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)

• Covers 2007 Polaris 2-stroke snowmobiles, including 340 Touring, 440 IQ, 550 Edge, 600 HO IQ, 700 CFI, 800 Dragon, 800 RMK, 900 XC SP, and 500 XC SP variants.
• Original 327-page OEM publication (P/N 9920463).
• Features 136 exploded-view diagrams, 14 circuit-specific electrical schematics, and 22 chassis-specific torque tables.
• Explores the Cleanfire Injection (CFI), Variable Exhaust System (VES), Throttle Position Sensor (TPS), PERC electronic reverse, and Digital Wrench diagnostics.
• Details M-10 rear suspensions, TEAM driven clutches, alongside Ryde FX, Walker Evans, and Fox shock rebuilding.

Engine and Chassis Technical Details

When a sled rolls into the bay, you need accurate specs right now, not hours of hunting through forums. This official Polaris PDF publication provides the complete technical documentation required to tear down and rebuild the entire two-stroke lineup, from the reliable Fuji 340/550 to the high-performance Liberty 500/600/700 powerplants. It details mechanical theory and shop procedures for the engine assembly, fuel delivery systems, PVT clutching setups, and final drive components. You also get deep-dive chapters documenting chassis geometry, front and rear suspension teardowns, and complex electrical circuits like CDI routing and lighting outputs. Accessing these factory procedures directly on your shop laptop allows you to perform highly profitable jobs in-house, preventing a disassembled sled from tying up your lift while waiting on dealership service. Instead of outsourcing, you can confidently tackle advanced tasks using the step-by-step instructions for synchronizing Mikuni TM38 carburetors, setting TPS baselines, bleeding the DOT 4 hydraulic brake system, and overhauling mono-tube shocks.

Specifications and Maintenance Data

Real workshop value comes down to hard numbers and effective diagnostic routines. The manual delivers critical factory specifications, including specific torque values like 50 ft-lbs for the P-85 drive clutch bolt and 18 ft-lbs for exhaust manifold fasteners. Need to check tolerances? Cylinder head warp limits are strictly set at .003 inches, and the 500/600/700 Liberty rod side clearance is specified right at .011–.030 inches. You will also find comprehensive maintenance interval charts covering fluids, track tension settings, and jetting configurations for altitudes from sea level up to 12,000 feet. To accelerate your troubleshooting process, the text incorporates essential visual aids, including complete Wiring diagrams, chaincase speed charts, ignition timing charts, shock valving charts, MFD blink code tables, and cylinder head torque patterns.

When executing a repair on these specific platforms, technicians must be aware of critical reassembly pitfalls. For example, replacing a failed Cleanfire Injection (CFI) fuel injector requires matching the exact factory color code (Red, Blue, or Yellow) or performing a complete ECU reflash; installing a mismatched injector will result in severe engine detonation. Furthermore, during another common repair, always verify the TEAM driven clutch retains its mandatory +/- 0.030-inch float on the jackshaft after tightening the retaining bolt. Restricting this movement will quickly destroy the jackshaft bearing due to extreme side-loading. Working on high-performance sleds requires precision and caution; ensure you safely relieve fuel rail pressure and review all factory safety protocols outlined in the text before beginning any tear-down to protect both yourself and the machine.