Polaris 340, 500, 550, 600, 700 Classic, Indy, Supersport, Touring, Widetrak LX, XC SP, Fusion, Switchback, RMK 2006 - In-Depth Two Stroke Snowmobile Service, Maintenance & Troubleshooting Manual

Polaris 2006 Two Stroke Snowmobile Service Manual

Technical integrity for the 2006 model year is maintained through high-precision tolerances and specific fluid requirements, such as the use of Polaris VES Gold Plus oil to ensure exhaust valve longevity. Utilizing the correct torque sequence for cylinder head bolts prevents thermal warping and ensures optimal combustion seal across varied elevation ranges. Accessing factory-grade electrical pin-out data allows for immediate diagnostic isolation of the Speed Limit circuit, minimizing downtime during complex troubleshooting.

Chassis Configurations & Model Applicability

EDGE / GEN II Chassis Group

• 340 Classic, 500 Classic, 550 Classic, 600 Classic, 700 Classic (2006)
• 500 Indy, Supersport (2006)
• 340 Indy Touring, Trail Touring, 600 Edge Touring, 700 Touring (2006)
• Widetrak LX, 500 XC SP (2006)
• Trail RMK (2006)
• 120 Indy (2006)

IQ / Fusion Chassis Group

• 600 HO Standard Fusion, 600 HO Dragon Fusion (2006)
• 700 Fusion, 900 Fusion (2006)
• 600 HO Switchback, 900 Switchback (2006)
• 600 HO RMK, 700 RMK, 900 RMK (2006)

IQ Four-Stroke / Turbo Chassis Group

• FS Classic, FST Classic (2006)
• FS IQ Touring, FST IQ Touring (2006)
• FST Switchback (2006)

Operational Reliability & Precision Metrics

• Precision electrical schematics facilitate the tracing of the 84-pin R/W & BRN splice saver connections for rapid sensor fault isolation.
• Detailed internal engine clearances provide the exact wear limits necessary for determining crankshaft and piston replacement intervals.
• Specific suspension tuning parameters allow for consistent handling performance across varied trail conditions and rider weights.

Document Metadata

• Publication Number: PN 9920224
• Page Count: Approx. 600+
• Document Type: Full Factory Service Manual

Technical Depth & Factory Benchmarks

Engine performance is regulated by strict synchronization of the oil pump and throttle cable, ensuring a precise fuel-to-lubricant ratio across the entire RPM band. Factory benchmarks include specific idle speeds, ignition timing curves, and exhaust valve opening pressures tailored to each displacement category from the 340cc to the 900cc power plants. Detailed drive clutch spring rates and weight profiles provide the necessary data for optimizing power transfer based on ambient temperature and altitude variables.

Diagnostic Architecture & Visual Aids

Full-color wiring diagrams and transparent component overlays allow technicians to identify circuit 27 (BLK/BLU stop switch) and circuit 72 (R/BLK charge relay) with total accuracy. Exploded views of the Cleanfire Injection system and the traditional carburation setups illustrate fuel flow paths and critical gasket placement. Cutaway illustrations of the TEAM Industries Driven Clutch and Polaris P-85 Drive Clutch assist in identifying internal wear patterns before catastrophic component failure occurs.

Table of Contents

• Chapter 1: Specifications (Model Data, Torque, Fluids)
• Chapter 2: General Information (Maintenance, Storage, VIN)
• Chapter 3: Fuel System (Carburetion, EFI, Oil Injection)
• Chapter 4: Engine (Disassembly, Inspection, Assembly)
• Chapter 5: Cooling (Circulation, Pressure Testing)
• Chapter 6: Final Drive (Clutches, Chaincase, Drive Shaft)
• Chapter 7: Chassis (Suspension, Ski, Steering)
• Chapter 8: Electrical (Ignition, Charging, Schematics)

Operational Limits & Fluid Specifications

• Spark Plug Gap: .028" (.70 mm) for standard NGK applications.
• Coolant Mix: 60/40 or 50/50 Premium 60/40 Anti-Freeze.
• Drive Chain Tension: 1/4 inch (6.35 mm) deflection.
• Brake Fluid Type: Polaris DOT 4 High Temp Brake Fluid.
• Cylinder Head Torque: Specific multi-stage sequences varying by engine displacement (refer to Chapter 1).