Polaris IQ Snowmobile Service Manual: 600/700/800 HO, RMK, Shift, Switchback, Dragon, LX & Touring 2007-2008

Polaris IQ Snowmobile Service Manual - 2007-2008

This technical service manual provides authoritative factory procedures for the maintenance, repair, and overhaul of Polaris IQ chassis snowmobiles. Engineering-level data ensures precision for critical tasks such as exhaust valve guillotine cleaning, which is vital for preventing carbon-induced performance degradation and ensuring instantaneous throttle response. Service technicians and owners can utilize these factory-validated protocols to maintain peak operational reliability and machine uptime throughout the winter season.

Technical Applicability & Model Variants

Liberty Liquid-Cooled Case Reed Induction Models

• 600 HO Series (2007): IQ, Switchback, RMK (144/155)
• 600 Series (2008): IQ Shift, RMK (144/155), Dragon IQ, Dragon Switchback, IQ LX, IQ Touring
• 700 HO Series (2007): IQ Dragon, RMK Dragon
• 700 Series (2008): IQ, Dragon IQ, Switchback, Dragon Switchback, RMK 155, Dragon RMK (155/163)
• 800 Series (2008): Dragon RMK (155/163)

Cleanfire Direct Injection (CFI) Performance Groups

• 600 CFI (2007): IQ, Switchback, IQ LX, IQ Touring
• 700 CFI (2007): IQ Dragon, RMK Dragon
• 800 CFI (2008): Dragon RMK variants

Operational Efficiency & Technical Integrity

• Factory-calibrated jetting and clutching charts allow for precise tuning based on ambient temperature and altitude to prevent engine lean-out or power loss.
• Detailed diagnostic procedures for the Cleanfire Injection system and Digital Wrench software facilitate rapid troubleshooting of electrical and fuel delivery faults.
• Specific torque sequences and values for critical fasteners, such as cylinder head bolts and drive clutch bolts, prevent mechanical failure under high-stress conditions.
• Standardized periodic maintenance schedules ensure safety through systematic inspection of brake fluid condition, belt deflection, and ski toe alignment.

Document Metadata

• Publication Number: PN 9921044
• Total Page Count: 316
• File Format: PDF High-Resolution Technical Reference

Technical Depth & Factory Benchmarks

Polaris engineering standards define the calibration data within this manual, including precise piston-to-cylinder clearances of .004-.006" (.105-.159 mm) for 600 HO engines. Ignition timing benchmarks are strictly set, such as 26° @ 3500 RPM for 600 HO carbureted models with the TPS unplugged. For CFI variants, fuel pressure is regulated at a constant 58 PSI (4.0 bar) to maintain injector spray patterns and combustion stability.

Visual Navigation Aids & Technical Schematics

Full-chassis wiring diagrams and system-specific schematics provide clear paths for electrical troubleshooting across both carbureted and CFI platforms. Exploded views of front and rear suspension architectures, including IQ 42.5 IFS and M-10/RMK rear skids, detail every pivot point, bushing, and fastener location. Hydraulic brake system diagrams illustrate the master cylinder compensating port and caliper piston orientation for proper bleeding and pad replacement.

Table of Contents

• Chapter 1: Model Specifications (Jetting, Gearing, Clutching)
• Chapter 2: General Information (VIN, Torque Conversions, Engine Formulas)
• Chapter 3: Maintenance (Schedules, Lubricants, Adjustments)
• Chapter 4: Fuel Systems (Mikuni TM38 Carburetors, Cleanfire Injection)
• Chapter 5: Engine Systems (Liberty 600/700/800 Overhaul)
• Chapter 6: Final Drive and Brake Systems (Chaincase, Jackshaft, Calipers)
• Chapter 7: PVT System (Drive/Driven Clutch Calibration)
• Chapter 8: Suspension and Steering (IFS Setup, Rear Skid Service)
• Chapter 9: Shocks (Walker Evans, Fox, Ryde FX Rebuilding)
• Chapter 10: Chassis (Hood, Tunnel, Seat, Fenders)
• Chapter 11: Electrical Systems (Ignition, Charging, PERC Reverse)
• Chapter 12: Wiring Schematics (System Diagrams)

Operational Limits & Specifications

Lubricant and Fluid Requirements

• Engine Oil: Polaris VES Gold Synthetic 2-Cycle Oil
• Chaincase Lubricant: Polaris Synthetic Chaincase Lubricant (11 oz / 325.3 ml)
• Brake Fluid: DOT 4 High-Temperature Fluid
• Coolant: Polaris Premium 60/40 Pre-Mix Antifreeze (-62°F / -52°C rating)

Critical Torque Values

• Drive Clutch Bolt: 80 lb.ft. (108 Nm) for CFI; 50 lb.ft. (68 Nm) for Carbureted
• Cylinder Head Bolts (600 HO): 25 lb.ft. (34 Nm)
• Flywheel Nut: 90 lb.ft. (122 Nm)
• Ski-to-Spindle Fastener: 36 lb.ft. (49 Nm)