2006 Polaris 340, 500, 550, 600, 700 & 900 Snowmobile Service Manual – Classic, Fusion, RMK, Touring, Switchback & Indy (P/N 9919763)

The Polaris 2006 Two Stroke Snowmobile Service Manual, P/N 9919763, covers the 340, 500, 550, 600, 700, and 900 series, including Classic, Fusion, RMK, Touring, Switchback, and Indy variants. Model-specific coverage includes the 340 Classic, 600 HO Standard and Dragon Fusion, Supersport, 500 XC SP, and Widetrak LX.

A 301-page PDF with searchable service text and image-based wiring diagrams.

• Engine repair: Fuji and Liberty engine removal, teardown, inspection, and reassembly, including reed valves, exhaust valves, and water/oil pump service.

• Fuel systems: Mikuni TM38 carburetor rebuilding and synchronization, Cleanfire injector replacement, fuel-pressure testing, and throttle-position sensor setup.

• Clutching and final drive: P-85 clutch service, Polaris and TEAM driven-clutch adjustments, chaincase bearing replacement, and Widetrak transmission repair.

• Suspension and steering: Edge, IQ, and M-10 adjustments, rear suspension removal, track alignment, steering alignment, and serviceable shock rebuilding.

• Brake service: Hydraulic brake bleeding, line and pad replacement, disc inspection, and separate Widetrak mechanical caliper disassembly and assembly.

• Electrical diagnosis: Ignition timing charts, no-spark troubleshooting, IQ blink codes, sensor tests, ECU connector views, and model-specific wiring diagrams.

Suited to technicians familiar with mechanical theory and shop procedures; the manual restricts clutch repair to authorized, trained Polaris technicians and calls for trained Polaris technicians with specialized equipment for crankshaft repair.

Model Identification and Seasonal Setup

The model-number and VIN guides help match a sled to its configuration before selecting service data. The 500 Classic and 500 Indy use Fuji engines, while the 500 XC SP uses a Liberty engine. FS/FST four-strokes and the 120 youth model use separate service manuals.

More than 300 model-specification tables cover jetting by temperature and altitude, clutch calibration, fluid capacities, component torque, and electrical specifications. Maintenance schedules and off-season storage procedures support seasonal preparation.

Fuji and Liberty Engine Repair

Engine sections cover crankcase separation, crankshaft removal, piston and ring replacement, and recoil/stator service. Inspection information includes piston-to-cylinder clearance for the 600 Liberty and other engines, ring end gaps, cylinder taper, bearing fit, and crankshaft indexing and runout.

Cylinder honing coverage distinguishes oversize work on 340/500/550 Fuji engines from the limited honing permitted on Nikasil cylinders. Oil-pump adjustment and bleeding, check-valve testing, thermostat replacement, and cooling-system bleeding are also covered.

The water-pump procedures identify mechanical-seal installation tooling, including PW-46986 for the 700/900 engines, and warn that hammering the seal into place can damage it.

Mikuni Carburetors and Cleanfire Injection

The carburetor chapter explains fuel-metering circuits and TM38 float inspection and needle-and-seat testing. Cleanfire coverage separates TPS baseline adjustment from elevation-dependent idle setup and identifies fuel-pressure gauge PV-43506-A and TPS tester kit 2201519.

For the 700 Fusion and other Cleanfire models, injector color identification is tied to the ECU calibration, helping establish the correct replacement injector and when ECU reprogramming is required. Digital Wrench connections and reflash requirements are identified.

The in-tank Cleanfire pump is treated as nonserviceable, with fuel-tank assembly replacement specified for pump failure.

P-85 Clutches, Chaincases, and Widetrak Transmission

Clutch coverage extends to spider indexing, rollers, bushings, spring identification, and belt alignment and deflection. The Belt Wear / Burn Diagnosis chart connects wear symptoms with operating conditions and clutch faults.

Separate procedures address the 7.92-inch and 8.37-inch chaincase variants, drive-chain tension adjustment, jackshaft service, and Widetrak high/low/reverse transmission internals. TEAM ramp tables distinguish electric-reverse from non-reverse applications; using a non-reverse ramp with reverse engaged can damage the driven clutch.

Edge, IQ, and M-10 Suspension and Brakes

Suspension data includes camber and toe settings, limiter straps, scissor stops, and the M-10 FRA Initial Set Up Reference. Shock tables identify rebuildable units and list production compression/rebound valving, internal floating-piston depths, and charging specifications.

Ryde FX mono-tube rebuilding is covered. FOX PS-5 coverage includes disassembly and seal replacement, but stops short of a full reassembly and recharge procedure.

Hydraulic caliper coverage specifies pad service and caliper replacement, while the Widetrak section covers its mechanical actuating components.

Electrical Fault Finding

The No Spark Condition chart and ECU Plug #1 and ECU Plug #2 views support ignition and wiring diagnosis. The 700 / 900 Engine and Engine Call Outs diagram identifies connectors and wire terminations.

Further tests cover the starter, regulator/rectifier, detonation sensor, and exhaust-valve solenoid. Polaris Electronic Reverse Control (PERC) operation and altitude settings are also explained.

Service involves high-tension springs, heavy moving parts, and pressurized fuel systems; follow the manual's precautions for the assembly being serviced.

File Format and Readability

The total includes one title page, one Notes page, five otherwise blank chapter-end pages, and 294 other pages. The 12-page wiring section is already included.

Fourteen chapter bookmarks provide navigation. Most wiring-diagram labels and some illustrated reference tables are not searchable. Small schematic details require zooming; some fine connector and wire-code labels in the 700/900 diagrams remain pixelated and difficult to distinguish when enlarged.