Snowmobile Polaris Two Stroke (2007 year). Instruction - part 64

 

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Snowmobile Polaris Two Stroke (2007 year). Instruction - part 64

 

 

10.5

CHASSIS & HOOD

10

COOLANT/OIL TANK

Coolant Tank Removal

1.

Drain coolant.

2.

Remove the 2 torx screws that hold the coolant tank to the
oil tank.

3.

Remove the coolant lines from bottle.

4.

Remove coolant bottle.

Coolant Tank Installation

1.

Connect coolant lines to the bottle.

2.

Tighten the fasteners that hold the coolant bottle to the oil
tank.

3.

Fill to the correct fluid level.

4.

Bleed the cooling system.

OIL TANK

Oil Tank Removal

1.

Remove the two fasteners that hold the tank to the chassis.

2.

Remove the two fasteners that hold the cooling bottle on the
oil tank.

3.

Remove the cross shaft oil supply line.

4.

Lift the rear of the tank and remove the supply line.

5.

Disconnect the oil sender connections.

6.

Remove tank.

Oil Tank Installation

1.

Attach the supply line to the supply fitting at the bottom of
the oil tank.

2.

Attach the cross shaft supply line to the fitting on the right
hand side.

3.

Line up the centering shafts with the chassis centering
bracket.

4.

Install the coolant bottle on the oil tank.

5.

Install the fasteners that hold the tank to the chassis.

SEAT INFORMATION

Seat & Base Removal/Installation

1.

If unit is equipped with a seat latch (1), remove the seat or
passenger seat if so equipped.

2.

Remove the fasteners (2) that hold the seat base onto the
tunnel or rear seat brace.

3.

Unplug the tail light harness if applicable and remove the
seat base.

Overflow

Throttle body*

Radiator

Center cooler

Rear coolers

1

2

2

2

2

10.6

CHASSIS & HOOD

SEAT AND FUEL TANK

IQ Fuel Tank Removal

1.

Remove the seat and seat base.

2.

Drain any fuel from the fuel tank.

3.

Remove the console. 

4.

Bleed the pressure from the fuel rail if applicable. See “Fuel
Rail Bleeding” on page 4.20. 

5.

Remove the fuel lines from the ridged fuel lines using the
fuel line removal tool (PS-47152).

6.

Remove the two fasteners (E) that hold the fuel tank (F)
onto the chassis.

7.

Carefully lift the rear of the fuel tank and slide the fuel tank
back so that you can reach the fuel pump harness, and
disconnect the harness.

8.

Disconnect the fuel tank vent line (J) at the fitting located
at the top of the tank.

9.

Remove the fuel tank from the chassis.

IQ Fuel Tank Installation

1.

Replace the vent line (J) at the fitting located at the top of
the tank.

2.

Lift the rear of the fuel tank and carefully slide the tank far
enough forward to assemble the fuel lines to the fuel pump. 

3.

Make sure that the fuel tank vent assembly will not be
pinched.

4.

Slide the fuel tank into place and place the washers and
fasteners (E) on that hold the fuel tank (F) to the chassis.

5.

Replace the console.

6.

Connect the tail light if applicable.

7.

Place seat into position.

8.

Replace seat fasteners.

Edge Fuel Tank Removal/Installation

1.

Remove any fuel that may be in the fuel tank.

2.

Remove the seat.

3.

Remove the fuel tank fasteners (1) at the rear of the fuel
tank.

4.

Disconnect the fuel tank vent line (2).

5.

Disconnect the fuel supply line (3).

6.

Remove the fuel tank.

7.

Install in reverse order.

Arrow should be facing
outward in the orientation
shown

Words “VAC” should appear on side
of valve facing the “Y” fitting

To vent fitting on top
left of fuel tank

1

2

3

10.7

CHASSIS & HOOD

10

Seat Cover Replacement

1.

Remove seat.

2.

Remove the old covering by removing the staples that hold
it on the base.

3.

If replacing the tail light assembly. See “Tail Light
Assembly Replacement” on page 10.7.

4.

Drape the new cover over the seat foam.

5.

Turn the assembly over and begin upholstering by lining up
the seat cover vinyl side flaps with the indented square
location indicators located on the plastic seat base.

6.

Using a staple fun, tack each side of the vinyl cover in place
using two staples (1). If cover has a Polaris emblem
carefully align emblem with the bottom edge of the seat.
This will help ensure that the cover is positioned properly.

7.

Align the two sewn seams located at the rear of the seat
cover with the two back corners of the seat base.

8.

Pull the vinyl tight and tack the seat cover to the plastic seat
base in each corner. Use two or three staples per corner.

9.

Now that the cover is positioned, and tacked to the plastic
seat base in for places, turn the assembly over an inspect it.
If the seat cover seems to fit correctly and everything looks
straight, including the tool compartment flap, continue.

10. Staple the remainder of the unattached seat cover to the

plastic seat base. Always staple between two existing
staples and follow this procedure until the seat cover is
completely stapled to the seat base see the staple sequence
above.

11. Turn the seat cushion assembly over and inspect for

wrinkles or imperfections. If imperfections are visible,
remove the staples in the affected area and staple correctly.

12. Trim excess vinyl from the bottom around the back of the

seat area only after a satisfactory fit is obtained.

CONSOLE

Console Removal/Installation

1.

Place the adjustable steering in the center (if equipped).

2.

Remove the two T25 Torx screws (A).

3.

Remove filler cap and the threaded filler retainer (B).

4.

Remove the two T25 Torx screws on each side of the shroud
(C).

5.

You can set the console aside with the starter rope still
installed or you can carefully un-tie the knot in the recoil
handle and route it through the chassis, then secure a knot
and let the rope rest on the recoil housing.

TAIL LIGHT

Edge Tail Light Assembly Replacement

1.

Remove the tail light lens.

2.

Remove the taillight assembly.

3.

Replace taillight assembly.

4.

Replace seat.

Tail Light Assembly Replacement

1.

After removal of seat cover, drill out three rivets from top
of taillight.

2.

Remove taillight assembly and wire harness.

3.

Install new taillight assembly and rivet into place.

4.

Connect taillight wire harness. Taillight harness wires must
be routed away from any possible contact with seat cover
staples to prevent electrical shorts.

5.

Pull seat cover tightly and evenly into position and re-staple
to seat pan.

6.

Inspect cover for a wrinkle-free finish before reinstalling on
the snowmobile.

WARNING

Apply staples in the stapling channel only. If you apply 
staples outside the channel, you will damage the fuel 
tank reservoir in the seat base. If this happens you will 
have to replace the entire seat assembly.

10.8

CHASSIS & HOOD

HANDLEBAR COVER

HANDLE BAR COVER REMOVAL/

INSTALTION

1.

Slide handle bar covers slide (A) off on each side.

2.

Remove the handle bar cover darts (B) on each side.

3.

Remove handle bar cover (C).

4.

Installation is in reverse order of removal.

SKIS

SKI REMOVAL

1.

Securely lift the front of the machine off the ground.

2.

Remove the ski to spindle bolt and washers.

3.

Remove ski, bushing and ski bumper.

SKI INSTALLATION

1.

Place ski, bushing and bumper onto spindle.

2.

Insert the ski to spindle bolt through the ski and spindle.

NOTE: The ski bumper is orientated so that the
“FRONT” label is installed toward the toe of the ski.

3.

Tighten the nuts.

NOSEPAN

REPLACEMENT

IMPORTANT: 

When installing a replacement

nosepan, the open circles represent rivets installed

from inside the nosepan through the bottom. The

filled in circles represent rivets installed from the

under side of nosepan through to the top.

NOTE: Rivet holes may require drilling into the
bulkhead. When transfer drilling holes do not force
the nosepan into a position which is not uniform to
the other side. Rivet holes across from each other.

C

A

B

 

 

 

 

 

 

 

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