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340 CLASSIC 2006
Polaris 340 CLASSIC 2006 User Manual
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10.4
FRONT SUSPENSION/STEERING
42.5 EDGE
Apply Polaris All Season Grease to all zerks
201
203
Table of Contents
Table of Contents
1
340 Classic
2
Chapter 1
2
550 Classic
6
700 Classic
10
500 Indy
12
Supersport
14
340 Indy Touring
16
Trail Touring
18
600 Edge Touring
20
700 Touring
22
Widetrak Lx
24
500 XC Sp
26
600 Ho Standard Fusion
28
600 Ho Dragon Fusion
30
700 Fusion
32
600 Ho Switchback
36
900 Switchback
38
Trail Rmk
40
600 Ho Rmk
42
700 Rmk
44
Specifications Notes
49
Chapter 2 General
50
How to Use this Manual
50
Locating Information
50
Explination Method of this Manual
50
Snowmobile Model Number Designation
51
Example
51
Tunnel Decal
51
Tunnel Decal Located on the Right Hand Side of the Sled
51
Publication Part Numbers
52
2006 Part Numbers
52
Vin (Vehicle Identification Number)
52
Vin Explination
52
General Reference
54
Standard Bolt Specifications
54
Sae Tap Drill Sizes
55
Metric Tap Drill Sizes
55
Mesurement Conversion Chart
56
Piston Wash / Spark Plug Reading
57
Gasoline Information
57
Gasoline Volatility
57
Stroke Gasoline / Oil Pre MIX
58
Special Tools
59
Fuel Pressure Gauge (Pv-43506-A)
59
Throttle Position Sensor Tester Kit (2201519)
59
Fuel Line Disconnection Tool (Ps-47152)
59
Mity-Vac Pressure Test Kit (2870975)
59
Special Tools
60
General
63
Chapter 3 Polaris Recommended Program
65
Maintenance Program
65
Inspectons
67
Cylinder Head Inspection
67
Cylinder Measurement
68
Cylinder Honing
68
Honing Procedure
69
Honing to over Size (340/550/500 Fuji Engines Only)
69
Cleaning the Cylinder after Honing
69
Piston Inspection
69
Piston Ring Installed Gap
70
Coolant Level
70
Recommended Coolant
70
Cooling System Bleeding
70
Bearing Fit
71
Main Bearing
72
Connecting Rod (Big End) Bearing
72
Wrist Pin Bearing
72
Crankshaft Indexing
73
Checking Crankshaft Index
73
Crankshaft Truing
73
Crankshaft Runout Inspection
74
Oil Pump Bleeding
75
Fitting Types
75
Verifying Check Valve Operation
75
Oil / Fuel Filter
76
Brake Lever Travel
76
Brake Fluid
76
Brake Fluid Bleeding
77
Exhaust System
78
Exhaust Removal
78
Exhaust Installation
78
Belt Deflection
79
Measuring Belt Deflection
79
Lubrication
79
Grease Points
79
Jackshaft Bearing
79
Driveshaft Bearing
80
Rear Suspension
80
Chaincase
80
Steering U Joint
80
Adjustment
81
Chaincase Drive Tension
81
Track Alignment
82
Track Lubrication
82
Track Tension
83
Oil Pump Adjustment
84
Headlight Adjustment
84
Handlebar Adjustment
85
Handlebar Riding Position Adjustment (Rider Select Only)
85
Throttle Lever Free Play
86
Torque Stop
86
Cleaning
86
Table of Contents
89
Chapter 4 Warnings
90
General Information
90
Service Precautions
90
Gasoline Votalitiy
91
Stroke Gasoline / Oil Pre MIX
91
Fuel Delivery System (Carbureted)
91
Carbureted System Overview
91
Fuel Pump (Non-Injected Units)
92
Fuel Pump Overview
92
Maintenance
93
Operation
93
Cleaning
93
Inspection
93
Mikuni Jet Needle
93
Overview
93
Mikuni Tm 38
94
Carburetor Overview
94
Mikuni Carburetor
95
Function
95
Float System
95
Fuel Metering
96
Fuel Delivery
96
Pilot Jet
96
Pilot Air Screw
96
Main Jet
96
Jetting Guidelines
97
Piston Valve or Throttle Valve
97
Jet Needle / Needle Jet
97
Jet Needle
97
Needle Jet
98
Throttle Opening Vs Fuel Flow
98
Mikuni Tm38 Flat Slide Service
99
Disassembly
99
Assembly
100
Carburetor Syncronization
101
Throttle Valve Syncronization
101
Throttle Position Sensor
102
Setting the Tps
102
Carburetor Cable Adjustments
103
Choke Adjustment
103
Throttle Lever Freeplay
103
Carburetor Component Part Numbers
104
Mikuni Pilot Jets
104
Mikuni Main Jets
104
Mikuni Jet Needles
104
Mikuni Starter Jets
104
Mikuni Pilot Air Jets
105
Mikuni Piston Valves
105
Cleanfire Fuel
107
Chapter 5 Warnings
108
Fuel Delivery System (Cleanfiret)
108
Cleanfire System Overview
108
General Information
108
Gasoline Voltality
108
Stroke Gasoline / Oil Pre MIX
108
Fuel Rail
109
Fuel Rail/Injector Removal
109
Fuel Rail/Injector Installation
109
Fuel Rail Bleeding
110
Pump Flange Assembly
109
Fuel Pump
109
Fuel Level
109
Injector
110
Injector Replacement
110
Throttle Body
110
Setting the Throttle Body Tps
110
Setting the Base Line Voltage
110
Setting the Idle Voltage
112
Throttle Body Removal
112
Fuel Filter
112
Fuel Filter Removal
112
Fuel Filter Installation
112
Table of Contents
113
Chapter 6
114
Exhaust Valve Removal
114
General Engine Information
114
Exhaust Valve Installation
115
Reed Valve Disassembly
115
Exhaust Valve Springs
116
Reed Valve Assembly
116
Thermostat Replacement
116
Water Temperature Sensor Replacement
116
700/900 Engine
117
700/900 Torque Specifications
117
700/900 Liberty Engine Removal
118
700/900 Liberty Engine Installation
120
700/900 Engine Rebuilding
123
700/900 Disassembly
123
700/900 Torque Patterns
124
700/900 Assembly
124
700/900 Water/Oil Pump Cross Shaft Disassembly
124
700/900 Water/Oil Pump Cross Shaft Assembly
126
700/900 Recoil/Stator Disassembly
126
700/900 Recoil/Stator Assembly
126
500/600 Ho Engine
127
500/600 Ho Torque Specifications
127
600 Ho Iq Engine Removal
127
600 Iq Engine Installation
131
500/600 Ho Engine Rebuilding
134
500/600 Liberty Engine Disassembly
134
500/600 Ho/600 Liberty Torque Patterns
136
500/600 Engine Assembly
136
500/600 Liberty Water/Oil Pump Cross Shaft Disassembly
136
500/600 Liberty Water/Oil Pump Cross Shaft Assembly
137
Liberty Cylinder Stud Installation
137
500/600 Recoil/Stator Removal
138
500/600 Recoil/Stator Assembly
138
340/550 Fuji Engine/500 Liberty
138
340/550 Fuji/500 Liberty Engine Removal/Installation
138
340/550 Engine Rebuilding
139
340/550 Engine Disassembly
140
340/550 Engine Assembly
140
500 Fuji
141
Disassembly
141
Assembly
142
Table of Contents
145
Chapter 7 Clutch Tools
147
Special Clutch Tools
147
Drive Belt
148
Belt Inspection
148
Belt Diagnosis
148
Drive Belt Removal with Team Clutch
149
Belt Installation (Team Driven Clutch)
149
Drive Belt Removal with Polaris Driven Clutch
150
Belt Installation (Polaris Driven Clutch)
150
Drive System Terminology
151
System Overview
151
Drive Spring
151
Clutch Weight
151
Neutral Speed
151
Engagement Rpm
151
Shift out Overrev
151
Shift out Rpm
151
Driven Spring
151
Back-Shifting
152
Final Gearing
152
1:1 Shift Ratio
152
Low / High Ratio Lines
152
Driven Helix / Ramp
152
Centrifugal Drive System
153
Theory of Operation
153
Drive Clutch
153
Operation
153
Drive Clutch Identification
154
Drive Clutch Removal
154
Drive Clutch Components
155
Drive Clutch Disassembly
157
Clutch Assembly
157
Drive Clutch Spider Removal/Installation
158
Roller Removal
158
Roller Installation
159
Spider Indexing
159
Spring Free Length
160
Drive Clutch Weights
162
Drive Clutch Installation
163
Driven Clutch
164
Driven Clutch Overview
164
Driven Clutch Types
164
Driven Clutch Removal
164
Driven Clutch Installation
164
Team Ramps Explained
165
Polaris P-85 Helix
167
Drive System Adjustments
169
Clutch Alignment
169
Clutch Alignment Inspection
169
Clutch Alignment Adjustment
169
Clutch Offset
169
Off Set Adjustment
169
Table of Contents
173
Chapter 8
178
Gears
178
Gears and Chains
178
Chain Case
179
Exploded View
179
8.37 Chaincase Removal
180
8.37 Chaincase Installation
181
7.92 Chaincase Removal
181
7.92 Chaincase Assembly
181
Chaincase Seal/Bearing Replacement
182
Drive Chain
179
Drive Train
183
Jackshaft Exploded View
183
Jackshaft Removal
184
Jackshaft Installation
184
Driveshaft
185
Drive Shaft Removal
185
Widetrak Transmission
186
Removal
186
Inspection
187
Low/Reverse Shaft Disassembly
189
Shift Fork Disassembly
189
Transmission Assembly
190
Transmission Installation
190
Final Drive
193
Chapter 9
194
Compensating Port
194
General Guidelines
194
Hydraulic Brake System
194
Overview
194
Brake Fluid Replacement & Bleeding
195
Brake Line Replacement
195
Brake Light Switch Replacement
196
Caliper
196
Caliper Removal
196
Caliper Replacement
197
Caliper Assembly
197
Brake Pad Replacement
197
Brake Disc Replacement
197
Widetrak Brake Caliper
197
Removal
197
Assembly
198
Installation
198
Front Suspension/
199
Chapter 10
200
Fusion/Iq Rmk
200
Edge Rmk
201
42.5 Edge
202
Widetrak
203
Front Suspension Adjustment Procedures
204
Set up and Adjustments
204
Ifs Shock Springs
205
Springs
206
Compression Damping Adjustable Shocks
206
Shock Information
207
Ifs Shock Specifications
207
Ifs Shock Production Valving
208
Iq Front Suspension
210
Spindle Removal
212
Spindle Assembly
212
Lower Spherical Bearing Replacement
212
Upper / Lower Control Arm Removal
212
Upper / Lower Control Arm Installation
212
Steering
212
Inspection
212
Alingment Bar Specifications
213
Camber Definition
213
Rod End Procedure
213
Rod End Engagement
213
Camber &Toe Specifications
213
Alignment Adjustments
214
Edge Set up Width
214
Edge Camber Adjustment
214
Iq Camber Adjustment
215
Handlebar Centering
215
Toe Adjustment
215
Ski Stance
216
Adjustment (Rmk Only)
216
Chapter 11 Rear Suspension
217
Rear Suspension Operation
218
Operation
218
Weight Transfer
218
Suspension Coupling
218
Rear Torsion Spring Tension Adjustment
219
Rear Suspension Specifications
218
Rear Suspension Adjustments and Settings
219
Rear Suspension Adjustment Procedures
219
Setting Rear Suspension Ride Height
220
Scissor Stop Adjustments
220
Torsion Spring Adjustment
221
Installing Heavier Springs on Afusion Suspension
225
M-10 Suspension
226
M-10 Overview
226
M-10 Adjustments
226
M-10 Terminology
226
M-10 Adjustments
227
M-10 Fra Initial Set up Reference
227
M-10 Rear Spring Preload
228
Ski Pressure
228
Rail Slider
229
Rail Slide Wear Limit
229
Rail Slide Removal
229
Rail Slider Break
229
Rear Suspension Removal / Installation
229
Rear Suspension Removal
229
Rear Suspension Installation
229
Shock Information
230
Valving Specifications
231
Rear Suspension Front Track Shock (Fts) Stock Valving
231
Rear Suspension Rear Track Shock (Rts) Stock Valving
233
Shock Valve Part Numbers
236
Ryde Fxt Shock Valve Part Numbers
237
Foxt Shock Valve Part Numbers
237
Shock Valving Arrangement
238
Shock Maintenance
239
Ryde Fx Mono-Tube Shock Disassembly
240
Ryde Fx Mono-Tube Shock Assembly
241
Fox Ps-5 Assembly
242
Special Tools
239
Shock Rebuilding Tools
239
Rear Suspension Troubleshooting
243
Chapter 12 Chassis / Hood
245
Bumper
246
Iq Front Bumper Removal / Installation
246
Headlight
246
Iq Headlight Removal / Installation
246
Hood
246
Hood Repair
246
Instrument / Mfd
246
Edge Instrument Removal / Installation
246
Iq Mfd Removal / Installation
246
Removal / Installation
246
Coolant/Oil Tank
247
Coolant Tank Removal
247
Coolant Tank Installation
247
Fuel Clips
247
Fuel Clip Removal
247
Fuel Clip Installation
247
Oil Tank
247
Oil Tank Removal
247
Oil Tank Installation
247
Seat and Fuel Tank
248
Fusion Seat and Base Removal/Installation
248
Iq Rmk Seat Removal/Installation
248
Iq Rmk Seat Base Removal/Installation
249
Iq Fuel Tank Removal
249
Iq Fuel Tank Installation
249
Edge Seat Removal / Installation
250
Seat Cover Replacement
250
Iq Seat Cover Replacement
250
Air Intake Removal
250
Edge Air Box Removal
250
Edge Air Box Installation
251
Iq 700/900 Air Intake Removal
251
Iq 700/900 Air Intake Installation
251
Iq Carbureted Air Intake Removal
251
Console
250
Iq Console Removal / Installation
250
Edge Console Removal / Installation
250
Tail Light
250
Tail Light Assembly Replacement
250
Handlebar Cover
252
Handle Bar Cover Removal/Instaltion
252
Skis
252
Ski Removal
252
Ski Installation
252
Decals
253
Decal Removal
253
Decal Installation
254
Nosepan
253
Replacement
253
Chapter 13 Electrical
257
Ignition Timing (Carbureted Units)
259
Ignition Timing
259
Multimeter
259
Battery
261
Preparing a New Battery for Service
261
Battery Testing
261
Open Circuit Voltage Testing (Ocv)
261
Load Test
261
Refilling a Low Battery
261
Off Season Storage
262
Charging Procedure
262
Starter System
262
Dynamic Testing of the Electric Starter System
262
Starter Motor Static Testing
264
Starter Housing and Field Coil Inspection
264
Armature Testing
264
Starter Assembly
265
Starter Solinoid Bench Test
265
Starter Installation
265
Voltage
265
Unregulated Voltage
265
Regulated Voltage
266
Short Circuit Current (Ac Amp Test)
266
Alternators
266
Electrical Testing
267
Headlight Bulb Filiment Continuity Test
267
Hi / Low Beam Switch Testing
267
Seat Harness Troubleshooting
267
Ignition Switch Testing (Non-Electric Start)
267
Ignition Switch Testing (Electric Start Models)
268
500/600 Temperature Light
268
Speed Control Assurance Switch
268
Speed Control Assurance Switch Adjustment
268
Auxiliary Shut-Off Switch Testing
269
Fuel Sender Testing
269
Troubleshooting Charts
270
No Spark
270
Tps Tool Set up
272
Tps Set
272
Tps Adjustment
272
Clean Fire Electrical
273
Iq Throttle Position Sensor
273
Iq Temperature Light
273
Lamp Circuit Test
273
Thermistor Sensor Test
273
Iq Detonation Elimination Sensor (Det)
274
Det Troubleshooting
275
Effect of Det
275
Sensor Fail Safe
275
Iq Temerature Sensor
275
Exhaust Temperature Sensor
275
Intake Air Temperature Sensor
276
Barometric Pressure Sensor
276
Crankshaft Position Sensor (Cps)
276
Speed Sensor
277
Ecu Plug #1
278
Ecu Plug #2
279
Stator
280
Ignition Coil
281
Exhaust Valve Solinoid
281
Regulator Rectifier
283
Capacitor
284
Chassis Relay
284
Chassis Ground
284
General Electrical Items
285
Oil Level Sender
285
Polaris Electronic Reverse Control (Perc)
286
Operation
286
Reverse Operation
286
Forward Operation
286
Altitude Setting
286
Perc Notes
286
Digital Wrench
287
Connections
287
4
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Polaris 340 CLASSIC 2006 Specifications
General
Brand
Polaris
Model
340 CLASSIC 2006
Category
Offroad Vehicle
Language
English
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