-
This workshop repair service manual PDF download for the 2006-2008 FS / FST Polaris Snowmobile has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.
APPLICABLE MODELS :
2006 FS Classic
2006 FST Classic
2006 FS Touring
2006 FST Touring
2006 FST Switchback
2007 FST IQ
2007 FST IQ LX
2007 FS IQ Touring
2007 FST IQ Touring
2007 FST IQ Cruiser
2007 FST IQ Switchback
2008 IQ Turbo Dragon
2008 IQ Turbo LX
2008 Turbo Switchback
2008 FS IQ Touring
2008 FST IQ Touring
2008 IQ Cruiser
TABLE OF CONTENTS :
Model Specifications
General Information
Maintenance
EFI / Ignition Systems
Engine Removal and Installation
FS / FST Engine
Final Drive and Brake Systems
PVT System
Front Suspension / Steering
Rear Suspension
Chassis
Chassis Electrical System
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9921066
Total Pages : 337
This Polaris service manual, repair manual, workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!
Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail!, You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.
More Info : http://www.sitelux.com
-
2006 - 2008 FS / FST SERVICE MANUAL
FOREWORD
understanding manual safety labels and directions
TRADEMARKS
Model Specifications
2006 FS Classic
2006 FST Classic
2006 FS Touring
2006 FST Touring
2006 FST Switchback
2007 FST IQ
2007 FST IQ LX
2007 FS IQ Touring
2007 FST IQ Touring
2007 FST IQ Cruiser
2007 FST IQ Switchback
2008 IQ Turbo Dragon
2008 IQ Turbo LX
2008 Turbo Switchback
2008 FS IQ Touring
2008 FST IQ Touring
2008 IQ Cruiser
General Information
VIN Organization
TUNNEL DECAL
2006 Publication Part Numbers
2007 Publication Part Numbers
2008 Publication Part Numbers
Miscellaneous Publications
SAE
Metric
Decimal Equivalents
Conversion Table
Standard Bolt Specifications
GASOLINE VOLATILITY
Maintenance
Break-In Period Maintenance Interval
Maintenance Program
Engine Oil Level Check
Engine Oil and Filter Change Procedure
Airbox Oil Breather Foam Element
Spark Plug Servicing
Air Box Intake Boots
Engine Lubrication System Overview
FST Air Filter
Alternator Belt Inspection / Adjustment
Valve Lash Adjustment
Expansion Tank
Engine Coolant Removal
Adding Engine Coolant / Air Bleed
Cooling System Pressure Test
Engine Cooling System Overview
Oil Cooler Configurations
Drive Belt Deflection
Chaincase Chain Tension
Track Alignment
Track Tension
Track Lubrication
Lubrication Points
Driveshaft Bearing
Rear Suspension
Chaincase Oil Level
Chaincase Drain Plug
Handlebar Adjustment
Rider Select Adjustment
Throttle Lever Freeplay
Brake Lever
Brake Fluid
Brake Fluid Bleeding
Storage Procedures
EFI / Ignition Systems
System Overview
Safety Information
Bosch M7.4.4 System Specifications
Diagnostic Trouble Codes (DTCs)
ECU Connector Orientation
EFI - Engine Harness Repair Kits
Wiring Harness Connector Identification
ECU 100 Harness Connector (Gray Color)
ECU 200 Harness Connector (Brown Color)
ECU 300 Harness Connector (Black Color)
Engine RPM / Vehicle Speed Limit Modes
Turbo Boost Reduction Modes
Fuel Injection Circuit
Ignition Coil Circuit
Throttle Position Sensor Circuit (TPS)
TPS Baseline Adjustment
TPS Idle Speed Adjustment
Throttle Plate Synchronization
Ambient Pressure Sensor Circuit (FST Only)
Intake Manifold Pressure / Temperature Sensor Circuit
Boost Pressure Sensor Circuit (FST Only)
Coolant Temperature Sensor Circuit
Crank Position Sensor (CPS) Circuit
Camshaft Phase Sensor Circuit
Knock Sensor Circuit (FST Only)
Wastegate Solenoid Pulse Valve Circuit (FST Only)
Wide Band Lambda Sensor Circuit
Idle Air Control Actuator Circuit
Roll Over Sensor Circuit
Diagnostic Communications Circuit
Digital Wrench Diagnostic Cable Connection
Ignition Switch Jumper Tool
Fuel Rail / Intake / Exhaust Cylinder Head Components
Posi-Lock Fuel Hose Connectors
2006 Fuel Tank / Fuel Supply
2006 Fuel Pump Supply / Return Fittings
2006 Pump / Sender Specifications
2006 Fuel Pump Replacement
Drop-in Fuel Tank / Fuel Supply
Drop-in Fuel Supply / Return Fittings
Drop-in Pump / Sender Specifications
Fuel Pump Replacement (Drop-In Style)
Fuel Tank Pressure Test
Fuel Pressure Test
FS Induction System
FST Induction System
FST Airbox
Turbocharger Assembly
FST Boost / Vacuum Reference Hose System
Wastegate Solenoid Pressure Testing
Wastegate Actuator Pressure Testing
Turbocharger Inspection
Charge Air Cooler (Intercooler) Inspection
Boost / Vacuum Reference Hose System (FST)
FS Exhaust System
FST Exhaust
Troubleshooting
Ignition Switch Jumper Tool
Digital Wrench Diagnostic Cable Connection
Digital Wrench Overview
Digital Wrench Operating Requirements
Updating Digital Wrench
Version / Fileset Identification
Engine Controller Reprogramming
Data Display Screenshots - Engine OFF
Data Display Screenshots - Engine at Idle
Service Reports
Performance Issues with No Diagnostic Codes
Fuel System Minimum and Maximum Adaptation
Multiple Diagnostic Codes
Wire Harness Diagnostics
Engine Removal and Installation
Before You Begin
Suspending Engine
Engine Removal
MAG-Side Engine Mounting
PTO-Side Engine Mounting
FS / FST Engine
Engine Specifications
Fastener Torque Specifications
Cylinder Head / Crankcase Torque Patterns
Special Tools
Components
Valve Cover Assembly
Valve Train Assembly
Bed Plate / Scavenge Oil Pump Assembly
Oil Filter Assembly
Water Outlet Manifold Assembly
Water Pump Assembly
High Pressure Oil Pump Assembly
Chain Tensioner / Chain Guide Assembly
Crankcase Assembly
Piston Assembly
Valve Assembly
Crankshaft / Balance Shaft Assemblies
Front (MAG-END) Gear Cover Assembly
MAG Engine Mount / Alternator Bracket
Starter Motor Assembly
Valve Cover
Bedplate / Scavenge Pump
Water Outlet Manifold-Thermostat Assembly
Water Pump Assembly
MAG Gear Cover Assembly / Water Pump Driveshaft Removal and Installation
Flywheel Removal and Installation
High Pressure Oil Pump
Gear Train
Cylinder Head / Valve Train
Crankcase / Crankshaft / Pistons / Balance Shaft
Connecting Rod Bearing Oil Clearance Inspection
Bearing Replacement Guide
Crankshaft Main Bearing Oil Clearance Inspection
Bearing Replacement Guide
Crankcase / Crank Train / Piston Assembly
Timing Chain Installation / Locating TDC
Final Drive and Brake Systems
Optional Parts
Speed Chart
Drive Chain Deflection Adjustment
Chaincase Oil Level
Chaincase Oil Drain
Chaincase Disassembly
Jackshaft Removal
Jackshaft Installation
Driveshaft Removal
Driveshaft Installation
Overview
Compensation Port
GENERAL GUIDELINES
BRAKE FLUID REPLACEMENT & BLEEDING
BRAKE LINE REPLACEMENT
REMOVAL
ASSEMBLY
PAD REPLACEMENT
BRAKE DISC REPLACEMENT
PVT System
Overview
Drive Spring
Clutch Weight
Neutral Speed
Engagement RPM
Shift Out Over-Rev
Shift Out RPM
Driven Spring
Back-Shifting
Final Gearing
1:1 Shift Ratio
Low / High Ratio
Driven Helix / Ramp
Special Tools
Drive Clutch Springs
Spring Free Length
Drive Clutch Weights
PERC Team LWT Driven Helixes (24 Fin)
Non-PERC Team LWT Driven Helixes (24 Fin)
Non-PERC Team Driven Helixes (12 Fin)
Team Ramp Angles
Team Driven Springs
Drive Belts
Belt Inspection
Drive Clutch Bolt Torque
Belt Wear / Burn Diagnostics
Drive Belt Removal - Team Driven Clutch
Drive Belt Installation - Team Driven Clutch
Adjusting Belt Deflection - Team Driven Clutch
Clutch Alignment / Offset
Offset Adjustment
Identification
Drive Clutch Removal
Drive Clutch Disassembly
Roller Removal
Roller Installation
Clutch Assembly
Spider Indexing
Drive Clutch Installation
Components
Driven Clutch Removal
Driven Clutch Installation
Driven Clutch Disassembly
Driven Clutch Assembly
Front Suspension / Steering
Inspection
Camber / Toe Specifications
Springs
Adjustable Shocks
Ryde FX Air 2.0 Shock
Rebuildable IFS Shock Specifications
7043141 Piston Valve Specifications
7043245 Piston Valve Specifications
Front Suspension
Steering Linkage
Steering Mount
Handlebar Post - Rider Select
Setup and Adjustments
Alignment Bar Specifications
Camber
Rod Ends
Rod End Engagement
Camber Adjustment
Handlebar Centering
Toe Adjustment
Spindle Removal
Spindle Assembly
Spherical Bearing Replacement
Upper / Lower Control Arm Removal
Upper / Lower Control Arm Installation
Rear Suspension
Rear Suspension Type by Model
Suspension Mounting Fastener Torque
IQ Rear Suspension Shock Rod
IQ Rear Track Shock Pivot Orientation
Operation
Weight Transfer
Coupling
Torsion Spring Adjustment
IQ 121 Pivots / Rear Idler
IQ 121 Rail Assembly
IQ 121 Front / Rear Torque Arms
M-10 128 Pivots / Rear Idler
M-10 128 Rail
M-10 128 Front / Rear Torque Arms
M-10 136 Pivots / Rear Idler
M-10 136 Rail
M-10 136 Front / Rear Torque Arms
IQ 136 Comfort Pivots / Rear Idler
IQ 136 Comfort Rail Assembly
IQ 136 Comfort Front / Rear Torque Arms
IQ 136 Coupled Pivots / Rear Idler
IQ 136 Coupled Rail Assembly
IQ 136 Coupled Front / Rear Torque Arms
IQ 144 Pivots / Rear Idler
IQ 144 Rail Assembly
IQ 144 Front / Rear Torque Arms
Adjustment Procedures
Rear Suspension Ride Height
Scissor Stop Adjustment
Limiter Strap Adjustment
Torsion Spring Adjustment
IQ 121 Heavy Torsion Spring Installation
M-10 OVERVIEW
M-10 ADJUSTMENTS
M-10 TERMINOLOGY
M-10 ADJUSTMENTS
M-10 FRA INITIAL SET UP REFERENCE
M-10 REAR SPRING PRELOAD
M-10 SKI PRESSURE
Wear Limit
Removal
Break-In
Removal
Installation
Specifications
Front Track Shock (FTS) Valving
Rear Track Shock (RTS) Valving
Shock Rebuilding Tools
Ryde FX™ Shock Valve Part Numbers
Fox™ Shock Valve Part Numbers
Valve Shim Arrangement
Piston Orientation
Ryde FX Air 2.0 Shock Disassembly
Ryde FX Air 2.0 Shock Assembly
Ryde FX Remote Reservoir Shock Disassembly
Ryde FX Remote Reservoir Shock Assembly
RYDE FX MONO-TUBE SHOCK DISASSEMBLY
RYDE FX MONO-TUBE SHOCK ASSEMBLY
FOX PS-5 DISASSEMBLY
FOX PS-5 ASSEMBLY
Assembly Illustration
Rear Suspension
Chassis
Assembly Illustration
Hood / Plastic Repair
Assembly Illustration
Assembly Illustration
IQ Fixed Seat Assembly
IQ Removable Seat Assembly
IQ Touring Seat Assembly
IQ Raw Seat Assembly
Seat Cover Replacement
Assembly (Typical)
Replacement
Decal Removal
Decal Installation
Chassis Electrical System
System Overview
Battery / Charging System Specifications
Battery Preparation
Battery Preparation
Testing Procedures
OPEN CIRCUIT VOLTAGE TESTING (OCV)
LOAD TEST
OFF SEASON STORAGE
Relay Overview
Relay Panel Wire Routing
Fuse Overview
Fusible Links
Circuit Breaker
Diodes
External Relays (Relays Located Outside of the Main Relay Panel)
EFI / Ignition Relay Circuit
EFI Relay Circuit
Ignition Relay Control Circuit
Ignition Relay Power Circuit
Chassis Relay Circuit
Chassis Relay
Start Solenoid Relay Circuit
Start Solenoid Relay Control Circuit
Start Solenoid Grounding Relay Circuit
Fuel Pump Relay Circuit
Fuel Pump Relay Circuit
Charge Air Cooler (Intercooler) Fan Relay Circuit
Charge Air Cooler Relay Circuit
Engine Stop / Throttle Safety Stop Circuits
Throttle Safety System
Perc 4 Reverse System Circuits
Perc 4 Button Circuit
Forward / Reverse Limit Switch Circuits
Perc 4 Forward Reverse Controller Circuit
Multi-Function Display (MFD) Circuits
Multi-Function Display Power Circuit
Multi-Function Display Inputs / Outputs
Mode / Set Switch Circuit (Non-ACE)
Vehicle Speed Sensor Circuit
Power-Up / Power-Down Sequence Overview
Power-Up / Power-Down Troubleshooting
Cylinder Head Routings
Crankcase / Throttle Body Routings
LH Foot Rest Routings
Ambient Pressure / Wastegate Solenoid Routings
Overview
Checking Components
Troubleshooting
Operation
Feedback
Enable / Disable
Display Select
Suspension Position
ACE Important Notes
2006 FS / FST Chassis 1 of 2
2006 FS / FST Chassis 1 of 2
2006 FS / FST Chassis 2 of 2
2006 FS / FST Engine 1 of 2
2006 FS / FST Engine 2 of 2
2006 FS / FST Hood
2006 FS / FST System Diagram
2007 FS / FST Chassis 1 of 2
2007 FS / FST Chassis 2 of 2
2007 FS / FST M10 ACE Chassis 1 of 2
2007 FS / FST M10 ACE Chassis 2 of 2
2007 FS / FST Engine 1 of 2
2007 FS / FST Engine 2 of 2
2007 FS / FST Hood
2007 FS / FST System Diagram
2007 FS / FST M10 ACE Suspension
2008 FS / FST Chassis 1 of 2
2008 FS / FST Chassis 2 of 2
2008 FS / FST M10 ACE Chassis 1 of 2
2008 FS / FST M10 ACE Chassis 2 of 2
2008 FS / FST Hood Harness
2008 FS / FST M10 ACE Suspension
2008 FS / FST Engine 1 of 2
2008 FS / FST Engine 2 of 2
-
Polaris FS / FST Snowmobiles Repair Service Manual 2006-2008.pdf
Source : Sitelux.com