2007-2011 Polaris IQ Snowmobile Service Repair Manual

2007 ·- 2015 . IQ SN SERVICE MAN PN 9925101 R

POLARIS® 2007 - 2015 IQ Snowmobile Service Manual FOREWORD The information printed within this publication includes the latest product information at time of print. The most recent version of this Service Manual is available in electronic format at www.polarisdealers.com. Th is Service Manual is designed primarily fo r use by certi fi ed 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 no rmal rid in g positio n. 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 t he text and be familiar with the service procedures before starting any repair. Certain procedures require t he use of special tools . Use only the proper tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service Manual, contact an authorized dealer for service. We va l ue your input an d appreciate any assistance you can provide in helping make these publications more useful. Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask Polaris'. Click on 'Ask Polaris ', and then click on 'Service Manual I Service Literature Question'. Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN : Service Publications Department, 2100 Hwy 55 , Medina , MN 55340. Publication Printed August 2014 (PN 9925101 R01) © Copyright 201 4 Polari s Indust ries Inc. Al l information contained within th is publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quali ty of production components, some minor discrepancies may result between the actual vehicle and th e informati on presented in th is publicati on. Depictions and/or procedures in this publi cation are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions an d/or procedures contained wit hi n, whether whole or in part, is expressly prohibited. Printed in U.S.A.

UNDERSTANDING SAFETY LABELS AND DIRECTIONS Throughout this manual, important information is brought to your attention by the following symbols: A wARNING 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. A CAUTION SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle. CAUTION 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 Nyoge l, Trademark ofWm . F. Nye Co. Fluke, Registered Trademark of John Fluke Mfg. Co. Mity-Vac, Registered Trademark of Neward Enterprises, Inc. Torx, Registered Trademark of Textron FOX, Registered Trademark of FOX RACING SHOX RydeFX, Registered Trademark of ArvinMeritor Walker Evans, Registered Trademark of Walker Evans Racing Some Polaris factory publications can be downloaded from www.polarisindustries.com , purchased from www.pu repolaris.com or by contacting the nearest Polaris dealer.

MODEL SPECIFICATIONS I GENERAL INFORMATION Ill MAINTENANCE lfll ENGINE I COOLING I LUBRICATION IJI FUEL SYSTEMS Ill FINAL DRIVE I BRAKE SYSTEMS IJII PVTSYSTEM B STEERING I SUSPENSIONS lfll SHOCKS B CHASSIS IDI BATTERY I ELECTRICAL 10

MODEL SPECIFICATIONS I GENERAL INFORMATION CHAPTER 1 MODEL SPECIFICATIONS I GENERAL INFORMATION VEHICLE IDENTIFICATION . ... ..... ... ... ............ ... .. .... ..... .... . ... .. . ....... ........... .. ... ... 1.4 MODEL NUMBER DESIGNATION . .. ... ..... .. . ... . .. ... .. .... .. ............. .. .... . ... .. . ... . .. ... 1.4 VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION .... .. ....... .. ... ... .. .... . ....... .. .. . 1.4 TUNNEL DECAL ...... ... ...... .. .... ..... .. .. .... .. . .. .. .. .. ..... .... ... ... ... ... ... ..... ... .... .. 1.4 MODEL SPECIFICATIONS .... ... ....... ... ............ .. ................. .. ......................... ... . 1.5 2007 600 HO IQ ... . .. ... .... ... ... ... •.. .. . .. . .. ........ ... .... .. .... .. • ..•... ... .. .•... ... . .. . .... 1.5 2007 600 HO SWITCHBACK . . ....... . ........ .. ... ... .. . .. . .. .. . ... . .. ....... .. .... • ..•... .. .. .. .. 1.7 2007 600 HO RMK . .. .. .. .... ... ... .. ... .. .. .. ... . .... . .. .. .. .. ... . .. . .. .. . .. . .... . .... .. .. . ....... 1.9 2007 600 HO IQ CFI. .. ... ... .. .. ... ... .. ..... .. .. .. ..... .. . .. .... ... .. .. .. ... ..... .. . .. ..... ... . .. 1. 11 2007 600 HO SWITCHBACK CFI . .. ... . .. . ... . ......... ... .. .. .. . .. .... ... .... .. .... ... ... ... . .. .. 1.13 2007 600 HO IQ LX CFI .... . ... ...... .. ... ... .. ...... .......... .. ........ .... . .. . ... .. .. ... ... .. .. 1.15 2007 600 HO IQ TOURING CFI . . ... .... .. ... .. .. ... .. . ... . .. ... .. .. ... ... ..... .. . .... ... .. . .. . ... . 1.17 2007 700 HO IQ DRAGON .. ..... .. ... ... . .. ... ... .. ..... ... .... ... ... ... . .... .. . .. .. .. .. .. ....... 1. 19 2007 700 HO RMK DRAGON . . .. . .. ... ... ...... ..... ....... .. . .. . .. . .. ... ....... . ..• ... .. .... ..... 1.2 1 2008 IQ SHIFT .. . .. .... .. .. ... .. ..... ..... ... .. .. .. .. ... . ... ..... ... .. .... .. . .. .. .. .. .... .. .. . .. .. 1.23 2008 600 RMK 1441600 RMK SHIFT 155 .. ... .. ... .. .. ... .. .. . ..... .. .... ... ... .. . .. . .. .. ... ... . .. 1.25 2008 600 DRAGON IQ .. .. .. ... .... , . ... ..... . ... . .. ... .... .. ... .. ... . ... .. .. .. .. ... . ... ... ... .... 1.27 2008 600 SWITCHBACK 1600 DRAGON SWITCHBACK .. .. .. ..... ... ......... .. .. .. .. .. . .. .... ... 1.29 2008 600 IQ LX . ... .. .... .. . ...... . .. ............. .. .. .. .. ... . .. .. ........ ..... .... . .. .... ... ... .. 1.31 2008 600 IQ TOURING ... . .. . .. .. .. .. ... ........... .. . .... ...... .. ..... .. . .. .. .•... .. ....... .. .... 1.33 2008 600 RMK 155 ... ..... .. .... ... ...... .. ... ... ... .... ... .. ... .. .......... •.. ........ .. .. .. . .... 1.35 2008 700 IQ 1700 DRAGON IQ . .... . .. .. ........ .. .. .... .. .• .... .. •..• .. ...... .. . ... .. ....... ... .. 1.37 700 SWITCHBACK I DRAGON SWITCHBACK ........ . ... . ..... .. .. . .. .. . .. . .. •. ... . .. .. .. ....... 1.39 2008 700 RMK 1551700 DRAGON RMK 1551163 . .. . .. .. .. ... .. ..... ..... . .. . .... . ... . .. ... .. .. .... 1.41 2008 800 DRAGON RMK 1551163 .. .. ... .. .. .. .. .. ... ... .. .. .. .... .. .... .. .. .. .. ....... ... . ... .... 1.43 2009 550 IQ SHIFT ....... ... ...... ..... . .... .. ....... . ... .. .. . ... ... .. . ... .. . .. . ........ . .. ... .... 1.45 2009 600 IQ SHIFT ... . .. ... . ..... .... ...... .. ...... .. .... .. . ... .. ..... .. .... .... .. .... ... ... ... ... 1.47 2009 600 IQ I 600 DRAGON IQ SP .. . .. ...... ... . .. .. ... .. ..... ... . .. . .. •.. .. .. . .... ..... . .. .... . . 1 .49 2009 600 IQ SHIFT 136 .. ... .. .. ...... ... .. . .. . ...... .. .. .. .. .. ... .. .. .. ... .. .. ... .. ..... .. .. .. ... 1.51 2009 600 SWITCHBACK I DRAGON SWITCHBACK . . ... .. ... .... .. .. • ... . ..... . ..... . ..... .. .... . 1.53 2009 600 IQ TOURING ...... ... . .. . .. ....... ...... ... ... . .. .. .. . .. . .. .... .. ...... .... ...... ..... .. 1.55 2009 600 RMK SHIFT 1441155 ... ........ .. .. .. ...... .. ....... .. .... ... •. ... .. ... .. . ..... .. .. .. .. 1.57 2009 700 RMK 155 . ... ... ... .. .. .. .. ..... ..... .. ..... . .. .. .. . .. .... .. .... ... ....... .. .... .. . .. . ... 1.59 2009 800 IQ 1800 DRAGON SP .... .. ... .. .. .. ...... ..... .. . ... .. .. .. ...... ... .. ... .. .. .. ....... .. 1.61 2009 800 SWITCHBACK/DRAGON SWITCHBACK .. . .. ... ... ..... .. .. .... .. ..•. ..• .. • .... .... .. .. 1.63 2009 800 RMK SHIFT . . ... ... .. .. ... ... ..... ... .. .. .. .. ........ .. ..... .. . .. ... .. . .. .. ........ ..... 1.65 2009 800 RMK ASSAULT 146 . .. .. ..... ..... .. .. .. .. ......... .. .. ... .. ... .... .. .. .... .. . .... .. .. . . 1.67 ASSAULT "ON-TRAIL" OPTIONAL SETTINGS .. .. ... .. .. ... .. ... .. . .. .......... ... ...... .. ..•. .. .. 1.68 2009 800 RMK 1551800 DRAGON RMK 1551163 ... .. .. .. . ... .. . ... . .. . .. .. ......... .. • .. ... .•. .. . . 1.69 2010 550 IQ SHIFT . . . .. ... .. .. .. . .. . .. .. . ......... . .. . ... . .... . ... .. ... .. .. .. . .. . ..... .. ... .. ..... 1.71 2010 600 IQ SHIFT 1600 IQ ........ .. .............. .. .. .. .. . ... . .. ... ...... ...... .. .. ........ .. .. . 1.73 9925101 R01 - 2007- 20 15 IQ Snowmobile Service Manual © Copyright 2014 Polaris Industries Inc. 1.1

MODEL SPECIFICATIONS I GENERAL INFORMATION 1.2 2010 600 LX .... .. .... ... 00 . .. ..... 00 ... 00 00 .. 00 . 00 .. 00 ... .. 00 . 00 00 00 00 .. 00 .. 00. 00. 00 . .. . .. 00 . .. .. 00 .. . 1.75 2010 600 SWI TCHBACK/DRAGON SWITCHBACK . .. .. . .. .. ... ... ... ....................... .. ......... 1 .77 2010 600 10 TOURING ... . .. ...... .. ....... .. .. .. . .. .. .. ... ..... .. ........ .. .... .. ... .... ... .. ....... .. 1.79 20 10 600 WIDETRAK 10 .. .. .. .. .... •... .. .•. ..• .. ... ..... .. ... .. . ..... . ... ..... ... ...... ... ........... 1.81 2010 800 10 I BOO DRAGON 10 . .... ............. ... ... ...... .. .. ..... .. . ... .... •. . •........ .. . ... ...... 1 .83 20 10 800 SWITCHBACK I DRAGON SWITCHBACK . . . .. .• . . . • .. ........ .. ..... .. ...... .. .............. 1.85 2010 600 RMK 1 441155 .. . .. 00 .. ... ... .. ... .. .. ... .. . 00 ... . .... 00 ... ..... . .. . .. .. .. . 00 .. .. .. ... .... .. 00 1.87 20 10 700 RMK 155 .. . 00 .. .. .... ... .. .. .... .. .. ... 00 ..... 00 .. 00 .00 .. . 00 .. . 00 .. .. ... . .. . ... . .. .. 00 .. .. . 00 1.89 20 10 800 RMK 1441155 . ... ....................... .. ..... .. . ... ............. ..... . ... ..... .. ........... 1.91 2010 800 RMKASSAULT 146 . . . 00 ..... 00 .. ... ... 00 . 00 . .. . .. 00 . 00 00 . 00 00 . 00 .. 00 .00 .. 00 . .. .. ..... .. . ... . 1.93 ASSAULT "ON-TRAIL" OPTIONAL SETTINGS ..... .. ..... .. ... .. . .. . ... .. .... .. ...... .. .. . .. . .. .. ... . .. 1.94 2010 800 DRAGON RMK 1551163 . . 00 . .. .. 00 .. 00 .. .. 00 .. .... 00 .. . .. .. ..... . .... . 00 .. 00 . 00 .. 00 . .. ..... .. 1.95 2011 550 10 SHIFT ......... .. . .. .. ... ..... .. ........... .. ... ... ...... ... ............ ... . ... .. .. .. . . ... . 1.97 20 11 550 SHIFT 136 . 00 .. ... 00 .. .. .. 00 ... .. ... .. .. . .. . .. 00 ... .. 00 .. .. ... .. . ... ... .. .. . .. ..... . 00 ... .... 1.99 20 11 55010 LXT . ... . 00 .... ..... .. ..... .. .. .. ...... .. ... 00 ... . .. . .. . .. .. ......... . .. .. .. . ... .. 00 .. ... 1.101 2011 60010 SHIFT .... ..... ....... ... ..... ... ... .... ... .. .. ... ........... .. .. ... ............ .. • ...... 1.103 2011 600 SHIFT 1361600 SWI TCHBACK 136 . .. 00 . .. .. 00 ... . .. . 00 ...... .. .. .. 00 ..... 00 ......... . ... .. 1.1 05 20 11 600 10 LXT . .. .... .. .. . ... .. .. ......... ... ... .. .......... ... . ... .. .. .. .. ......... .. ... .. .. ... ... 1. 107 2011600WIDETRAKIO · oo·oo ·· ·· ···oooo ... .. .. . oo. oo .. .. .. .. oo . ....... . oo .. . .. oo oo .. . oo . .. .. oo ..... 1.109 2011 600 RMK 14411 55 .. ... .. .. . 00 . 00 ... .. .. .. 00 . .. .. 00 . ... .. ......... 00 .. .. .... . ... 00 . 00 .. .. 00 00 . 00 . . 1. 111 201255010SHIFT .............. ... . .. .. .. .. ...... .. .. . .. . ... . .. .. ..... ... .. .. ... .. .. . .. .. . .. .. .. . ... 1.113 2012 550 SHIFT 136 .. ... ......... .. .. 00 . .. .. ..... ... 00 .. ... 00 . .. .. .. ..... .. . 00 .. .... .. .. ... 00 00 00 ... 1. 115 201255010LXT ..... oo .. oo .. . .. . .... .. . .... .. .. ... . oo .. oo ..... .. ..... ... .. . ... . .. .. oo . oo ....... .. .. . 1.117 20 12600IOSHIFT ... oo .. oo .. . ... .... .. ... oo ... .. r .. .... oo ..... .... oo.oo . .. .. ..... .. oo .... . .... .. . oo . 1.119 2012600IOLXT ..... oo ...... .. ... ... .. oo . .. ... .. oo .... .. ... oo . ... . oo. oo . .. .. oo . ... . oo . .... .. .. ... oo. 1.121 2012 600 WIDETRAK 10 .... 00 .. 00 .00 .. 00 .. . .. ... 00 .. 00 . .. .. .. . 00 . ... .. .. 00 .. 00 ..... 00 . 00 .... .. .. . . .. 1.123 201355010SHIFT .. ............. .. ........ .. .. . .. .. .... ... ........ ... ................... .. .... ... .. . 1.125 2013550SHIFT 136 ooo oo .. . .. .. .. . oo .. .. . .. oo ... ... oo . .. ... oo .. .. ... .... .. .. ... oo .. ... oo .. . .... .. ... 1.127 20 13 55010 LXT ..... 00 ..... .. .. .. . 00 .. .. . .. .. ... 00 .. 00 . .. .. 00 . 00 .. 00. 00 .. .. . .. . 00 .. .. .. ... 00 .00 .. 00 . 1.129 201360010LXT . ... . .. .. ... oo oo o oo oo oooo• oooooo o oo oo oo o oo oooooo • .. oo • oo oo •• oo oo oo .. oo oo •· oo ·· oo ·· oo · 1.131 2013 600 WIDETRAK 10 .. ....... .. ... .. .. .. .. ... ... ... .. .. ....... ...... . ... ... .. .. ... .. .. .. .. . ... ... 1. 133 2014 60010 LXT .. .. . .. ........... ... . ... ..... ... . .. ..... .. .. ..... .. .. . .. ........ .. ...... .. . .. ..... .. 1. 135 2014600WIDETRAKIO .. .. ... ... .. ..... .. ... . .. . .. oo .... . .. .. .. .. .. .. .. .. . .. .. .. .. oo .. . .. .. . .. .. .. . 1. 137 2015 600 10 LXT .. . ....... ...•...• .... ...... ... ........ ... ... .. ... ...... .. ..... .... . ... ............ .. 1. 139 2015 600 WIDETRAK 10 .... .... ... .... .. .. . ... .. .. . ... .. .. .... .. . .. .......... ..... .. .. ... .. .. . .. .. .. 1.141 GENERAL SPECIFICATIONS I CHARTS .............. .. .. ... ..... ... .. .. . .. .. .... ... ... ........ ... ..... .. 1.143 2007 PUBLI CATIONS ... .... . ... .... .. . ... ............ .. .. ... ..... .... ...... .. .. ... ...... .. ..... ... . . 1.143 2008 PUBLICATIONS .. .. .... .. .. . .. .. .. .. ... .... .... ... . .. . ... ... .. .... .. ... .. .. ..... .. .. .. . .. .. . .. . 1.143 2009 PUBLICATIONS . . . ... ... .. ....... ....... ..... .. . .. ....... ... ............ .. . ..... .. .. ........ ... 1.144 2010 PUBLICATIONS .. .... .. ......... .. .. .... .. ... ........ .. .. ... ..... .. ..... .. ........... ... .. ... .. 1.145 20 11 PUBLICATIONS .... ... . .. .. .. .• ... ... .. . .. .. ........... ... ......... .. ...... .. .. ... .. . ... . .. .. .. 1. 145 2012 PUBLICATIONS ...... .. . .. ..... .. . .. ... .. .. . .... .. .. ... .. ..... .. . .. .. ...... .. ....... .. .... ..... 1 . 146 2013 PUB LI CATIONS .. .. .. .... .. .. .. .. ... .. .. ..... .. ...... ... .. .. ... .. .... .. ... ........ .. ..... ... ... 1. 146 2014 PUBLICATIONS . . .. .. .. .. .. .. .. ... ... . ..... ..... ... .. .. .. ... .. ... .. .. .... .. ...... ... • ... . .. .. .. 1.146 2015 PUBLICATIONS .... .... .. . .. .. . .. . .. .......... .. . .... . ... . .. ...... .. ... .............. ... .... ... 1. 146 SPECIAL TOOLS .. . ..... ... ... . .. ... ... . .... . ... ......... ... .. .. . ... ........................... .. ... 1.147 POLARIS MOBILE DIGITAL WRENCH (PMDW) ........... .. ............... ... ..... .. ......... .. .. ... 1.148 CONVERSION TABLE .... .. . .. . .. .. ... ..... .. .. ... ....... .... .... .. .... ... ........... .. .. .... ... .. . . 1 .149 9925101 R01- 2007-2015 10 Snowmobi le Service Manual © Copyrig ht 201 4 Polaris Industries Inc.

MODEL SPECIFICATIONS I GENERAL INFORMATION STANDARD BOLT TORQUE SPECIFICATION ... .. ..... .. . .... ..• ... ... • .... .... .. ..• . .. •... ...•.. .. . 1. 150 METRIC BOLT TORQUE SPECIFICATION . .. . .. .. ..... .. .. .. .. .. ... .. ... .. . .. .. . .... ... ... .. .. ... ... 1.150 SAE TAP I DRILL SIZES ....... . .. ... ..... . .. .......... .. .. ......... .. .. . ... ... ... .. . ... .. ... .. . .. . .. 1.151 METRIC TAP I DRILL SIZES .. . .. ..... ... . ... ... .... ...... .... .. .. .. . ..... .. ....... .. .. . .. . .. . .. ... .. 1.151 DECIMAL EQUIVALENTS ... .... .. . .. .. ..... .. ..... ... .... .. .. ...... .. .. ....... ..... .. .. ...... ... .... 1. 152 FUEL I OIL PRE-MIX RATIOS . . .. ...... .. ... .. . .. . .. ........ .. ..... ........... .. . ...... .. .. ...•.. ... . 1. 152 SERVICE PRECAUTIONS ...... ...... .. ... .. ....... .. ....... .. . .. .. .. .. ...... .. .. .. .. .. .. ... .... .. .. 1. 153 9925101 R01 - 2007- 2015 IQ Snowmobile Service Ma nual ©Copy right 2014 Polaris Industri es Inc. 1.3

2007-2011 Polaris IQ Snowmobile Service Repair Manual

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