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General Information
CHAPTER 2
General Information
2
STANDARD BOLT TORQUE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12
9922854 - 2007-2011 IQ Service Manual
©2010 Polaris Sales Inc.
2.1
General Information
SNOWMOBILE NUMBER
DESIGNATIONS
Model Number Designation
Example: S08MX6FS
G
ROUP
1st digit
S
S=Snow
M
ODEL
Y
EAR
M
ODEL
L
INE
M
ODEL
T
YPE
E
NGINE
M
ODIFIER
VIN I
DENTIFIER
O
PTION
I
DENTIFIER
2/3rd digit
08
08 = 2008
09 = 2009
10 = 2010
11 = 2011
12 = 2012
13 = 2013
14 = 2014
15 = 2015
4th digit
M
M=Race IQ
N=Edge
P= IQ
S=Gen II
W=Mini Indy
5th digit
X
B = Basic
D = LX
E = Dragon SP
G = 155 RMK
H = 163 RMK
J = 136 RMK
K = 144 RMK
L = 146 Assault
M = 155 STD.
N = 163 STD.
P = Performance
R = Switchback
S = Switchback
Prem.
T = Touring
U = Utility
X = Race
Y = Touring LTD.
6th digit*
6
7th digit*
F
8th digit
S
1A=121 F/C OHV 4 Cycle Fuji
3A=340 F/C Piston Port
4B=488 L/C Piston Port
5B=544 F/C Cylinder Reed
6F=600 EV L/C Case Reed
6H=600 EV L/C Case Reed CFI
6J = 600 EV L/C Case Reed Race
6K = 600 EV L/C Case Reed CFI -
DC-CFI (MY10-11 600 WT = 600
2+2)
7E=750 Four Stroke
7F=750 Four Stroke Turbo
7J=700 EV L/C Case Reed CFI
8E / 8F = 794 EV L/C Case Reed
CFI
E=Europe
M=Military
R=Rolling
Chassis
S=Standard
*=digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively
**=9th digit will be used on color/featured versions of models (not including the base)
First 3 digits and 9th digit are used in the model number only. They are not used with the 17 digit VIN.
9th digit**
Option
L = Electric
Start
2.2
9922854 - 2007-2011 IQ Service Manual
©2010 Polaris Sales Inc.
VEHICLE IDENTIFICATION NUMBER
(VIN)
Tunnel Decal
The Tunnel Decal has the Model Number (1), V.I.N.
Number (2), and the Manufactured Date (3).These
1
2
General Information
3
numbers should be referred to in any correspondence regarding warranty, service or replacement parts.The
machine model and V.I.N. number identification decal is located on the right front side of the tunnel. The V.I.N (2) number is permanently stamped into the tunnel. The model number is embossed on the decal.
2
VIN Number Designation
World Mfg. ID
Vehicle Descriptors Vehicle Identifiers
Individual Serial No.
1
S
2
N
3
1
4
S
5
B
6
5
7
B
8
S
9
0
10
2
11
2
12
0
13
0
14
0
15
0
16
0
17
0
9922854 - 2007-2011 IQ Service Manual
©2010 Polaris Sales Inc.
2.3
General Information
PUBLICATION PART NUMBERS
2011 Publications
MODEL
550 IQ Shift
550 Shift 136
550 IQ LXT
600 IQ Shift
600 Shift 136
600 Switchback 136
600 IQ LXT
600 Widetrak IQ
600 RMK 144/155
2010 Publications
OWNER'S MANUAL
9922858
9922861
9922883
9922890
9922868
SUPPLEMENT
9923237
9923236
9923238
9922862
9922877
9922879
9922884
9922891
9922869/9922871
PARTS BOOK
(
ONLINE PART MANUALS AVAILABLE ONLINE
AT WWW
.
POLARISINDUSTRIES
.
COM
)
9922860
9922875
9922882
9922863
9922878
9922880
9922885
9922892
9922870
MODEL
550 IQ Shift
600 IQ Shift
600 LX
600 Switchback
600 Dragon
Switchback
600 IQ Touring
600 Widetrak IQ
800 IQ
800 Dragon IQ
800 Switchback
800 Dragon
Switchback
600 RMK 144
600 RMK 155
700 RMK 155
800 RMK 144
800 RMK 155
800 RMK Assault
800 Dragon RMK 155
800 Dragon RMK 163
OWNER'S MANUAL
9922316
9922322
9922288
9922596
9922322
9922332
SUPPLEMENT
9922317
9922320
9922303
9922323
9922325
9922289
9922308
9922350
9922298
9922330
9922325
9922338
9922344
9922649
9922340
9922348
9922342
9922335
9922337
PARTS BOOK
(
ONLINE PART MANUALS AVAILABLE ONLINE
AT WWW
.
POLARISINDUSTRIES
.
COM
)
9922318
9922321
9922324
9922326
9922291
9922309
9922351
9922299
9922331
9922326
9922339
9922650
9922341
9922343
9922336
2.4
9922854 - 2007-2011 IQ Service Manual
©2010 Polaris Sales Inc.
General Information
2009 Publications
MODEL
550 IQ Shift
600 IQ Shift
600 IQ
800 IQ
600 Dragon SP
800 Dragon SP
600 Switchabck
600 IQ Touring
600 IQ Shift 136
600 Dragon
Switchback
800 Switchback
800 Dragon
Switchback
600 RMK Shift 144
600 RMK Shift 155
700 RMK 155
800 RMK Shift 144
800 RMK Assault
800 RMK 155
800 Dragon RMK 155
800 Dragon RMK 163
OWNER'S MANUAL
9921597
9921599
9921220
9921709
9921220
9921613
SUPPLEMENT
9921641
9921643
9921616
9921632
9921633
9921629
9921931
9921634
9921614
9921615
9921598
9921601
9921603
9921606
9922117
9921612
9921928
9921644
9921638
9921642
PARTS BOOK
(
ONLINE PART MANUALS AVAILABLE ONLINE
AT WWW
.
POLARISINDUSTRIES
.
COM
)
9921982
9921983
9921984
9921986
9922118
9922119
9921994
9921998
9922120
9921994
9921997
2
9921988
9922151
9921989
9921991
9921987
9922854 - 2007-2011 IQ Service Manual
©2010 Polaris Sales Inc.
2.5
General Information
2008 Publications
MODEL
IQ Shift
600 RMK 144
600 RMK Shift 155
600 Dragon IQ
600 Switchback
600 Dragon
Switchback
600 IQ LX
600 IQ Touring
600 RMK 155
700 IQ
700 Dragon IQ
700 Switchback
700 Dragon
Switchback
700 RMK 155
700 Dragon RMK 155
/ 163
800 Dragon RMK 155
/ 163
2007 Publications
OWNER'S MANUAL
9921427
9921102
9921065
9921102
9921065
9921102
SUPPLEMENT
9921067
9921108
9921545
9921069
9921076
9921072
9921082
9921109
9921071
9921078
9921104
9921104 / 9921106
9921301 / 9921107
PARTS BOOK
(
ONLINE PART MANUALS AVAILABLE ONLINE
AT WWW
.
POLARISINDUSTRIES
.
COM
)
9921068
9921112
9921075
9921081
9921070
9921083
9921549
9921070
9921081
9921549
9921114
MODEL
600 HO IQ
600 HO Switchback
600 HO RMK
600 HO IQ CFI
600 HO Switchback
CFI
600 HO IQ LX CFI
600 HO IQ Touring
CFI
700 HO IQ Dragon
700 HO RMK Dragon
OWNER’S MANUAL
9920459
9920476
9920464
9920648
9920476
SUPPLEMENT
9920460
9920597
9920477 / 9920483
9920487
9920495
9920465
9920501
9920910
9920484
PARTS BOOK
(O
NLINE PART MANUALS AVAILABLE ONLINE AT
WWW
.
POLARISINDUSTRIES
.
COM
)
9920461
9920598
9920478
9920466
9920496
9920466
9920502
9921200
9920912
2.6
9922854 - 2007-2011 IQ Service Manual
©2010 Polaris Sales Inc.
General Information
Service / Safety Bulletins
NOTE: Polaris dealers should use Unit Inquiry at www.polarisdealers.com to determine affected models.
BULLETIN
S-06-13
S-06-14A/B
S-07-01
S-07-05A/B/C
S-07-09O
S-07-10
S-07-13A/B
S-07-15A/B
MODEL/YEAR
600 HO IQ LX CFI/2007
600 HO IQ CFI/2007
600 HO IQ TOURING CFI/2007
600 HO SWITCHBACK CFI/2007
600 HO IQ LX CFI/2007
600 HO IQ CFI/2007
600 HO IQ TOURING CFI/2007
600 HO SWITCHBACK CFI/2007
IQ Dragon/2007
RMK Dragon/2007
IQ Dragon/2007
RMK Dragon/2007
600 HO Switchback/2007
600 HO IQ LX CFI/2007
600 HO IQ CFI/2007
600 HO IQ TOURING CFI/2007
600 HO SWITCHBACK CFI/2007
600 HO IQ LX CFI/2007
600 HO IQ CFI/2007
600 HO IQ TOURING CFI/2007
600 HO SWITCHBACK CFI/2007
IQ Shift/2008
600 RMK 144/2008
600 RMK Shift 155/2008
600 Dragon IQ/2008
600 Switchback/2008
600 Dragon Switchback/2008
600 IQ LX/2008
600 IQ Touring/2008
600 RMK 155/2008
700 IQ/2008
700 Dragon IQ/2008
700 Switchback/2008
700 Dragon Switchback/2008
700 RMK 155/2008
700 Dragon RMK 155/2008
700 Dragon RMK 163/2008
DESCRIPTION
2007 600 CFI Throttle Body Cooling Hose Length Reduction
2007 600 CFI Oil Pump/Throttle Body Synchronization Inspection
2007 700 CFI Fuel Vapor Separator/PFA Wiring Inspection
2007 700 CFI Dragon ECU Reflash/Thermostat Update
(Safety Bulletin) Fuel Tank Replacement
2007 600 CFI ECU Reflash
2007 600 CFI Throttle Cable Bracket
(Select Models)2008 IQ Snowmobile Oil Tank Sender Inspection/
Replacement
2
2.7
9922854 - 2007-2011 IQ Service Manual
©2010 Polaris Sales Inc.
General Information
BULLETIN
S-07-16
S-08-02A/B
S-08-05
S-09-01/A
S-09-06/A/B/C
S-09-07
S-09-08/A/B
S-09-09/A
S-09-11
S-10-02
MODEL/YEAR
IQ Shift/2008
600 RMK 144/2008
600 RMK Shift 155/2008
600 Dragon IQ/2008
600 Switchback/2008
600 Dragon Switchback/2008
600 IQ LX/2008
600 IQ Touring/2008
600 RMK 155/2008
700 IQ/2008
700 Dragon IQ/2008
700 Switchback/2008
700 Dragon Switchback/2008
700 RMK 155/2008
700 Dragon RMK 155/2008
700 Dragon RMK 163/2008
800 Dragon RMK 155/2008
800 Dragon RMK 163/2008
IQ Shift/2008
800 IQ Switchback/2009
600 IQ Shift 136/2009
600 RMK Shift 144/2009
600 RMK Shift 155/2009
600 HO IQ LX CFI/2007
600 HO IQ CFI/2007
600 HO IQ TOURING CFI/2007
600 HO SWITCHBACK CFI/2007
600 IQ LX/2008
600 Dragon IQ/2008
600 Switchback/2008
600 Dragon Switchback/2008
600 IQ Touring/2008
700 IQ/2008
700 Dragon IQ/2008
700 Switchback/2008
700 Dragon Switchback/2008
600 Touring CFI/2009
800 RMK Assault/2009
800 IQ 121/2008-2009
800 IQ Dragon SP/2009
800 IQ Switchback/2009
800 IQ Dragon Switchback/2009
800 Dragon RMK 155/2008
800 Dragon RMK 163/2008
800 RMK 144/2009
800 RMK Assault/2009
800 RMK 155/2009
800 Dragon RMK 155/2009
800 Dragon RMK 163/2009
600 IQ Widetrak
600 IQ Widetrak
DESCRIPTION
(Select Models) Hand Warmer Solder Joint Shorting to Ground
2008 IQ Shift Speedometer Cable Inspection/Replacement
(Select Models) 2009 800 IQ Switchback Drive Clutch Replacement
(Select Models) 2009 600 IQ Shift 136 Driven Clutch Update and 600 IQ Shift
136 / 600 Shift RMK 144 / 600 Shift RMK 155 Reflash
(Safety Bulletin) 2007 – 2009 IQ CFI Fuel Hose Routing Inspection / Fuel
Hose Replacement
(Safety Bulletin) 2009 IQ 800 RMK Assault Rail Tip Fastener Replacement
2008-2009 800 IQ 121/IQ Switchback Engine Durability Update Kit
2008-2009 800 RMK Engine Durability Update Kit
2010 600 IQ Widetrak Cooling Hoses
2010 600 IQ Widetrak ECU Reflash
Use Unit Inquiry located at www.polarisdealers.com to determine affected models and which bulletins have been applied or are outstanding.
2.8
9922854 - 2007-2011 IQ Service Manual
©2010 Polaris Sales Inc.
ENGINE DATA FORMULAS
Compression Ratio
General Information
2
R= (IHV + DISP)
IHV
I= S
(DISP x 25.4)
DISP = (PI x B x S)
4
IHV= INSTALLED HEAD VOLUME (cc)
DISP= CYLINDER DISPLACEMENT (cc)
R= COMPRESSION RATIO
S= FULL ENGINE STROKE (cm)
I= INCHES PER cc OF IHV
B= CYLINDER BORE (cm)
PI= 3.1416
9922854 - 2007-2011 IQ Service Manual
©2010 Polaris Sales Inc.
2.9
General Information
Compression Ratio Example
Bore = 6.5cm
Stroke = 6.0 cm
IHV = 17.1cc
Displacement = 3.1416 (PI) x 42.25 (Bore squared) x 6.0
(stroke) / 4 = 199.098cc
Displacement = 199.098cc
R= 17.1 + 199.098 / 17.1 = 12.643 Full Stroke
Compression Ratio
To calculate the Effective Compression Ratio, substitute the exhaust port height for the stroke in the formulas above:
Exhaust = 2.95cm (exhaust port height is 29.5mm)
Effective Displacement = 3.1416 (PI) x 42.25 (bore squared) x 2.95 (exhaust port height cm) / 4 = 97.89cc
Effective Displacement = 97.89cc
Effective Compression Ratio = 17.1 (IHV cc) + 97.89
(Effective Displacement cc) / 17.1 (IHV cc) = 6.725
Effective Compression Ratio = 6.725
In order to increase the Full Stroke Compression Ratio to
13.6, how much material do you need to remove from the cylinder head?
You know that: R = IHV + Displacement / IHV, and you want to find out IHV.
Displacement = 199.098cc, and we want R to = 13.6, so then IHV (desired) = Displacement (199.098cc) / R (13.6)
- 1 = (12.6)
IHV (desired) = 15.801cc desired IHV to have 13.6:1 Full
Compression Ratio
Head cc Removal Example
The total number of cc’s to remove from the head = Old
IHV (17.1) - Desired IHV (15.801) = 1.299cc’s
Removed cc’s = 1.299cc’s
I = Stroke (6.0cm) / (Displacement (199.098) x 2.54
I= 0.01186 inches
To find out how much to machine off, multiply the number of cc’s you need to remove by the number of inches to remove per cc.
Thickness to remove = I (0.01186) x 1.299cc = 0.015”
Port Opening Duration
Port open = 81.5° This indicates the degrees after TDC that the exhaust port opens, and also the degrees before
TDC that the port closes.
Duration closed = 2 x 81.5 (port open)
Duration closed = 163
°
Total Duration = 360
°
Duration Open = Total Duration (360) - Duration Closed
(163)
360-163=197
Duration Open = 197
°
Percent Open = Duration Open (197) / Total Duration (360) x 100
197/360 = 0.54722 x 100 = 54.722
Percent Open = 54.722
2.10
9922854 - 2007-2011 IQ Service Manual
©2010 Polaris Sales Inc.
TORQUE CONVERSION
US to Metric ft.lb - Nm
N
M
31.2
32.5
33.9
35.3
36.6
38.0
39.3
40.7
20.3
21.7
23.1
24.4
25.8
27.1
28.5
29.8
9.5
10.8
12.2
13.6
14.9
16.3
17.6
19.0
1.4
2.7
4.1
5.4
6.8
8.1
52.9
54.2
55.6
57.0
58.3
59.7
61.0
42.0
43.4
44.7
46.1
47.5
48.8
50.2
51.5
FT
.
LB
72
73
74
75
68
69
70
71
64
65
66
67
60
61
62
63
56
57
58
59
52
53
54
55
46
47
48
49
50
51
84
85
86
87
88
89
90
80
81
82
83
76
77
78
79
FT
.
LB
27
28
29
30
23
24
25
26
19
20
21
22
15
16
17
18
11
12
13
14
7
8
9
10
3
4
1
2
5
6
39
40
41
42
43
44
45
35
36
37
38
31
32
33
34
N
M
92.2
93.6
94.9
96.3
97.6
99.0
100.3
101.7
81.4
82.7
84.1
85.4
86.8
88.1
89.5
90.9
70.5
71.9
73.2
74.6
75.9
77.3
78.6
80.0
62.4
63.7
65.1
66.4
67.8
69.2
113.9
115.3
116.6
118.0
119.3
120.7
122.0
103.1
104.4
105.8
107.1
108.5
109.8
111.2
112.5
FT
.
LB
91
92
93
94
95
9922854 - 2007-2011 IQ Service Manual
©2010 Polaris Sales Inc.
General Information ft.lb - Nm
N
M
123.4
124.8
126.1
127.5
128.8
FT
.
LB
96
97
98
99
100
N
M
130.2
131.5
132.9
134.2
135.6
2
2.11
General Information
GENERAL REFERENCE
Standard Bolt Torque Specification
Grade 2
Grade 5
Grade 8
1/4
1/4
5/16
5/16
3/8
3/8
7/16
7/16
1/2
1/2
16
24
14
20
20
28
18
24
13
20
5 (7)
6 (8)
11 (15)
12 (16)
20 (27)
23 (32)
30 (40)
35 (48)
8 (11)
10 (14)
17 (23)
19 (26)
30 (40)
35 (48)
50 (69)
55 (76)
12 (16)
14 (19)
25 (35)
29 (40)
45 (62)
50 (69)
70 (97)
80 (110)
50 (69) 75 (104) 110 (152)
55 (76) 90 (124) 120 (166)
FT
-
LB
X 1.356 = N-
M
N-
M
X.7376 =
FT
-
LB
Fuel / Oil Premix Ratios
FUEL
(G
ALLONS
)
1
5
10
Formula:
20:1 RATIO
(O
UNCES OF
O
IL
)
6.4
32
64
40:1 RATIO
(O
UNCES OF
O
IL
)
3.2
16
32
• 1 Gallon = 128 Ounces
• 128
Desired Ratio) = Ounces of oil for every 1 gallon of fuel.
• 128
20:1 Ratioounces of oil for every 1 gallon of fuel
Always mix ratio in 5 gallon increments.
Gasoline Volatility
M
AXIMUM
R
EID
V
APOR
A
MBIENT
A
IR
T
EMP
R
ANGE
CLASS
A
B
PRESSURE
7.0 psi (0.5 bar)
9.0 psi (0.6 bar)
LOW
60°F
(16°C)
50°F
(10°C)
HIGH
110°F+
(43°C+)
110°F
(43°C)
C
D
10.5psi (0.7 bar)
12.0psi (0.8 bar)
40°F
(4°C)
30°F
(-1°C)
97°F
(36°C)
85°F
(29°C)
E 13.5psi (0.9 bar)
20°F
(-7°C)
69°F
(21°C)
Add 2.45°F for each 1000 ft (305m) above sea level
When gasoline is blended, it is given a Reid Vapor
Pressure (RVP) number which reflects its ability to vaporize or mix with air at a given temperature range.
Gasoline vapor pressure is measured by putting a sample of fuel inside a closed container and applying a specified amount of heat to the container for a certain amount of time. RVP will vary from about 7.0 PSI during the summer to approximately 13.5 PSI during the colder months.
Service stations selling a large volume of fuel will normally have the correct blend to work well at all times throughout the year in their local area.
When the weather is very cold, gasoline must be able to vaporize very quickly in order for an engine to start and warm up properly. If summer blend fuel is being used in the winter, little or no vaporization will occur. Droplets will form causing flooding and very hard starting.
If winter blend fuel is being used during the summer months, it may cause vapor lock (boiling fuel) inside the fuel lines, fuel pump, or carburetor. This will cause warm engine drive ability problems and hard starting when warm.
2.12
9922854 - 2007-2011 IQ Service Manual
©2010 Polaris Sales Inc.
General Information
Tap Size
3x.50
3x.60
4x.70
4x.75
5x.80
5x.90
6x1.00
7x1.00
8x1.00
8x1.25
9x1.00
9x1.25
10x1.25
10x1.50
11x1.50
12x1.50
12x1.75
SAE Tap Drill Sizes
#6-32
#6-40
#8-32
#8-36
#10-24
#10-32
#12-24
#12-28
1/4-20
1/4-28
5/16-18
5/16-24
3/8-16
3/8-24
7/16-14
7/16-20
Thread Size/ Drill Size
#0-80 3/64
#1-64
#1-72
#2-56
53
53
51
#2-64
#3-48
#3-56
#4-40
#4-48
#5-40
#5-44
50
5/64
45
43
42
38
37
F
I
O
36
33
29
29
24
21
7
3
17
4.6mm
Q
U
25/64
Metric Tap Drill Sizes
Thread Size / Drill Size
1/2-13 27/64
1/2-20
9/16-12
9/16-18
29/64
31/64
33/64
5/8-11
5/8-18
3/4-10
3/4-16
7/8-9
7/8-14
1-8
17/32
37/64
21/32
11/16
49/64
13/16
7/8
1-12
1 1/8-7
1 1/8-12
1 1/4-7
1 1/4-12
1 1/2-6
1 1/2-12
1 3/4-5
1 3/4-12
2-4 1/2
2-12
2 1/4-4 1/2
2 1/2-4
2 3/4-4
3-4
59/64
63/64
1 3/64
1 7/64
1 11/64
1 11/32
1 27/64
1 9/16
1 43/64
1 25/32
1 59/64
2 1/32
2 1/4
2 1/2
2 3/4
Drill Size
16/64
J
17/64
5/16
5/16
11/32
R
3/8
13/32
13/32
#39
3/32
#30
1/8
#19
#20
#9
Decimal
Equivalent
0.0995
0.0937
0.1285
0.125
0.166
0.161
0.196
0.234
0.277
0.265
0.3125
0.3125
0.3437
0.339
0.375
0.406
0.406
5/32
13/64
15/64
9/32
17/64
5/16
5/16
11/32
Nearest
Fraction
3/32
3/32
1/8
1/8
11/64
11/32
3/8
13/32
13/32
Decimal Equivalents
1/64 - - -- - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - -.0156
- - - - - - 1/32 - - - - - - - - - - - - - - - -.0312 - - 1 mm= .0394"
3/64 - - -- - - - - - - - - - - - - - - - - - - -.0469
- - - - - - 1/16 - - - - - - - - - - - - - - - -.0625
5/64 - - -- - - - - - - - - - - - - - - - - - - -.0781 - - 2 mm = .0787"
- - - - - - 3/32 - - - - - - - - - - - - - - - -.0938
7/64 - - -- - - - - - - - - - - - - - - - - - - -.1094 - - 3 mm =.1181"
- - - - - - 1/8 - - - .1250
9/64 - - -- - - - - - - - - - - - - - - - - - - -.1406
- - - - - - 5/32 - - - - - - - - - - - - - - - -.1563 - - 4 mm = .1575"
11/64 - -- - - - - - - - - - - - - - - - - - - -.1719
- - - - - - 3/16 - - - - - - - - - - - - - - - -.1875 - - 5mm= .1969"
13/64 - -- - - - - - - - - - - - - - - - - - - -.2031
- - - - - - 7/32 - - - - - - - - - - - - - - - -.2188
15/64 - -- - - - - - - - - - - - - - - - - - - -.2344 - - 6 mm = .2362"
- - - - - - 1/4 - - - .25
17/64 - -- - - - - - - - - - - - - - - - - - - -.2656 - - 7 mm = .2756"
- - - - - - 9/32 - - - - - - - - - - - - - - - -.2813
19/64 - -- - - - - - - - - - - - - - - - - - - -.2969
- - - - - - 5/16 - - - - - - - - - - - - - - - -.3125 - - 8mm= .3150"
21/64 - -- - - - - - - - - - - - - - - - - - - -.3281
- - - - - - 11/32 - - - - - - - - - - - - - - -.3438 - - 9 mm = .3543"
23/64 - -- - - - - - - - - - - - - - - - - - - -.3594
- - - - - - 3/8 - - - .375
25/64 - -- - - - - - - - - - - - - - - - - - - -.3906 - - 10 mm = .3937"
- - - - - - 13/32 - - - - - - - - - - - - - - -.4063
27/64 - -- - - - - - - - - - - - - - - - - - - -.4219 - - 11 mm =.4331"
- - - - - - 7/16 - - - - - - - - - - - - - - - -.4375
29/64 - -- - - - - - - - - - - - - - - - - - - -.4531
- - - - - - 15/32 - - - - - - - - - - - - - - -.4688 - - 12 mm = .4724"
31/64 - -- - - - - - - - - - - - - - - - - - - -.4844
- - - - - - 1/2 - - - .5 - - - - - - - - - - - - - - - - - 13mm = .5118"
33/64 - -- - - - - - - - - - - - - - - - - - - -.5156
- - - - - - 17/32 - - - - - - - - - - - - - - -.5313
35/64 - -- - - - - - - - - - - - - - - - - - - -.5469 - - 14 mm = .5512"
- - - - - - 9/16 - - - - - - - - - - - - - - - -.5625
37/64 - -- - - - - - - - - - - - - - - - - - - -.5781 - - 15 mm = .5906"
- - - - - - 19/32 - - - - - - - - - - - - - - -.5938
39/64 - -- - - - - - - - - - - - - - - - - - - -.6094
- - - - - - 5/8 - - - .625 - - - - - - - - - - - - - - - 16mm=. 6299"
41/64 - -- - - - - - - - - - - - - - - - - - - -.6406
- - - - - - 21/32 - - - - - - - - - - - - - - -.6563 - - 17 mm =.6693"
43/64 - -- - - - - - - - - - - - - - - - - - - -.6719
- - - - - - 11/16 - - - - - - - - - - - - - - -.6875
45/64 - -- - - - - - - - - - - - - - - - - - - -.7031 - - 18 mm = .7087"
- - - - - - 23/32 - - - - - - - - - - - - - - -.7188
47/64 - -- - - - - - - - - - - - - - - - - - - -.7344 - - 19 mm = .7480"
- - - - - - 3/4 - - - .75
49/64 - -- - - - - - - - - - - - - - - - - - - -.7656
- - - - - - 25/32 - - - - - - - - - - - - - - -.7813 - - 20 mm = .7874"
51/64 - -- - - - - - - - - - - - - - - - - - - -.7969
- - - - - - 13/16 - - - - - - - - - - - - - - -.8125 - - 21 mm =.8268"
53/64 - -- - - - - - - - - - - - - - - - - - - -.8281
- - - - - - 27/32 - - - - - - - - - - - - - - -.8438
55/64 - -- - - - - - - - - - - - - - - - - - - -.8594 - - 22 mm = .8661"
- - - - - - 7/8 - - - .875
57/64 - -- - - - - - - - - - - - - - - - - - - -.8906 - - 23 mm = .9055"
- - - - - - 29/32 - - - - - - - - - - - - - - -.9063
59/64 - -- - - - - - - - - - - - - - - - - - - -.9219
- - - - - - 15/16 - - - - - - - - - - - - - - -.9375 - - 24 mm = .9449"
61/64 - -- - - - - - - - - - - - - - - - - - - -.9531
- - - - - - 31/32 - - - - - - - - - - - - - - -.9688 - - 25 mm = .9843"
63/64 - -- - - - - - - - - - - - - - - - - - - -.9844
- - - - - - 1- - - - - 1.0
9922854 - 2007-2011 IQ Service Manual
©2010 Polaris Sales Inc.
2.13
2
General Information
Measurement Conversion Chart
U
NIT OF
M
EASURE
M
ULTIPLIED BY
ft-lb in-lb ft-lb in-lb
N-m kg-m kg-m kg-m in mm in mile km
Ounces (oz) grams (g) x 12 x.0833
x 1.356
x.0115
x.7376
x 7.233
x 86.796
x 10 x 25.4
x.03937
x 2.54
x 1.6
x.6214
x 28.35
x.035
cc’s lbs kg x.03381
x.454
x 2.2046
Cubic Inches
Cubic Centimeters
Imperial pints liters (l)
Imperial quarts liters (l)
Imperial quarts
US quarts
US quarts liters
US gallon liter
Pounds force per square inch (psi)
Kilo pascals (kPa) x 16.387
x.061
x.568
x 1.76
x 1.137
x.88
x 1.201
x.833
x.946
x 1.057
x 3.785
x.264
x 6.895
x.145
C
ONVERTS TO
= Cubic
Centermeters
= Cubic Inches
= liters (l)
= Imperial pints
= liters (l)
= Imperial quarts
= US quarts
= Imperial quarts
= liters
= US quarts
= liter
= US gallon
= Kilo pascals
(kPa)
= Pounds force per square inch (psi)
= in-lb
= ft-lb
= N-m
= kg-m
= ft-lb
= ft-lb
= in-lb
= N-m
= mm
= in
= cm
= km
= mile
= grams (g)
= Ounces (oz)
= Fluid Ounces
(oz)
= kg
= lbs
Piston Wash / Spark Plug Reading
Changing temperature, barometer, altitude, and fuel supply are just a few of the factors that can affect the day to day performance of your engine. That is why using
Exhaust Gas Temperatures (EGT) are important for maintaining optimum performance. There are two methods for helping you determine what the EGTs are for your machine. Piston wash and the coloring of your spark plug.The piston wash is by far the most valuable tool in concluding EGTs, with the spark plug color running a distant second. Use the illustrations below to help you establish the EGTs for your machine.
Once the proper jetting is established, you can reference the EGT gauge for your baseline numbers. Then, if there is a rise or fall of 25 degrees, you must jet accordingly to return your EGTs to the baseline numbers.
2.14
9922854 - 2007-2011 IQ Service Manual
©2010 Polaris Sales Inc.
SERVICE PRECAUTIONS
GENERAL PRECAUTIONS
In order to perform service work efficiently and to prevent costly errors, the technician should read the text in this manual, thoroughly familiarizing him/herself with procedures before beginning. Photographs and illustrations have been included with the text as an aid.
Notes, cautions and warnings have also been included for clarification of text and safety concerns. However, a knowledge of mechanical theory, tool use and shop procedures is necessary to perform the service work safely and satisfactorily. Use only genuine Polaris service parts.
CAUTION
Cleanliness of parts and tools as well as the work area is of primary importance. Dirt and foreign matter will act as an abrasive and cause damage to precision parts. Clean the snowmobile before beginning service. Clean new parts before installing.
Watch for sharp edges which can cause personal injury, particularly in the area of the tunnel. Protect hands with gloves when working with sharp components.
CAUTION
If difficulty is encountered in removing or installing a component, look to see if a cause for the difficulty can be found. If it is necessary to tap the part into place, use a soft face hammer and tap lightly.
CAUTION
Some of the fasteners in the snowmobile were installed with locking agents. Use of impact drivers or wrenches will help avoid damage to fasteners.
CAUTION
Always follow torque specifications as outlined throughout this manual. Incorrect torquing may lead to serious machine damage or, as in the case of steering components, can result in injury or death for the rider(s).
General Information
CAUTION
If a torquing sequence is indicated for nuts, bolts or screws, start all fasteners in their holes and hand tighten. Then, following the method and sequence indicated in this manual, tighten evenly to the specified torque value. When removing nuts, bolts or screws from a part with several fasteners, loosen them all about 1/4 turn before removing them.
CAUTION
If the condition of any gasket or O-Ring is in question, replace it with a new one. Be sure the mating surfaces around the gasket are clean and smooth in order to avoid leaks.
CAUTION
Some procedures will require removal of retaining rings or clips. Because removal weakens and deforms these parts, they should always be replaced with new parts. When installing new retaining rings and clips use care not to expand or compress them beyond what is required for installation.
CAUTION
Because removal damages seals, replace any oil or grease seals removed with new parts.
CAUTION
Polaris recommends the use of Polaris lubricants and greases, which have been specially formulated for the top performance and best protection of our machines. In some applications, such as the engine, warranty coverage may become void if other brands are substituted.
CAUTION
Grease should be cleaned from parts and fresh grease applied before reassembly of components.
Deteriorating grease loses lubricity and may contain abrasive foreign matter.
2
2.15
9922854 - 2007-2011 IQ Service Manual
©2010 Polaris Sales Inc.
General Information
NOTES
2.16
9922854 - 2007-2011 IQ Service Manual
©2010 Polaris Sales Inc.
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