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Widetrak LX 2008
Polaris Widetrak LX 2008 User Manual
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10.10
Battery and Electrical Systems
9923396 - 2007-2012 EDGE/Wide
trak LX Service Manual
©201
1 Polaris Sales Inc.
ELECTRIC START
- GEN II / EDGE
System Schematic
246
248
Table of Contents
Table of Contents
4
Specifications
5
2007 340 Lx
5
2007 340 Touring
7
2007 Supersport / 550 Lx
9
2007 Trail Touring Deluxe
11
2007 Trail Rmk
13
2007 Widetrak Lx
15
2007 500 Xcsp
17
2008 340 Transport
21
2008 Supersport / 550 Lx
23
2008 Trail Touring Deluxe
25
2008 Trail Rmk
27
2008 Widetrak Lx
29
2009 550 Transport
31
2009 Trail Touring
33
2009 Trail Rmk
35
2009 Widetrak Lx
37
2010 Trail Rmk
39
2010 Trail Touring
41
2010 Widetrak Lx
43
2011 Widetrak Lx
45
2012 Widetrak Lx
47
Chapter 2 General Information 2
50
Model Number Designation
51
Snowmobile Number Designations
51
Tunnel Decal
51
Vehicle Identification Number (Vin)
51
Vin Number Designation
51
2007 Publications
52
Publication Part Numbers
52
Service / Safety Bulletins
53
Fuel / Oil Premix Ratios
54
Gasoline Volatility
54
General Reference
54
Standard Bolt Torque Specification
54
Decimal Equivalents
55
Metric Tap Drill Sizes
55
Sae Tap Drill Sizes
55
Measurement Conversion Chart
56
Piston Wash / Spark Plug Reading
56
Glossary of Terms
57
Chapter 3 Maintenance
60
Periodic Maintenance
61
Periodic Maintenance Schedule
61
Maintenance Products
63
Belt Deflection Inspection
64
Break-In Procedures
64
Drive / Driven Clutches
64
Drive Belt Break-In Procedure
64
Engine Break-In Procedure
64
Fuel/Oil Premix Ratio
64
Deflection Adjustment - Polaris Driven / P2
65
Deflection Adjustment - Spa-P2 / Team Driven
66
Torque Stop Adjustment
66
Widetrak Torque Stop Adjustment
66
Engine Maintenance
67
Exhaust Valve Cleaning
67
Fill Tube / Pressure Cap
68
Surge Tank
68
Widetrak Cooling System
68
500 XCSP Cooling System
69
Surge Tank
69
Cooling System Bleeding
70
Oil Pump Adjustment - 340 / 550 Engines
70
Oil Pump Adjustment - 488 Lc Engine
70
Recommended Coolant
70
Water Pump Drive Belt Tension
70
Oil Pump Adjustment - 500 Xcsp
71
Oil Pump Bleeding
71
Oil Pump Bleeding - 550 Engines
71
Oil / Fuel Filter
72
Oil Pump Bleeding - 550 Engines with Auto Bleed
72
Chassis Lubrication
73
Water Sediment Trap
73
Brake System Maintenance
76
Idle Speed Gap / Throttle Free Play Adjustment - VM Carburetors
77
Throttle and Choke Cable Adjustments
77
Choke Lever Adjustment - Mikuni VM
78
Throttle Lever Free Play - Tm Carburetor
78
Choke Adjustment - Mikuni Tm
79
Handlebars
79
Steering / Suspension Maintenance
79
Ski / Ski Skag Fasteners
80
Track Tension
80
Track Alignment
81
Electrical Systems
82
Headlight Bulb Replacement
82
Headlight Height Adjustment
82
Off-Season Storage
83
Chapter 4 Fuel System
84
Assembly View
86
Mikuni VM Carburetor
86
Mikuni VM Carburetor Function
86
Throttle Opening and Fuel Flow
87
Air Screw
88
Float System
88
Idle Speed Adjustment
88
Jetting Guidelines
88
Main Jet
88
Pilot Jet
88
Starting / Enrichment System
88
Jet Needle
89
Jet Needle/Needle Jet
89
Needle Jet
89
Piston / Throttle Valve
89
VM Carburetor Disassembly
90
VM Carburetor Disassembly / Inspection / Assembly
90
Float Arm Adjustment
91
Needle and Seat Leak Testing
91
Disassembly
92
Mikuni Tm Carburetor
92
Assembly
94
Mikuni Tm Carburetor Adjustment
95
Throttle Valve Synchronization
95
Fuel Pump
96
Operation
96
Fuel Tank
97
Widetrak Fuel Tank Assembly
97
Edge Fuel Tank Assembly (Typical)
98
Venting System
98
Chapter 5 Engine Systems
100
Crankcase Torque Patterns
101
Cylinder Head Torque Patterns
101
Cylinder Torque Patterns
101
Engine Torque Sequences
101
Engine Inspections
102
Exhaust Valve Maintenance
110
Recoil Pulley
111
Rope Removal and Installation
111
Engine Mounts
112
550 Engine Mounting
113
488 Engine Mounting
114
500Ev Engine Mounting
115
340 Fan Engine
116
Blower Housing Assembly
116
Cylinder Assembly
117
Oil Pump Assembly
118
Magneto Assembly
119
Crankcase Assembly
120
Piston and Crankshaft Assembly
121
550 Fan Engine
122
Blower Housing Assembly
122
Cylinder Assembly
123
Oil Pump Assembly
124
Oil Pump Assembly - Fleet Models
125
Magneto Assembly
126
Crankcase Assembly
127
Piston and Crankshaft Assembly
128
488 Liquid-Cooled Engine
129
Recoil / Waterpump Housing Assembly
129
Water Pump Assembly
130
Cylinder Assembly
131
Oil Pump Assembly
132
Magneto Assembly
133
Crankcase Assembly
134
Piston and Crankshaft Assembly
135
500Ev Cylinders / Cylinder Head
136
500Ev Liquid-Cooled Engine
136
500Ev Recoil / Magneto
137
500Ev Pistons / Crankshaft
138
500Ev Crankcase
139
500Ev Water / Oil Pump
140
Chapter 6 Drive and Brake Systems
142
7.92 C.D. Chaincase Jackshaft RPM / MPH
143
Gear Ratio Tables
143
Drive Gears
146
Drive Gears and Chains
146
7.92 C.D. Assembly Notes
147
7.92 C.D. Chaincase
147
7.92 C.D. Fastener Torque
147
Assembly View
147
Chaincase Installation
148
Chaincase Removal
148
Assembly View
150
Driveshaft / Jackshaft Fastener Torque
150
Driveshaft and Jackshaft
150
Seal Sleeve / O Ring Installation
150
Driveshaft Removal/Installation
151
Jackshaft Installation
151
Jackshaft Removal
151
Removal
152
Widetrak Gearcase
152
Inspection
153
Input Shaft Inspection
155
Low / Reverse Shaft Inspection
155
Output Shaft Inspection
156
Shift Drum Inspection
156
Gearcase Assembly
157
Gearcase Installation
157
Compensating Port
159
Hydraulic Brake System
159
Overview
159
Warnings and Cautions
160
Brake Fluid Replacement & Bleeding
161
Brake Hose Replacement
162
Brake Light Switch Replacement
162
Brake Caliper
163
Brake Caliper Piston and Seal Replacement
163
Brake Pad Replacement
163
Caliper Removal / Installation
163
Brake Disc Replacement
164
Chapter 7 Pvt System
166
Clutch Weight
167
Drive Spring
167
Driven Spring
167
Engagement Rpm
167
Neutral Speed
167
Overview
167
Pvt System
167
Shift out Over-Rev
167
Shift out Rpm
167
1:1 Shift Ratio
168
Back-Shifting
168
Driven Helix / Ramp
168
Final Gearing
168
Low / High Ratio
168
Pvt System Fastener Torques
168
General Information
169
Clutch Alignment / Offset
181
Offset/Float Adjustment
181
Pvt System Adjustments
181
Drive Clutch
182
Drive Clutch Removal
182
Identification
182
Drive Clutch Disassembly
183
Roller Installation
184
Roller Removal
184
Spider Button Installation
184
Cover Bushing
185
Clutch Assembly
186
Belt-To-Sheave Clearance Adjustment
187
Spider Indexing
187
Drive Clutch Installation
188
Driven Clutch
189
Driven Clutch Installation
189
Driven Clutch Removal
189
Team Lwt Components
190
Widetrak Driven Clutch Components
191
Polaris P2 Driven Clutch Components
192
Polaris Spa-P2 Driven Clutch Components
194
Chapter 8 Steering and Suspension Systems
196
Edge 42.5
197
Front Suspension Torque & Specifications
197
Edge 41
198
Widetrak
199
Camber / Toe Specifications
200
Inspection
200
Overview / Specifications
200
Springs
200
Adjustable Shocks
201
Front Suspension / Steering
201
Setup and Adjustments
201
Camber
202
Front Suspension Alignment Bar
202
Handlebar Centering
203
Rod End Engagement
203
Camber Adjustment
204
Maximum Width Adjustment
204
Operation
205
Rear Suspension
205
Toe Adjustment
205
Weight Transfer
205
Rear Torsion Spring Tension Adjustment
206
Suspension Coupling
206
Edge Shock Rods
207
Rear Track Shock Control Rods
207
Adjustment Procedures
208
Rear Suspension Adjustments
208
Setting the Rear Suspension Ride Height
208
Front Torque Arm Limiter Strap Adjustment
209
Scissor Stop Adjustments
209
Torsion Spring Adjustment
209
Widetrak Ski Pressure Adjuster
210
Widetrak Torsion Spring Adjustments
210
Rear Suspension Assembly Illustrations
211
Rebuildable Shocks
225
Shock Rebuilding Tools
225
Ryde Fx™ Shock Valve Part Numbers
226
Piston Orientation
227
Valve Shim Arrangement
227
Rebuildable Ifs Shock Specifications
228
Shock Valve Shim Stack Configurations
228
Front Track Shock (Fts) Valving
229
Rebuildable Front Track Shock Specifications
229
Ryde Fx Mono-Tube Shock Disassembly
230
Ryde Fx Mono-Tube Shock Assembly
231
Suspension Set-Up
232
Troubleshooting
232
Chapter 9 Chassis
234
Bumper
235
Edge Front Bumper Removal/Installation
235
Edge Instrument Removal/Installation
235
Hood Assembly
235
Hood Removal/Installation
235
Hood Repair
235
Edge Fuel Tank Removal/Installation
236
Edge Headlight Removal/Installation
236
Headlight
236
Rear Bumper Removal/Installation
236
Seat & Base Removal/Installation
236
Seat and Fuel Tank
236
Seats
236
Console
237
Console Removal/Installation
237
Edge Tail Light Assembly Replacement
237
Seat Cover Replacement
237
Tail Light
237
Tail Light Assembly Replacement
237
Chapter 10 Battery and Electrical Systems
238
Battery and Electrical Systems
239
Battery Preparation
239
Charging System
239
Conventional Battery
239
Engine Models
239
Ignition Timing
239
Spark Plugs
239
Specifications
239
Battery Preparation
240
Battery Testing
240
Fresh Pack Battery
240
Load Test
240
Open Circuit Voltage Test (Ocv)
240
Refilling a Conventional Battery
240
Specifications
240
Testing Procedures
240
Battery Conductance Analyzer
241
Specific Gravity Test (Conventional Battery)
241
Off Season Storage
242
Ignition Timing
243
Timing Procedure - Carbureted Engines
243
Ignition Timing Chart
244
Throttle Position Sensor (Tps)
245
Tps Test Tool Setup
245
Using the Tps Test Tool
245
Tps Adjustment - Carbureted Models
246
Electric Start - Gen II / Edge
247
System Schematic
247
Starter Motor Assembly (Typical)
248
Battery Box
249
Dynamic Testing
250
Armature Testing
251
Starter Housing / Field Coil Testing
251
Carbureted Electrical Systems
252
No Spark
253
Troubleshooting Tables
253
Altitude Setting
254
Electronic Reverse (Perc)
254
Forward Operation
254
Important Notes
254
Operation
254
Hand/Thumb Warmers
255
Thumb Warmer Diagnostics
255
Thumb Warmer Resistance Checks
255
Hand Warmer Diagnostics
256
Hand Warmer Resistance Checks
256
Left Hand Control
257
Left Hand Control Continuity Checks
257
Left Hand Control Diagnostics
257
Left Hand Control Power Input/Output Check
257
4
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Polaris Widetrak LX 2008 Specifications
General
Brand
Polaris
Model
Widetrak LX 2008
Category
Offroad Vehicle
Language
English
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