Polaris Snowmobile 340 Touring, 550 Edge, and 600 HO IQ 700 CFI, 800 Dragon, 800 RMK, 900 XC SP, and 500 XC SP 2007 Service Manual (P/N 9920463)

This Polaris factory service manual, P/N 9920463, covers the 2007 two-stroke snowmobiles listed above, with separate procedures for Fuji engines, carbureted Liberty engines and Liberty Cleanfire Injection (CFI) systems. Its engine, drivetrain and chassis procedures support in-house maintenance, fault diagnosis and repair planning.

PDF Search, Bookmarks and Wiring Detail

Search and diagram access: The main text is searchable, but some tool-table and diagram labels are not. Embedded bookmarks provide chapter and subsection navigation. Small wiring labels require zooming and, on sideways sheets, page rotation; some wiring lines appear faint at full-page size.

Supplied as one 327-page printable PDF, including the introductory material, index, seven notes pages and two blank pages. These pages are already included in the total.

Two-Stroke Engines, PVT Clutches and CFI Diagnostics

The following selected workshop topics outline part of the coverage; additional subjects include recoil-starter service and seasonal storage.

• Engine repair: Engine removal, crankcase separation, piston and cylinder inspection, crankshaft checks, reed-valve service and Variable Exhaust System (VES) disassembly.

• Fuel delivery: Mikuni TM38 overhaul and synchronization, temperature- and altitude-specific jetting charts, CFI injector replacement and fuel-pump testing.

• PVT clutching: Drive-clutch disassembly, roller inspection, spider indexing, TEAM driven-clutch service, clutch alignment and belt-wear diagnosis.

• Final drive and brakes: Chaincase bearing and seal replacement, jackshaft and driveshaft service, Widetrak transmission work and hydraulic-brake bleeding.

• Suspension and steering: Front-end alignment, rear-suspension setup, M-10 adjustments, shock specifications and service procedures for selected rebuildable shocks.

• Electrical diagnosis: Throttle Position Sensor (TPS) adjustment, CFI trouble codes, MFD blink codes, starter testing, wiring diagrams and Polaris Electronic Reverse Control (PERC) operation.

Written primarily for certified Polaris Master Service Dealer technicians in a properly equipped shop, this manual assumes mechanical knowledge and familiarity with specialized service tools.

Carburetor Service and Cleanfire Fuel Delivery

Step-by-step instructions cover Mikuni TM38 disassembly, assembly and throttle-valve synchronization. Jet and needle identification accompanies the model-specific jetting charts.

Fuel-pump differences: The 600 CFI section describes replacement of its drop-in pump. For the 700 CFI system, the manual specifies replacement of the fuel-tank assembly when its nonserviceable pump fails.

Fuel-rail testing and pressure-relief instructions distinguish shallow- and deep-core Schrader valves, including the deep-core adapter PS-48167. CFI injector information explains the Red, Blue and Yellow flow classifications and ECU calibration requirements; mixed injector colors can cause severe engine damage.

Review the manual’s fuel-pressure relief and shop-safety precautions before fuel-system or engine disassembly.

Engine Inspection and Reassembly References

Separate sections address Fuji 340/550 engines, the liquid-cooled Fuji engine used in the Widetrak, carbureted Liberty engines and Liberty CFI engines. Procedures extend to internal disassembly, piston and ring installation, crankshaft indexing and runout inspection, with cylinder-head and crankcase torque patterns.

Cooling-system layouts and bleeding procedures accompany thermostat and water/oil-pump service. The cross-shaft section identifies mechanical-seal installation tool 2872010 and its role in establishing seal height.

Clutch Alignment, Final Drive and Brake Service

The PVT chapter explains clutch operation alongside spring, weight and helix references. Belt Wear / Burn Diagnostics and chaincase speed charts support evaluation of belt condition and gearing.

Driven-clutch fit: The alignment section explains how restricting the specified clutch float can side-load and damage the jackshaft bearing. Widetrak installation is treated separately and specifies no driven-clutch float.

Final-drive coverage includes Widetrak low/reverse-shaft and shift-fork service. Brake sections distinguish hydraulic-system bleeding and caliper work from the Widetrak’s cable-operated caliper.

Suspension Setup and Shock-Service Limits

Front-end procedures cover camber, toe, spindle bearings and control arms. Rear-suspension material includes M-10 Full Range Adjuster settings, ride-height checks, limiter straps, shock valving charts and suspension troubleshooting.

Ryde FX and selected Walker Evans shocks have dedicated servicing instructions. Fox monotube coverage is incomplete: the assembly section ends after the initial seal-installation work and does not provide the remaining final assembly, oil-filling and charging procedure.

Electrical Fault Tracing and Digital Wrench

Ignition timing charts, no-spark troubleshooting tables and ECU connector references accompany the electrical tests. CFI schematics separate ignition/injection power, crank-position signals and safety-stop circuits; MFD blink-code tables connect reported faults with affected components and circuits before replacement parts are selected.

Digital Wrench procedures cover live data, guided diagnostics and ECU reflashing. These functions require the separate software and interface equipment described in the manual; the documented reflash process also requires dealer-portal authorization.

Examples of Engine Inspection Limits

The cylinder-head inspection section gives a warp service limit of 0.003 in. (0.08 mm), alongside a cylinder-measurement worksheet for evaluating bore condition.

For 500/600/700 Liberty engines, connecting-rod big-end side clearance is specified at 0.011–0.030 in. (0.28–0.75 mm), with rod-to-rod variation limited to 0.002 in. (0.05 mm). These inspection references accompany the bearing checks and crankshaft assessment procedures.