Polaris 2007 Two Stroke User Manual

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
area click on Service & Warranty link and the feedback link is at the bottom of the page named
Polaris Manual Correction Feedback
link.
2007 Two Stroke Snowmobile Service Manual PN 9920463
© 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.

Polaris 2007 Two Stroke Specifications

General

Engine Type	2-Stroke
Cylinders	2
Track Length	121 in.
Track Width	15 in
Brake Type	Hydraulic
Fuel System	Carburetor
Carburetion	Dual VM34

Summary

GENERAL

HOW TO USE THIS MANUAL

Guide on how to navigate and understand the service manual.

MAINTENANCE

MAINTENANCE PROGRAM

Overview of recommended maintenance schedule and procedures.

INSPECTONS

Details essential inspections for engine and chassis components.

FUEL DELIVERY

MIKUNI CARBURETOR

Overview of components and functions of the Mikuni carburetor.

CLEANFIRE INJECTION (CFI)

Details on the Cleanfire fuel injection system and injector replacement.

ENGINE

GENERAL ENGINE INFORMATION

Exploded views and disassembly/assembly of engine components.

500/600 (CARBURETED) ENGINE DISASSEMBLY

600/700 CFI ENGINE DISASSEMBLY

CLUTCHING

PVT SYSTEM

DRIVE CLUTCH

DRIVEN CLUTCH

FINAL DRIVE/BRAKES

GEARING CHARTS

CHAIN CASE

HYDRAULIC BRAKE SYSTEM

Overview, guidelines, and procedures for brake fluid service and replacement.

FRONT SUSPENSION & STEERING

FRONT SUSPENSION TORQUE & SPECIFICATIONS

FRONT SUSPENSION ADJUSTMENT PROCEDURES

REAR SUSPENSION

SHOCK CONTROL RODS

REAR SUSPENSION OPERATION

CHASSIS & HOOD

HOOD ASSEMBLY

SEAT AND FUEL TANK

BATTERY & ELECTRICAL SYSTEMS

BATTERY TESTING

Methods for testing battery voltage, load, and specific gravity.

IGNITION TIMING

Procedure and chart for checking and adjusting ignition timing.

THROTTLE POSITION SENSOR (TPS)

Information on TPS test tool setup, adjustment, and synchronization.

CLEANFIRE™ FUEL INJECTION

Overview of system components and their functions.

Diagnostic Trouble Codes (DTCs)

List of DTCs, P-codes, MFD blink codes, and their descriptions.