . . . . . .5313
35/64 . . . . . . . . . . . . . . . . . .5469. . . 14 mm = .5512"
9/16 . . . . . . . . . . . . . .5625
37/64 . . . . . . . . . . . . . . . . . .5781. . . 15 mm = .5906"
19/32 . . . . . . . . . . . . .5938
39/64 . . . . . . . . . . . . . . . . . .6094
5/8 . . . . . . . .625. . . . . . . . . . 16mm=. 6299"
41/64 . . . . . . . . . . . . . . . . . .6406
21/32 . . . . . . . . . . . . .6563 . . . 17 mm =.6693"
43/64 . . . . . . . . . . . . . . . . . .6719
11/16 . . . . . . . . . . . . .6875
45/64 . . . . . . . . . . . . . . . . . .7031. . . 18 mm = .7087"
23/32 . . . . . . . . . . . . .7188
47/64 . . . . . . . . . . . . . . . . . .7344. . . 19 mm = .7480"
3/4 . . . . . . . .75
49/64 . . . . . . . . . . . . . . . . . .7656
25/32 . . . . . . . . . . . . .7813 . . . 20 mm = .7874"
51/64 . . . . . . . . . . . . . . . . . .7969
13/16 . . . . . . . . . . . . .8125 . . . 21 mm =.8268"
53/64 . . . . . . . . . .
27/32 . . . . . . . . . . . . .8438
55/64 . . . . . . . . . . . . . . . . . .8594. . . 22 mm = .8661"
7/8 . . . . . . . .875
57/64 . . . . . . . . . . . . . . . . . .8906. . . 23 mm = .9055"
29/32 . . . . . . . . . . . . .9063
59/64 . . . . . . . . . . . . . . . . . .9219
15/16 . . . . . . . . . . . . .9375 . . . 24 mm = .9449"
61/64 . . . . . . . . . . . . . . . . . .9531
31/32 . . . . . . . . . . . . .9688 . . . 25 mm = .9843"
63/64 . . . . . . . . . . . . . . . . . .9844
1 . . . . . . . . . 1.0
. . . . . . . .8281
2.8
GENERAL
Measurement Conversion Chart Piston Wash / Spark Plug Reading
UNIT OF MEASURE MULTIPLIED BY CONVERTS TO
ft-lb x 12 = in-lb
in-lb x.0833 = ft-lb
ft-lb x 1.356 = N-m
in-lb x.0115 = kg-m
N-m x.7376 = ft-lb
kg-m x 7.233 = ft-lb
kg-m x 86.796 = in-lb
kg-m x 10 = N-m
in x 25.4 = mm
mm x.03937 = in
in x 2.54 = cm
mile x 1.6 = km
km x.6214 = mile
Ounces (oz) x 28.35 = grams (g)
grams (g) x.035 = Ounces (oz)
cc’s x.03381 = Fluid Ounces (oz)
lbs x.454 = kg
kg x 2.2046 = lbs
Cubic Inches x 16.387
Cubic Centimeters x.061 = Cubic Inches
Imperial pints x.568 = liters (l)
liters (l) x 1.76 = Imperial pints
Imperial quarts x 1.137 = liters (l)
liters (l) x.88 = Imperial quarts
Imperial quarts x 1.201 = US quarts
US quarts x.833 = Imperial quarts
US quarts x.946 = liters
liters x 1.057 = US quarts
US gallon x 3.785 = liter
liter x.264 = US gallon
Pounds force per
square inch (psi)
Kilo pascals (kPa) x.145
x 6.895 = Kilo pascals (kPa)
= Cubic
Centermeters
= Pounds force per
square inch (psi)
Changing temperature, barometer, altitude, and fuel supply are
just a few of the factors that can affect the day to day
performance of your engine. That is why using Exhaust Gas
Temperatures (EGT) are important for maintaining optimum
performance. There are two methods for helping you determine
what the EGTs are for your machine. Piston wash and the
coloring of your spark plug.The piston wash is by far the most
valuable tool in concluding EGTs, with the spark plug color
running a distant second. Use the illustrations below to help you
establish the EGTs for your machine.
Once the proper jetting is established, you can reference the
EGT gauge for your baseline numbers. Then, if there is a rise or
fall of 25 degrees, you must jet accordingly to return your EGTs
to the baseline numbers.
2
2.9
GENERAL
Glossary Of Terms
ABDC: After bottom dead center.
ACV: Alternating current voltage.
Alternator: Electrical generator producing voltage
alternating current.
ATDC: After top dead center.
BBDC: Before bottom dead center.
BDC: Bottom dead center.
BTDC: Before top dead center.
CC: Cubic centimeters.
Center Distance: Distance between center of crankshaft
and center of driven clutch shaft.
Chain Pitch: Distance between chain link pins (No. 35 =
3/8" or 1 cm). Polaris measures chain length in number of
pitches.
CI: Cubic inches.
Clutch Buttons: Plastic bushings which aid rotation of the
movable sheave in the drive and driven clutch.
Clutch Offset: Drive and driven clutches are offset so that
drive belt will stay nearly straight as it moves along the
clutch face.
Clutch Weights: Three levers in the drive clutch which
relative to their weight, profile and engine RPM cause the
drive clutch to close and grip the drive belt.
Crankshaft Run-Out: Run-out or “bend” of crankshaft
measured with a dial indicator while crankshaft is
supported between centers on V blocks or resting in
crankcase. Measure at various points especially at PTO.
CVT: Continuously Variable Transmission (Drive Clutch
System)
DCV: Direct current voltage.
Dial Bore Gauge: A cylinder measuring instrument which
uses a dial indicator. Good for showing taper and out-ofround in the cylinder bore.
Electrical Open: Open circuit. An electrical circuit which
isn't complete.
Electrical Short: Short circuit. An electrical circuit which
is completed before the current reaches the intended load.
(i.e. a bare wire touching the chassis).
End Seals: Rubber seals at each end of the crankshaft.
Engagement RPM: Engine RPM at which the drive clutch
engages to make contact with the drive belt.
ft.: Foot or feet.
ft-lb: (foot pounds) A force of one pound at the end of a
lever one foot in length, applied 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, applied in a rotational direction. 12
in. lbs. = 1 ft. lb.
2
kg/cm
kg-m: Kilogram meters.
Kilogram/meter: A force of one kilogram at the end of a
lever one meter in length, applied in a rotational direction.
l or ltr: Liter.
lbs/in
: Kilograms per square centimeter.
2
: Pounds per square inch.
Left or Right Side: Always referred to based on normal
operating position of the driver.
m: Meter/meters.
Mag: Magneto.
Magnetic Induction: As a conductor (coil) is moved
through a magnetic field, a voltage will be generated in the
windings. Mechanical energy is converted to electrical
energy in the stator.
mi.: Mile/miles.
mm: Millimeter. Unit of length in the metric system. 1 mm
= approximately .040".
N-m: Newton meters.
OD: Outside diameter.
Ohm: The unit of electrical resistance opposing current
flow.
oz.: Ounce/ounces.
Piston Clearance: Total distance between piston and
cylinder wall.
psi.: Pounds per square inch.
PTO: Power take off.
qt.: Quart/quarts.
Regulator: Voltage regulator. Regulates battery charging
system output at approx. 14.5 DCV as engine RPM
increases.
Reservoir Tank: The fill tank in the liquid cooling system.
Resistance: In the mechanical sense, friction or load. In
the electrical sense, ohms, resulting in energy conversion
to heat.
RPM: Revolutions per minute.
Seized Piston: Galling of the sides of a piston. Usually
there is a transfer of aluminum from the piston onto the
cylinder wall.
Possible causes: 1) improper lubrication; 2) excessive
temperatures; 3) insufficient piston clearance; 4) stuck
piston rings.
Stator Plate: The plate mounted under the flywheel
supporting the battery charging coils.
TDC: Top dead center. Piston's most outward travel from
crankshaft.
Volt: The unit of measure for electrical pressure of
electromotive force. Measured by a voltmeter in parallel
with the circuit.
Watt: Unit of electrical power. Watts = amperes x volts.
WOT: Wide open throttle.
2.10
SPECIAL TOOLS
Special Tools
GENERAL
2
2.11
GENERAL
2.12
GENERAL
2
2.13
GENERAL
2.14
MAINTENANCE
CHAPTER 3
MAINTENANCE
MAINTENANCE PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
POLARIS RECOMMENDED PROGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
INSPECTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
CYLINDER MEASUREMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
CYLINDER HONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
HONING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
HONING TO OVER SIZE (340/500 FUJI ENGINES ONLY) . . . . . . . . . . . . . . . . . . . . . . 3.6
CLEANING THE CYLINDER AFTER HONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
PISTON INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
RECOMMENDED COOLANT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
COOLING SYSTEM BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
BEARING FIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
MAIN BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
CONNECTING ROD (BIG END) BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
WRIST PIN BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
CRANKSHAFT INDEXING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
CHECKING CRANKSHAFT INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
CRANKSHAFT TRUEING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
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 DEFLECTION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
MEASURING BELT DEFLECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
FRONT SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
JACKSHAFT BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
DRIVESHAFT BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
THROTTLE CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
CHOKE AND CHOKE CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
CHAINCASE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
CHOKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
THROTTLE LEVER FREE PLAY - NON CFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
THROTTLE LEVER FREE-PLAY - CFI MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
OIL PUMP ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
TRACK ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
TRACK TENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
REAR ENGINE TORQUE STOP ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
ENGINE ISOLATOR LIMITER SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
AIR FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
WATER SEDIMENT TRAP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
NOSEPAN CARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
3
3.1
MAINTENANCE
CHASSIS AND HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
CLUTCH AND DRIVE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
CONTROLS AND LINKAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
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
IQ HEADLIGHT BULB REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
IQ SNOW BEAM BULB REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
COOLANT DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
3.2
MAINTENANCE
MAINTENANCE PROGRAM
Polaris Recommended Program
To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and service checks
outlined in this manual. The recommended maintenance schedule on your snowmobile calls for service and maintenance inspections
at 150 miles (240 km), 1000 miles (1600 km), and 2000 miles (3200 km). These inspections should be performed by a qualified
service technician. For continued optimum performance and component life, continue maintenance checks at 1000 mile (1600 km)
intervals. All necessary replacement parts and labor incurred, with the exception of authorized warranty repairs, become the
responsibility of the registered owner. If, during the course of the warranty period, part failures occur as a result of owner neglect
in performing recommended regular maintenance, the cost of repairs are the responsibility of the owner.
Personal safety is critical when attempting to service 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 authorized Polaris dealer
for service.
The following chart is a guide based on average riding conditions. You may need to increase frequency based on riding conditions.
When inspection reveals the need for replacement parts, always use genuine Polaris parts, available from your Polaris dealer.
3
FREQUENCY MILES (KM)
ITEM
Clutch
Alignment
Offset (without
belt)
Drive Belt
Condition
Clutches
(disassemble)
Belt Tension II I I
Clutch Sheaves II I I
Engine Mounts II I I
Heat Exchangers II I I I
Recoil Rope IIIII
Engine Torque
Stop
Cylinder Head
Bolts
Cylinder Base
Nuts
Ignition Timing
BTDC
VES System CC C I
Coolant Level IIIRI
Coolant Hose II I I
Coolant
Circulation
Coolant Leaks II I I
Spark Plug
Condition
Exhaust Pipe II
PRE-
RIDE
150
500
1000
(240)
(240)
(1600)
CLUTCH
II I
IIIII
CC C
ENGINE/COOLING
II I I
II I
II I I
II I
II I
II I R I
2000
(3200)
PRE-
SEASON
I:INSPECT (CLEAN, ADJUST, TIGHTEN, LUBRICATE, REPLACE IF
NECESSARY) C:CLEAN R:REPLACE L:LUBRICATE
3.3
MAINTENANCE
FREQUENCY MILES (KM)
ITEM
Exhaust
Retaining
Springs
Hose Routing II I I
Hose Condition II I I
Fluid Leaks II I I
Brake Pads II I I
Brake Disc II I I
Parking Brakes IIIII
Brake System I
Brake Fluid R
Pilot Air Screws II I
Carburetor
(synchronize)
Idle RPM II I
Throttle Lever II I I I
Oil Pump Lever
(synchronize)
Throttle Cable LL L
Choke Cable LL L
Choke II I
Vent Lines II I I
Throttle Position
Sensor
Fuel Lines II I I I
Fuel Filter (Carb) R
Fuel Filter (CFI) RR
Oil Filter RR
Oil Lines II I
Air Box II I I I
Drain and Water
Trap s
Auxiliary Shut-
Off Switch
Throttle Safety
Switch
Ignition Switch II I I I I
Taillight II I I I I
Brakelight II I I I I
Headlight III I I I
Tether Switch
and Strap
Ski Toe
Alignment
PRERIDE
150
500
1000
(240)
(240)
(1600)
II I I
BRAKES
FUEL MANAGEMENT
II I
II I
II I
II I
ELECTRICAL
II I I I I
II I I I I
II I I I I
CHASSIS
II I
2000
(3200)
PRE-
SEASON
I:INSPECT (CLEAN, ADJUST, TIGHTEN, LUBRICATE, REPLACE IF
NECESSARY) C:CLEAN R:REPLACE L:LUBRICATE
FREQUENCY MILES (KM)
ITEM
Suspension
Mounting Bolts
Steeri ng
Fasteners
Rear Suspension
Fasteners
Suspension
Shock Oil
Cooling Fins and
Shroud
Drive Shaft
Bearing
Jackshaft
Bearings
Skags (Wear
Bars)
Ski Saddle/
Spindle Bolts
Drive Chain
Tension
Hood Straps II I I I I
Seat Latches I
Rear Wheel Idler
Bolts
Idler Bolt Jam
Nut
Rear Suspension
Pivot Shafts
Handle Bar U-
Joint
Camber
Alignment
Handlebar
Centering
Track Alignment II I I I I
Track Tension II I I I
Rail Slide
Condition
Chaincase Oil III I R I
Injection Oil
Level
PRE-
RIDE
150
500
(240)
II I I I I
II I I C
II I I I
II I I I I
II I I I I
II I I I
II I I I I
II I I I
II
I
1000
(240)
(1600)
II I I
II I I
LL L I
LL L I
LL L
LL L
II I
2000
(3200)
PRE-
SEASON
I
I:INSPECT (CLEAN, ADJUST, TIGHTEN, LUBRICATE, REPLACE IF
NECESSARY) C:CLEAN R:REPLACE L:LUBRICATE
3.4
MAINTENANCE
INSPECTONS
Cylinder Head Inspection
Inspect each piston dome area of the cylinder head for warping
by placing a straight edge across the dome area.
With a feeler gauge measure any gap under the straight edge.
Replace cylinder head if measurement exceeds the service limit
of .003" (.08mm).
Cylinder Measurement Worksheet
Taper limit = Ty - By and Tx - Bx
Cylinder taper limit is .002"(.051mm) Max
Cylinder out of round limit is
.002"(.051mm)
3
NOTE: Cylinder head warp service limit is:
.003"(.08mm).
Cylinder Measurement
Inspect each cylinder for wear, scratches, or damage. If no
damage is evident, measure the cylinder for taper and out of
round with a telescoping gauge or a dial bore gauge. Measure the
bore .50" from the top of the cylinder; in line with the piston pin
and 90° to the pin to determine if the bore is out of round. Repeat
the measurements at the middle of the cylinder and the bottom
of the cylinder to determine taper or out of round at the bottom.
Use the chart below and record all measurements.
Cylinder Measurement Worksheet
TOP
Tx Ty
MIDDLE
Mx My
BOTTOM
Bx By
Cylinder Honing
The cylinder bore must be de-glazed whenever new piston rings
are installed. A light honing with fine stones removes only a
very small amount of material. A proper crosshatch pattern is
important to provide a surface that will hold oil, and allow the
rings to seat properly. If the crosshatch is too steep, oil retention
will be reduced. A crosshatch angle which is too shallow will
cause ring vibration, poor sealing, and overheating of the rings
due to blow-by and reduced contact with the cylinder wall.
Service life of the pistons and rings will be greatly reduced.
NOTE: A Nikasil cylinder can be lightly honed with a
soft stone hone but an not be oversized.
EXAMPLE OF A CROSS HATCH PATTERN
Out of round = Tx - Ty and By - Bx
3.5
MAINTENANCE
Honing Procedure
1. Wash the cylinder with cleaning solvent.
2. Clamp the cylinder in a soft jawed vise by the cylinder
studs.
3. Place hone in cylinder and tighten stone adjusting knob
until stone contacts the cylinder walls (DO NOT
OVERTIGHTEN). Cylinders may be wet or dry honed
depending on the hone manufacturer's recommendations.
Wet honing removes more material faster and leaves a
more distinct pattern in the bore. Using a .50" (13 mm) drill
motor rotating at a speed of 300-500 RPM, run the hone in
and out of the cylinder rapidly until cutting tension
decreases. Remember to keep the hone drive shaft centered
to prevent edge loading and always bring the stone
approximately 2" (1.3 cm) beyond the bore at the end of
each stroke.
4. Release the hone at regular intervals to inspect bore size
and finish.
Honing To Over Size (340/500 Fuji Engines
Only)
If cylinder wear or damage is excessive, it will be necessary to
oversize the cylinder using a new oversize piston and rings. This
may be accomplished by either boring the cylinder and then
finish honing to the final bore size, or by rough honing followed
by finish honing.
Cleaning The Cylinder After Honing
It is very important that the cylinder be thoroughly cleaned after
honing to remove all grit material. Wash the cylinder in a
solvent, then in hot soapy water. Pay close attention to areas
where the cylinder sleeve meets the aluminum casting (transfer
port area). Use electrical contact cleaner if necessary to clean
these areas. Rinse thoroughly, dry with compressed air, and oil
the bore immediately with Polaris Premium 2 Cycle Lubricant.
NOTE: Always check piston to cylinder clearance
and piston ring installed gap after honing or boring
is complete.
Piston Inspection
Check piston for scoring or cracks in piston crown or pin area.
Excessive carbon buildup below the ring lands is an indication
of piston, ring or cylinder wear. For Liberty™ engines, measure
piston outside diameter at a point .375" (10mm) up from the
bottom of the skirt at a 90° angle to the direction of the piston
pin. For Fuji engines, measure piston outside diameter at a point
that is .50" (12.7mm) up form the bottom of the skirt at a 90°
angle to the direction of the piston pin.
For oversize honing always wet hone using honing oil and a
coarse roughing stone. Measure the new piston at room
temperature (see piston measurement) and rough hone to the
size of the piston or slightly larger. Always leave .002" - .003"
(.05 - .07 mm) for finish honing. Complete the sizing with fine
grit stones to provide the proper cross-hatch finish and required
piston clearance.
Inspect cylinder for taper and out-of-round. Taper or out-ofround on the finished bore should not exceed .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 cylinder
clearance and piston ring installed gap after boring/
honing is complete.
NOTE: The piston is measured at this point to
provide an accurate piston to cylinder
measurements.
Subtract this measurement from the minimum cylinder
measurement (90° to the pin) recorded previously when you
recorded the cylinder measurements. If clearance exceeds the
service limit, the cylinder should be re-bored and new pistons
and rings installed. Refer to piston to cylinder clearance limits
in the General Information section listed per model.
3.6
MAINTENANCE
Piston Ring Installed Gap
Position the ring .50" (1.3 cm) from the top of the cylinder using
the piston to push it squarely into place. Measure installed gap
with a feeler gauge at both the top and bottom of the cylinder.
NOTE: A difference in end gap indicates cylinder
taper. The cylinder should be measured for
excessive taper and out of round. Replace rings if
the installed end gap exceeds the service limit.
Always check piston ring installed gap after reboring a cylinder or when installing new rings.
Recommended Coolant
Polaris snowmobiles 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 coolant every 2
years or if contaminated.
Cooling System Bleeding
1. Allow the cooling system to cool completely.
2. Check the coolant reservoir and make sure it is at the FULL
COLD mark.
3. Place the snowmobile in its normal riding position and
apply the parking brake and run the engine at the specified
idle RPM until the thermostat opens up.
4. Elevate the front of the machine slightly.
5. Open the bleed screw (A) at the top of the water outlet
manifold.Only open slightly, do not remove the screw.
A
3
Piston rings are installed with marking or beveled side up see
diagram above.
Coolant Level
Coolant level in the coolant bottle must be maintained to prevent
overheating and serious engine damage. Check the coolant with
the engine temperature cold. The coolant level should be at the
FULL COLD level mark. If it is not add coolant to the FULL
COLD mark on the bottle. If you have coolant over the FULL
COLD level you may have air in the system and need to “bleed”
the air out of the system.
500 Fuji
A
500/600/700 Liberty
6. Cycle the RPM from idle to 3000-4000 so that the coolant
can move around the system and push out the air from the
system.
7. Tighten the bleed screw when coolant starts to come out of
the screw area.
8. Turn off the machine and release the parking brake.
9. Allow the system to cool completely and recheck the
coolant level.
NOTE: It is important that the thermostat stays open
@ 120° F (50° C).When the thermostat opens it will
draw in cold coolant from the heat exchangers and
the cold coolant may close the thermostat again.
3.7
MAINTENANCE
Make sure the thermostat opens and stays open!
Cycle the RPM from idle to enough RPM (3500) to
get coolant to flow but not enough RPM to engage
the clutch. This allows air to bleed from the rear
crossover tube. It is important to get enough coolant
flow to purge the air from the front close-off cooler
and observe this air reaching the bottle.
NOTE: Once the thermostat is open tip the
snowmobile slightly on its right side and cycle the
RPM from idle to enough RPM (4000) to get coolant
to flow but not enough RPM to engage the clutch.
Then tilt the machine slightly on its left side so that
the coolant bottle is the highest point in the cooling
system and cycle the RPM from idle to enough RPM
(4000) to get coolant to flow but not enough RPM to
engage the clutch.
WARN IN G
When performing the following checks and
adjustments, stay clear of all moving parts to avoid
serious personal injury. Never remove the pressure
cap when the engine is warm or hot. If the pressure
cap is to be removed, the engine must be cool.
Severe personal injury could result from stream or hot
liquid.
or tight. Normal hand installation will be an indication of 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: Crankcase bearing interference fit is .001.002" (.026-.051mm).
= In. / mm.
Bearing Interference Fit: .001-.002" (.026-.051mm)
Main Bearing
Clean crankshaft thoroughly and oil main and connecting rod
bearings with Polaris engine oil. Carefully check each main
bearing on the shaft.
Due to extremely close tolerances, the bearings must be
inspected visually, and by feel. Look for signs of discoloration,
scoring or galling. Turn the outer race of each bearing. The
bearings should turn smoothly and quietly. The inner race of
each bearing should fit tightly on the crankshaft. The outer race
should be firm with minimal side to side movement and no
detectable up and down movement. Replace any loose or rough
bearings.
Bearing Fit
Any time crankshaft bearing failure occurs and the case is to be
reused, Polaris recommends checking the bearing fit into the
case halves using the following procedure.
With case halves cleaned, press a replacement bearing into each
of the main bearing journals to determine a basic amount of
press fit.
Do a comparison check of all journals by manually forcing the
bearing into the bearing seats noting if any are noticeably loose
Connecting Rod (Big End) Bearing
Specialized equipment and a sound knowledge of crankshaft
repair and straightening is required to perform crankshaft work
safely and correctly. Crankshaft repair should be performed by
trained Polaris service technicians in a properly equipped shop.
3.8
MAINTENANCE
Measure connecting rod big end side clearance with a feeler
gauge. 500/600/700 Liberty™ engines should have a clearance
of .011 - .030" (.28 -.75mm) and be equal on all rods within .002"
(.05mm).
= In. / mm.
500/600/700 Liberty Engine Connecting Rod (Big
End) Side Clearance: .011-.030" (.28-.75mm)
Rotate the connecting rod on the crankshaft and feel for any
rough spots. Check radial end play in rod by supporting rod
against one thrust washer and alternately applying up and down
pressure. Replace bearing, pin, and thrust washers if side
clearance is excessive or if there is any up and down movement
detectable in the big end bearing.
6. With pin and bearing centered in rod, twist ends back and
forth in all directions to check for excessive axial play.
7. Pull up and down evenly on both ends of pin to check for
radial play.
8. Replace pin and bearing if there is any resistance to rotation
or excessive axial or radial movement. If play or roughness
is evident with a new pin and bearing, replace the
connecting rod.
Crankshaft Indexing
3
CAU TION
Disconnect the battery ground cable and ALL spark
plug high tension leads. Ground high tension leads to
the engine. Disconnect lanyard (if equipped) and/or
press the engine stop switch before proceeding with
the following procedure.
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
verify that one cylinder has not been forced out of position
relative to the other cylinder. Some causes for a “out of index”
crankshaft include but are not limited to the following:
Wrist Pin Bearing
1. Clean the end of the connecting rod and inspect inner bore
with a magnifying glass. Look for any surface
irregularities including pitting, wear, or dents.
NEEDLE BEARING
2. Run you fingernail around the inside of the rod and check
for rough spots, galling, or wear.
3. Oil and install needle bearing and pin in connecting rod.
4. Rotate pin slowly and check for rough spots or any
resistance to movement.
5. Slide pin back and forth through bearing while rotating and
check for rough spots.
• Hydrolock from water or fuel
• Impact to drive clutch from object or accident
• Abrupt piston or other mechanical failure
• Engine lock-up due to drive belt failure
Checking Crankshaft Index
1. Remove the drive belt. See “Drive Belt Removal” on
page 6.10.
2. Remove the drive clutch. See “Drive Clutch Removal” on
page 6.15.
3. Securely fasten a large degree wheel on the flywheel or
PTO end of the crankshaft. Make sure that it is mounted
concentrically with the crankshaft center line.
4. With a section of wire (wire coat hanger), anchor it to a
convenient spot. Bend one end at the outer perimeter of the
degree wheel as shown below.
5. Install a dial indicator into the magneto end cylinder spark
plug hole. The ignition timing is referenced by the magneto
end.
6. Locate TDC as accurately as possible by finding the center
of the point where there is no piston movement note the
“Zero” the dial indicator at this point.
3.9
MAINTENANCE
7. Continue to rotate the crankshaft in the normal direction of rotation until the dial indicator reads .100" (2.54mm) after top dead
center (ATDC).
8. Bend the pointer or move the degree wheel until the pointer aligns with a 180° mark on the degree wheel.
9. With the pointer aligned, make sure the degree wheel and pointer are secured and will not move out of position. Re-check
accuracy of this location a few times. The pointer should align with the 180° mark when the dial indicator reads .100” (2.54mm)
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 PTO cylinder. Repeat finding TDC. Note the degree wheel indication when the dial
indicator reads .100" ATDC. It should be 180° (+/-2°) from the MAG cylinder mark.
Symptoms of an out of index crankshaft can include but are not limited to the following:
• Difficulty calibrating carburetor (repetitive plug fouling on one cylinder with no other cause)
• Unexplained piston failure on one cylinder (i.e. severe detonation, broken ring lands, piston holing)
• Excessive vibration of engine, back firing, etc.
• Rough idle, poor top speed.
3.10
MAINTENANCE
Crankshaft Trueing
Lubricate the bearings and clamp the crankshaft securely in the holding fixture.If trueing the crankshaft requires striking with a
hammer, always be sure to re-check previously straightened areas to verify trueing. Refer to the illustrations below. Use Crankshaft
alignment kit PN 2870569.
NOTE: The Rod Pin position in relation to the dial indicator tells you what action is required to straighten the
shaft.
Truing Examples
To correct a situation like this. Strike the shaft at point A
with a brass hammer.
3
To correct a situation like the one shown in this. Squeeze
the crankshaft at point A. You will use the tool from the
alignment kit PN 2870569.
If the crank rod pin location is 180° from the dial
indicator (opposite of above), it will be necessary to
spread the crankshaft at the A position as shown in
illustration 3. When rebuilding and straightening a
crankshaft, straightness is of utmost importance. Runout
must be as close to zero as possible.
3.11
MAINTENANCE
7
Crankshaft Runout Inspection
Crankshaft runout can be checked with the engine in the
machine. Using a dial indicator with the crankshaft holding
fixture (PN 2870569) will yield the most accurate results.
When checking the crankshaft runout on the MAG side. Place
the dial indicator end at 1/2” (12.7mm) from the bearing flat (A).
MAG END
A
1/2”(12.
When checking the crankshaft runout from the PTO side. Place
the dial indicator end where the taper starts after the bearing flat
(B).
PTO END
PTO END
Oil Pump Bleeding
A
1. To aid in bleeding the air out of the oil lines, fill oil
reservoir with the appropriate Polaris injector oil. This will
add pressure to the oil lines.
2. Loosen the bleed screw (A). After approximately 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 is important that the oil supply from the
oil pump be checked and full of oil.
IMPORTANT: The oil pump must always be bled
following any service to the oil injection system or
engine.
Oil / Fuel Filter
B
NOTE: Acceptable crankshaft runout (in a crank
fixture) is 0 - .0015" (0 - .04mm) on Liberty™
engines. 0 - .0025" (0 - .07mm) on Fuji engines.
CAU TION
The in tank fuel filter and fuel lines should be inspected
regularly. Special attention should be given to the fuel
line condition after periods of Summer storage. Normal
deterioration from weather and fuel can occur during this
storage period. Do not damage fuel lines when removing
them. If a fuel line has been damaged or kinked it must
be replaced.
NOTE: The direction of the arrow indicates the
direction of the flow through the filter. After
changing the oil filter, the oil injection system must
be bled of all trapped air. see “Oil Pump Bleeding”
on page 3.12.
3.12
MAINTENANCE
Most models use an oil and fuel filters which are of a special
design and must not be substituted. These filters should be
changed and the oil and fuel lines should be inspected annually
or every 1000 miles (1600 km).
These filters may have an arrow on the filter or line. This arrow
is the direction of flow. Install accordingly.
EDGE models utilize a special oil filter that is built into the oil
sending unit located in the bottom of the oil tank. It should be
replaced every two years or 2400 miles (3862 km).
CFI models fuel filter should be replaced every 1000 miles
(1600km).
Brake Lever Travel
1/2” (1.27cm)
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.
LOW
FULL
Exhaust System Removal/Installation
(Gold colored springs)
1
5
4
3
8
3
The brake lever travel should have a clearance no less than 1/2”
(1.27cm) from the handlebar grip. Inspection should be made
with the lever firmly depressed. If the lever has less than this
amount you may need to bleed the brake system. See “Brake
Fluid Replacement & Bleeding” on page 7.20.
Brake Fluid
WARN IN G
Do not over fill the master cylinder. Fluid expansion
could cause brakes to lock, resulting in serious injury or
death. Once a bottle of brake fluid is opened, use what
is necessary and discard the rest. Do not store or use
a partial bottle of brake fluid. Brake fluid is hygroscopic,
meaning it rapidly absorbs moisture from the air. This
causes the boiling temperature of the brake fluid to
drop, leading to early brake fade and the possibility of
serious injury
Inspect the reservoir to be sure it contains the correct amount of
fluid. Use only Polaris DOT 4 high temperature brake fluid.
Change fluid every 2 years or whenever the fluid is dark or
contamination is suspected.
7
2
(Stainless steel springs)
1. Remove the exhaust springs (1,2) with Exhaust Spring
Tool PN PU-45485.
2. Disconnect exhaust temperature sensor (3) if so equipped.
3. Remove the exhaust pipe (4).
4. Remove resonator fasteners if equipped.
5. Remove the resonator (5).
6. Replace in reverse order.
NOTE: The light gray springs (2) are made stainless
steel and should be used at the head pipe.
6
Manifold Installation
1. Install new exhaust manifold gaskets (8).
2. Place the exhaust manifold (7) on to the engine and torque
the mounting bolts (6) to 18 ft-lb (24 N-m).
= T
Manifold Fasteners: 18 ft-lb (24 N-m)
See “Brake Fluid Replacement & Bleeding” on page 7.20.
3.13
MAINTENANCE
Belt Deflection Inspection
Belt deflection is critical for optimum belt performance and belt
life. It should be checked at 500 miles (800km) and then in 1000
mile (1600km) increments after that.
Too much belt deflection is when the belt is too 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 engagement (A).
Not enough 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 the internal face of the drive belt.
Measuring Belt Deflection
1. Measure the belt deflection with both clutches at rest and
in their full neutral position.
2. Place a straight edge across the tow clutches, on top the belt.
3. Apply downward pressure to the belt and measure the
distance at point (D).
4. The measurement should be 1 1/4" (3.2cm).
= In. / mm.
Belt Deflection: 1.25" (3.2cm)
5. If the measurement is not correct adjust driven clutch. See
“Adjusting Belt Deflection” on page 6.11.
3.14
MAINTENANCE
LUBRICATION
Lack of lubrication will adversely affect your ride and the life of the sleds components. Lubricate with Polaris 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 lubricate all fittings.
Rear Suspension
• The following diagrams are examples of lubrication points found on some rear suspensions.
IQ
EDGE
3
M-10
3.15
MAINTENANCE
Front Suspension
• If grease zerks are present grease the left and right
spindles. Raise the front end of the machine to permit
better grease penetration into the spindle area.
Steering
• Lubricate the steering post U-Joint and lower pivot with
Polaris engine fogging oil.
• Grease the center steering arms.
Driveshaft Bearing
Inject grease into the fitting on the speedometer sensor housing
until grease purges from the seal on the inside of the tunnel. This
should take approximately two pumps. Do not use more than
four pumps.
Throttle Cable
Lubricate the throttle cable lightly with fresh oil. With the
engine off, turn the handlebars to the left and lubricate well as
shown.
Jackshaft Bearing
Loosen the driven clutch retaining bolt and pull the clutch
toward you to expose the bearing and grease fitting. Inject
grease into the grease fitting in the flangette until grease purges
from the inside or outside of the bearing seal (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).
Choke And Choke Cable
Lubricate the choke slide and cables lightly with oil or grease.
Before turning the engine off, operate the choke intermittently
to draw moisture out of the choke plunger area and reduce the
possibility of the choke becoming frozen.
3.16
MAINTENANCE
Chaincase Oil
Check the chaincase oil level at the interval outlined in this
maintenance section. Change the chaincase oil after the first 500
miles (800 km), then every 1000 miles (1600 km) or seasonally.
Maintain the oil level between the “safe” marks on the dipstick
whenever checking or changing oil.
1. Position the vehicle on a level surface
2. Remove the dipstick or fill plug and view the oil level on
the dipstick.
3. Add the recommended oil as needed. Do not overfill.
4. Level indication:
A
• Units equipped with a sight glass need should be filled
to the 1/2 way mark (A)
• Units 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 dip stick and check the fluid level on the
dipstick. Make sure it is within the “safe” level.
ADJUSTMENTS
Choke Adjustment
1. Flip the choke toggle to the “OFF” position.
2. Loosen locknuts (1) on the carburetor.
2
1
3. Turn sleeve adjusting nut (2) counter-clockwise until the
choke toggle shows no free play when pulled, then rotate
it clockwise until there is between 1/8 - 1/4in (3.2-.6.4mm)
free play (3).
NOTE: Verify the cable does not lift the plungers
when checking the free play.
1/8 - 1/4in. (3.2-6.4mm)
3
3
4. Tighten adjustment locknut (2).
5. On VM carburetors, repeat steps 2 and 3 for on the other
carburetor.
3.17
MAINTENANCE
Throttle Lever Free Play - Non CFI
F
C
A
gap=.010-.030”
.25-.80mm
B
THROTTLE FREE PLAY
= In. / mm.
Throttle Lever Free Play: 0.010"-0.030" (.25-.8mm)
5. Verify the oil pump index marks are within specification.
6. Check the idle RPM and verify it is within the specified
D
E
range.
NOTE: If the idle speed screw is adjusted inward
and the cable sleeve is not adjusted to take up the
throttle lever clearance, the engine may misfire or
kill upon initial throttle opening.
Throttle Lever Free-Play - CFI Models
CAU TION
When adjusting throttle lever free-play, always verify the
engine RPM does not rise with bars in the full low and
full up-right Rider Select positions (if applicable) and
while turning the handlebars to the full left and full right
positions.
= In. / mm.
Throttle Lever Free Play: 0.010"-0.030" (.25-.8mm)
CAU TION
When adjusting throttle lever free-play, always verify the
engine RPM does not rise with bars in the full low and
full up-right Rider Select positions (if applicable) and
while turning the handlebars to the full left and full right
positions.
Throttle lever free play must always be at a specified clearance
(A) 0.010”-0.030” (0.25-0.80 mm) between the throttle lever
(B) and the throttle block (C). This clearance is controlled by the
throttle cable (D).
If adjustment is needed follow these steps:
CAU TION
After any idle speed adjustments are made, the throttle
lever clearance and the oil pump adjustment must be
checked and adjusted.
1. Check the idle RPM and verify it is within the specified
range.
2. Shut off engine.
3. Locate the throttle cable that is attached to the carburetors
and adjust the throttle free play by adjusting the barrel nut
(E) and lock nuts (F).
4. Once you achieve the proper free play of 0.010”-0.030”
(.25-.80mm), tighten the lock nuts.
The inline adjuster should only be used to set free play and to
remove cable slack that occurs if the cable has stretched over
time.
ADJUSTER
LOCK NUT
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 no longer
rests against the idle air gap screw.
Turning the in-line adjuster inwards (clockwise) will increase
throttle lever free-play.
Turning the in-line adjuster outwards (counter-clockwise) will
decrease throttle lever free-play.
3.18
MAINTENANCE
After setting the throttle lever free play, always verify the oil
pump adjustment is set correctly.
Oil Pump Adjustment
NOTE: Use a mirror to accurately view the alignment
marks.
1. On some engines the oil pump is located under the intake
boots and you may have to remove the air box and may
need to unplug the CDI box and coils.
2. Verify carburetor/throttle body synchronization.
3. Loosen the carburetor boot adapters and carefully move
them so that you can see and adjust the oil pump cable.
4. Verify that the oil pump alignment marks are aligned at the
point where the throttle slides begin to rise from their fullyclosed positions.
5. If they are not aligned, make the necessary adjustments by
adjusting the oil pump cable. In small increments, loosen
the lock nut that is closest to the oil pump (A). and move
the mark that is on the oil pump arm by tightening or
loosening the adjustment nut (B) as needed to get the line
to the desired position.
600 IQ HO
A
C
6. Lock the lock nut (A).
7. Verify that the oil pump marks line up (C) as outlined in
step 4.
8. Re-install carburetors, air box and plug in the CDI and coils
if they were taken off in step 1.
9. Check idle to specification and adjust if needed.
B
3
3.19
MAINTENANCE
Track Alignment
A
B
C
NOTE: Track alignment affects track tension.
Misalignment of the track will cause excessive wear
to the track, rail slides, and rail.
NOTE: Excessive rail slide wear occurs due to
running in inadequate snow conditions.
Periodically check that the track is centered and running evenly
on the slide rails. Misalignment will cause excessive wear to the
track and slide rails.
1. Safely lift and support the rear of the snowmobile off the
ground.
2. Rotate the track by hand to check for any possible damage.
3. Inspect the track rods (A) carefully and examine the track
along the entire length of each rod, bending the track edge
and inspecting it for breakage. If any rod damage is found,
the track should be replaced.
4. Warm up the track by starting the engine and apply a small
amount of throttle so the track runs slowly at least five
complete revolutions.
5. Stop the engine and turn the ignition off.
6. Inspect track alignment by carefully looking through the
track window (B) to make sure the rails (C) are evenly
spaced on each side.
7. If the track runs to the left, loosen the left locknut and
tighten the left adjusting bolt (D). If the track runs to the
right, loosen the right locknut and tighten the right adjusting
bolt. It may be necessary to check this with the engine
rotating the track. Be sure to SHUT THE MACHINE OFF
before making any further adjustments.
8. Loosen up the rear idler shaft (F).
F
D
E
9. After any adjustments are complete, be sure to torque the
locknuts (E) to 35 ft-lb (48 N-m).
= T
Adjuster Lock Nuts: 35 ft-lb (48 N-m)
10. Torque both idler shaft bolts (F) to 35 ft-lb (48 N-m).
= T
Idler Shaft Bolt: 35 ft-lb (48 N-m)
WARN IN G
Broken track rods can cause a rotating track to come off
the machine. Never operate or rotate a damaged track
under power with a broken rod. Serious injury or death
may occur.
WARN IN G
When performing the following checks and
adjustments, stay clear of all moving parts to avoid
personal injury. Never make any adjustments with the
engine running, as serious personal injury can result.
3.20
MAINTENANCE
Track Tension
F
B
C
A
D
TRACK
Track tension is critical for maintaining correct suspension
operation. If the track tension is too loose it may cause the track
to slip or “ratchet” on the drive shaft drivers and cause the track
and rear suspension durability problems. If the track is too tight
it will wear down the rail slides, reduce top speeds, cause rear
suspension vibration and cause track and rear suspension
durability problems.
o
16”(41cm)
E
NOTE: Track alignment affects track tension.
Misalignment will cause excessive wear to the track
and slide rails. Excessive slide wear will appear on
units with the track tension set too tight (or below
measurement specification).
SUSPENSION MEASUREMENT
IQ 121, IQ Touring, IQ LX
RMK, Switchback, 340 LX,
500 XCSP, 550 LX,
SuperSport, Trail RMK
Wide Track LX
340 Touring, Trail Touring
7/8" - 1 1/8"
(2.2-2.9cm)
3/8" - 1/2"
(1-1.3cm)
3/4" "- 1"
(1.9-2.5cm)
1 1/8" - 1 3/8"
(2.9-3.5cm)
Rear Engine Torque Stop Adjustment
B
A
3
1. Lift the rear of the machine and place a jack stand or secure
the rear of the machine so that the track is off of the
ground.
2. Start the engine and slowly let the engine turn the track
over. This will warm up the track for a correct
measurement.
3. Shut off the engine.
4. Place a 10 lb. (4.54kg) weight at point (A). Point (A) is 16”
(41cm) ahead of the rear idler shaft (E).
5. Measure the distance (D) between the rail slider and the
track. This measurement should fall with in the
measurement range for the appropriate vehicle, see chart o
this page.
6. If adjustment is needed, loosen up the lock nuts (B) on each
side.
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
(counterclockwise) if you need a greater measurement.
9. When you achieve the correct tension listed below, torque
the lock nuts (B) and idler shaft bolts on each side to 35 ftlb (48 N-m).
TORQUE STOP
After aligning clutches, adjust the rear torque stop (A) by
loosening the lock nut and rotating the stop so that the clearance
is 0.010” - 0.030” (0.25 - 0.75mm) from the whole surface of the
torque stop.
If replacing a new torque stop, adjust the torque stop so that the
tip (B) is touching the engine case.
= T
Torque Stop Jam Nut: 15-17 ft-lb. (21-24 N-m)
3.21
MAINTENANCE
Engine Isolator Limiter Setting
Adjust the front engine isolator limiter so that the stop (D) is
bottomed out on the brace (E).
Hold the engine isolator limiter (D) and torque the jam nut (F)
to specification.
NOTE: Do not adjust this engine isolator limiter as a
torque stop or damage may occur. The approximate
distance from the face of the isolator to the face of
the engine strap is 0.107" (2.72mm).
F
E
D
Isolator Limiter touching base
Water Sediment Trap
WARN IN G
When draining the traps, fuel spillage will occur. Be
sure to work in a well ventilated area away from
anything which may cause the fuel to ignite such as an
open flame, heaters, trouble lights or cigarettes.
Most Polaris snowmobiles incorporate a patented carburetor
bowl water / sediment traps located at the bottom of each
carburetor. The trap consists of a hose with a plug which should
be inspected for contamination every 1000 miles (1600 km).
A
B
= T
Jam Nut: 15-17 ft-lb. (21-24 N-m)
CLEANING
Air Filter
A
AIR FILTER CLEANING
The intake foam filter (A) limits snow ingestion into the intake
system. When operating in loose powder, check the top of the
foam filter periodically to remove any accumulation of snow.
NOTE: Do not operate a machine with the intake
filters removed. This may cause carburetor icing
resulting poor fuel economy or engine damage.
A
A
1. Turn the fuel tank supply valve to the “OFF” position.
2. Position a container or shop towels 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 bowl. Repeat for each
carburetor.
4. Wipe off the residue from the plug and reinstall the clamps.
Nosepan Care
If your nosepan becomes dirty with soot, you can use Polaris
Carbon Clean (PN 2872890) to remove the soot.
STORAGE
Chassis And Hood
Proper storage starts by cleaning, washing and waxing the hood,
chassis, upholstery and plastic parts. Clean and touch up with
paint any rusted or bare metal surfaces. Ensure that all corrosive
salt and acids are removed from surfaces before beginning
preservation with waxes and rust inhibitors (grease, oil, or
paint).
If the machine is equipped with a battery, disconnect the battery
cables and clean the cables and battery posts. Fill battery to
proper level with distilled water and charge to full capacity.
Remove and store the battery in a cool dry place.
3.22
MAINTENANCE
The machine should be stored in a dry garage or shed out of the
sunlight and covered with a fabric snowmobile cover. Do not use
plastic to cover the machine; moisture will be trapped inside
causing rust and corrosion problems.
Clutch And Drive System
Remove drive belt and store in a cool dry location. Lubricate
sheave faces and ramps of drive and driven clutches with light
oil or rust inhibitor. All lubrication applied as a rust preventative
measure must be cleaned off before installing belt for service
and operating machine.
Controls And Linkage
All bushings, spindle shafts and tie rod ends should be coated
with a light coat of oil or grease. Throttle controls and cables
should be lubricated. Force a small amount of lubricant down
cables.
Electrical Connections
Separate electrical connector blocks and clean corrosive buildup from connectors. Lubricate or pack connector blocks with
Nyogel™ grease and reconnect. Replace worn or frayed
electrical wire and connectors.
Battery
Disconnect and remove the battery. Clean the terminals and
cables. Apply dielectric grease to the terminals. Store in a cool
dry place for storage.
3
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. If Polaris
Carbon Clean is not used, fuel tank, fuel lines, and carburetor
should be completely drained of gasoline.
Corrosion
To prevent corrosion, always grease jackshaft and drive shaft
(clutch side) bearings with Polaris Premium all season grease.
Loosen driven clutch retaining bolt and pull clutch outward to
expose bearing. Use a point type grease gun fitting to inject
grease through hole in flangette into bearing until grease purges
out inside or outside bearing seal. Push clutch back on shaft and
replace clutch retaining bolt. Inject grease into fitting on
speedometer drive adaptor until grease purges out inside or
outside the bearing seal. Lubricate both front ski pivots at
bushings and spindles.
Shocks
Use T-9 Metal Protectant (or equivalent) on shock absorber
shafts to help prevent corrosion.
3.23
MAINTENANCE
REPLACEMENT
Headlight Bulb Replacement
NOTE: Do not touch the bulb with your fingers. The
grease from body oil will cause a hot spot on the
bulb and cause bulb failure. If you do touch the bulb
clean the bulb with isopropyl alcohol.
Edge Headlight Bulb Replacement
SLIDE
PUSH
1. Push in on the “PUSH” section of the plenum.
2. Slide the access panel down to gain access to the bulb.
3. Squeeze and move the bulb clip up.
4. Replace the bulb, clip and access panel.
4. Lift spring carefully around the wire harness and flip it to
the outside of the housing.
5. Grasp the bulb (4) by the metal base and carefully separate
the bulb from the harness.
6. Instal new bulb by the base and reverse the process for
installation.
5
6
7
IQ Snow Beam Bulb Replacement
1. Twist the light base (5) counterclockwise and pull it out
from the housing.
2. Remove the rubber boot (6).
3. Remove the bulb (7) by pulling it straight out from the
housing.
4. Replace bulb with new and reverse the process for
installation.
1
2
3
4
IQ Headlight Bulb Replacement
1. Unplug the headlight 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.
3.24
Coolant Draining
WARN IN G
Wait until the engine is cool before removing the
pressure cap. Removing the cap while engine is hot
and the coolant is under pressure may cause
serious scalding.
One method of draining coolant from an engine is to use low air
pressure to aid the extraction of coolant.
1. Remove pressure cap.
2. Siphon as much coolant as you can from the coolant bottle
and coolant lines.
3. Remove the top hose 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 container.
NOTE: This will only get the majority of the coolant
out. Some may remain in the system.
MAINTENANCE
3
3.25
MAINTENANCE
NOTES
3.26
FUEL DELIVERY
CHAPTER 4
FUEL DELIVERY
WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
SERVICE PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
FUEL DELIVERY SYSTEM (CARBURETED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
CARBURETED SYSTEM OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
FUEL PUMP (CARBURETED UNITS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
FUEL PUMP OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
MIKUNI JET NEEDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
MIKUNI TM 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
CARBURETOR OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
MIKUNI CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
FLOAT SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
FUEL METERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
FUEL DELIVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
PILOT JET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.8
FUEL SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
MAIN JET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
JETTING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.9
PISTON VALVE OR THROTTLE VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
JET NEEDLE / NEEDLE JET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
JET NEEDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
NEEDLE JET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
THROTTLE OPENING 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
MIKUNI PILOT JETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
MIKUNI MAIN JETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
MIKUNI JET NEEDLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
MIKUNI STARTER JETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
MIKUNI (SHORT) PILOT AIR JETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
MIKUNI (LONG) PILOT AIR JETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
MIKUNI PISTON VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
MIKUNI (NOTCHED) PISTON VALVES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
CLEANFIRE INJECTION (CFI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
INJECTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
600/700 CFI INJECTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
600/700 CFI FUEL RAIL/INJECTOR(S) REMOVAL/INSTALLATION . . . . . . . . . . . . . . 4.17
CLEANFIRE SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19
FUEL PUMP (700) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19
FUEL LEVEL INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19
2007 FUEL SUPPLY / RETURN FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.20
FUEL RAIL BLEEDING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.20
600 CFI FUEL TANK / FUEL SUPPLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
600 CFI PUMP / SENDER SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
4
4.1
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
4.2
FUEL DELIVERY
WARNINGS
When servicing the carburetor or fuel
system, it is important to heed the following
warnings.
WARN IN G
Always stop the engine and refuel outdoors or in a well
ventilated area
WARN IN G
Do not smoke or allow open flames or sparks in or near
the area where refueling is performed or where
gasoline is stored or used.
WARN IN G
Do not overfill the tank. Do not fill the tank neck.
thoroughly familiarizing him/herself with procedures before
beginning. Photographs and illustrations have been included
with the text as an aid. Notes, cautions and warnings have also
been included for clarification of text and safety concerns.
However, a knowledge of mechanical theory, tool use and shop
procedures is necessary to perform the service work safely and
satisfactorily. Use only genuine Polaris service parts.
Cleanliness of parts and tools as well as the work area is of
primary importance. Dirt and foreign matter will act as an
abrasive and cause damage to precision parts. Clean the
snowmobile before beginning service. Clean new parts before
installing.
Watch for sharp edges which can cause personal injury,
particularly in the area of the tunnel. Protect hands with gloves
when working with sharp components.
If difficulty is encountered in removing or installing a
component, look to see if a cause for the difficulty can be found.
If it is necessary to tap the part into place, use a soft face hammer
and tap lightly.
Some of the fasteners in the snowmobile were installed with
locking agents. Use of impact drivers or wrenches will help
avoid damage to fasteners.
4
WARN IN G
If you get gasoline in your eyes or if you swallow
gasoline, see your doctor immediately.
WARN IN G
If you spill gasoline on your skin or clothing,
immediately wash it off with soap and water and
change clothing.
WARN IN G
Never start the engine or let it run in an enclosed area.
Gasoline powered engine exhaust fumes are
poisonous and can cause loss of consciousness and
death in a short time.
GENERAL INFORMATION
Service Precautions
In order to perform service work efficiently and to prevent
costly errors, the technician should read the text in this manual,
Always follow torque specifications as outlined throughout this
manual. Incorrect torquing may lead to serious machine damage
or, as in the case of steering 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 and sequence indicated in this manual. Tighten evenly
to the specified torque value. When removing nuts, bolts or
screws from a part with several fasteners, loosen them all about
1/4 turn before removing them.
If the condition of any gasket or O-Ring is in question, replace
it with a new one. Be sure the mating surfaces around the gasket
are clean and smooth in order to avoid leaks.
Some procedures will require removal of retaining rings or
clips. Because removal weakens and deforms these parts, they
should always be replaced with new parts. When installing new
retaining rings and clips use care not to expand or compress
them beyond what is required for installation.
Because removal damages seals, replace any oil or grease seals
removed with new parts.
Polaris recommends the use of Polaris lubricants and greases,
which have been specially formulated for the top performance
and best protection of our machines. In some applications, such
4.3
FUEL DELIVERY
as the engine, warranty coverage may become void if other
brands are substituted.
Grease should be cleaned from parts and fresh grease applied
before reassembly of components. Deteriorating grease loses
lubricity and may contain abrasive foreign matter.
Whenever removing or reinstalling batteries, care should be
taken to avoid the possibility of explosion resulting in serious
burns. Always disconnect the negative (black) cable first and
reconnect it last. Battery electrolyte contains sulfuric acid and
is poisonous! Serious burns can result from contact with the
skin, eyes or clothing. ANTIDOTE: External - Flush with
water. Internal - Drink large quantities or water or milk. Follow
with milk of magnesia, beaten egg, or vegetable oil. Call
physician immediately. Eyes - Flush with water for 15 minutes
and get prompt medical attention.
FUEL DELIVERY SYSTEM
(CARBURETED)
Carbureted System Overview
The carbureted fuel system contains many components which
directly affect fuel mixture and performance. When performing
diagnosis or carburetor maintenance, the entire fuel delivery
system should be inspected.
Fuel filters should be replaced at least once per season. More
often if contamination is suspected.
Fuel lines should be replaced every other season. More often if
they become brittle or swollen. Fittings should be inspected for
cracks or leaks. Do not use pliers or other tools that may damage
fuel lines when installing or removing fuel lines.
Test run and check the fuel system for leaks any time parts are
replaced. Verify that all lines are routed correctly and away from
any moving parts.
NOTE: Some models use fuel filters that are located
inside the fuel tank. To inspect/replace filter, remove
fuel cap and use a long clean wire, bend one end
into a hook shape. Pull the fuel line that is in the
tank up through the filler hole. Inspect filter on end
of fuel pick up line. Replace if worn or clogged.
When replacing fuel line, be sure to use the correct color line for
inside or outside the fuel tank. Also, be very careful not to bend
fuel line to a point of kinking it. If it becomes kinked, it must be
replaced. Always inspect fuel lines when replacing, or if carbs,
carburetor racks, or fuel pumps are removed from chassis.
FUEL PUMP (CARBURETED UNITS)
Fuel Pump Overview
The differences are in the size and
location of the pumps. Pumps may
be mounted to the engine, air/oil box
or to the chassis.
In the two cycle engine, the pressure
in the crankcase changes with the up
and down stroke of the piston. The
amplitudes of pressure vary
according to the RPM and degree of
throttle opening. Whether idling or at
full throttle, the pressure built up in
the crankcase has enough amplitude
to operate the pump.
When the piston is on the upstroke,
crankcase pressure in that cylinder
becomes less positive. The
diaphragm in the fuel pump moves
toward the engine, causing a
negative pressure or suction in the
pump chamber. This causes the inlet
valve from the fuel supply to open
and permits fuel to enter the chamber. This same suction causes
the outlet valve (to the carburetor) to close so that fuel cannot
return to the carburetor. (340/550 style shown)
When the piston begins its downward stroke, the pressure from
the crankcase becomes positive, causing the fuel pump
diaphragm to move in the opposite direction and reversing the
pressure in the fuel pump chamber. This causes the inlet valve
in the pump to close and the outlet valve to open, filling the float
bowl in the carburetor. When the float level in the carburetor
reaches its standard level, the needle valve will close,
preventing more fuel from entering the carburetor, even though
the fuel pump continues to try to provide the carburetor with
fuel.
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 fade and
turn clear after a relatively short time. This does not affect the
function or durability of the line.
4.4
FUEL DELIVERY
Maintenance
The impulse operated diaphragm fuel pump does not require any
specific scheduled maintenance. However, the following
procedures should be observed:
• Operation
The pump may be checked for operation by removing the fuel
supply line from the carburetor and placing it into a container.
With the engine idling at approximately 2000 RPM, a steady
flow of fuel should be visible.
• Cleaning
The pump and impulse line must be disassembled and cleaned
of foreign material in the event of piston or other internal engine
part failures which produce fragments.
• Inspection
Disconnect impulse line from pump. Connect a Mity Vac to
impulse fitting (or line) and apply 4-6 PSI pressure. Diaphragm
should hold pressure indefinitely.
The diaphragms and check valves must be carefully examined
for cracks, holes, or other damage. If in doubt as to the condition
of any internal parts, replace all diaphragms, check valves, and
gaskets.
9DH01-57
4
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. The 9 indicates the needle is approximately 90mm but
less that 100mm in length.
The letters on the jet needle indicate the angle of both tapers. The
first letter designates the taper angle of the top section (closest
to the grooves) and the second letter designates the angle of the
bottom taper. The taper angles are graduated in 15' (15 minute)
increments. The jet needle marked 9DH01-57 would have a top
taper of 1_0' and a bottom taper of 2_0'.
The number following the letters on the jet needle is the serial
number and it varies with individual jet needles.
The last number, 57 indicates that the outside diameter is
2.57mm. The smaller the O.D., the richer the mixture.
DESIGNATOR DESCRIPTION
9 Overall length in 10mm increments
D Taper of the top section of the needle
H
01 Serial number
-57
taper of the bottom section of the
needle
Outside diameter (O.D.) of the straight
portion
4.5
FUEL DELIVERY
MIKUNI TM 38
Carburetor Overview
The advantages of the TM flatslide system include improved
throttle response and a significant reduction in throttle effort
due to rack style carbs and the use of cable cam. The following
are the main components of TM carburetors and the functions
of each components.
Pilot Air Jet (A): The pilot air jet controls the amount of air
entering the engine in the idle circuit. The pilot air jet size is
imprinted on it. Bigger pilot air jets allow more air to enter,
leaning the idle mixture. If engine loads up at idle, first try
turning fuel screw in. If not correct, try larger pilot air jet.
Starter Jet (B): The starter jet's function is to meter fuel
entering the engine when choked. Larger numbered starter jets
pass more fuel, therefore more fuel will enter the system when
jetting to a larger size. Like the pilot air jet, the jet size is
imprinted.
Jet Needle (C): The jet needle performs the same functions as
on Mikuni VM carburetors. However, the 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.
Reach inside with a long nose pliers and pull the needle out. The
C-clip can then be adjusted for the desired effect.
Needle Jet (D): The needle jet is press fit into carbs and is not
replaceable.
P is to n Va lv e o r T hr ot tl e Va lv e ): The throttle valve controls the
rate of engine air intake by moving up and down inside the main
bore. At small throttle openings, air flow control is performed
chiefly by the cutaway. By controlling air flow the negative
pressure over the needle valve is regulated, in turn varying the
fuel flow
Main Jet and Pilot Jet (F): The main jets (hex) and pilot jets
(air bleed type) are identical in style and function as the Mikuni
VM carbs. There is a washer on a main jet that is staked and
should not come out. The part numbers for main jets and pilot
jets are the same as Mikuni VM round slide carburetors.
Fuel Screw (G): The fuel screw controls the low speed air/fuel
mixture at idle. Turning the fuel screw out makes the mixture
richer and can be adjusted up to three turns out.
4.6
FUEL DELIVERY
Float/Needle & Seat Assembly (H): The float/needle & seat are
sold as an assembly and cannot be replaced as individual
components. The float level is pre-set in the molding and cannot
be adjusted.
WARN IN G
DO NOT pressurize the fuel system by forcing compressed
air through the fuel tank. Forcing air through the needle and
seat will cause damage and the float/needle & seat assembly
will have to be replaced.
Carburetor Synchronization: Remove the top caps on all
carburetors. In the body of the carburetors, there is a Phillips
head set screw (I) that connects the slide lever to the throttle
lever shaft. The carburetor with the fixed set screw is the base
carburetor (middle carburetor on triples, PTO carburetor on
twins) and the remaining carbs are synchronized to it.
Carburetor synchronization is measured at wide open throttle.
Open the throttle to wide open. The bottom of the slide should
be flush with the top of the throttle bore. If it is not flush, locate
the wide open throttle stop screw (J) and turn it until the base
carburetor is set flush. Loosen the Phillips head set screw in the
remaining carburetor(s). Turn the adjusting nut (K) that
surrounds the set screw until the throttle slide is set the same as
the base carburetor. Tighten all set screws and replace the top
caps making sure gaskets are properly positioned.
MIKUNI CARBURETOR
4
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,
to mix the fuel with air in a proper ratio, and to deliver the
mixture to the engine. A proper ratio means an ideal air/fuel
mixture which can burn without leaving an excess of fuel or air.
Whether the proper mixture ratio is maintained or not is the key
to efficient engine operation.
The engine of a vehicle is operated under a wide range of
conditions, from idling with the throttle valve remaining almost
closed, to full load or maximum output with the throttle valve
fully opened. In order to meet the requirements for the proper
mixture ratio under these varying conditions, a low speed fuel
system, or pilot system, and a main fuel system are provided in
Mikuni type carburetors. The Mikuni carburetor has varying
operations depending upon varying driving conditions. It is
constructed of a float system, pilot system, main system, and
starter system or initial starting device.
4.7
FUEL DELIVERY
Float System
The float system is designed to maintain a constant height of
gasoline during operation. When the fuel flowing from the fuel
pump into the float chamber through the needle valve reaches
the constant fuel level, the floats rise. When the buoyancy of the
float and the fuel pressure of the fuel pump balance, the needle
valve sticks fast to the needle seat, preventing further delivery
of gasoline, thereby holding the standard level of gasoline.
The fuel level in the bowl assists in controlling the amount of
fuel in the fuel mixture. Too high a level allows more fuel than
necessary to leave the nozzle, enriching the mixture. Too low a
level results in a leaner mixture, since not enough fuel leaves the
nozzle. Therefore, the predetermined fuel level should not be
changed arbitrarily.
Fuel Metering
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 continuously
throughout the
entire operating
range.
Fuel for the pilot
jet is drawn from
the float bowl,
mixed with air jet,
and delivered to
the engine through the pilot outlet.
The mixture is regulated to some degree by adjusting the fuel
screw.
The main system is designed to deliver fuel between low speed
and high speed operation. This system is made up of the jet
needle, needle jet, and main jet. The main system begins to take
effect as soon as there is enough air flow into the carburetor
venturi to draw fuel up through the main jet and needle jet
assembly. This system works in conjunction with the needle jet
system.
FUEL METERING
Mikuni carburetors use a starter enricher system rather than a
choke. In this type of carburetor, fuel and air for starting the
engine are metered with entirely independent jets. The fuel
metered in the starter jet is mixed with air and is broken into tiny
particles in the emulsion tube. The mixture then flows into the
plunger area, mixes again with air coming from the air intake
port for starting and is delivered to the engine through the fuel
discharge nozzle in the optimum air/fuel ratio. The starter is
opened and closed by means of the starter plunger. The starter
type carburetor is constructed to utilize the negative pressure of
the inlet pipe, so it is important that the throttle valve is closed
when starting the engine
4.8
During low speed driving, there is very little clearance between
the jet needle and the needle jet; therefore, very little fuel from
the main jet can pass between the jet needle and the needle jet.
As the throttle valve opening is increased, the tapered jet needle
is raised farther out of the needle jet, allowing greater fuel flow.
Under full throttle opening, the cross sectioned area of
clearance between the jet needle and the needle jet becomes
greater than the cross sectioned area of the main jet. Thus the
main jet is now controlling the amount of fuel flow.
Pilot Jet
From idling to low speeds, the fuel supply is metered by the pilot
jet. There are several air bleed openings in the sides of the pilot
jet which reduce the fuel to mist. The number stamped on the jet
is an indication of the amount of fuel in cc's which passes
through the jet during a one minute interval under a given set of
conditions.
FUEL DELIVERY
Fuel Screw
The fuel screw controls the fuel mixture from idle to low speeds.
The tapered tip of the fuel screw projects into the passage
leading to the by pass out let. By turning the screw in or out, the
cross sectional area of the air passage is varied, in turn varying
the fuel screw varies the amount of air/fuel.
Main Jet
When the throttle
opening becomes
greater and the area
between the needle jet
and jet needle increases,
fuel flow is metered by
the main jet. The number
on the jet indicates the amount of fuel which will pass through
it in one minute under controlled conditions. Larger numbers
give a greater flow, resulting in a richer mixture. Main jets are
screwed directly into the needle jet base.
Jetting Guidelines
Changes in altitude and temperature affect air density, which is
essentially the amount of oxygen available for combustion. In
low elevations and cold temperatures, the air has more oxygen.
In higher elevations and higher temperatures, the air is less
dense.
always use the lowest elevation and temperature
that is likely to be encountered.
CAU TION
A Main Jet that is too small will cause a lean operation
condition and may cause serious engine damage. Jet
the carburetors carefully for elevation and temperature
according to the jetting charts in the, Specifications
Chapter of this manual or the models Owner’s Manual
Supplements.
Piston Valve Or Throttle Valve
4
Verify the production setting for your specific model. All
carburetors must be re-calibrated if operated outside the
production temperature and/or altitude range. The main jet
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 ranges.
NOTE: It is the owner's responsibility to ensure that
the correct jets are installed in the machine for a
geographical area. Be very careful when jetting
down in warm weather. As the weather turns colder
it will be necessary to re-jet upward to prevent
engine damage. When selecting the proper main jet
intake side
The throttle valve controls the rate of engine air intake by
moving up and down inside the main bore. At small throttle
openings, air flow control is performed chiefly by the cutaway.
By controlling air flow the negative pressure over the needle
valve is regulated, in turn varying the fuel flow.
The throttle valves are numbered 1.0, 1.5, 2.0, etc., according to
the size of the cutaway in millimeters. The higher the number,
the leaner the gasoline/air mixture.
4.9
FUEL DELIVERY
Jet Needle / Needle Jet
The jet needle and needle jet have the most effect between 3/8
and 3/4 throttle opening. Some mixture adjustment can be
accomplished by changing the location of the “E” clip on the
needle. Moving the clip down raises the needle in the jet passage
and enriches the mixture. Moving the clip up lowers the needle
in the jet passage and leans the mixture. Letter and number
codes are stamped into the needle and the jet indicating sizes
and tapers (taper of needles only) of each.
Jet Needle
The jet needle tapers off at one end and the clearance between
the jet needle and the needle jet increases as the throttle valve
opening gets wider. The air/fuel mixture ratio is controlled by
the height of the “E” ring inserted into one of the five slots
provided in the head of the jet needle.
Needle Jet
The needle jet works in conjunction with the jet needle.
4.10
Throttle Opening Vs. Fuel Flow
FUEL DELIVERY
VM only
4
4.11
FUEL DELIVERY
MIKUNI TM38 FLAT SLIDE SERVICE
Disassembly
CAU TION
WEAR EYE PROTECTION WHEN USING COMPRESSED AIR OR
WHEN USING CLEANING SOLVENTS. REVIEW ALL FUEL
SYSTEM WARNINGS LOCATED AT THE BEGINNING OF THIS
CHAPTER BEFORE PROCEEDING.
1. Remove the carburetor from the engine before
disassembling. Clean the outside of the carburetor
thoroughly with solvent. Do not use compressed air to dry
at this time. The float chamber could become pressurized
resulting in damage to the floats or inlet needle and seat.
2. Remove all top cap screws (1), top cap (2) and gasket (3).
2
1
3
NOTE: Keep track of the plastic washer (9), and
place it so it is on the top of the throttle valve when
installing the needle and e-ring back into the
carburetor.
4. Inspect the needle (7), e-clip (8), and plastic washer (9) for
wear.
8
7
9
5. Remove the four screws (10) on the funnel face.
6. Turn throttle shaft so the throttle slide (11) slides open all
the way.
7. With slide fully open, pull funnel (12) out from the bottom
first. Inspect the gasket (13).
8. Check for wear on the faces of the slides.
10
3. Locate the arm screw (4) and loosen it just enough to move
the arm (5) out of the way so that you can remove the needle
(6) e-clip and the plastic washer from the throttle slide.
4
5
6
4.12
13
11
12
FUEL DELIVERY
9. Inspect e-rings, plate, spring, and rings (14) connecting the
slide to the lever if needed.
14
10. Remove water trap/drain plug (15) and single screw (16) on
the bottom of the carburetor.
11. Remove and drain the float bowl (17).
NOTE: Float bowl will not come off unless the water
trap/drain plug and screw are removed.
13. Inspect the contents for wear and debris.
18
19
14. Remove and inspect the main jet (20), pilot jet (21), and
starter jet (22). Clean them out.
15. Remove the air jet screw if so equipped.
4
17
16
15
12. Remove the two screws (18) holding the float/needle and
seat assembly (19) in position and remove this assembly.
22
21
20
16. Clean out all passages in carburetor body with carburetor
cleaner. Dry all passages and jets with compressed air.
17. Replace gaskets and any parts that show wear or damage.
18. Repeat steps 1-18 for disassembly for the other carburetor
if needed.
4.13
FUEL DELIVERY
Assembly
1. Install the main jet (20), pilot jet (21), and starter jet (22).
2. Install float/needle & seat assembly (19).
3. Place carburetor in an inverted position.
4. Connect a pressure tester (PN 2870975) to fuel inlet fitting.
Apply 5 psi pressure and observe for one minute. The
needle and seat should hold pressure indefinitely. If the
pressure drops, carefully inspect the needle and the needle
seat. The needle can be replaced (needle comes with float
and seat).
5. Carefully inspect float bowl gasket and replace if
necessary.
6. Install float bowl (16) on carburetor with water trap/drain
plug (15) and single screw (16) on the bottom of the
carburetor.
7. If throttle slide was removed, install throttle slide (11) so
that the wider face is facing the engine side of the
carburetor.
8. Install the funnel gasket (13) and funnel (12) onto the
carburetor. You will have to lift the throttle slide up and
place the smaller face into the funnel area.
9. Install funnel screws (10).
10. Install the e-clip (8) in the desired position on the jet needle
(7).
11. Slide the plastic washer (9) on the jet needle so that it is
positioned 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 gaskets (3), cover (2) and screws (1).
15. Check throttle lever free play. See “THROTTLE LEVER
FREE PLAY” on page 3.24.
CARBURETOR SYNCRONIZATION
Throttle Valve Synchronization
Mikuni TM style carburetors are synchronized at wide open
throttle without the engine running. The MAG side carburetor
is the adjusting carburetor, the PTO side carburetor has a non
adjustable set screw on the throttle shaft. The PTO carburetor is
considered the base carburetor. All adjustments are made to the
MAG carburetor
1. Remove the air box.
2. Remove the carburetor tops.
3. Hold the throttle wide open with the bell crank on the
carburetor.
4. The bottom of the throttle valve should be flush with the
top of the carburetor intake area.
5. If they are not flush, hold the PTO carburetor flush with the
top of the intake area of the carburetor.
6. Turn the throttle slide synchronization screw until both of
the throttle slides are flush with the top of the intake area
of the carburetor.
Throttle slide sync screw
7. Once the PTO carburetor slide is flush, loosen the Phillips
head screw, located under the top cover on the MAG
carburetor.
4.14
FUEL DELIVERY
8. While holding the PTO carburetor slide flush to the top of
the carburetor, rotate the synchronization nut clockwise to
raise the slide and counterclockwise to lower the slide.
Lock Screw
Sync Nut
9. Adjust the synchronization nut until it is even with the PTO
slide.
10. Once this is flush, lock the locking screw.
11. Replace the tops of the carburetor.
12. Install carburetor back onto the sled.
13. Install all cables.
14. Install all vent lines, and fuel lines.
15. Check throttle free play.see “THROTTLE LEVER FREE
PLAY” on page 3.24.
CARBURETOR COMPONENT PART
NUMBERS
Mikuni Pilot Jets
PILOT JET NUMBER PART NUMBER
25 3130064
30 3130065
35 3130066
40 3130067
45 3130068
50 3130629
55 3130070
60 3130071
Mikuni Main Jets
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 190 3130121 340 3130137 510 N 3131400
115 3130106 195 3130122 350 3130138 520 N 3131401
120 3130107 200 3130123 360 3130139 530 N 3131402
125 3130108 210 3130124 370 3130290 540 N 3131408
130 3130109 220 3130125 380 3130140 550 N 3131409
135 3130110 230 3130126 390 3130480 560 N 3131410
140 3130111 240 3130127 400 3130141
145 3130112 250 3130637 410 3130599
150 3130113 260 3130129 420 3130142
155 3130114 270 3130130 430 3130143
160 3130115 280 3130131 440 3130144
165 3130116 290 3130132 450 3130145
170 3130117 300 3130133 460 3130146
MAIN JET
PART NUMBER
MAIN JET
MAIN JET
PART NUMBER
Mikuni Jet Needles
JET NEEDLE PART NUMBER
J8-9FH04-57 3130794
J8-9EH01-57 3130795
J8-9DH01-54 3130796
J8-8BEY01 3131250
J8-9DFH06-57 3131253
J8-9EFH01-60 3131207
J8-9DFH07-60 3131268
J8-9DFH10-57 3131313
J8-9DGI01-60 3131377
J8-9DGJ02-57 3131378
J8-9EFY02-61 3131202
PART NUMBER
4
4.15
FUEL DELIVERY
Mikuni Starter Jets
STARTER JET PART NUMBER
130 3130805
135 3130767
140 3130768
145 3130769
150 3130770
155 3130771
160 3130772
Mikuni (Short) Pilot Air Jets
AIR JET PART NUMBER
0.5 3130773
0.6 3130774
0.7 3130775
0.8 3130776
0.9 3130777
1.0 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
Mikuni (Long) Pilot Air Jets
AIR JET PART NUMBER
0.5 3131255
0.6 3131249
0.7 3131256
0.8 3131254
0.9 3131203
1.0 3131257
1.1 3131258
1.2 3131259
1.3 3131260
1.4 3131261
1.5 3131262
1.6 3131263
1.7 3131264
1.8 3131265
1.9 3131266
2.0 3131267
Mikuni Piston Valves
PISTON VALVE PART NUMBER
1.5 3130940
2.0 3131252
2.5 3130790
3.0 3130791
3.5 3130792
4.0 3130793
Mikuni (Notched) Piston Valves
PISTON VALVE PART NUMBER
1.5 3131216
2.0 3131206
2.5 3131217
3.0 3131218
3.5 3131219
4.0 3131220
4.16
FUEL DELIVERY
CLEANFIRE INJECTION (CFI)
Injector Replacement
The Cleanfire system utilizes 3 different color injectors. If you
are replacing an injector you must replace it with the same color
injector you remove.
The color is indicated in three ways, 1) it will be on the short wire
harness that is attached to the injector, 2) the injector will have
a colored dot on the shaft of the injector 3)it is indicated on the
label of the ECU.
If the color injector is not available you may replace all injectors
with a different color and you must program the ECU to run the
new installed color.
INJECTOR COLOR
1202853-053 Yellow
1202853-027 Blue
1202853-015 Red
INJECTOR KITS
2203325-053 Yellow
COLOR
NOTE: If the injector is on the upper fuel rail, only
the air box needs to be removed to gain access to
the failed injector.
NOTE: If the injector is on the lower fuel rail, engine
removal is necessary for injector access. See “600 /
700 HO CFI ENGINE” on page 5.29.
600/700 CFI Fuel Rail/Injector(s) Removal/
Installation
NOTE: When installing replacement injector(s) keep
the red protective cap on the end of the injector to
prevent damage when installed. Follow the steps
and remove when instructed to do so.
1. Depressurize the fuel rail. See “Fuel Rail Bleeding” on
page 4.20.
2. Remove the panduit straps (1-4) as shown.
1
2
4
2203325-027 Blue
2203325-015 Red
If it is verified that an injector needs to be replaced, you must
first find out what injector color is on the unit. You can do this
by checking the decal that is located on the top portion of the
ECU or by the color band that is next to the injector on the
harness.
1. Bleed the fuel rail. See “Fuel Rail Bleeding” on page 4.20.
2. Remove the seat and fuel tank. See “IQ Fuel Tank
Removal” on page 10.6.
3. If removal of the engine is needed. See “600/700 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 Replacement
If an injector is suspect to failure please use the following
procedure to replace injector(s) on the
CFI engine.
3
3. Remove the fuel rail by taking out the two hex bolts (5,6)
holding it to the engine.
5
4
6
Using Digital Wrench, identify which injector needs to be
replaced.
4.17
FUEL DELIVERY
4. If replacing a lower injector, remove the lower two bolts
from the lower part of the fuel rail.
7
5. Remove the failed injector(s).
NOTE: Make sure that the green rubber washer (9)
comes out with the failed injector(s).
8
8. Crimp the ends of the new injector firmly on to the wire
harness (10).
10
9. Tape exposed wire and splices (11).
9
6. Measure from the end of the injector (as shown below)
3" (76.2mm) and cut the injector off.
3” (76.2mm)
7. Strip the harness end injector wire covering .25" - .375"
(6.35 - 9.525mm).
11
10. Apply 2-stroke oil to the fuel injector 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 specification.
= T
Fuel Rail Hex Bolt Torque: 9 ft-lb (12N-m)
13. Replace the harness to the original routing and apply
panduit straps back to the original locations, making sure
they are not applied over any mesh part of the fuel rail.
NOTE: Refer to Step 2 for proper routing and strap
location.
14. Install the engine if it was removed. See “600 / 700 HO CFI
ENGINE” on page 5.29.
15. If different color injectors were installed you will need to
re-flash the ECU to accept the new colors.
16. Clear all codes with Digital Wrench.
4.18
FUEL DELIVERY
Cleanfire System Overview
B
A
D
C
700 CFI
The Cleanfire fuel system uses a fuel pump (A) that is located
inside the fuel tank, a fuel rail (C) with in-line fuel filter (B), and
injectors (D). The fuel pump will create a pressure in the system
and deliver the fuel mixture to the injectors. The injectors get a
signal from the engine controller unit (ECU) and sprays into the
engine.
The only maintenance that is needed with this system is that the
fuel filter (B) needs to be changed every 1,000 miles (1600km).
Fittings should be inspected for cracks or leaks. Do not use pliers
or other tools that may damage fuel lines when installing or
removing fuel rail.
Fuel Pump (700)
4
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 replaced.
FUEL PUMP: Located inside tank. It provides system with fuel
at 58psi (4bar) pressure. If the fuel pressure is suspect to be
defective apply 12 VDC to the fuel pump prime (Red (#1) and
the Brown (#3) wires) and check for audible fuel pump
operation as well as fuel rail pressure. The fuel pump should
sound when pumping and the pressure should show 58psi (4 bar)
pressure.
Fuel travels from the fuel pump through the fuel filter and to the
injectors. Any fuel that is not delivered through the injectors will
travel back to the fuel tank through the return line.
PIN COLOR ITEM
#1 Red power to the pump
#2 Violet/White fuel level signal
#3 Brown ground
#4 Brown fuel level ground
Fuel Level Indicator
If the fuel gauge is suspect to failure you can check the
continuity from the fuel sender to the gauge. The given
resistance below is from the Violet/White (#2) wire to the
Brown (#4) wire located at the front of the fuel pump.
TANK LEVEL RESISTANCE ()
FULL 2 - 4
EMPTY 85 - 95
4.19
FUEL DELIVERY
2007 Fuel Supply / Return Fittings
NOTE: Align pump flange so that the arrow is
between the two alignment lines.
SUPPLY FITTING
RETURN FITTING
ARROW
ALIGNMENT LINES
= T
PFA Nut Torque
21 Ft.Lb. (28 Nm)
Fuel Rail Bleeding
The 2007 600 CFI units will have one of two different styles of
Schrader valves.
A shallow core valve (1) and will use the adapter that comes with
the fuel pressure gauge (PN PV-43506-A).
A deep core valve (2) will need the adapter PN PS-48167.
1
The fuel pressure gauge (PN PV-43506-A) is used to check or
bleed the pressure in the fuel rail lines. You 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 shallow core valve.
2
• Adapter (4) is used on the deep core valve.
3
4
2. Attach the correct gauge to the valve on the fuel pressure
tool.
3. Once the gauge is onto the Schrader valve, the pressure
gauge will indicate the pressure in the fuel rail.
4. To bleed the pressure from the fuel rail, you can turn the
bleeder valve on the gauge and bleed the system safely.
5. At this point the fuel rail is ready for service.
4.20
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