Polaris 2007 Two Stroke Manual de usuario

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

proceduresinordertoperformtheworksafelyandcorrectly. Techniciansshouldreadthetextandbefamiliarwithservice

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

theNews,Forms&LinksareaclickonService&Warrantylinkandthefeedbacklinkisatthebottomofthepagenamed

Polaris Manual Correction Feedback link.

2007 Two Stroke Snowmobile Service Manual PN 9920463

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/orprocedures in this publication are intended for reference use only. No liability canbe 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.

UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS

Throughout this manual, important information is brought to your attention by the following symbols:

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.

SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.

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.

MEASUREMENT provides a key for a determined measurement specification.

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.

WARNING

CAUTION

= In. / mm.

= T

SPECIFICATIONS

GENERAL

MAINTENANCE

FUEL DELIVERY

ENGINE

CLUTCHING

FINAL DRIVE

FRONT SUSPENSION

REAR SUSPENSION

CHASSIS/HOOD

ELECTRICAL

ENGINE AND DRIVE TRAINCHASSIS AND ELECTRICAL

MODEL SPECIFICATIONS

1.1

CHAPTER 1

MODEL SPECIFICATIONS 1

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

1.2

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) .008-.014/.20-.41

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

Jetting

Altitude

meters (feet)

Ambient Temperature

< -25°F/<-35°C

-30°F to -10°F/-34°C to -23°C

-15°F to +5°F/-26°C to -15°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

>+60°F/>+16°C

0-600

(0-2000) 185

#4 180

#3 170

#3 165

#3 160

#3 155

#3 150

600-1200

(2000-4000) 175

#3 170

#3 160

#3 155

#3 150

#3 140

#2 140

1200-1800

(4000-6000) 165

#3 160

#3 155

#3 150

#3 145#

3140

#2 130

1800-2400

(6000-8000) 155

#3 150

#3 140

#3 135

#2 130

#2 120

#1 120

2400-3000

(8000-10000) 145

#3 140

#3 130

#2 130

#2 125

#2 120

#1 110

3000-3700

(10000-12000) 135

#3 130

#2 120

#2 115

#1 110

#1 100

Clutching

Altitude meters

(feet)

Drive Clutch (P-85) Driven Clutch (TEAM)

Shift

Weight Clutch

Spring Clutch

Spring Driven

Helix Gearing

0-900

(0-3000) 10 110/290

(Black-

2287)

Red/

Black S36 LW

ER 16:41-72

900-1800

(3000-6000) 10-M

Blue

110/290

(Black-

2287)

Red/

Black S36 LW

ER 16:41-72

1800-2700 (6000-

9000) 10MW 110/290

(Black-

2287)

Red/

Black S36 LW

ER 16:41-72

2700-3700 (9000-

12000) 10MR 110/290

(Black-

2287)

Red/

Black S36 LW

ER 16:41-72

Drive clutch bolt torque 50 ft-lbs (69 N-m)

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

1.3

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

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°

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

1.4

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) .008-.014/.20-.41

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

Jetting

Altitude

meters (feet)

Ambient Temperature

< -25°F/<-35°C

-30°F to -10°F/-34°C to -23°C

-15°F to +5°F/-26°C to -15°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

>+60°F/>+16°C

0-600

(0-2000) 185

#4 180

#3 170

#3 165

#3 160

#3 155

#3 150

600-1200

(2000-4000) 175

#3 170

#3 160

#3 155

#3 150

#3 140

#2 140

1200-1800 (4000-

6000) 165

#3 160

#3 155

#3 150

#3 145

#3 140

#2 130

1800-2400 (6000-

8000) 155

#3 150

#3 140

#3 135

#2 130

#2 120

#1 120

2400-3000

(8000-10000) 145

#3 140

#3 130

#2 130

#2 125

#2 120

#1 110

3000-3700

(10000-12000) 135

#3 130

#2 120

#2 115

#1 110

#1 100

Clutching

Altitude meters

(feet)

Drive Clutch (P-85) Driven Clutch (TEAM)

Shift

Weight Clutch

Spring Clutch

Spring Driven

Helix Gearing

0-900

(0-3000) 10 (110/290)

Black-

2287

Blue/

Black 54/38-25

LW ER 17:41-72

900-1800

(3000-6000) 10-M

Blue

(110-290)

Black-

2287

Blue/

Black 54/38-25

LW ER 17:41-72

1800-2700 (6000-

9000) 10 MW (110-290)

Black-

2287

Blue/

Black 54/38-25

LW ER 17:41-72

2700-3700 (9000-

12000) 10 MR (110-290)

Black-

2287

Blue/

Black 54/38-25

LW ER 17:41-72

Drive clutch bolt torque 50 ft-lbs(69 N-m)

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

1.5

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

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) 7041940/7041941

Torsion spring diameter (in/mm) .405/10.3

Torsion spring tail angle 77°

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

1.6

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

Altitude

meters (feet)

Ambient Temperature

< -25°F/<-35°C

-30°F to -10°F/-34°C to -23°C

-15°F to +5°F/-26°C to -15°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

>+60°F/>+16°C

0-600

(0-2000) 210

#2 200

#2 195

#2 190

#2 185

#2 175

#2 170

600-1200

(2000-4000) 195

#2 185

#2 180

#2 175

#2 170

#2 165

#2 155

#1 155

1200-1800

(4000-6000) 185

#2 175

#2 170

#2 165

#2 160

#1 155

#1 145

1800-2400

(6000-8000) 170

#2 165

#2 155

#1 150

#1 140

#1 135

2400-3000

(8000-10000) 160

#2 155

#2 145

#1 145

#1 140

#1 130

#1 120

3000-3700

(10000-12000) 150

#2 140

#1 135

#1 130

#1 125

#1 120

#1 110

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)

Drive Clutch (P-85) Driven Clutch (P-85)

Shift

Weight Clutch

Spring Clutch

Spring Driven

Helix Gearing

0-900

(0-3000) 10 Brown Silver 36D #2 19:41-66

900-1800

(3000-6000) 10 Red/

White Silver 36D #2 19:41-66

1800-2700

(6000-9000) 10-M

Blue Red/

White Silver 36D #2 19:41-66

2700-3700

(9000-12000) 10 MW Red/

White Silver 36D #2 19:41-66

Drive clutch bolt torque 50 ft-lbs (69 N-m)

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) N/A

Reverse type Hi/Low/Reverse

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