Snowmobile Polaris IQ (2007-2008 year). Instruction - part 17

3.8

Maintenance

11. Verify that all of the coolers are warm, including the tunnel-

length cooling system. Turn off the engine once the tunnel
coolers are sufficiently warmed-up. Release the parking
brake.

12. Allow time for the coolant temperature to cool. Re-check

the coolant level in the surge tank. Add more coolant if
required.

Oil Pump Adjustment - Carbureted Models

NOTE: Before adjusting oil pump, always verify the
throttle lever free play and idle speed RPM are set to
specification.

Always verify the throttle cable free play is set to
specification (.010

″

- .030

″

NOTE: The oil pump lever arm line mark MUST be
aligned with the oil pump boss index mark at the
exact moment when the throttle slides begin to lift
from the idle position.

Remove the air box, drive belt, drive clutch and driven
clutch from the engine compartment.

Remove the rear engine torque stop plate from the bulkhead
the bulkhead.

Remove the 2 left-hand console mounting screws and
electrical center cover piece.

Remove the rear 2 lower clutch guard mounting screws and
3 forward mounting nuts and plate.

Remove the 3 screws securing the lower clutch guard to the
upper plate leaving the electrical center components in
place.

Loosen and remove the throttle body assembly and set
aside.

Using a mirror or a bore scope and a light, visually inspect
the current oil pump setting.

NOTE: The oil pump jam nuts can be manipulated
using the special tool set part number: PS-49001 (Oil
Pump Cable Wrenches).

If the oil pump lever requires adjustment or the cable is

going to be replaced, insert the two oil pump cable
wrenches between the bulkhead and the rear of the engine.

10. If the oil pump lever requires adjustment or the cable is

going to be replaced, insert the two oil pump cable
wrenches between the bulkhead and the rear of the engine.

NOTE: The wrench with the large opening is
designed to fit around the cable sheath, while the
wrench with the small opening is designed to fit
around the inner cable wire.

11. When adjusting the lever, make adjustments in small

increments, then re-check the timing mark alignment.

12. After setting the oil pump lever correctly, apply a small

drop of Loctite 242 to the cable barrel threads, then secure
the jam nuts.

13. Re-check the oil pump alignment marks after securing the

jam nuts to verify the marks are set correctly.

14. Re-assemble the removed components in the reverse they

were removed. Reference the appropriate service manual
chapter for component assembly fastener torques.

CAUTION

Always verify all tunnel coolers / radiator are warm to the

touch. A tunnel cooler or return hose that is significantly

“colder” than another cooler or hose is an indication of

trapped air within the cooling system.

CAUTION

The oil pump lever and pump boss marks must be observed

straight-on to yield accurate results.

WRENCHES

3.9

Maintenance

Oil Pump Adjustment - CFI Models

NOTE: Before adjusting oil pump, always verify the
throttle lever free play and idle speed RPM are set to
specification.

33mm Lever - No Pointer Oil Pump

28mm Lever - Pointer Oil Pump

Always verify the throttle cable free play is set to
specification (.010

″

- .030

″

) and the throttle lever is

synchronized to the throttle plates.

NOTE: The oil pump lever arm MUST begin to move
at the exact moment the throttle plates move from
the throttle stop position.

The oil pump part number and/or lever marking determines
where to set the oil pump lever.

INDEX MARK (PUMP BOSS)

LEVER MARK

ARM MARKING

INDEX MARK (PUMP BOSS)

POINTER

ARM MARKING

Oil Pump Adjustment Settings (CFI Models Only)

PART

NUMBER

ARM

MARKING

LENGTH

(

) (

)

LEVER

SETTING

2520552

600 / 33mm - No Pointer

(Lever will not clear engine strap.)

Pump used on all 2007 600 CFIs and

some early-build 2008 600 CFIs.

Set lever line mark to 1 full line width (.050

″) above original oil pump boss

index mark.

2520831

600 / 28mm - w/Pointer

(Lever will clear engine strap.)

Pump phased in for 2008 600 CFIs.

Service replacement pump for ALL

600 CFIs.

Lever mark is a pointer. Oil pump lever pointer is set POINTER-TO-LINE.

2520622

700 / 33mm - No Pointer

(Lever will not clear engine strap.)

Pump used on all 2007 700 CFIs and

some early-build 2008 700 CFIs.

Set lever line mark set to 1 full line width (.050

″) above original oil pump boss

index mark. Some 2007 700 CFI models had 2nd line scribed above original

pump boss mark and were marked with red paint.

2520832

700 / 28mm - w/Pointer

(Lever will clear engine strap.)

Pump phased in for 2008 600 CFIs.

Service replacement pump for ALL

600 CFIs.

Lever mark is a pointer. Oil pump lever pointer is set POINTER-TO-LINE.

2520833

800 / 28mm

- w/Pointer

(Lever will clear engine strap.)

Early Build Engines: Oil pump index mark boss is scribed with 2 lines from the

factory. Oil pump lever pointer is set BETWEEN the 2 scribe lines.

Late Build Engines: Oil pump index mark boss features 1 scribe line.

Oil pump lever pointer is set POINTER-TO-LINE.

3.10

Maintenance

NOTE: Some 2008 600 and 700 CFI engines were
manufactured with model year 2007 oil pumps (PNs
2520552 and 2520622). Always reference the oil
pump adjustment chart to determine the oil pump
lever setting based on the oil pump and not the
engine model year.
All service parts will be the 28mm w/Pointer oil
pumps.

Remove the air box, throttle body adapter plate, drive belt,
drive clutch and driven clutch from the engine
compartment.

Remove the rear engine torque stop plate from the bulkhead
the bulkhead.

Remove the 2 left-hand console mounting screws and
electrical center cover piece.

Remove the rear 2 lower clutch guard mounting screws and
3 forward mounting nuts and plate.

Remove the 3 screws securing the lower clutch guard to the
upper plate leaving the electrical center components in
place.

Loosen and remove the throttle body assembly and set
aside.

Using a mirror or a bore scope and a light, visually inspect
the current oil pump setting.

NOTE: The oil pump jam nuts can be manipulated
using the special tool set part number: PS-49001 (Oil
Pump Cable Wrenches).

10. If the oil pump lever requires adjustment or the cable is

going to be replaced, insert the two oil pump cable
wrenches between the bulkhead and the rear of the engine.

NOTE: The wrench with the large opening is
designed to fit around the cable sheath, while the
wrench with the small opening is designed to fit
around the inner cable wire.

11. When adjusting the lever, make adjustments in small

increments, then re-check the timing mark alignment.
Reference the OIL PUMP ADJUSTMENT SETTING
TABLE to verify where the oil pump lever is set in relation
to the oil pump boss index mark.

12. After setting the oil pump lever correctly, apply a small

drop of Loctite 242 to the cable barrel threads, then secure
the jam nuts.

13. Re-check the oil pump alignment marks after securing the

jam nuts to verify the marks are set correctly.

14. Re-assemble the removed components in the reverse they

were removed. Reference the appropriate service manual
chapter for component assembly fastener torques.

CAUTION

Failure to properly set the oil pump lever arm may cause

severe engine damage.

CAUTION

The oil pump lever and pump boss marks must be observed

straight-on to yield accurate results.

WRENCHES

3.11

Maintenance

Oil Pump Bleeding

Verify oil tank is filled with oil.

Loosen the bleed screw (A). Verify a stream of oil flows
from the bleed screw.

After bleeding oil pump, secure bleed screw and wipe up
oil residue.

NOTE: Any time that the engine is disassembled or
repaired, it is important to purge air within the hoses
and oil pump.

FUEL / INTAKE SYSTEM

Water Sediment Trap

Vehicles with carburetors incorporate a patented float bowl
water / sediment traps located at the bottom of each carburetor.

Turn the fuel tank supply valve to the “OFF” position.

Position a container or shop towels under the work area to
help catch some of the contaminated gasoline.

Slide the clamp (A) away from the drain plug (B) and

remove it from the sediment tube and drain the
contaminated material from the bowl. Repeat for each
carburetor.

Wipe off the residue from the plug and reinstall the clamps.

Fuel Filter - Carbureted Models

All models feature a fuel pick with filter located inside the fuel
tank. To inspect and replace:

Remove the gas cap.

Use a coat hanger to carefully pickup the fuel hose inside
the tank.

Inspect and replace the pickup/filter at the end of the hose.

WARNING

When draining the traps, fuel spillage will occur. Be

sure to work in a well ventilated area away from

anything which may cause the fuel to ignite such as an

open flame, heaters, trouble lights or cigarettes.

CAUTION

The in-tank fuel filter and fuel lines should be inspected

regularly. Special attention should be given to the fuel

line condition after periods of storage.

Normal deterioration from weather and fuel can occur

during this storage period. Do not damage fuel lines

when removing them. If a fuel line has been damaged or

kinked it must be replaced.

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