Polaris IQ Snowmobiles Repair Service Manual 2007-2011

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This workshop repair service manual PDF download for the 2007-2011 IQ Polaris Snowmobile has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

2007 600 HO IQ
2007 600 HO Switchback
2007 600 HO RMK
2007 600 HO IQ CFI
2007 600 HO Switchback CFI
2007 600 HO IQ LX CFI
2007 600 HO IQ Touring CFI
2007 700 HO IQ Dragon
2007 700 HO RMK Dragon
2008 IQ Shift
2008 600 RMK 144 / 600 RMK Shift 155
2008 600 Dragon IQ
2008 600 Switchback 600 Dragon Switchback
2008 600 IQ LX
2008 600 IQ Touring
2008 600 RMK 155
2008 700 IQ / 700 Dragon IQ
2008 700 Switchback 700 Dragon Switchback
2008 700 RMK 155 700 Dragon RMK 155 / 163
2008 800 Dragon RMK 155 / 163
2009 550 IQ Shift
2009 600 IQ Shift
2009 600 IQ / 600 Dragon IQ SP
2009 600 IQ Shift 136
2009 600 Switchback / Dragon Switchback
2009 600 IQ Touring
2009 600 RMK Shift 144 / 155
2009 700 RMK 155
2009 800 IQ / 800 Dragon SP
2009 800 Switchback / Dragon Switchback
2009 800 RMK Shift
2009 800 RMK Assault 146
Assault “On-Trail” Optional Settings
2009 800 RMK 155 / 800 Dragon RMK 155 800 Dragon RMK 163
2010 550 IQ Shift
2010 600 IQ Shift / 600 IQ
2010 600 LX
2010 600 Switchback / Dragon Switchback
2010 600 IQ Touring
2010 600 Widetrak IQ
2010 800 IQ / 800 Dragon IQ
2010 800 Switchback / Dragon Switchback
2010 600 RMK 144 / 155
2010 700 RMK 155
2010 800 RMK 144 / 155
2010 800 RMK Assault 146
Assault “On-Trail” Optional Settings
2010 800 Dragon RMK 155 / 163
2011 550 IQ Shift
2011 550 Shift 136
2011 550 IQ LXT
2011 600 IQ Shift
2011 600 Shift 136 / 600 Switchback 136
2011 600 IQ LXT
2011 600 Widetrak IQ
2011 600 RMK 144 / 155

TABLE OF CONTENTS :

Polaris_Service_Manual
01 – Model Specifications
02 – General Information
03 – Maintenance
04 – Fuel Systems
05 – Engines and Cooling Systems
06 – Final Drive and Brakes
07 – PVT System
08 – Steering and Suspensions
09 – Shocks
10 – Chassis
11 – Battery and Electrical Systems
12 – Wiring Diagrams

Polaris_Owners_Manual

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9922854
Total Pages : 655

This Polaris service manual, repair manual, workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail!, You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

More Info : http://www.sitelux.com

9922854
Polaris_Service_Manual
01 – Model Specifications
Model Specifications

Specifications
2007 600 HO IQ
2007 600 HO Switchback
2007 600 HO RMK
2007 600 HO IQ CFI
2007 600 HO Switchback CFI
2007 600 HO IQ LX CFI
2007 600 HO IQ Touring CFI
2007 700 HO IQ Dragon
2007 700 HO RMK Dragon
2008 IQ Shift
2008 600 RMK 144 / 600 RMK Shift 155
2008 600 Dragon IQ
2008 600 Switchback 600 Dragon Switchback
2008 600 IQ LX
2008 600 IQ Touring
2008 600 RMK 155
2008 700 IQ / 700 Dragon IQ
2008 700 Switchback 700 Dragon Switchback
2008 700 RMK 155 700 Dragon RMK 155 / 163
2008 800 Dragon RMK 155 / 163
2009 550 IQ Shift
2009 600 IQ Shift
2009 600 IQ / 600 Dragon IQ SP
2009 600 IQ Shift 136
2009 600 Switchback / Dragon Switchback
2009 600 IQ Touring
2009 600 RMK Shift 144 / 155
2009 700 RMK 155
2009 800 IQ / 800 Dragon SP
2009 800 Switchback / Dragon Switchback
2009 800 RMK Shift
2009 800 RMK Assault 146
Assault “On-Trail” Optional Settings
2009 800 RMK 155 / 800 Dragon RMK 155 800 Dragon RMK 163
2010 550 IQ Shift
2010 600 IQ Shift / 600 IQ
2010 600 LX
2010 600 Switchback / Dragon Switchback
2010 600 IQ Touring
2010 600 Widetrak IQ
2010 800 IQ / 800 Dragon IQ
2010 800 Switchback / Dragon Switchback
2010 600 RMK 144 / 155
2010 700 RMK 155
2010 800 RMK 144 / 155
2010 800 RMK Assault 146
Assault “On-Trail” Optional Settings
2010 800 Dragon RMK 155 / 163
2011 550 IQ Shift
2011 550 Shift 136
2011 550 IQ LXT
2011 600 IQ Shift
2011 600 Shift 136 / 600 Switchback 136
2011 600 IQ LXT
2011 600 Widetrak IQ
2011 600 RMK 144 / 155
02 – General Information
General Information

Snowmobile Number Designations
Model Number Designation
Vehicle Identification Number (VIN)
Tunnel Decal
VIN Number Designation
Publication Part Numbers
2011 Publications
2010 Publications
2009 Publications
2008 Publications
2007 Publications
Service / Safety Bulletins
Engine Data Formulas
Compression Ratio
Compression Ratio Example
Head cc Removal Example
Port Opening Duration
Torque Conversion
US to Metric
General Reference
Standard Bolt Torque Specification
Fuel / Oil Premix Ratios
Gasoline Volatility
SAE Tap Drill Sizes
Metric Tap Drill Sizes
Decimal Equivalents
Measurement Conversion Chart
Piston Wash / Spark Plug Reading
Service Precautions
GENERAL PRECAUTIONS
03 – Maintenance

Maintenance
Periodic Maintenance
Periodic Maintenance Schedule
Maintenance Products
Engine Oils / Lubricants / Misc.
Break-In Procedures
Engine Break-In Procedure
Fuel/Oil Premix Ratio
Drive Belt Break-In Procedure
Drive / Driven Clutches
Belt Deflection Inspection
Deflection Adjustment – SPA-P2 / Team Driven
Torque Stop Adjustment
Engine Isolator Limiter Setting
Engine Maintenance
Exhaust Valve Cleaning
Exhaust Valve Springs
Spark Plugs
Spark Plug Caps/Spark Plug Terminals
Surge Tank (Recovery Bottle)
Recommended Coolant
Cooling System Bleeding
600 Widetrak IQ Cooling System Fill/Air Bleed
Oil Pump Adjustment – 550 Engines
Oil Pump Bleeding – 550 Engines
Oil Pump Adjustment – Carbureted Models
Oil Pump Adjustment – CFI Models
Oil Pump Bleeding
600 IQ Widetrak Self-Bleeding Oil Tank
Fuel / Intake System
Water Sediment Trap
Fuel Filter – Carbureted Models
Fuel Filter – CFI Models
Oil Filter
Fuel Tank Vent System
Air Intake Box / Pre-Filters
Chassis Lubrication
Rear Suspension
Driveshaft Bearing
Throttle Cable
Choke And Choke Cable
Chaincase Oil Level Check
Chaincase Oil Replacement
Drive Chain Tension Adjustment
Brake System Maintenance
Brake Lever Travel
Brake Fluid
Throttle and Choke Cable Adjustments
Idle Speed Gap / Throttle Free Play Adjustment – VM Carburetors
Choke Lever Adjustment – Mikuni VM
Throttle Lever Free Play – Non CFI
Throttle Lever Free-Play – CFI Models
Choke Adjustment
Steering / Suspension Maintenance
Handlebars
Rider Select Steering U-Joint
Ski/Ski Skag Fasteners
Track Tension
Track Alignment
Electrical Systems
Headlight Bulb Replacement
MFD Service Interval
Function
Off-Season Storage
Chassis And Hood
Clutch And Drive System
Controls And Linkage
Electrical Connections
Carburetor/Throttle Body
Fuel System
Corrosion
Shocks
Battery
04 – Fuel Systems
Fuel Systems

Service Warnings and Precautions
Service Warnings
Carburetor Fuel Systems
Mikuni Main Jets
Mikuni Pilot Jets
Mikuni Starter Jets
Mikuni Jet Needles
Mikuni (Short) Pilot Air Jets
Mikuni (Long) Pilot Air Jets
Mikuni TM Piston Valves
Mikuni TM (Notched) Piston Valves
Carbureted Fuel System (Typical)
Mikuni VM Carburetor
Assembly View
Mikuni VM Carburetor Function
Throttle Opening and Fuel Flow
Starting / Enrichment System
Float System
Idle Speed Adjustment
Air Screw
Pilot Jet
Main Jet
Jetting Guidelines
Piston / Throttle Valve
Jet Needle/Needle Jet
Jet Needle
Needle Jet
VM Carburetor Disassembly / Inspection / Assembly
VM Carburetor Disassembly
Float Arm Adjustment
Needle and Seat Leak Testing
Mikuni TM Carburetor
Function
Float System
Fuel Metering
Fuel Delivery
Pilot Jet
Fuel Screw
Main Jet
Jetting Guidelines
Piston/Throttle Valve
Jet Needle
Needle Jet
Throttle Opening Vs. Fuel Flow
Carburetor Fuel Pump
Fuel Pump Overview
Maintenance
Carburetor Service
Disassembly
Assembly
Carburetor Adjustment
Throttle Valve Synchronization
Cleanfire™ Fuel Injection
System Overview
Detonation Control System (DET)
CFI Fuel Select Modes
DC-CFI Fuel Select Modes
CFI RPM/Engine Speed Limit Modes
CFI Diagnostic Trouble Codes (DTCs)
DC-CFI Diagnostic Trouble Codes (DTCs)
MFD Blink Codes
DTC Troubleshooting
CFI Clutch Guard Electrical Center
DC-CFI/600 IQ Widetrak Ignition Coil Mount
600 IQ Widetrak Electrical Center
2007 CFI 34 Pin CNA ECU Connector
2008 – 2010 CFI 34 Pin CNA ECU Connector
2007 – 2010 CFI 26 Pin CNB ECU Connector
2009 – 2010 DC-CFI 34 Pin CNA ECU Connector
2009 – 2010 DC-CFI 26 Pin CNB ECU Connector
Exhaust Temperature Sensor
Temperature / Air Pressure Sensor (TMAP)
Crankshaft Position Sensors (CPS)
Crankshaft Position Sensor Air Gaps
Exhaust Valve Solenoid
CFI Ignition Coils
Engine Coolant Temperature Sensor
Knock Sensor
Fuel Injectors
Fuel Rail Bleeding / Pressure Testing
Disconnect Fittings
Fuel Tank Pressure Test
Fuel Rail and Injector Removal / Installation
Throttle Body/Throttle Position Sensor (TPS)
Throttle Position Sensor (TPS) Overview
Throttle Position Sensor (TPS)- Idle Base Setting
Idle Speed Adjustment – CFI Engines
Digital Wrench TPS Replacement Procedure
Fuel Hose Mounting/Routing
Fuel Tank / Pump Service
Fuel Tank Front Flange-Type Fuel Pump
Flange-Type Fuel Pump Service
2007 700 CFI Fuel System
Drop In Pump Fuel Supply (Typical)
600 IQ Widetrak Fuel Supply
Drop In Fuel Pump Service
Drop In Fuel Pump Replacement
Drop In Pump Service
Digital Wrench Diagnostic Software
Overview
CFI Digital Wrench Connections
DC-CFI Digital Wrench Connections
Updating Digital Wrench
Version Identification
Engine Controller Reprogramming (Reflash)
Troubleshooting
Flowchart
05 – Engines and Cooling Systems
Engine and Cooling Systems

Engine Specifications
Fastener Torque Guide
Vehicle/Engine Matrix
Engine Specifications
Piston / Cylinder Specifications
Engine Service Specifications – All Engines
Component Torque Sequences
Special Tools
Special Tools – Engine
Engine Inspections
Cylinder Head Inspection
Cylinder Measurement
Crankshaft Runout Inspection
Piston Inspection
Piston Ring Installed Gap
Reed Valve Inspection
Bearing Fit
Main Bearing
Connecting Rod Lower Bearing
Piston Needle Bearing
Crankshaft Index
Checking Crankshaft Index
Cylinder Honing
Honing Tools
Honing Procedure
Cleaning The Cylinder After Honing
Crankshaft Truing
Oil Pump Bushing End Play – Fuji Engines
Carbureted Recoil Assembly
Rope Removal and Installation
CFI Recoil Assembly
Rope Removal and Installation
Exhaust Valve Maintenance
Exhaust Assembly View
Exhaust Valve Disassembly
Exhaust Valve Assembly
Exhaust Valve Springs
Engine Mounting Systems
550 IQ Engine Mounting
2007 IQ Carbureted Engine Mounting
2007 IQ 600 CFI Engine Mounting
2008-2009 IQ Carbureted Engine Mounting
2007 IQ 700 CFI/2010-2011 IQ CFI Engine Mounting
2008-2009 IQ CFI/2010-2011 IQ CFI Touring/ 600 IQ Widetrak Engine Mounting
Engine Component Assemblies
550 Blower Housing Assembly
550 Cylinder Assembly
550 Oil Pump Assembly
550 Magneto Assembly
550 Crankcase Assembly
550 Piston and Crankshaft Assembly
600 HO Carbureted Cylinders / Cylinder Head
600 HO Carbureted Recoil / Magneto
600 HO Carbureted Pistons / Crankshaft
600 HO Carbureted Crankcase
600 HO Carbureted Water / Oil Pump
600/700 CFI Cylinder Head / Cylinders / Pistons
800 CFI Cylinder Head/Cylinder/Pistons
800 CFI Cylinder Head/Cylinder/Pistons Compatibility
800 CFI Cylinder Head/Cylinder/Pistons Disassembly and Assembly.
600/700/800 CFI Recoil / Stator Assembly
600/700 CFI Crankcase/Crankshaft Assembly
800 CFI Crankcase/Crankshaft
600/700/800 CFI Water-Oil Pump Assembly
600/700/800 CFI Oil Hose Routing
Engine Removal (Typical)
Engine Installation (Typical)
Cooling Systems
Thermostat Replacement
Thermostat Orientation
800 CFI Thermostats
2007 700 Dragon IQ Cooling System
2007 600 IQ 121/Switchback/LX-2008 CFI LX Cooling System
2007-2011 IQ Touring Cooling System
2007-2010 IQ 600 RMK/700 RMK Cooling System
2008 IQ 121/Switchback Cooling System
2009-2011 IQ 121/Switchback Cooling System
800 RMK (With Bulkhead Cooler)
800 RMK / Assault (Without Bulkhead Cooler)
600 Widetrak Bypass Circuit
600 Widetrak Tunnel Circuit
Exhaust Systems
Assembly View (Typical)
06 – Final Drive and Brakes
Final Drive and Brakes

Gear Ratio Speed Charts
8.373 CD Chaincase Speed Chart
Drive Gears and Chains
Drive Gears
Drive Chains
8.373 Chaincase
Assembly View
Chaincase Disassembly
Chaincase Assembly
Drive Train
Speedometer Cable Type Drive Train Assembly
Electronic Speedometer Drive Train Assembly
Jackshaft Removal
Jackshaft Installation
Driveshaft Removal/Installation
IQ Widetrak Gear Case
Driveshaft and Jackshaft
Gearcase Oil Level Check
Gearcase Oil Change
Gearcase Mounting
Gear Selector Assembly
Gear Selector Linkage Adjustment
Gear Case Removal
Inspection
Input Shaft Inspection
Low Gear Shaft Inspection
Output Shaft Inspection
Shift Drum Inspection
Gearcase Assembly
Gearcase Installation
Brake System
Overview
Compensating Port
General Guidelines
Brake Fluid Replacement & Bleeding
Master Cylinder / Lever Service
Cyclone Master Cylinder / Lever Service
Brake Line Replacement
Brake Light Switch Replacement
Caliper Removal
Caliper Replacement
Caliper Assembly
Brake Caliper Piston and Seal Replacement
Brake Pad Replacement
Brake Disc Replacement
07 – PVT System
PVT System
PVT System
Overview
Drive Spring
Clutch Weight
Neutral Speed
Engagement RPM
Shift Out Over-Rev
Shift Out RPM
Driven Spring
Back-Shifting
Final Gearing
1:1 Shift Ratio
Low / High Ratio
Driven Helix / Ramp
PVT System Fastener Torques
General Information
Special Tools
Drive Clutch Springs
Spring Free Length
Drive Clutch Weights
PERC Team LWT Driven Helixes (24 Fin)
Team Ramp Angles
Team Driven Springs
Polaris P2 Driven Helixes
Polaris P2 Driven Springs – Team / 2009 550cc P2
Polaris P2 Tab Driven Springs
P2 Helix Angles
Drive Belts
Belt Inspection
Belt Wear / Burn Diagnostics
Drive Belt Removal – Team Driven
Drive Belt Installation – Team Driven
Adjusting Belt Deflection – Team Driven Clutch
Drive Belt Removal – SPA P2
Drive Belt Installation – SPA P2
Adjusting Belt Deflection – SPA P2
PVT System Adjustments
Clutch Alignment/Offset
Offset/Float Adjustment
Belt-to-Sheave Clearance Adjustment
Drive Clutch
Identification
Drive Clutch Removal
Drive Clutch Disassembly
Roller Removal
Roller Installation
Spider Button Installation
Bushing/Insert Replacement
Moveable Sheave Bushing/Insert Removal and Installation
Cover Bushing
Clutch Assembly
Spider Indexing
Drive Clutch Installation
Driven Clutch
Driven Clutch Removal
Driven Clutch Installation
Team LWT Components
Polaris SPA-P2 Driven Clutch Components
PVT System Troubleshooting
Drive Belt
Drive Clutch
Driven Clutch
08 – Steering and Suspensions
Steering and Suspensions

Overview / Specifications
Inspection
Camber / Toe Specifications
Springs
Adjustable Shocks
Front Suspension Type by Model
Rear Suspension Type by Model
Suspension Mounting Fastener Torque
IQ Rear Suspension Shock Rod
IQ Rear Track Shock Pivot Orientation
Front Suspension Assembly Illustrations
IQ Front Suspension
IQ LWT Front Suspension
IQ Fixed Steering Post Assembly
IQ Rider Select Steering Post Assembly
IQ Steering Linkage
600 Widetrak IQ Steering Assembly
600 Widetrak IQ Steering Linkage
600 Widetrak IQ Steering Mount
Handlebar Assemblies
Front Sway Bar Assemblies
Front Suspension Settings
Overview
Alignment Bar Specifications
Maximum Width
Handlebar Centering
Camber
Camber Adjustment
Toe Adjustment
Disassembly and Assembly
Spindle Removal
Spindle Assembly
Spherical Bearing Replacement
Upper / Lower Control Arm Removal
Upper / Lower Control Arm Installation
Rear Suspension Assembly Illustrations
IQ 121 Pivots/Rear Idler
IQ 121 Shift Pivots/Rear Idler
IQ 121 Rail Assembly
IQ 121 Shift Rail Assembly
IQ 121/Shift Front/Rear Torque Arms
M-10 128 Pivots/Rear Idler
M-10 128 Rail Assembly
M-10 128 Front/Rear Torque Arms
M-10 136 Pivots/Rear Idler
M-10 136 Rail Assembly
M-10 136 Front/Rear Torque Arms
IQ Switchback 144 Pivots/Rear Idler
IQ Switchback 144 Rail Assembly
IQ Switchback 144 Front/Rear Torque Arms
IQ 136 Comfort Pivots/Rear Idler
IQ 136 Comfort Rail Assembly
IQ 136 Comfort Front/Rear Torque Arms
IQ 136 Coupled Pivots/Rear Idler
IQ 136 Coupled Rail Assembly
IQ 136 Coupled Front/Rear Torque Arms
IQ RMK 144/155/163 Pivots/Rear Idler
IQ RMK 144/155/163 Rail Assembly
IQ RMK 144/155/163 Front/Rear Torque Arms
IQ LWT Pivots/Rear Idler
IQ LWT Rail Assembly
IQ LWT Front/Rear Torque Arms
IQ Assault RMK Pivots/Rear Idler
IQ RMK Assault Rail Assembly
IQ RMK Assault Front/Rear Torque Arms
IQ RMK Assault “ON-Trail” FTA Mounting
Widetrak IQ 156 Pivots/Rear Idler
Widetrak IQ 156 Rail Assembly
Widetrak IQ Front/Rear Torque Arms
Rear Suspension Operation
Operation
Weight Transfer
Coupling
Rear Suspension Adjustments
Adjustment Procedures
Rear Suspension Ride Height
Scissor Stop Adjustment
Torsion Spring Adjustment
Limiter Strap Adjustment
M-10 Suspension
M-10 OVERVIEW
M-10 ADJUSTMENTS
M-10 TERMINOLOGY
M-10 ADJUSTMENTS
M-10 FRA INITIAL SET UP REFERENCE
M-10 REAR SPRING PRELOAD
M-10 SKI PRESSURE
Rail Sliders
Wear Limit
Removal
Break-In
Rear Suspension Removal and installation
Removal
Installation
09 – Shocks
Shocks

Special Tools
Shock Rebuilding Tools
Valve Shims
Ryde FX™ Shock Valve Part Numbers
Fox™ Shock Valve Part Numbers
Walker Evans™ Shock 3/8″ Valve Part Numbers
Walker Evans™ Shock Valve Part Numbers – 7/16² I.D.
Valve Shim Arrangement
Piston Orientation
Specifications
2007 Shock Specifications
2007 Shock Valve Shim Stack Configurations
2008 Shock Specifications
2008 Shock Valve Shim Stack Configurations
2009 Shock Specifications
2009 Shock Valve Shim Stack Configurations
2010 Shock Specifications
2010 Shock Valve Shim Stack Configurations
2011 Shock Specifications
2011 Shock Valve Shim Stack Configurations
Optional Shock Settings
Walker Evans Monotube IFS Air Shock
Walker Evans IFS Air Remote Reservoir Piggyback Shock
Ryde FX Air 2.0 Shock
Shock Maintenance
Ryde FX Air 2.0 Shock Disassembly
Ryde FX Air 2.0 Shock Assembly
Walker Evans Air Shock Disassembly
Walker Evans Air Shock Assembly
Walker Evans Air Piggyback Shock Disassembly
Walker Evans Air Piggyback Shock Assembly
Walker Evans Remote Reservoir / Piggyback Shock Disassembly
Walker Evans Remote Reservoir / Piggyback Shock Assembly
Ryde FX Remote Reservoir Shock Disassembly
Ryde FX Remote Reservoir Shock Assembly
RYDE FX MONO-TUBE SHOCK DISASSEMBLY
RYDE FX MONO-TUBE SHOCK ASSEMBLY
FOX PS-5 DISASSEMBLY
FOX PS-5 ASSEMBLY
10 – Chassis

Chassis
IQ Chassis Components
Steering Hoop Assembly (Typical)
Hood Assembly
Hood / Plastic Repair
LWT Hood Hinge Assembly
Front Bumper Assembly (Typical)
LWT Front Bumper / Fenders
IQ Console Assembly (Typical)
RMK Tunnel
Fenders and Side Panels
600 Widetrak IQ Fender Assembly
600 Widetrak IQ Console
600 Widetrak IQ Nosepan/Bumper Assembly
600 Widetrak IQ Shock Tower Assembly
600 Widetrak IQ Chassis
Seat Assemblies
IQ Fixed Seat Assembly
IQ Raw Seat Assembly
IQ Removable Seat Assembly
2007 IQ Touring Seat Assembly
2008 IQ Touring Seat Assembly
2011 IQ 550 136/LXT Seat and Rear Rack
Seat Cover Replacement
Decals
Decal Removal
Decal Installation

11 – Battery and Electrical Systems
Battery and Electrical Systems

Specifications
Engine Models
Spark Plugs
Charging System
Ignition Timing
Fresh Pack Battery
Battery Preparation
Specifications
Sealed Battery
Specifications
Battery Testing
Testing Procedures
Open Circuit Voltage Test (OCV)
Load Test
Battery Conductance Analyzer
Off Season Storage
Ignition Timing
Timing Procedure – Carbureted Engines
Timing Procedure – CFI Engines
Ignition Timing Chart
Electric Start – IQ Carbureted / CFI
System Schematic – 600 Carbureted
Electric Start System – CFI
Electric Start System – DC-CFI
Electric Start System – Widetrak IQ 600
Starter Motor / Flex Drive Assembly
IQ Battery Box Assembly
CFI / DC-CFI Electrical Systems
CFI Stator Assembly
DC-CFI Stator Assembly
CFI / DC-CFI Chassis Power Capacitor
CFI DC Regulator / Rectifier
DC-CFI DC Regulator / Rectifier
CFI Regulator/Rectifier Diode Testing
Over-Voltage / Voltage Spike Test
DC-CFI AC Regulator/Battery Charge Rectifier
CFI Chassis Relay
DC-CFI Regulated (RED) Power Circuits
600 IQ Widetrak Regulated (RED) Power Circuits
DC-CFI/600 IQ Widetrak Chassis (Red/White) Power Circuits
600 IQ Widetrak Brake/Fan Relay Control
DC-CFI AC Power (Lighting) Circuits
600 IQ Widetrak AC Power (Lighting) Circuits
CFI Throttle / Ignition Kill System
DC-CFI/600 IQ Widetrak Throttle / Ignition Kill System
CFI/DC-CFI Vehicle Speed Sensor
600 IQ Widetrak Vehicle Speed Sensor
Carbureted Electrical Systems
600 HO Stator Specifications
550 Stator Specifications
Ignition Coil Packs
Exhaust Valve Solenoid
Knock Sensor
600HO Coolant Temperature Sensor
Oil Level Sender
Throttle Position Sensor (TPS)
TPS Test Tool Setup
Using the TPS Test Tool
TPS Adjustment
2007 600 HO Regulator / Rectifier
2008 RMK Shift 155 Regulator / Rectifier
2008-2009 IQ Shift 121 Regulator / Rectifier
Detonation Control (DET)
Overview
Variable Exhaust System (VES)
Overview
Diagnostic Plugs
Carbureted / CFI Chassis Power Plug
DC-CFI DC Power Test Plug
CFI / DC-CFI Fuel Pump Prime Plug
Electronic Reverse (PERC)
Overview
Operation
FORWARD OPERATION
Altitude Setting
Important Notes

12 – Wiring Diagrams
Wiring Diagrams

2007 600 HO Carbureted 1 of 2
2007 600 HO Carbureted 2 of 2
2007 600 HO Carbureted Hood Harness
2007 600 / 700 CFI Chassis Harness 1 of 2
2007 600 / 700 CFI Chassis Harness 2 of 2
2007 600 / 700 CFI Hood Harness
2007 600 / 700 CFI Engine Harness
2008 – 2009 IQ Shift 1 of 2
2008 – 2009 IQ Shift 2 of 2
2008 – 2009 IQ Shift Hood Harness
2008 IQ Shift RMK 1 of 2
2008 IQ Shift RMK 2 of 2
2008 IQ Shift RMK Hood Harness
2008 – 2011 IQ CFI Chassis Harness 1 of 2
2008 – 2011 IQ CFI Chassis / Hood Harness 2 of 2
2009 – 2010 IQ / RMK / Assault CFI Premium Chassis Harness 1of 2
2009 – 2010 IQ / RMK / Assault CFI Premium Chassis / Hood Harness 2 of 2
2008 – 2011 IQ Standard / Premium CFI Engine Harness
2009 – 2011 IQ 550 Chassis / Engine 1 of 2
2009 – 2011 IQ 550 Chassis / Engine 2 of 2
2009 – 2011 IQ 550 Hood Harness
2009 600 2 Injector DC-CFI Chassis 1 of 2
2009 600 2 Injector DC – CFI Chassis 2 of 2
2009 600 2 Injector DC – CFI Hood
2009 600 2 Injector DC – CFI Engine
2010-2011 600 Widetrak IQ Chassis 1 of 2
2010-2011 600 Widetrak IQ Chassis 2 of 2
2010-2011 600 Widetrak IQ Hood
2010-2011 600 Widetrak IQ Engine
Polaris_Owners_Manual
WELCOME
TABLE OF CONTENTS
INTRODUCTION
Important Notes for Owners and Drivers
Preservation of the Environment
Noise Level
Vehicle Identification Numbers
SAFETY
Operator Safety
Safety Decals and Locations
FEATURES
Adjustable Headlights
Headlight DimmerSwitch
Adjustable Steering
Accessory Cargo System
Detonation Elimination Technology
Instrumentation
THE PERFECT FIT
IQ Front Suspension Adjustments
Rear Suspension Adjustments
Handlebar Adjustments
Accessories
PRE-RIDE INSPECTIONS
Pre-Ride Checklist
Before Starting the Engine
Start the Engine and Check
OPERATION
Starting the Engine
Break-In Period
Fuel Safety
Fuel
Oil
Engine Stop Switch
Throttle Safety Switch
Throttle Lever
Emergency Stopping
Electronic Reverse
Daily Storage
Towing
MAINTENANCE
Emission Control Information
Polaris Recommended Maintenance Program
Periodic Maintenance Interval Table
Lubrication
Spark Plugs
Intake Filters
Oil Lines
Oil Filter
Fuel Injectors
Fuel Pump
Fuel Filter
Fuel Lines
Exhaust System
Cooling System
Drive Chain Tension
Brakes
Lights
Clutch System
Track Replacement
Track Inspection
Track Lubrication
Track Tension
Track Alignment
Steering System
Steering System
Matte Clear Coat Cleaning
Extended Storage
Cleaning and Preservation
Extended Storage
POLARIS PRODUCTS
TROUBLESHOOTING
WARRANTY
MAINTENANCE LOG
INDEX

 

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