2006-2014 Polaris Four Stroke Snowmobile Repair Manual

FS / FST SERVICE MANUAL 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 be directed to: Service Publications Dept. @ Polaris Sales Inc. 2100 HWY 55 Medina, Minnesota 55340. FS / FST Service Manual PN 9921066 © Copyright 2007 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.

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. 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 Rapid Reaction Clutch, Registered Trademark of Team Industries, 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 CAUTION

Model Specifications 1.1 CHAPTER 1 Model Specifications 1 FS / FST Service Manual 9921066 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 2006 FS CLASSIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 2006 FST CLASSIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 2006 FS TOURING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 2006 FST TOURING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 2006 FST SWITCHBACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 2007 FST IQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 2007 FST IQ LX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 2007 FS IQ TOURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16 2007 FST IQ TOURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.18 2007 FST IQ CRUISER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20 2007 FST IQ SWITCHBACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22 2008 IQ TURBO DRAGON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.24 2008 IQ TURBO LX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.26 2008 TURBO SWITCHBACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.28 2008 FS IQ TOURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.30 2008 FST IQ TOURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.32 2008 IQ CRUISER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.34

1.2 Model Specifications FS / FST Service Manual 9921066 SPECIFICATIONS 2006 FS Classic Model Number: S06PD7ES Engine Engine Type 8 Valve - SOHC - Parallel Twin Cylinder w/ Counter Balancer Displacement 749cc Bore (inches/mm) 3.45 / 85 Stroke (inches/mm) 2.60 / 66 Piston to Cylinder Clearance (inches/mm) 0.0006-0.002 / 0.017-0.052 Ring Installed End-Gap Top Ring Middle Ring Oil Control Ring (inches / mm) 0.009-0.019 / 0.25-0.50 0.007 - 0.013 / 0.20 - 0.35 0.005 - 0.011 / 0.15 - 0.30 Operating RPM ±200 8000 Idle RPM 1450 Engagement RPM ±200 3500 Table 1-1: Clutching ALTITUDE meters (feet) DRIVE CLUTCH DRIVEN CLUTCH Shift Weight Clutch Spring Clutch Spring Driven Helix Gearing 0-600 (0-2000) 11-50 3120 60/340 Red/Black 62/40.46 64/40.55 NON-ER 21:46-80 600-1200 (2000-4000) 11-48 1200-1800 (4000-6000) 11-44 1800-2400 (6000-8000) 11-42 3076 40/340 2400-3000 (8000-10,000) 11-40 3000-3600 (10,000-12,000) 11-40 Drive Clutch Bolt Torque: 50 lb.ft. (68Nm) Table 1-2: General Width (in/cm) 48 / 121.9 Length (in/cm) 115 / 292.1 Height (in/cm) 53 / 134.6 Estimated Dry Weight (lb/kg) 591 / 268 Fuel (Gallons / Liters) 9.2 / 34.8 Oil qts/l 3/2.8 Engine Oil - PS4 Plus Equivalent = 0W-50 Synthetic SL Minimum Rating 2876244 (Quart) 2875522 (Oil Kit) Kit includes 3 quarts oil, filter, o-ring, and ignition jumper. Oil Filter (paper cartridge) 0451848 Oil Breather Foam 5813009 Coolant qts/l 6.34/6.0 Brake Fluid DOT 4 Drive Belt Part Number Width (inches / cm) Side Angle Circumference (inches / cm) Center Distance (inches / cm) 3211099 1.49 / 3.78 28_ 46.063 / 116.9 11 / 28 Chaincase Center Distance (inches) Top Gear (Stock) Bottom Gear (Stock) Chain (Stock) Gear Lube Capacity (oz / ml) Reverse System 8.42 21 46 80 Polaris Synthetic 9 / 266.2 Perc 4 Table 1-3: Fuel Delivery Type Sequential Fuel Injection Throttle Body Marking 1253520-01 Throttle Body Bore 46mm TPS Voltage @ Idle 0.56 Vdc Fuel Pressure - PSI (bar) 43.5 (3.0) Recommended Fuel Octane (R+M/2) 87 (Minimum)

1.3 Model Specifications 1 FS / FST Service Manual 9921066 Table 1-4: Electrical Alternator Output Operating Voltage Watts @ 13.5 Vdc (Total) Watts @ 13.5 Vdc (After EMS) Amps @ 13.5 Vdc (No Load) 13.5 - 14.5 Vdc 780 630 60 Ignition Timing Variable Spark Plug Gap in.(mm) .030 (.75) Spark Plug OE Equivalent Champion RC7YC 3070195 Champion RC7PYCBX 3021837 Table 1-5: Track Width - Inches (cm) 15 (38) Length - Inches (cm) 128 (325) Lug Height - Inches (cm) 1.25 (3.175) Track tension sag in/cm with 10 lbs/4.54kg placed 16 in/ 40cm ahead of rear idler shaft 7/8″- 1 1/8″ (2.2 - 2.9cm) Table 1-6: Front Suspension Suspension Type IQ Shocks Nitrex Select IFS Spring Rate lbs/in (N/mm) 120 (21) Spring Installed Length Inches (cm) 9.95 (25.3) Front Vertical Travel Inches (cm) 9.92 (25.2) Ski Center Distance Inches (cm) 42.5 (108) Camber Inches (cm) 2.25 ± 0.31 (57.2 ± 0.79) Toe Out Inches (cm) 0 - 0.12 (0 - 0.31) Table 1-7: Rear Suspension Suspension Type Fast M-10 128 Front Track Shock (FTS) Fox HPG w/IFP (Rebuildable) FTS Spring Rate lbs/in (N/mm) 180 (31) FTS Spring Installed Length Inches (cm) 8.5 (21.6) Rear Track Shock (RTS) Fox HPG w/IFP (Rebuildable) Lower Outer Spring Rate lbs/in (N/mm) 715 (125) Lower Inner Spring Rate lbs/in (N/mm) 425 (74.4) Upper Spring Rate lbs/in (N/mm) 273 (48) Rear Travel Inches (cm) 13 (33)

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2006-2014 Polaris Four Stroke Snowmobile Repair Manual

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