Name: Polaris 2007 Two Stroke Service Manual
Brand: Polaris
Rating: 5 (1 reviews)

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5. Table of Contents
7. Front suspension
8. 340 TOURING
10. WIDETRAK LX
12. 500 XC SP
14. SUPER SPORT
18. TRAIL RMK
20. TRAIL TOURING DELUXE
22. 600 HO IQ
24. 600 HO IQ CLEANFIRE
26. 600 HO IQ LX CLEANFIRE
28. 600 HO SWITCHBACK
30. 600 HO SWITCHBACK CLEANFIRE
32. HO RMK 144/155 (F/O)
34. 600 HO IQ TOURING CLEANFIRE
36. DRAGON
38. DRAGON RMK
42. HOW TO USE THIS MANUAL
43. SUSPENSION SPRING PRE-LOAD/INSTALLED LEN...
44. SNOWMOBILE NUMBER DESIGNATIONS
45. VEHICLE IDENTIFICATION NUMBER (VIN)
46. 2007 SERVICE PUBLICATIONS
47. GENERAL REFERENCE
48. SAE TAP DRILL SIZES
49. MEASUREMENT CONVERSION CHART
50. GLOSSARY OF TERMS
51. SPECIAL TOOLS
57. MAINTENANCE PROGRAM
59. INSPECTONS
60. HONING PROCEDURE
61. PISTON RING INSTALLED GAP
62. BEARING FIT
63. WRIST PIN BEARING
65. CRANKSHAFT TRUEING
66. CRANKSHAFT RUNOUT INSPECTION
67. BRAKE LEVER TRAVEL
68. BELT DEFLECTION INSPECTION
69. LUBRICATION
70. FRONT SUSPENSION
71. CHAINCASE OIL
72. THROTTLE LEVER FREE PLAY - NON CFI
73. OIL PUMP ADJUSTMENT
74. TRACK ALIGNMENT
75. TRACK TENSION
76. ENGINE ISOLATOR LIMITER SETTING
77. Clutch and drive system
78. Headlight bulb replacement
79. Coolant draining
83. WARNINGS
84. FUEL DELIVERY SYSTEM (CARBURETED)
85. MAINTENANCE
86. MIKUNI TM 38
87. MIKUNI CARBURETOR
88. FLOAT SYSTEM
89. FUEL SCREW
90. JET NEEDLE / NEEDLE JET
91. THROTTLE OPENING VS. FUEL FLOW
92. MIKUNI TM38 FLAT SLIDE SERVICE
94. ASSEMBLY
95. CARBURETOR COMPONENT PART NUMBERS
96. MIKUNI STARTER JETS
97. CLEANFIRE INJECTION (CFI)
99. CLEANFIRE SYSTEM OVERVIEW
100. 2007 FUEL SUPPLY / RETURN FITTINGS
101. 600 CFI Fuel Tank / Fuel Supply
102. FUEL TANK PRESSURE TEST
103. FUEL FILTER REMOVAL
106. GENERAL ENGINE INFORMATION
107. EXHAUST VALVE DISASSEMBLY
108. REED VALVE ASSEMBLY
109. WATER TEMPERATURE SENSOR REPLACEMENT
110. 500/600/700 WATER/OIL PUMP CROSS SHAFT D...
111. CYLINDER HEAD / HEAD COMPONENTS
112. RECOIL/STATOR ASSEMBLY
113. COOLING SYSTEMS
114. 500/600 TOURING / WIDETRAK LX
115. 340/550 FUJI ENGINE
116. 340/550 ENGINE DISASSEMBLY (550 SHOWN)
117. ENGINE ASSEMBLY
120. FUJI ENGINE
121. ASSEMBLY
123. 500/600 HO ENGINE
126. 500/600 (CARBURETED) ENGINE DISASSEMBLY
127. 500/600 (CARBURETED) TORQUES
128. 500/600 (CARBURETED) CYLINDER BASE
129. 500/600 (CARBURETED) RECOIL/STATOR REMOV...
132. TORQUE SPECIFICATIONS
133. 600 / 700 HO CFI ENGINE
137. 600/700 CFI ENGINE DISASSEMBLY
138. ENGINE ASSEMBLY
139. 600/700 CFI CYLINDER HEAD TORQUE PATTERN
144. TORQUE SPECIFICATIONS
145. SPECIFICATIONS
148. PVT SYSTEM
149. FINAL DRIVE
150. GENERAL INFORMATION
151. DRIVE CLUTCH SPRINGS
152. SPRING FREE LENGTH
153. NON-ER LWT DRIVEN HELIXES
154. TEAM DRIVEN SPRINGS
155. BELT WEAR / BURN DIAGNOSTICS
156. DRIVE BELT REMOVAL
157. ADJUSTING BELT DEFLECTION
158. DRIVE BELTS
159. BLET PN 3211115 BREAK -IN PROCEEDURE
160. PVT SYSTEM ADJUSTMENTS
161. DRIVE CLUTCH
162. DRIVE CLUTCH DISASSEMBLY
163. ROLLER REMOVAL
164. CLUTCH ASSEMBLY
166. DRIVE CLUTCH INSTALLATION
167. DRIVEN CLUTCH
168. DRIVEN CLUTCH ASSEMBLY
169. BELT DEFLECTION INSPECTION
172. Gearing charts
176. GEARS
177. CHAIN CASE
178. CHAINCASE REMOVAL
179. CHAINCASE SEAL & BEARING REPLACEMENT
180. DRIVE TRAIN
181. JACKSHAFT REMOVAL
182. DRIVESHAFT
183. WIDETRAK TRANSMISSION
184. INSPECTION
186. LOW/REVERSE SHAFT DISASSEMBLY
187. TRANSMISSION ASSEMBLY
189. HYDRAULIC BRAKE SYSTEM
190. BRAKE FLUID REPLACEMENT & BLEEDING
191. BRAKE LINE REPLACEMENT
192. BRAKE LIGHT SWITCH REPLACEMENT
193. CALIPER
194. WIDETRAK BRAKE CALIPER
195. FRONT SUSPENSION
196. MODEL FRONT SUSPENSION TYPE
197. FRONT SUSPENSION TORQUE & SPECIFICATIONS
198. EDGE/EDGE LX
199. EDGE RMK
200. WIDETRACK LX
201. FRONT SUSPENSION ADJUSTMENT PROCEDURES
202. IFS SHOCK SPRINGS
203. SPRINGS
205. SHOCK INFORMATION
206. IFS SHOCK PRODUCTION VALVING
207. IQ FRONT SUSPENSION
208. SPINDLE REMOVAL
209. UPPER / LOWER CONTROL ARM REMOVAL
210. ROD END
211. EDGE/EDGE LX/EDGE RMK CAMBER ADJUSTMENT
212. HANDLEBAR CENTERING
213. HANDLEBAR
216. Rear suspension type per model
217. SPECIAL TOOLS
218. REAR SUSPENSION TORQUE SPECIFICATIONS
219. SUSPENSION TO CHASSIS FASTENERS SPECIFIC...
220. SHOCK CONTROL RODS
221. REAR SUSPENSION OPERATION
222. REAR SUSPENSION ADJUSTMENTS AND SETTINGS
223. FRONT TORQUE ARM LIMITER STRAP ADJUSTMEN...
224. Torsion spring detail
226. INSTALLING HEAVIEST SPRINGS ON A IQ 121"...
227. WIDETRAK TORSION SPRING ADJUSTMENTS
228. M-10 SUSPENSION
229. M-10 Terminology
230. M-10 FRA Initial Set Up Reference
231. RAIL SLIDER
232. REAR SUSPENSION REMOVAL / INSTALLATION
233. REAR SUSPENSION INSTALLATION
235. SHOCK INFORMATION
236. REAR SUSPENSION FRONT TRACK SHOCK (FTS) ...
237. REAR SUSPENSION REAR TRACK SHOCK (RTS) S...
238. RYDE FX™ SHOCK VALVE PART NUMBERS
239. WALKER EVANS SHOCK VALVE PART NUMBERS
240. REAR SHOCK SPECIFICATIONS
241. WALKER EVANS FTS 7043234
242. WALKER EVANS RTS 7043205
243. FOX RTS 7043266
244. SHOCK MAINTENANCE
245. WALKER EVANS SHOCKS (7043234, 7043233)
246. RYDE FX MONO-TUBE SHOCK DISASSEMBLY
247. FOX MONOTUBE DISASSEMBLY
248. REAR SUSPENSION TROUBLESHOOTING
250. SIDE PANELS
251. HOOD ASSEMBLY
252. HOOD REPAIR
253. COOLANT/OIL TANK
254. SEAT AND FUEL TANK
255. SEAT COVER REPLACEMENT
256. HANDLEBAR COVER
257. DECALS
258. DECAL INSTALLATION
263. SPECIFICATIONS
264. CONVENTIONAL BATTERY
265. BATTERY TESTING
266. IGNITION TIMING
267. IGNITION TIMING CHART
268. THROTTLE POSITION SENSOR (TPS)
269. TPS ADJUSTMENT - CARBURETED MODELS
271. TPS IDLE SPEED ADJUSTMENT - CFI MODELS
272. ELECTRIC START - GEN II / EDGE
273. STARTER MOTOR ASSEMBLY (TYPICAL)
274. BATTERY BOX
275. DYNAMIC TESTING
276. ELECTRIC START - IQ CARBURETED / CFI
277. SYSTEM SCHEMATIC - 600 / 700 CFI
278. STARTER MOTOR / FLEX DRIVE ASSEMBLY
279. IQ BATTERY BOX ASSEMBLY
280. CLEAN FIRE FUEL INJECTION
281. DIAGNOSTIC TROUBLE CODES (DTCS)
282. MFD BLINK CODES
283. CFI CLUTCH GUARD ELECTRICAL CENTER
284. CHASSIS/HOOD
285. 26 Pin CNB ECU Connector
286. CHASSIS RELAY
287. THROTTLE / IGNITION KILL SYSTEM
288. VEHICLE SPEED SENSOR
289. EXHAUST TEMPERATURE SENSOR
290. Stator assembly
291. EXHAUST VALVE SOLENOID
292. ENGINE COOLANT TEMPERATURE SENSOR
293. CFI POWER SYSTEM
294. CFI CRANK POSITION SYSTEM
295. CFI FULL LOAD FUEL INJECTORS
296. CFI CHASSIS POWER
297. CFI TBAP SENSOR
298. CFI EXHAUST SOLENOID
299. CFI FUEL PUMP
300. CFI MFD CIRCUITS
301. CFI FUEL LEVEL CIRCUIT
302. CFI MODE SET SWITCH
303. DIGITAL WRENCH DIAGNOSTIC SOFTWARE
304. UPDATING DIGITAL WRENCH
305. VERSION / FILESET IDENTIFICATION
307. CARBURETED ELECTRICAL SYSTEMS
308. 600HO COOLANT TEMPERATURE SENSOR
309. TROUBLESHOOTING TABLES
310. DETONATION CONTROL (DET)
311. DIAGNOSTIC PLUGS
312. FORWARD OPERATION

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5. Table of Contents
7. Front suspension
8. 340 TOURING
10. WIDETRAK LX
12. 500 XC SP
14. SUPER SPORT
18. TRAIL RMK
20. TRAIL TOURING DELUXE
22. 600 HO IQ
24. 600 HO IQ CLEANFIRE
26. 600 HO IQ LX CLEANFIRE
28. 600 HO SWITCHBACK
30. 600 HO SWITCHBACK CLEANFIRE
32. HO RMK 144/155 (F/O)
34. 600 HO IQ TOURING CLEANFIRE
36. DRAGON
38. DRAGON RMK
42. HOW TO USE THIS MANUAL
43. SUSPENSION SPRING PRE-LOAD/INSTALLED LEN...
44. SNOWMOBILE NUMBER DESIGNATIONS
45. VEHICLE IDENTIFICATION NUMBER (VIN)
46. 2007 SERVICE PUBLICATIONS
47. GENERAL REFERENCE
48. SAE TAP DRILL SIZES
49. MEASUREMENT CONVERSION CHART
50. GLOSSARY OF TERMS
51. SPECIAL TOOLS
57. MAINTENANCE PROGRAM
59. INSPECTONS
60. HONING PROCEDURE
61. PISTON RING INSTALLED GAP
62. BEARING FIT
63. WRIST PIN BEARING
65. CRANKSHAFT TRUEING
66. CRANKSHAFT RUNOUT INSPECTION
67. BRAKE LEVER TRAVEL
68. BELT DEFLECTION INSPECTION
69. LUBRICATION
70. FRONT SUSPENSION
71. CHAINCASE OIL
72. THROTTLE LEVER FREE PLAY - NON CFI
73. OIL PUMP ADJUSTMENT
74. TRACK ALIGNMENT
75. TRACK TENSION
76. ENGINE ISOLATOR LIMITER SETTING
77. Clutch and drive system
78. Headlight bulb replacement
79. Coolant draining
83. WARNINGS
84. FUEL DELIVERY SYSTEM (CARBURETED)
85. MAINTENANCE
86. MIKUNI TM 38
87. MIKUNI CARBURETOR
88. FLOAT SYSTEM
89. FUEL SCREW
90. JET NEEDLE / NEEDLE JET
91. THROTTLE OPENING VS. FUEL FLOW
92. MIKUNI TM38 FLAT SLIDE SERVICE
94. ASSEMBLY
95. CARBURETOR COMPONENT PART NUMBERS
96. MIKUNI STARTER JETS
97. CLEANFIRE INJECTION (CFI)
99. CLEANFIRE SYSTEM OVERVIEW
100. 2007 FUEL SUPPLY / RETURN FITTINGS
101. 600 CFI Fuel Tank / Fuel Supply
102. FUEL TANK PRESSURE TEST
103. FUEL FILTER REMOVAL
106. GENERAL ENGINE INFORMATION
107. EXHAUST VALVE DISASSEMBLY
108. REED VALVE ASSEMBLY
109. WATER TEMPERATURE SENSOR REPLACEMENT
110. 500/600/700 WATER/OIL PUMP CROSS SHAFT D...
111. CYLINDER HEAD / HEAD COMPONENTS
112. RECOIL/STATOR ASSEMBLY
113. COOLING SYSTEMS
114. 500/600 TOURING / WIDETRAK LX
115. 340/550 FUJI ENGINE
116. 340/550 ENGINE DISASSEMBLY (550 SHOWN)
117. ENGINE ASSEMBLY
120. FUJI ENGINE
121. ASSEMBLY
123. 500/600 HO ENGINE
126. 500/600 (CARBURETED) ENGINE DISASSEMBLY
127. 500/600 (CARBURETED) TORQUES
128. 500/600 (CARBURETED) CYLINDER BASE
129. 500/600 (CARBURETED) RECOIL/STATOR REMOV...
132. TORQUE SPECIFICATIONS
133. 600 / 700 HO CFI ENGINE
137. 600/700 CFI ENGINE DISASSEMBLY
138. ENGINE ASSEMBLY
139. 600/700 CFI CYLINDER HEAD TORQUE PATTERN
144. TORQUE SPECIFICATIONS
145. SPECIFICATIONS
148. PVT SYSTEM
149. FINAL DRIVE
150. GENERAL INFORMATION
151. DRIVE CLUTCH SPRINGS
152. SPRING FREE LENGTH
153. NON-ER LWT DRIVEN HELIXES
154. TEAM DRIVEN SPRINGS
155. BELT WEAR / BURN DIAGNOSTICS
156. DRIVE BELT REMOVAL
157. ADJUSTING BELT DEFLECTION
158. DRIVE BELTS
159. BLET PN 3211115 BREAK -IN PROCEEDURE
160. PVT SYSTEM ADJUSTMENTS
161. DRIVE CLUTCH
162. DRIVE CLUTCH DISASSEMBLY
163. ROLLER REMOVAL
164. CLUTCH ASSEMBLY
166. DRIVE CLUTCH INSTALLATION
167. DRIVEN CLUTCH
168. DRIVEN CLUTCH ASSEMBLY
169. BELT DEFLECTION INSPECTION
172. Gearing charts
176. GEARS
177. CHAIN CASE
178. CHAINCASE REMOVAL
179. CHAINCASE SEAL & BEARING REPLACEMENT
180. DRIVE TRAIN
181. JACKSHAFT REMOVAL
182. DRIVESHAFT
183. WIDETRAK TRANSMISSION
184. INSPECTION
186. LOW/REVERSE SHAFT DISASSEMBLY
187. TRANSMISSION ASSEMBLY
189. HYDRAULIC BRAKE SYSTEM
190. BRAKE FLUID REPLACEMENT & BLEEDING
191. BRAKE LINE REPLACEMENT
192. BRAKE LIGHT SWITCH REPLACEMENT
193. CALIPER
194. WIDETRAK BRAKE CALIPER
195. FRONT SUSPENSION
196. MODEL FRONT SUSPENSION TYPE
197. FRONT SUSPENSION TORQUE & SPECIFICATIONS
198. EDGE/EDGE LX
199. EDGE RMK
200. WIDETRACK LX
201. FRONT SUSPENSION ADJUSTMENT PROCEDURES
202. IFS SHOCK SPRINGS
203. SPRINGS
205. SHOCK INFORMATION
206. IFS SHOCK PRODUCTION VALVING
207. IQ FRONT SUSPENSION
208. SPINDLE REMOVAL
209. UPPER / LOWER CONTROL ARM REMOVAL
210. ROD END
211. EDGE/EDGE LX/EDGE RMK CAMBER ADJUSTMENT
212. HANDLEBAR CENTERING
213. HANDLEBAR
216. Rear suspension type per model
217. SPECIAL TOOLS
218. REAR SUSPENSION TORQUE SPECIFICATIONS
219. SUSPENSION TO CHASSIS FASTENERS SPECIFIC...
220. SHOCK CONTROL RODS
221. REAR SUSPENSION OPERATION
222. REAR SUSPENSION ADJUSTMENTS AND SETTINGS
223. FRONT TORQUE ARM LIMITER STRAP ADJUSTMEN...
224. Torsion spring detail
226. INSTALLING HEAVIEST SPRINGS ON A IQ 121"...
227. WIDETRAK TORSION SPRING ADJUSTMENTS
228. M-10 SUSPENSION
229. M-10 Terminology
230. M-10 FRA Initial Set Up Reference
231. RAIL SLIDER
232. REAR SUSPENSION REMOVAL / INSTALLATION
233. REAR SUSPENSION INSTALLATION
235. SHOCK INFORMATION
236. REAR SUSPENSION FRONT TRACK SHOCK (FTS) ...
237. REAR SUSPENSION REAR TRACK SHOCK (RTS) S...
238. RYDE FX™ SHOCK VALVE PART NUMBERS
239. WALKER EVANS SHOCK VALVE PART NUMBERS
240. REAR SHOCK SPECIFICATIONS
241. WALKER EVANS FTS 7043234
242. WALKER EVANS RTS 7043205
243. FOX RTS 7043266
244. SHOCK MAINTENANCE
245. WALKER EVANS SHOCKS (7043234, 7043233)
246. RYDE FX MONO-TUBE SHOCK DISASSEMBLY
247. FOX MONOTUBE DISASSEMBLY
248. REAR SUSPENSION TROUBLESHOOTING
250. SIDE PANELS
251. HOOD ASSEMBLY
252. HOOD REPAIR
253. COOLANT/OIL TANK
254. SEAT AND FUEL TANK
255. SEAT COVER REPLACEMENT
256. HANDLEBAR COVER
257. DECALS
258. DECAL INSTALLATION
263. SPECIFICATIONS
264. CONVENTIONAL BATTERY
265. BATTERY TESTING
266. IGNITION TIMING
267. IGNITION TIMING CHART
268. THROTTLE POSITION SENSOR (TPS)
269. TPS ADJUSTMENT - CARBURETED MODELS
271. TPS IDLE SPEED ADJUSTMENT - CFI MODELS
272. ELECTRIC START - GEN II / EDGE
273. STARTER MOTOR ASSEMBLY (TYPICAL)
274. BATTERY BOX
275. DYNAMIC TESTING
276. ELECTRIC START - IQ CARBURETED / CFI
277. SYSTEM SCHEMATIC - 600 / 700 CFI
278. STARTER MOTOR / FLEX DRIVE ASSEMBLY
279. IQ BATTERY BOX ASSEMBLY
280. CLEAN FIRE FUEL INJECTION
281. DIAGNOSTIC TROUBLE CODES (DTCS)
282. MFD BLINK CODES
283. CFI CLUTCH GUARD ELECTRICAL CENTER
284. CHASSIS/HOOD
285. 26 Pin CNB ECU Connector
286. CHASSIS RELAY
287. THROTTLE / IGNITION KILL SYSTEM
288. VEHICLE SPEED SENSOR
289. EXHAUST TEMPERATURE SENSOR
290. Stator assembly
291. EXHAUST VALVE SOLENOID
292. ENGINE COOLANT TEMPERATURE SENSOR
293. CFI POWER SYSTEM
294. CFI CRANK POSITION SYSTEM
295. CFI FULL LOAD FUEL INJECTORS
296. CFI CHASSIS POWER
297. CFI TBAP SENSOR
298. CFI EXHAUST SOLENOID
299. CFI FUEL PUMP
300. CFI MFD CIRCUITS
301. CFI FUEL LEVEL CIRCUIT
302. CFI MODE SET SWITCH
303. DIGITAL WRENCH DIAGNOSTIC SOFTWARE
304. UPDATING DIGITAL WRENCH
305. VERSION / FILESET IDENTIFICATION
307. CARBURETED ELECTRICAL SYSTEMS
308. 600HO COOLANT TEMPERATURE SENSOR
309. TROUBLESHOOTING TABLES
310. DETONATION CONTROL (DET)
311. DIAGNOSTIC PLUGS
312. FORWARD OPERATION

Description

The Service Manual of the Polaris 2007 Two Stroke and 2007 340 LX, 2007 340 Touring, 2007 Widetrack LX, 2007 500 XC SP, 2007 Super Sport, 2007 550 LX, 2007 Trail RMK, 2007 Trail Touring Deluxe, 2007 HO IQ:2007 HO IQ Cleanfire, 2007 HO IQ LX Cleanfire, 2007 HO Switchback, 2007 HO Switchback Cleanfire, 2007 HO IQ Touring Cleanfire, 2007 Dragon, 2007 Dragon RMK, 2007 HO RMK 144 F/O, 2007 HO RMK 155 F/O Snowmobiles provides detailed instructions on how to maintain and service your snowmobile. This manual covers front suspension, fuel system, electrical system, exhaust system, engine, drive system, brakes and much more. It also contains detailed diagrams, step-by-step instructions, and troubleshooting tips to help you get the most out of your snowmobile. In addition to the detailed instructions, it includes a table of contents for easy navigation. The Service Manual of the Polaris 2007 Two Stroke and 2007 340 LX, 2007 340 Touring, 2007 Widetrack LX, 2007 500 XC SP, 2007 Super Sport, 2007 550 LX, 2007 Trail RMK, 2007 Trail Touring Deluxe

Also for: 2007 340 LX, 2007 340 Touring, 2007 Widetrack LX, 2007 500 XC SP, 2007 Super Sport, 2007 550 LX, 2007 Trail RMK, 2007 Trail Touring Deluxe, 2007 HO IQ:2007 HO IQ Cleanfire, 2007 HO IQ LX Cleanfire, 2007 HO Switchback, 2007 HO Switchback Cleanfire, 2007 HO IQ Touring Cleanfire, 2007 Dragon, 2007 Dragon RMK, 2007 HO RMK 144 F/O, 2007 HO RMK 155 F/O

File size: 23.14 MB

Created: January 30, 2023

Last updated: March 22, 2023