Home

Fuel Systems - Les Entreprises Marc Latulippe inc.

Contents

1. 4 38 DISCONNECT FITTINGS il etl sade 4 39 FUEL TANK PRESSURE TEST a uu eth bue Peer Rte e de 4 39 FUEL RAIL AND INJECTOR REMOVAL INSTALLATION 4 40 THROTTLE BODY THROTTLE POSITION SENSOR TPS 4 42 THROTTLE POSITION SENSOR TPS OVERVIEW 4 43 THROTTLE POSITION SENSOR TPS IDLE BASE SETTING 4 43 IDLE SPEED ADJUSTMENT CFI 6 4 44 DIGITAL WRENCH TPS REPLACEMENT 4 44 FUEL HOSE 4 47 FUEE TANK Z PUMP SERVICES w 4 48 FUEL TANK FRONT FLANGE TYPE FUEL 4 48 FLANGE TYPE FUEL PUMP SERVICE 4 50 2007 700 CFI FUEL SYSTEM 2 4 51 DROP IN PUMP FUEL SUPPLY TYPICAL 4 52 600 IQ WIDETRAK FUEL 2 4 53 DROP IN FUEL PUMP SERVICE 4 54 DROP IN FUEL PUMP 4 54 DROP IN PUMP 4 55 DIGITAL WRENCH DIAGNOSTIC SOFTWARE 4 55 OVERVIEW g a
2. 4 27 MFD BLINK CODES bre emen E EHE uvae Ari br 4 29 DTC 5 4 29 CFI CLUTCH GUARD ELECTRICAL 4 30 DC CFI 600 IQ WIDETRAK IGNITION COIL MOUNT 4 30 600 IQ WIDETRAK ELECTRICAL CENTER 4 30 2007 CFI 34 PIN ECU 4 31 2008 2010 CFI 34 PIN CNA ECU CONNECTOR 4 32 2007 2010 CFI 26 PIN CNB ECU CONNECTOR 4 33 2009 2010 DC CFI 34 PIN CNA ECU CONNECTOR 4 34 2009 2010 DC CFI 26 CNB ECU CONNECTOR 4 35 EXHAUST TEMPERATURE SENSOR 4 36 TEMPERATURE AIR PRESSURE SENSOR 4 36 CRANKSHAFT POSITION SENSORS 4 36 CRANKSHAFT POSITION SENSOR AIR 5 4 36 EXHAUST VALVE 4 37 CFILIGNITION COILS Saleh sv doses dedo tod 4 37 ENGINE COOLANT TEMPERATURE 4 38 KNOCK SENSOR ces ce eco i ee eae wie eed 4 38 FUELINJECGTORS xs pene yasa kus Laga Ed 4 38 FUEL RAIL BLEEDING PRESSURE
3. 4 41 Fuel Systems 9 Tape exposed wire and splices y 10 Apply oil to the fuel injector o rings seal and mating surfaces 11 Remove the protective caps Install the injector s into the fuel rail Verify the injector s are fully seated 12 Insert the fuel rail with injectors into the engine 13 Apply a light amount of 262 Loctite to the fuel rail fasteners and torque to specification e T Fuel Rail Hex Screw Torque 9 ft lb 12N m 14 Replace the harness to the original routing and apply panduit straps back to the original locations making sure they are not applied over any mesh part of the fuel rail NOTE Refer to Step 2 for proper routing and strap location 15 Install the engine if it was removed 16 If different color injectors were installed re flash the ECU to the new color code 4 42 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Throttle Body Throttle Position Sensor TPS Throttle Body Removal Installation 1 Remove the air box 2 Remove the throttle body air box adapter if equipped 3 Pinch off the coolant lines with the hose pincher tool PN PU 45149 Remove the coolant hoses from the throttle body 4 Loosen the intake boot clamps and pull the throttle body upward to gain access to the throttle cable and TPS connector 5 Loosen the throttle cable lock nuts and remove the cable from the throttle body Disconnect
4. be eee bs cu 4 15 NEEDLEJE T 2 aS au bad Aone oe cia hea OE cof e 4 15 THROTTLE OPENING VS FUEL FLOW 4 16 CARBURETOR FUELPUMP 4 17 FUEL PUMP OVERVIEW z u torte ERE EUR 4 17 4 17 CARBURETOR SERVICE 4 18 DISASSEMBEY Sere ok ss ele irc att ee TES mu ua th E ta etc 4 18 ASSEMBLY t 2 Lee ed ente deer ances Gow s SY a Ee dex ave 4 20 CARBURETOR ADJUSTMENT 4 21 THROTTLE VALVE SYNCHRONIZATION 4 21 CLEANFIRE FUEL INJECTION 4 22 SYSTEM 4 22 TERRAIN DOMINATION POLARIS 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 4 1 Fuel Systems DETONATION CONTROL SYSTEM 4 23 CFI FUEL SELECT MODES asiana br Rl wx en De auca 4 24 DC CFI FUEL SELECT MODES 4 25 CFI RPM ENGINE SPEED LIMIT 4 25 CFI DIAGNOSTIC TROUBLE CODES 4 26 DC CFI DIAGNOSTIC TROUBLE CODES DTCS
5. The ECU can communicate with the Polaris Digital Wrench software and can be re flashed monitored and display trouble codes POLARIS 9922854 2007 2011 IQ Service Manual 4 23 2010 Polaris Sales Inc Fuel Systems CFI Fuel Select Modes When using non oxygenated 91 or higher octane fuel plug the two wires together Ay CAUTION Always unplug the fuel selector jumper wires if unsure of fuel type Severe engine damage may occur if jumper wires are plugged together when using ethanol blended fuel Never use fuels containing more than a 10 ethanol blend Some 2009 2011 CFI models allow the operator to select between 91 octane ethanol and 91 octane oxygenated fuel modes Models with this feature are noted in the Model Specifications chapter The fuel selector switch consists of a PINK and a BLACK BLUE wire located at the rear of the clutch cover electrical center cover When using oxygenated fuel or when unsure of the fuel type inside the fuel tank unplug the two wires lac 4 braquag de capacit s twee eee Q 1ilN7l l 0T Q YI I IU IIYI 9922854 2007 2011 IQ Service Manual gt PELARIS 2010 Polaris Sales Inc Fuel Systems DC CFI Fuel Select Modes 10 ETHANOL 24 OHM Resistor Plug Part Number 2411280 Installed at the factory Ay CAUTION Always verify the ETHANOL resistor plug is installed in the selector plug if unsure of fuel typ
6. 14 Check throttle lever free play TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc gt POLRHRIS 4 20 Fuel Systems CARBURETOR ADJUSTMENT Throttle Valve Synchronization Allthrottle valve synchronization adjustments are made to the MAG throttle valve The PTO throttle valve is non adjustable and considered the base throttle valve Throttle valve synchronization can be performed with the carburetor rack installed or removed from the engine 1 If running turn off engine Remove the air box 2 Remove the carburetor covers 3 Hold the throttle bell crank wide open on the carburetor 4 The bottoms of each throttle valve should be flush with the top of the intake bores 5 If adjustment is required hold the PTO carburetor flush with the top of intake bore Turn the throttle stop screw in or out to set the PTO throttle slide flush with the intake bore 6 Once the PTO carburetor slide is flush loosen the Phillips head screw located under the top cover on the MAG carburetor TERRAIN DOMINATION gt POLARIS 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc While holding the PTO carburetor slide flush to the top of the carburetor rotate the synchronization nut clockwise to raise the slide and counterclockwise to lower the slide i Lock Screw j 1 Sync Nut Adjust the synchronization nut until it is even with the PTO sl
7. POLARIS Fuel Systems Fuel Pressure Gauge Adapters A 314249 305 32 shallow core fitting adapter supplied with PU 43506 A Fuel Pressure Gauge B PS 48617 305 32 deep core fitting C PS 48762 7 16 20 fitting 1 Select the appropriate adapter 2 Connect the adaptor to the fuel return hose Schrader valve 3 Connect the adapter to the fuel pressure bleed tool gauge 4 To observe running fuel system pressure start the engine and compare reading to the specification NOTE Observe pressure reading at idle and while operating the vehicle Fuel System Pressure 58 60 4 0 4 1 5 To bleed the fuel system pressure after the engine is stopped place the tool s bleed hose into an appropriate fuel handling container Open the valve to release the pressure and drain residual fuel 6 Close the valve then remove the gauge and adapter from the fuel hose Schrader valve Replace the Schrader valve dust cap TERRAIN DOMINATION POLARIS Disconnect Fittings The fuel hoses feature disconnect fittings that require special tools to remove The fuel line disconnect tool kit PS 47152 supplies both a 5 16 and a 3 8 quick disconnect tool These tools are also commercially available at local auto parts stores PS 47152 3 3 1 To disconnect a fuel hose from the fuel pump or fuel rail insert the tapered end of either the 5 16 or 3 8 tool into the female h
8. Adjustment Air Screw Idle Slow Speed Pilot Circuit Throttle Valve Cutaway Needle Jet Jet Needle High Speed Main Jet Circuit TERRAIN DOWNIN AT N m w snr vv sr rss rr POLARIS 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 4 7 Fuel Systems Throttle Opening and Fuel Flow This illustration can be helpful when trying to diagnose a fuel related problem when the throttle opening at which The illustration below depicts how each fuel metering the rich or lean condition occurs is determined circuit effects the total fuel flow of the carburetor as well as the fuel flow characteristics when the jet needle e clip is For example changing main jets to resolve an off idle moved from position 2 to position 4 4 8 hesitation or rich condition would nothing the main jet s effect on total fuel output is minimal at idle speeds 5 a Throttle Valve Opening INCREASING DECREASING Medium Large Clearance 75 100 Closed One half Full Throttle Throttle Throttle Ve 14 3 8 12 58 3 4 1 8 FULL THROTTLE OPENING TYPICAL MIKUNI VM e Throttle Valve Cut Away Jet Needle Needle Jet RRAIN DOMINATI 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc gt POLARIS Fuel Systems Starting Enrichment System The starting or enrichment system provides additional fuel required to start the engine i
9. B Loosen the jam nut Turn the idle speed screw clockwise to raise our counter clockwise to lower the 4 44 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc engine idle RPM Turn the screw at 1 8 1 4 increments 7 Securethe jam nut and reinstall the air box assembly Close the hood 8 Re testthe vehicle and note the change in engine idle speed Repeat steps 4 through 7 if further adjustment is required Digital Wrench TPS Replacement Procedure CAUTION The throttle position sensor TPS is set at the time of throttle body manufacture TPS adjustments should only be made if the TPS was loosened repositioned or replaced Any adjustments made to the TPS sensor or throttle synchronization screw will require performing the Digital Wrench Full Procedure TPS Replacement guided diagnostic The TPS Replacement Procedure must be performed when the following occurs TPS replacement The TPS screws have loosened or the TPS has been repositioned Throttle plate synchronization screw has been adjusted Adjusting the idle speed screw when it is not known if the TPS has been replaced adjusted TERRAIN DOMINATION POLARIS Fuel Systems NOTE The guard may need to be flexed to align the holes with the TPS fasteners 10 1 700 Deacon Special Tesis x PEL SS 1 ki gt Status 1 Click on the TOOLBOX i
10. Low 4 P0107 Sensor signal is below 1 25 VDC e Sensor signal is above 4 9 VDC for at least 2 minutes and the engine has Exhaust Temperature Sensor Circuit Voltage High 3 P0546 been running at or above 3000 RPM 173 5 T Sensor signal is below 0 06 VDC for at least 2 minutes and the engine has Exhaust Temperature Sensor Circuit Voltage Low 4 P0545 been running at or above 3000 RPM Engine speed is above 6000 RPM and the sensor signal is above 4 3 VDC Detonation Sensor Circuit Voltage Low 731 4 P0328 for at least 2 seconds 0 P1336 Maximum Detonation Correction Limit Reached Knock Level MAG 1352 6 16 P2336 Knock above critical level 0 P1337 Maximum Detonation Correction Limit Reached Knock Level PTO 1353 16 P2337 Knock above critical level 5 P0261 OPEN circuit or short to ground Can be caused by faulty wiring injector MAG Cylinder Port Injector Circuit 651 stator or ECU 3 P0262 Circuit shorted to battery voltage 5 P0264 OPEN circuit or short to ground Can be caused by faulty wiring injector PTO Cylinder Port Injector Circuit 652 stator on ECU 3 P0265 Circuit shorted to battery voltage 7 5 P1261 600 IQ Widetrak Only OPEN circuit or short to ground Can be caused MAG Crankcase Injector Circuit 520216 by faulty wiring injector stator or ECU 3 P1263 600 IQ Widetrak Only Circuit shorted to battery voltage 5 P1264 600 IQ Widetrak Only OPEN circuit or short to ground Can be caused PTO Crankcase Injector Circuit 520217 by f
11. a hacen ers Od ed MER hu oi ey eas 4 55 CFI DIGITAL WRENCH CONNECTIONS 4 56 DC CFI DIGITAL WRENCH CONNECTIONS 4 56 UPDATING DIGITALWRENCH e 4 57 VERSION IDENTIFICATION 72 1 4 57 ENGINE CONTROLLER REPROGRAMMING REFLASH 4 58 TROUBLESFHOOTING 5 u Re RR ERES YT ES ERR RR RS 4 60 FLOWCHART eem RERO RSA uc ui p lE ed Ewing 4 60 TERRAIN DOMIMATION 9922854 2007 2011 IQ Service Manual gt POLARIS 2010 Polaris Sales Inc 4 2 Fuel Systems SERVICE WARNINGS AND PRECAUTIONS Service Warnings When servicing the fuel system it is important to heed the following warnings A WARNING PROPOSITION 65 WARNING Snowmobile engines discharge fuel and exhaust which contain chemicals known to the State of California to cause cancer and birth defects or other reproductive harm onto the snow on which they operate Keep this engine properly tuned and avoid unnecessary idling and spillage during fueling Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored or used If you get gasoline in your eyes or if you swallow gasoline see your doctor immediately Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short tim
12. cap nuts Verify the EV base vent and cylinder holes are clean and free from carbon or heavy residue PISTONS STEP 10 1 With the exhaust valve assemblies removed from the cylinders insert a piston wash light or use a flashlight to inspect the exhaust Pistons side of the pistons Is heavy scoring scratching or ring damage visible 2 If piston skirt or ring damage is visible through the exhaust valve slots the pistons should be replaced and the cylinders inspected and lightly honed with an Ammco 320 grit or equivalent NiCaSil oversize honing stone TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc POLARIS 4 60
13. pump electrical connector 6 Remove the fuel hoses from the fuel pump See Disconnect Fittings on page 4 39 7 Remove the fasteners securing the fuel tank to the tunnel 4 48 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 8 Remove the fuel tank from the chassis 9 Place the fuel tank is a well ventilated area 10 Remove and discard the six fuel pump flange screws 11 Carefully extract the fuel pump assembly out of the tank CAUTION Use care when working the level sender arm through the flange hole Do not bend the arm as inaccurate fuel level readings may occur when reinstalled 12 Discard the fuel pump flange gasket If the pump has failed discard the fuel pump If the fuel tank is to be replaced obtain the new fuel tank CAUTION NEVER RE USE THE FUEL PUMP FLANGE GASKET ALWAYS INSTALL FUEL PUMP USING A NEW FALNGE GASKET 13 Saturate a clean rag with isopropyl alcohol and clean the surface of the fuel pump flange area and the fuel pump flange Dry all surfaces with a clean rag Allow adequate drying time for the alcohol TERRAIN DOMINATION POLARIS Fuel Systems 14 Install new clean gasket by carefully sliding it over 20 After completing the initial torque sequence tighten the fuel lines and pump components Position the each screw to 23 2 6 Nm in one continuous gasket with the barbs locating pins facing the fl
14. screen program to troubleshoot DTCs MFD blink codes and overall performance problems Digital Wrench can be used to display trouble codes and offers guided diagnostics Guided diagnostics allows the technician to perform diagnostic checks in an attempt to isolate the root problem 1 To access trouble codes click on the button If any codes are listed select a code to proceed Digita 2 access guided diagnostics click on the SPECIAL TESTS toolbox button Then click DIAGNOSTIC PROCEDURES 3 Select a code or system in the SYSTEM CHARTS menu A description of the DTC or system will be displayed TERRAIN DOMINATION C POLARIS 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 4 29 Fuel Systems CFI Clutch Guard Electrical Center COVER SPARE BELT HOLDER a 6 Ft Lbs 10 Nm W 44 1 e CAPACITOR 267 ES T IGNITION NS AN 8 GFtLbs 10 Nm 6 Ft Lbs 10 Nm COIL MOUNT GUARD PLATE LZ 6FtLbs 10 Nm DC CFI 600 IQ Widetrak Ignition Coil Mount The ignition coils on DC CFI models are mounted to the oil tank not within the clutch guard 600 IQ Widetrak Electrical Center The AC regulator DC regulator rectifier and capacitor are mounted to the RH steering hoop support plate PTO COIL SNe 9L ju 2 e s gt MAG COIL NUT TORQUE 6 Ft Lbs 10 Nm 25 CAPAC
15. the TPS harness connector 7 Remove throttle body NOTE Service replacement throttle body assemblies have the TPS already installed No TPS adjustment is required 8 Reinstall the throttle body assembly Torque throttle body boot clamps to specification 9 Turn the throttle cable inline adjuster clockwise until bottom out 10 Install throttle cable on to throttle body Adjust the jam nuts Verify the throttle cable is not pulling on the throttle plate cam Tighten jam nuts 11 Reinstall the cooling hoses and remove the pincher tools 12 Reinstall the air box adapter plate if equipped Reinstall the air box assembly 13 Install the throttle cable into the throttle lever use the inline adjuster to set the throttle lever free play to specification TERRAIN DOMINATION POLARIS Fuel Systems Throttle Position Sensor TPS Overview CAUTION The throttle position sensor TPS is set at the time of throttle body manufacture TPS adjustments should only be made if the TPS was loosened repositioned or replaced Any adjustments made to the TPS sensor or throttle synchronization screw will require performing the Digital Wrench Full Procedure TPS Replacement guided diagnostic The throttle position sensor TPS is set at the factory based on a throttle body idle air gap flow specification TPS adjustments should only be performed when replacing the TPS NOTE Follow these guidelines when
16. to some degree by adjusting the fuel screw The main system is designed to deliver fuel between low speed and high speed operation This system is made up of the jet needle needle jet and main jet The main system begins to take effect as soon as there is enough air flow into the carburetor venturi to draw fuel up through the main jet and needle jet assembly This system works conjunction with the needle jet system During low speed driving there is very little clearance between the jet needle and the needle jet therefore very little fuel from the main jet can pass between the jet needle and the needle jet As the throttle valve opening is increased the tapered jet needle is raised farther out of the needle jet allowing greater fuel flow Under full throttle opening the cross sectioned area of clearance between the jet needle and the needle jet becomes greater than the cross sectioned area of the main jet Thus the main jet is now controlling the amount of fuel flow Pilot Jet From idling to low speeds the fuel supply is metered by the pilot jet There are several air bleed openings in the sides of the pilot jet which reduce the fuel to mist The number stamped on the jet is an indication of the amount of fuel in cc s which passes through the jet during a one minute interval under a given set of conditions Fuel Screw The fuel screw controls the fuel mixture from idle to low speeds The tapered tip of the fuel screw proje
17. 0 CFI Only If the RPM limit mode occurs a Diagnostic Trouble Code DTC will be registered Digital Wrench will display the P1336 DTC venting When powered the solenoid is open allowing cylinder pressure to vent keeping the exhaust valves closed When power is removed the solenoid closes and the exhaust valves are allowed to open 600 IQ Widetrak Only If the RPM limit mode occurs a Diagnostic Trouble Code DTC will be registered Digital Wrench will display the following codes P1336 P2336 P1337 and P2337 Throttle Position Sensor TPS ALL The TPS relays the position of the throttle plates operator throttle input to the ECU Retroactive to 2008 2009 800 CFI models after Service Bulletins S 09 08 or S 09 09 are performed Coolant Temperature Sensor ALL Relays the engine temperature to the ECU Exhaust Temperature Sensor ALL Relays the temperature of the exhaust pipe to the ECU Temperature Barometric Air Pressure TMAP Sensor ALL Relays the current intake air temperature and ambient air pressure to the ECU The sensor is located on the airbox To function properly the sensor must be free from foreign material oil and grease Vehicle Speed Input ALL The ECU monitors the vehicle speed supplied by the vehicle speed sensor Fuel Pump ALL Supplies fuel to the fuel injectors Power to the fuel pump is supplied by the regulator rectifier Diagnostic Connector ALL
18. 0 GREY LH CONTROL SIGNAL PLUG PERC SWITCH 14 PK BLK FUEL MODE PLUG FUEL QUALITY SWITCH 13 WHT DB 600 WIDETRAK ONLY GEARCASE LOW RANGE SWITCH LOW GEAR SIGNAL 15 BROWN ECU GROUND SPLICE ECU GROUND 16 BROWN 17 ORANGE EXTERNAL POWER SPLICE EXTERNAL POWER 19 BN YEL FUEL PUMP PRIME GROUND SPLICE FUEL PUMP ON OFF CONTROL 20 ORANGE VOLTAGE BOOST FUEL INJECTION VOLTAGE BOOST 21 ORANGE 22 DB RED WATER TEMP SIGNAL CHASSIS HOOD 23 WHITE REVERSE LED SIGNAL 24 YEL BLK 600 WIDETRAK ONLY FAN RELAY FAN RELAY CONTROL 25 BK RED THROTTLE SAFETY SWITCH THROTTLE SOFT STOP 27 DARK GREEN CAN LOW CAN LOW SIGNAL 28 CAN HIGH CAN HIGH SIGNAL 30 WHT YEL EV SOLENOID SOLENOID ON OFF CONTROL WHT DB CHASSIS POWER RELAY RELAY COIL ON OFF CONTROL 34 RED REGULATOR POWER SPLICE DC REGULATED VOLTAGE DOMINATION POLARIS Fuel Systems 2009 2010 DC CFI 26 Pin CNB ECU Connector NOTE Wire Entry View PIN COLOR GOES TO CONNECTOR FUNCTION 1 BLUE PTO FULL LOAD INJECTOR 2 BLU WHT FUEL INJECTOR HARNESS PLUG PTO PART LOAD INJECTOR 3 RD BLU FUEL INJECTOR POWER SUPPLY 4 GREEN 5 TOOTH CPS SENSOR SENSOR SIGNAL 5 BENET WHTRED STATOR CPS HARNESS CONNECTOR SENSOR GROUND TPS CONNECTOR EXHAUST TEMP SENSOR 6 BLK BLU COOLANT TEMP SENSOR SENSOR GROUND TMAP SENSOR CONNECTOR COMMUNICATION CONNEC
19. 0 N 3131401 120 3130107 200 3130123 360 3130139 530 N 3131402 125 3130108 210 3130124 370 3130290 540 N 3131408 130 3130109 220 3130125 380 3130140 550 N 3131409 135 3130110 230 3130126 390 3130480 560 N 3131410 140 3130111 240 3130127 400 3130141 145 3130112 250 3130637 410 3130599 150 3130113 260 3130129 420 3130142 155 3130114 270 3130130 430 3130143 160 3130115 280 3130131 440 3130144 165 3130116 290 3130132 450 3130145 170 3130117 300 3130133 460 3130146 Mikuni Pilot Jets Mikuni Starter Jets PILOT JET NUMBER PART NUMBER STARTER JET PART NUMBER 25 3130064 130 3130805 30 3130065 135 3130767 35 3130066 140 3130768 40 3130067 145 3130769 45 3130068 150 3130770 50 3130629 155 3130771 55 3130070 160 3130772 60 3130071 RRAIN DOMINATI 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc gt POLARIS 4 4 Fuel Systems Mikuni Jet Needles Mikuni Long Pilot Air Jets JET NEEDLE PART NUMBER AIR JET PART NUNBER J8 9FH04 57 3130794 0 5 3131255 J8 9EH01 57 3130795 0 6 3131249 J8 9DH01 54 3130796 0 7 3131256 J8 8BEY01 3131250 0 8 3131254 J8 9DFH06 57 3131253 0 9 3131203 J8 9EFH01 60 3131207 1 0 3131257 J8 9DFH07 60 3131268 1 1 3131258 J8 9DFH10 57 3131313 1 2 3131259 J8 9DGI01 60 3131377 1 3 3131260
20. 2011 IQ Service Manual 2010 Polaris Sales Inc 4 37 Fuel Systems Engine Coolant Temperature Sensor Sensor Specifications Operating Temperature Range Resistance Installation Torque Knock Sensor 22 F 4248 F 30_ 120_ 2 4 2 6KO 68 F 20 C Measure in stirred water 29 ft lbs 39 2Nm 4 810 000 OHMS TORQUE TO 20 5 N M 1543 FT LBS Fuel Injectors COLOR DOT Specifications Resistance 120 68 F 20 C 4 38 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Fuel Rail Bleeding Pressure Testing All CFI engine fuel return hoses feature an inline Schrader valve that can be used to bleed the fuel system pressure and observe fuel system pressure when using the fuel pressure gauge and specified adapter SCHRADER VALVE 51333 SCHRADER VALVE The model year and engine model will determine which fuel pressure tool adapter is required to complete both tasks Fuel Pressure Gauge Adapters GAUGE YEAR MODEL ADAPTERS BLEED TOOL Select 2007 2011 600 CFI 314249 Shallow Core 305 32 Shallow Core fitting supplied with PU 43506 A PU 43506 A 2007 600 CFI PS 48617 Deep Core 305 32 Deep Core fitting Select 2008 2011 600s PS 48762 All 700s 800s_ 7 16 20 fitting Fuel Pressure Gauge PU 43506 A gt PU 43506 A TERRAIN DOMINATION
21. 48459 carefully remove the PFA nut Carefully extract the PFA out of the tank making sure 10 the float and fuel hoses do not become kinked or bent Remove the old gasket and destroy Never re use a used PFA gasket 11 12 13 14 15 Clean the tank s gasket mating surface with isopropyl alcohol Allow the surface to dry completely Install a new gasket ensuring the inside portion of the gasket hooks onto the bead on the inside diameter of the neck Remove any containments from the gasket with isopropyl alcohol Carefully place the PFA back into the tank Push the float assembly against the hoses to fit it into the hole Hand tighten the PFA nut keeping the arrow between the PFA alignment marks RETURN FITTING 7 ARROW ALIGNMENT LINES 16 17 Using the spanner wrench and nut socket PS48459 tighten the PFA to specification After installing the PFA nut verify the nut is not contacting the fuel tank surface If the nut makes contact with the tank the gasket may not seal Remove the PFA nut and install a new gasket or nut combination and recheck 6 T PFA Nut Torque 28 Ft Lbs 38 Nm 18 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Fueltank installation is the reverse of removal Always test the PFA gasket seal before tank installation by performing a pressure check TERRAIN DOMINATION POLAR
22. 7 4 P0178 Voltage too low 2 P0177 600 IQ Widetrak Only Signal Out of Range Chassis Relay Circuit Open Grounded 5 P1611 600 IQ Widetrak Only 520208 Chassis Relay Driver Shorted to Battery Voltage 3 P1614 600 IQ Widetrak Only TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc POLARIS 4 28 Fuel Systems MFD Blink Codes Trouble Code Information The check engine LED will display a blink code whenever the ECU determines there is a current problem with or on This Trouble Code sets if the Engine Speed is above more of the sensors Use Digital Wrench to troubleshoot 6000 RPM and the Detonation Sensor Signal is below fix and clear the codes 1 23 Volts for more than 2 seconds T Can be caused by Damaged Wiring a faulty Detonation Sensor or ECU Connections When blink code is displayed the CHECK ENGINE light A B will illuminate for 1 2 second on and 1 2 second off with 01 1 second off interval between close except for exhaust Le temperature sensor codes where the engine has to run over 3000 RPM for 60 to 90 seconds depending on model to trigger a blink code 4 Click on A to activate guided diagnostics DTC Troubleshooting 5 Click on B to view a wiring schematic of the component or system Always use the Digital Wrench diagnostic software 6 Click on X to exit the current
23. CHECK VALVE Front er FOAM PADS MT A 4 6 FLLbs 5 5 8 Nm B 28 Ft Lbs 38 Nm POLARIS 9922854 2007 2011 IQ Service Manual 4 53 2010 Polaris Sales Inc Fuel Systems Drop In Fuel Pump Service Some models feature drop in fuel pump and fuel level sender assemblies Reference the fuel level sender resistance table for models that display the fuel level on the MFD gauge NOTE The fuel pump may be mounted on the right side or left side of the fuel tank depending on model O PINS COLOR FUNCTION Full lt 8 1 1 Red Pump PWR 1 2 40 3 2 WHT BLU Fuel Level Sender Empty 85 4 3 Black Pump Ground 4 Pink Black Sender Ground Drop In Fuel Pump Replacement 1 9 4 54 Siphon the fuel out of the fuel tank into a suitable container Remove the console and the seat assembly Disconnect the positive battery cable from the battery if applicable Remove the fasteners securing the fuel tank to the tunnel Bleed the pressure from the fuel rail See Fuel Rail Bleeding Pressure Testing on page 4 38 Lift and move the tank back to gain access to the fuel lines Disconnect the fuel supply and return hoses from the pump flange See Disconnect Fittings on page 4 39 Disconnect the wiring harness then remove the tank from the snowmobile Place tank in a well ventilated area Using the PFA spanner wrench and nut socket PS
24. Fuel Systems CHAPTER 4 Fuel Systems SERVICE WARNINGS AND 6 4 3 SERVICE WARNINGS 4 3 CARBURETOR FUEL SYSTEMS 4 4 MIKUNI MAIN 5 4 4 MIKUNI PIEOT JETS 4 ce met mm mm ba a asa 4 4 MIKUNI STARTER JETS 4 4 MIK NIJET NEEDEES 4 eR Y A Rer Des 4 5 MIKUNI SHORT PILOT AIR JETS 4 5 MIKUNI LONG PILOT AIRJETS 4 5 MIKUNI TM PISTON VALVES 4 5 MIKUNI TM NOTCHED PISTON 4 5 CARBURETED FUEL SYSTEM TYPICAL 4 6 MIKUNI VM CARBURETOR 4 7 ASSEMBLY u i e agate ne 4 7 MIKUNI VM CARBURETOR FUNCTION 4 7 THROTTLE OPENING AND FUEL FLOW 4 8 STARTING ENRICHMENT SYSTEM 4 9 FEOAT SYSTEM ucro nee deterret v We ee E ORC S AUR ESI E A Qe S Meee sac 4 9 IDLE SPEED ADUUSTMENT 4 9 AIRE SCREW Zo teer ten good baro te t t
25. IL INJECTOR 550 ONLY E RING 7 PACKING FLOAT PIN 2 as a SF P fe FLOAT 1 FNS e i QO p WASHER JET 3 O RING pd DRAIN PLUNGER SPRING 1 PLUNGER Q PLUNGER CAP i Lf SPRING Yy A Q IDLE SPEED SCREW 1 ILOT JET D i p A Med 2 CAP Mikuni VM Carburetor Function The function of a carburetor is to produce a combustible air fuel mixture by breaking fuel into tiny particles in the form of vapor to mix the fuel with air in a proper ratio and to deliver the mixture to the engine A proper ratio means an ideal air fuel mixture which can burn without leaving an excess of fuel or air Whether the proper mixture ratio is maintained or not is the key to efficient engine operation The engine is operated under a wide range of conditions from idling with the throttle valve almost closed to full load or maximum output with the throttle valve fully opened In order to meet the requirements for the proper mixture ratio under these varying conditions a low speed fuel system or pilot system and a main fuel system are provided in Mikuni type carburetors A Mikuni VM carburetor uses several components and fuel metering circuits to deliver fuel at all throttle opening positions These components and circuits include Starting Enrichment Circuit Float System Idle Speed
26. IS Fuel Systems Drop In Pump Service DIGITAL WRENCH DIAGNOSTIC SOFTWARE The pickup hose vapor separator assembly can be ordered separately from the complete fuel pump Overview Digital Wrench diagnostic software allows the technician to perform the following tests and observations View clear trouble codes Analyze real time engine data Reflash ECU calibration files Guided diagnostics Create customer service account records The following components are required to use the Digital Wrench software PC or laptop with Microsoft Windows operating system Digital Wrench software part number PU 47063 Smart Link Module part number PU 47468 Interface Cable part number PU 47469 PC Interface Cable part number PU 47470 Smart Link Module Kit Includes PU 47468 PU 47469 and PU 47470 in one kit part number PU 47471 M 10 ACE ECU Chassis Power Up Cable part number PS 47296 A 12 volt battery Connect to Vehicle Diagnostic Connector Vehicle Interface SmariLink Module cx ny i Serial Intertace Cabie to PC Connect to Digital Wrench PC TERRAIN DOMINATION gt POLARIS 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 4 55 Fuel Systems CFI Digital Wrench Connections The access point for the ECU power up and Digital Wrench connectors is located in the front left
27. ITER COIL 16 GREEN YELLOW STATOR EXCITER COIL EXCITER COIL 17 WHITE GREEN CRANK POSITION SENSOR 5 TOOTH COIL GROUND 18 WHITE RED CRANK POSITION SENSOR 2 TOOTH COIL GROUND 19 BLACK BLUE DETONATION SENSOR GROUND 20 PURPLE DETONATION SENSOR SENSOR SIGNAL 21 RED BLUE MAG PTO FULL LOAD INJECTOR INJECTOR POWER SUPPLY 22 RED BLUE MAG PTO PART LOAD INJECTOR INJECTOR POWER SUPPLY 23 AQUA TPS SENSOR SIGNAL RETURN 24 BLACK BLUE COOLANT TEMP SENSOR TPS SENSOR GROUND 25 YELLOW COOLANT TEMP SENSOR SENSOR SIGNAL RETURN 26 RED EV SOLENOID REGULATED VOLTAGE TERRAIN DOMINATION POLARIS 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 4 33 Fuel Systems 2009 2010 DC CFI 34 Pin CNA ECU Connector 1 S NOTE Wire Entry View 4 34 wwe rrsx k ir TERRAIN 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc PIN COLOR GOES TO CONNECTOR FUNCTION 1 DG WHT IGNITION SWITCH STARTER LOCKOUT 3 RD BLK ELECTRIC START BATTERY VOLTAGE 4 LD EL 600 WIDETRAK ONLY TACHOMETER 5 DB WHT GHASSISMOOD HOT LED INDICATOR 6 BLK WHT CHECK ENGINE LED MIL 7 BLK DB SENSOR GROUND SPLICE SENSOR GROUND 8 DG RD GROUND SPEED SPLICE GROUND SPEED SIGNAL 9 BLACK IGNITION SWITCH HARD STOP SWITCH 1
28. ITOR lA DC REGULATOR RECTIFIER Ah END Y uu xr AC REGULATOR NUT TORQUE 6 Ft Lbs 10 Nm 4 30 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc TERRAIN DOMINATION POLARIS Fuel Systems 2007 CFI 34 Pin CNA ECU Connector NOTE Wire Entry View PIN COLOR GOES TO CONNECTOR FUNCTION 3 RED BLUE SPLICE K LINE POWER 4 ORANGE ECU POWER EXTERNAL POWER 5 WHITE BLACK EXHAUST TEMP SENSOR SIGNAL 6 BLUE TMAP AIR TEMP SIGNAL 7 GREEN BLUE IGNITION SWITCH STARTER LOCKOUT 8 RED WHITE TMAP 5 VDC POWER SUPPLY 9 GREEN RED GROUND SPEED SENSOR SPLICE SPEED SIGNAL 10 RED BLACK ELECTRIC START BATTERY VOLTAGE 11 WHITE BLUE CHASSIS RELAY COIL GROUND 12 RED BLACK THROTTLE FLIPPER SAFETY SWITCH SOFTWARE BASED IGNITION KILL SIGNAL 13 BROWN ECU GROUND SPLICE ECU GROUND 14 RED BLUE CHASSIS HOOD 2 WATER TEMP SIGNAL 16 YELLOW RED CHASSIS HOOD 1 TACHOMETER SIGNAL 17 ORANGE REGULATOR RECTIFIER VOLTAGE BOOST POWER 21 PINK DIAGNOSTIC K LINE 22 GRAY GRAY SPLICE MODE SELECT 28 CHASSIS HOOD 1 PERC LED 24 GREEN TMAP PRESSURE SENSOR SIGNAL 25 BLUE WHITE CHASSIS HOOD 1 OVERHEAT DET LED 26 ORANGE GREEN ELECTRIC START CHARGE RELAY COIL GROUND 27 BLACKMHITE DIAGNOSTIC SPLICE CHASSIS HOOD 4t DIAGNOSTICS CHECK ENGINE LED 29 BLACK MG ee HARDWARE ST
29. Inc Ls LA n mm Crankshaft Position Sensor Air Gap 020 030 0 5 0 8mm TERRAIN DOMINATION POLARIS Fuel Systems Air Gap Inspection Adjustment 1 Rotate the crankshaft flywheel so that an encoder rib is positioned directly underneath the sensor being measured 2 Insertthe blade of a 030 feeler gauge between the and sensor face If there is no drag felt on the feeler gauge the CPS must be adjusted 3 To adjust a CPS use a 8 inch pry bar to carefully deflect the sensor 4 Place the tip of the small pry bar between the back of the sensor and crankcase insert a 012 feeler gauge between the sensor face and encoder rib IMPORTANT Do not pry on the individual sensor wires TY ER FEELER GAUGE b 5 Gently pry the sensor towards the encoder rip until the gauge begins to bind between the components 6 Re measure the air gap The gap should be between 020 030 DOMINATION gt POLARIS Exhaust Valve Solenoid Y Specifications Coil Resistance WHT YEL to RED 150 4 15 68 F 20 C CFI Ignition Coils Specifications Primary Coil Resistance Black to White 0 450 1596 68 F 20 C Secondary Coil Resistance Without Plug Cap Black to High Tension Lead 18 0000 15 68 F 20 C Plug Cap Resistance 4 0000 6 0000 9922854 2007
30. J8 9DGJ02 57 3131378 1 4 3131261 J8 9EFY02 61 3131202 1 5 3131262 J8 9DGN6 57 3131438 1 6 3131263 1 7 3131264 Mikuni Short Pilot Air Jets 1 8 3131265 1 9 3131266 AIR JET PART NUMBER 20 3131267 0 5 3130773 0 6 3130774 Mikuni TM Piston Valves 0 7 3130775 0 8 3130776 PISTON VALVE PART NUMBER 0 9 3130777 1 5 3130940 1 0 3130778 2 0 3131252 1 1 3130799 2 5 3130790 1 2 3130780 3 0 3130791 1 3 3130781 3 5 3130792 1 4 3130782 4 0 3130793 1 5 3130783 16 3130784 Mikuni TM Notched Piston Valves 1 7 3130785 y 190586 VALVE PART NUMBER 19 3130787 1 5 3131216 20 3130788 2 0 3131206 2 5 3131217 3 0 3131218 3 5 3131219 4 0 3131220 POLARIS 9922854 2007 2011 IQ Service Manual 4 5 2010 Polaris Sales Inc Fuel Systems Carbureted Fuel System Typical VENTFITTING SEAT BRACKET FUEL CAP GAUGE SEAL FtLbs 4 6 Ft Lbs 5 5 8 Nm i FUEL ON OFF VALVE 4 FUEL PUMP iN Y le FOAM PADS HAND TORQUE 6 FITTING FASTENERS T FILTER 6 TE Carb DOM INMATI IOMNM 9922854 2007 2011 IQ Service Manual e 2010 Polaris Sales Inc gt POLRHRIS 4 6 Fuel Systems MIKUNI VM CARBURETOR Assembly View CHAMBER GASKET Q JET NEEDLE P FLOAT ARM NEEDLE AND SEAT p 7 THROTTLE VALVE A Pd SPRING NEEDLE JET THROTTLE PLATE d E ory gt 4 zd y 2 6 LU O
31. OP IGNITION KILL SIGNAL 30 BLACK BLUE SENSOR GROUND SPLICE 1 SENSOR GROUND 31 GRAY LH CONTROL PERC SIGNAL 32 RED REGULATOR POWER SPLICE REGULATED POWER 33 ORANGE REGULATOR RECTIFIER VOLTAGE BOOST POWER 34 ORANGE REGULATOR RECTIFIER VOLTAGE BOOST POWER POLARIS 9922854 2007 2011 IQ Service Manual 4 31 2010 Polaris Sales Inc Fuel Systems 2008 2010 CFI 34 Pin CNA ECU Connector NOTE Wire Entry View PIN COLOR GOES TO CONNECTOR FUNCTION 3 RED BLUE SPLICE K LINE POWER 4 ORANGE ECU POWER EXTERNAL POWER 5 WHITE BLACK EXHAUST TEMP SENSOR SIGNAL 6 BLUE TMAP AIR TEMP SIGNAL 7 GREEN BLUE IGNITION SWITCH STARTER LOCKOUT 8 RED WHITE TMAP 5 VDC POWER SUPPLY 9 GREEN RED GROUND SPEED SENSOR SPLICE SPEED SIGNAL 10 RED BLACK ELECTRIC START BATTERY VOLTAGE 11 WHITE BLUE CHASSIS RELAY COIL GROUND 12 RED BLACK THROTTLE FLIPPER SAFETY SWITCH SOFTWARE BASED IGNITION KILL SIGNAL 13 BROWN ECU GROUND SPLICE ECU GROUND 14 RED BLUE CHASSIS HOOD 2 WATER TEMP SIGNAL 16 YELLOW RED CHASSIS HOOD 1 TACHOMETER SIGNAL 17 ORANGE REGULATOR RECTIFIER VOLTAGE BOOST POWER 21 PINK DIAGNOSTIC K LINE 22 GRAY SPLICE MODE SELECT 23 WHITE CHASSIS HOOD 1 PERC LED 24 GREEN TMAP PRESSURE SENSOR SIGNAL 25 BLUE WHITE CHASSIS HOOD 1 OVERHEAT DET LED 26 ORANGE GREEN ELECTRIC START CHARGE RELAY COIL GROUND 27 BLACK
32. PM 2 Does the exhaust gas temperature value change with changing throttle lever input after running the engine for 60 seconds at or above 3 000 RPM 3 If the EGT value does not change inspect the sensor wiring and connections If the wiring and connections are good replace the sensor and retest STEP 7 EXHAUST SYSTEM Exhaust 1 Check exhaust system for leaks missing over stretched damaged springs and worn out seals Replace components as required System 2 Remove the resonator and shake Replace resonator if shaking reveals loose internal baffle plates STEP 8 IGNITION SYSTEM Ignition 1 Insect the spark plug caps and spark plugs Are the caps worn oblong or bent Replace cap s as required System 2 Have the spark plug s worn into the top of the cap s If so replace both the affected spark plug and cap as required STEP 9 EXHAUST VALVES Exhaust 1 Inspect the exhaust valve solenoid vent system discharge hose for leaks or plugged kinked hoses Repair or re route hoses Valves connections as required 2 Do the exhaust valves move as RPM increases Test exhaust valve motion by installing a 1 inch piece of clear fuel vent hose onto each EV cap nut through the hole in each EV housing Start the engine and increase the engine speed past 6 000 RPM to check for proper valve operation 3 Do both valves move at the same time rate If not inspect one or both EV assemblies Inspect for torn bellows worn EV springs and loose bellows
33. S 942 947 952 957 VDC ALL 800 CFI ENGINES 937 942 947 952 NOTE Setting the idle set voltage to the low end of the specification will result in a lower idle speed Setting the idle set voltage to the high end of the specification will result in a higher idle speed 19 When the correct idle set voltage is established the CONTINUUE button will turn from RED to GREEN When this occurs carefully tighten the lock nut B while maintaining the voltage setting 20 Reinstall the throttle cable into the throttle lever Set the throttle lever free play to specification Verify the TPS voltage does not change when setting turning the throttle cable inline adjuster 21 Reinstall the air box assembly Verify the air box is securely attached to the throttle body 22 Reinstall the driven clutch and drive belt 23 Test ride the vehicle at normal operating temperatures to verify the idle speed is within specification pyERRA gt POLARIS DOMINATION Fuel Hose Mounting Routing The fuel hoses must be routed properly and secured to the airbox as shown in the photo below to prevent the hoses from rubbing on each other or other components P CLAMP LOCATED WHERE HOSE MEETS METAL PIP pu Replace any fuel hose if the inner rubber core show signs of wear en RUBBER HOSE WORN REPLACE FUEL HOSE h 4 47 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Fuel Sy
34. TOR 7 AQUA BLUE TPS CONNECTOR TPS SIGNAL RETURN 8 YEL RED COOLANT TEMP SENSOR COOLANT TEMP SIGNAL 9 BLK WHT DETONATION SENSOR SIGNAL GROUND 10 YEL WHT TxD SIGNAL COMMUNICATION CONNECTOR 11 WHT BLK RxD SIGNAL 14 YELLOW MAG FULL LOAD INJECTOR 15 YEL WHT FUEL INJECTOR HARNESS PLUG MAG PART LOAD INJECTOR 16 RED BLU FUEL INJECTOR POWER 17 WHITE 2 TOOTH CPS SENSOR SENSOR SIGNAL 18 RED COIL POWER IGNITION COIL CONNECTOR 19 BLACK COIL GROUND 20 GREY TMAP SENSOR CONNECTOR INTAKE PRESSURE SIGNAL 21 ORANGE STATOR SYSTEM POWER CONNECTOR FUEL INJECTOR BOOST POWER 22 WHT BLK EXHAUST TEMP SENSOR EXHAUST TEMP SIGNAL 23 PINK TMAP SENSOR CONNECTOR INTAKE AIR TEMP SIGNAL TPS CONNECTOR 24 RED WHT TMAP SENSOR CONNECTOR 5VDC SENSOR VOLTAGE COMMUNICATION CONNECTOR 25 PURPLE VIOLET DETONATION SENSOR SENSOR SIGNAL 26 ORANGE STATOR SYSTEM POWER CONNECTOR FUEL INJECTOR POWER TERRAIN DOMINATION POLARIS 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 4 35 Fuel Systems Exhaust Temperature Sensor OIL D 1 e Lr Sensor Specifications Resistance Values 2 3MQ Q 392 F 200 C 760 1652 F 900 C e T Exhaust Temperature Sensor Torque 32 Ft Lbs 44 Nm Temperature Air Pressure Sensor TMAP Sensor Specifications 59 15 C 30000 68 F 20 C 25000 77 F 25 C 20000 P
35. Vs Fuel Flow Large Clearance 3 2 VM only 75 100 Throttle Valve Opening Closed One half Full Throttle Throttle Throttle INCREASING 1 8 1 4 38 1 2 58 3 4 1 8 FULL THROTTLE OPENING TYPICAL MIKUNI VM Throttle Valve Cut Away Jet Needle Needle Jet DECREASING c TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual gt PELARIS 2010 Polaris Sales Inc 4 16 Fuel Systems CARBURETOR FUEL PUMP Fuel Pump Overview FUEL IN FROM TANK IMPULSE HOSE FITTING RUE OUT sat Y ALWAYS ON BACK OF PUMP The impulse powered fuel pump carbureted engines works by using the positive and negative pressure pulses generated by the movement of the pistons inside the engine crankcase When the MAG piston is on the upward stroke negative vacuum pressure pulse is applied to the fuel pump This action draws fuel into the pump from the fuel tank When the MAG piston is on the downward stroke a positive pressure pulse is applied to the fuel pump This action forces fuel from the intake side of the pump to the supply side then to the carburetors A series of check valves prevents fuel from being drawn out of the carburetors on the vacuum stroke or forced back into the fuel tank during the pressure stroke TERRAIN DOMINATION POLARIS Maintenance The impulse operated powered fuel pump does not requir
36. WHITE DIAGNOSTIC SPLICE CHASSIS HOOD 41 DIAGNOSTICS CHECK ENGINE LED 29 BLACK RNV QL SAPETI SLAP HARDWARE STOP IGNITION KILL SIGNAL 30 BLACK BLUE SENSOR GROUND SPLICE 1 SENSOR GROUND 31 GRAY LH CONTROL PERC SIGNAL 32 RED REGULATOR POWER SPLICE REGULATED POWER 33 REGULATOR RECTIFIER VOLTAGE BOOST POWER 34 ORANGE REGULATOR RECTIFIER VOLTAGE BOOST POWER 4 32 2 p 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc POLARIS Fuel Systems 2007 2010 CFI 26 Pin CNB ECU Connector NOTE Wire Entry View PIN COLOR GOES TO CONNECTOR FUNCTION 1 ORANGE PTO IGNITION COIL COIL POWER 2 BLUE YELLOW STATOR FUEL INJECTOR COIL FUEL INJECTOR POWER COIL 3 BLUE YELLOW STATOR FUEL INJECTOR COIL FUEL INJECTOR POWER COIL 4 GREEN STATOR CRANK POSITION SENSOR 5 TOOTH COIL SIGNAL 5 WHITE STATOR CRANK POSITION SENSOR 2 TOOTH COIL SIGNAL 6 YELLOW MAG FULL LOAD INJECTOR INJECTOR CONTROL GROUND 7 YELLOW WHITE MAG PART LOAD INJECTOR INJECTOR CONTROL GROUND 8 GREEN PTO FULL LOAD INJECTOR INJECTOR CONTROL GROUND 9 GREEN WHITE PTO PART LOAD INJECTOR INJECTOR CONTROL GROUND 10 RED WHITE TPS 5 VDC POWER SUPPLY 13 WHITE YELLOW EV SOLENOID SOLENOID CONTROL GROUND 14 BROWN MAG IGNITION COIL STATOR STATOR GROUND 15 GREEN RED STATOR EXCITER COIL EXC
37. WOT operation only Temperature values between idle and WOT vary and are dependent on engine RPM and throttle position 4 25 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Fuel Systems CFI Diagnostic Trouble Codes DTCs MFD P TROUBLE CODE CODE BLINK DESCRIPTION CODE Throttle Position Sensor Unrealistic Transition P0120 TPS signal changes too rapidly to be correct Can be caused by faulty connections or a faulty TPS Throttle Position Sensor Voltage High P0123 1 TPS signal is above 4 39 VDC Can be caused by a faulty wire connection or faulty TPS Throttle Position Sensor Voltage Low P0122 TPS signal is below 0 7 VDC Can be caused by a faulty wire connection or faulty TPS Engine Coolant Temperature Sensor Voltage High P0118 PUE signal is above 4 8 VDC Can be caused by a faulty wire connection or faulty temperature 2 Engine Coolant Temperature Sensor Voltage Low P0117 idu signal is below 0 1 VDC Can be caused by a faulty wire connection or faulty temperature Intake Air Temperature Circuit Voltage High P0113 Sensor signal is above 4 9 VDC Can be caused by a faulty wire connection or faulty P 3 Intake Air Temperature Circuit Voltage Low P0112 Sensor signal is below 0 19 VDC Can be caused by a faulty wire connection or faulty TMAP Barometric Pressure Sensor Voltage High P0108 Sensor signal is abo
38. ange quick motion Align the pins barbs with the holes then push and pull the barbs pins through the holes in the flange 21 After installing the fuel pump assembly the fuel tank must be tested for leaks by pressurizing the tank See 15 Carefully slide the pump assembly into the fuel tank Fuel Tank Pressure Test on page 4 39 until the gasket rests on the tank 16 Using new screws supplied with the new gasket thread in one of the top two screws to locate the gasket and flange in the fuel tank A few turns of the Red Pump Power Screw is sufficient 1 17 Thread the remaining five screws in by hand 2 N A N A 18 Usinganut driver or socket and following the specified 3 Black Pump Ground torque sequence sequentially turn each screw a few 4 revolutions at a time until the gasket is just seated between the flange and the fuel tank 19 Using a torque wrench and the specified torque sequence tighten all screws to 10 in Ibs 1 13 Nm Tighten each screw in one continuous quick motion PIN COLOR ITEM Brown Chassis Ground TERRAIN DOMINATION C POLARIS 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 4 49 Fuel Systems Flange Type Fuel Pump Service The front tank mounted flange type fuel pump components can be service individually Reference the appropriate vehicle parts manual for a list of serviceable parts Reference the following illustration for com
39. ank replacement is required NOTE There may be bubbles present from the initial application of leak detector Slightly blow on the bubbles to pop them Watch for new bubble formation New bubble formation may very small so look closely Apply additional water detergent solution if required 4 40 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Fuel Rail and Injector Removal Installation NOTE Leave protective caps installed until instructed to remove Avoid touching the tip of the injector COLOR DOT BLUE OR BLACK O RING oN BROWN OR GREEN O RING ae BUSHING 600 700 INJECTOR KITS INJECTOR KITS COLOR 2203894 053 Yellow 2203894 027 Blue 2203894 015 Red 800 INJECTOR KITS INJECTOR KITS COLOR 2203575 053 Yellow 2203575 027 Blue 2203575 015 Red 800 fuel injectors are different than 600 700 fuel injectors A fuel injector regardless of color code can be accurately identified by the OEM part number stamped on plastic injector housing 800 OEM PN 1203628 600 700 OEM PN 1203491 When replacing a faulty fuel injector always verify the part number of the injector for the engine application and use the same color code If replacing an injector with a different color code all of the fuel injectors must be replaced with the new color so all four injectors are the same color TERRAIN DOMINATION POLARIS Fuel Systems Af
40. ash files CLUTCHING STEP 3 1 Do the drive clutch weights match what is specified for the elevation where the vehicle is operated If not install the specified drive Clutching clutch weights based model specifications for the vehicle located in the appropriate Service Manual or Owner s Manual Supplement 2 If the vehicle is a 2009 600 IQ Shift 136 has Service Bulletin S 09 01 A been performed and a new driven helix and spring been installed 3 Inspect drive belt deflection and adjust if required Replace the belt if it is hour glassed shows heavy glazing or severely worn THROTTLE LEVER FREEPLAY SIERA 1 Check the throttle lever freeplay Too much slack in the throttle cable can cause runability issues Throttle Lever 2 Is the throttle lever freeplay 010 030 inches If not reset the freeplay to specification and retest vehicle STEP 5 FUEL SYSTEM Fuel 1 Using Digital Wrench verify the fuel injector supply voltage is 16Vdc when the engine is running System 2 Using the appropriate fuel pressure gauge see Service Manual verify the fuel pressure when the engine is running is 58 PSI 4BAR 3 If the fuel pump voltage is good but the fuel pressure low replace the fuel filter and recheck fuel pressure STEP 6 EXHAUST GAS TEMPERATURE SENSOR EGT 1 Using the data display tool in Digital Wrench monitor the EGT sensor function while the engine is running vehicle raised off the Sensor ground on a sled lift or track stand at or above 3 000 R
41. assis relay supplies power to the MFD gauge accessory plug and DC power test plug Ignition Coils ALL Provide ignition energy to each spark plug Both coils are fired at the same time RRAIN DOMINATI Fuel Systems Fuel Injectors Detonation Control System DET DC CFI 2 600 A fuel injector is mounted to each cylinder All CFI Models When DET is sensing and taking action to reduce detonation the driver may notice a drop in DC CFI 2 2 CFI 4 A set of injectors are mounted engine RPM and or reduced performance as the ECU to the crankcase and a set are mounted to the takes action to reduce detonation cylinders 600 IQ Widetrak 800 CFI Only The check engine MIL Knock Sensor ALL Located onthe cylinder will illuminate when the DET system is active head the detonation sensor transforms internal acoustic information into a signal the ECU uses to 600 IQ Widetrak 800 CFI Only If the ECU determines determine the amount of combustion knock the detonation cannot be controlled by normal means and To function properly the knock sensor mounting further operation may cause engine damage the check bolt must be installed dry and torqued to engine MIL will flash and the ECU will limit the maximum specification engine speed to 6 000 RPM The RPM limit will remain active until the driver turns off and restarts the engine Exhaust Valve Solenoid ALL Activated n by the ECU the solenoid controls the VES 80
42. aulty wiring injector stator or ECU 3 P1265 600 IQ Widetrak Only Circuit shorted to battery voltage 5 P1477 Solenoid control circuit is OPEN Can be caused by faulty wiring Exhaust Valve Solenoid 520215 g selenoid on ECU 3 P1479 Circuit shorted to battery voltage Ignition Coil Circuit Malfunction 1268 5 P1351 9 Failure within the primary circuit Can be caused by faulty wiring ignition coil or ECU 8 P0336 Circuit fault Crankshaft Position Sensor 636 10 2 P0335 Plausibility fault TERRAIN DOMINATION POLARIS 4 27 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Fuel Systems MFD P TROUBLE CODE SPN FMI CODE BLINK DESCRIPTION CODE 1 P0502 Indicated vehicle speed to low Vehicle Speed Sensor 84 2 P0503 Data erratic or intermittent missing Fuel Pump Driver Circuit 1347 5 P0230 Drive circuit open or shorted to ground ECU Memory 628 13 P0601 Checksum CRC Error 3 P1569 Chassis voltage too high Alternator Power Supply 167 4 P1568 Chassis voltage too low Sensor Supply Voltage 1 3509 P06B1 4 Voltage too low Sensor Supply Voltage 2 3510 P06B4 3 P16A9 Voltage too high ECU Output Supply Voltage 3598 4 P16A8 Voltage too low 3 P1555 Voltage too high Throttle Safety Signal 520194 4 P1554 Voltage too low 7 P1552 Throttle is stuck 3 P0179 Voltage too high Fuel Type Selected 52400
43. con 2 Select OPTION 1 TPS SETUP 3 Select OPTION 2 FULL PROCEDURE A TPS Fasteners ET Choose an Answer Select the procedure you wish to perform 1 B TPS Harness Connector 2 1 Check the Base Throttle Setting with the Throttle Body installed on the engine 8 Remove the throttle cable from the throttle lever Turn Base Setting Check the inline adjuster in clockwise Verify the throttle 2 Throttle Body has been removed fora cable is not pulling on the throttle plate cam bis ore hoti 9 Digital Wrench will communicate with the ECU to ynchronization needs to be Full Procedure determine if the TPS zero offset is set correctly In orderto measure the zero offset the idle speed screw mustbe backed out so it no longer makes contact with the throttle stop Throttle Closing 4 Read and understand the next series of screens 2 the Locknut B the Idle Air FI When finished with each screen click CONTINUE t lockwi til the ti t 5 Note that removal of the throttle body is only required om ihe Ausiment Laver Tab C when replacing the TPS The throttle body can remain mounted to the engine if only performing the TPS BASE SETTING procedure 6 Remove the drive belt driven clutch and airbox Reconnect the air temperature pressure sensor and lay the airbox on top of the engine 7 The TPS
44. cts into the passage leading to the by pass out let By turning the screw in or out the cross sectional area of the air passage is varied in turn varying the fuel screw varies the amount of air fuel 4 13 Fuel Systems Main Jet When the throttle opening becomes greater and the area between the needle jet and jet needle increases fuel flow is metered by the main jet The number on the jet indicates the amount of fuel which will pass through it in one minute under controlled conditions Larger numbers give a greater flow resulting in a richer mixture Main jets are screwed directly into the needle jet base MAIN JET Jetting Guidelines Changes in altitude and temperature affect air density which is essentially the amount of oxygen available for combustion In low elevations and cold temperatures the air has more oxygen In higher elevations and higher temperatures the air is less dense Verify the production setting for your specific model All carburetors must be re calibrated if operated outside the production temperature and or altitude range The main jetinstalled in production is not correct for all altitudes and or temperatures Refer to the jetting cart in the Specifications Chapter of this manual for correct jetting for altitude temperature ranges NOTE It is the owner s responsibility to ensure that the correct jets are installed in the machine for a geographical area Be very careful when j
45. e If you spill gasoline on your skin or clothing immediately wash it off with soap and water and change clothing Do not overfill the tank past the bottom of the filler neck CAUTION A main jet that is too small will cause a lean operating condition and may cause serious engine damage Jet according to the jetting charts provided for each snowmobile Polaris snowmobile engines are calibrated to run using 91 octane oxygenated or 89 octane non oxygenated fuels Polaris snowmobiles requiring higher octane fuel have the required octane level noted on the fuel tank filler cap Never use fuel containing more than 10 ethanol or E85 fuels All fuel injectors must share the same color code Yellow Blue or Red Always verify the fuel injector part number prior to installation Never start the engine or let it run in an enclosed area TERRAIN DOMINATION POLARIS 4 3 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Fuel Systems CARBURETOR FUEL SYSTEMS Mikuni Main Jets m m m m z z z z z z z 5 5 k 5 k k 95 3130102 175 3130118 310 3130134 470 3130147 100 3130103 180 3130119 320 3130135 490 3130148 105 3130104 185 3130120 330 3130136 500 3130149 110 3130105 190 3130121 340 3130137 510 N 3131400 115 3130106 195 3130122 350 3130138 52
46. e Severe engine damage may occur if the PREMIUM resistor plug is installed when oxygenated fuel Never use oxygenated fuels containing more than a 10 ethanol blend DC CFI models allow the operator to select between 91 octane oxygenated and 91 octane non oxygenated fuel modes The fuel selector switch consists of a PK BLK BLK BLUE wired plug located at the rear of the clutch cover electrical center cover When using oxygenated fuel or when unsure of the fuel type inside the fuel tank plug the 10 ETHANOL 24 OHM resistor into the fuel selector plug When using non oxygenated 91 or higher octane fuel install the NON ETHANOL 160 OHM resistor into the fuel selector plug ECU CONNECTOR POLARIS ES NON ETHANOL 160 OHM Resistor Plug Part Number 2411282 Included in tool kit TREHAN Sean CFI RPM Engine Speed Limit Modes RPM Speed Limit Modes MODELS THRESHOLD RPM SPEED LIMIT FUNCTION 600 700 800 CFI m 6 000 RPM 600 IQ Widetrak Enabled 9 MPH Hot Lamp Illuminates 5 Idle 230 F 110 C 600 700 800 CFI WOT 185 85 600 IQ Widetrak Engine RPM Misfire at Overheat Idle 239 F 115 C Shutdown WOT 208 F 98 C FWD w Low 6 750 RPM 600 IQ Widetrak Gear 43 48 MPH Selected moon aco RPM Msi 600 IQ Widetrak Protection 9 NOTE Temperature values given for Idle wide open throttle
47. e any specific scheduled maintenance However the following procedures should be observed Operation The pump may be checked for operation by removing the fuel supply line from the carburetor and placing it into a container With the engine idling at approximately 2000 RPM a steady flow of fuel should be visible Cleaning The impulse line must be disassembled and cleaned of foreign material in the event of piston or other internal engine part failures which produce fragments Inspection Disconnect impulse line from pump Connect a Mity Vac to impulse fitting or line and apply 4 6 PSI pressure Diaphragm should hold pressure indefinitely 4 17 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Fuel Systems CARBURETOR SERVICE NOTE Keep track of the plastic washer 9 and place it so it is on the top of the throttle valve when Disassembly installing the needle and e ring back into the carburetor A CAUTION 4 Inspect the needle 7 e clip 8 and plastic washer 9 for wear WEAR EYE PROTECTION WHEN USING COMPRESSED AIR OR WHEN USING CLEANING SOLVENTS REVIEW ALL FUEL SYSTEM WARNINGS LOCATED AT THE BEGINNING OF THIS CHAPTER BEFORE PROCEEDING 1 Remove the carburetor from the engine before disassembling Clean the outside of the carburetor thoroughly with solvent Do not use compressed air to dry at this time 2 Remove all top cap screws 1 top cap 2 and gasket 5 Remov
48. e the four screws 10 on the funnel face 6 Turn throttle shaft so the throttle slide 11 slides open all the way 7 With slide fully open pull funnel 12 out from the bottom first Inspect the gasket 13 8 Check for wear on the faces of the slides 3 Locate the arm screw 4 and loosen it just enough to move the arm 5 out of the way so that you can remove the needle 6 e clip and the plastic washer from the throttle slide 9 Inspect e rings plate spring and rings 14 TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc gt PLRRIS 4 18 Fuel Systems connecting the slide to the lever if needed 13 Inspect the contents for wear and debris 10 Remove water trap drain plug 15 and single screw 14 Remove and inspect the main jet 20 pilot jet 21 16 on the bottom of the carburetor and starter jet 22 Clean them out 11 Remove and drain the float bowl 17 15 Remove the air jet screw if so equipped NOTE Float bowl will not come off unless the water trap drain plug and screw are removed 16 Clean out all passages in carburetor body with carburetor cleaner Dry all passages and jets with compressed air 17 Replace gaskets and any parts that show wear or 12 Remove the two screws 18 holding the float needle an damage 4 19 Position and removes 18 Repeat steps 1 18 for disassembly for the other carburetor if need
49. ecord the code Engine Controller Reprogramming Note the Request Code below and obtain an Authorization Key from the Dealer Web Site Enter the Authorization Key in the Proper Field to Continue DO NOT SHUTDOWN THE SOFTWARE UNTIL REPROGRAMMING IS COMPLETE OR THE AUTHORIZATION KEY WILL BE LOST Request Code AIBAFDBN Authorization Key B 3 Enter Authorization Key 9 Access www polarisdealers com Locate REFLASH AUTHORIZATION under the SERVICE AND WARRANTY drop down menu TERRAIN DOMINATION POLARIS Fuel Systems 10 Enter the REQUEST CODE generated by Digital Wrench into the information box 4 11 After entering the REQUEST CODE click CONTINUE Sad 1 sonam x 12 next screen asks for the following information Desired Reflash File Vehicle VIN Customer Name Address Zip Code 13 After entering the click CONTINUE 14 If all of the information was accurate the website will generate and AUTHORIZATION CODE 15 Copy the code and then enter the code into the AUTHORIZATION box in Digital Wrench Click CONTINUE required information TERRAIN DOMINATION gt POLARIS 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Engine Controller Reprogram TE POLARIS Invalid Authorization Key Please Verify and Reenter Reques
50. ed TERRAIN DOMINATION gt POLARIS 9922854 2007 2011 IQ Service Manual 4 19 2010 Polaris Sales Inc Fuel Systems Assembly 1 Install the main jet 20 pilot jet 21 and starter jet 22 2 Install float needle amp seat assembly 19 Place carburetor in an inverted position 4 Connect pressure tester 2870975 to fuel inlet fitting Apply 5 psi pressure and observe for one minute The needle and seat should hold pressure indefinitely If the pressure drops carefully inspect the needle and the needle seat The needle can be replaced needle supplied with float and seat e 5 Carefully inspect float bowl gasket and replace if necessary 6 Install float bowl 16 on carburetor with water trap drain plug 15 and single screw 16 on the bottom of the carburetor 7 If throttle slide was removed install throttle slide 11 so that the wider face is facing the engine side of the carburetor 8 Install the funnel gasket 13 and funnel 12 onto the carburetor You will have to lift the throttle slide up and place the smaller face into the funnel area 9 Install funnel screws 10 10 Install the e clip 8 in the desired position on the jet needle 7 11 Slide the plastic washer 9 on the jet needle so that itis positioned to rest on top of the throttle valve when assembled 12 Install carburetors on engine 13 Replace top cap gaskets 3 cover 2 and screws 1
51. el Systems Fuel Metering THROTTLE VALVE JET NEEDLE 55 HOLE D NEEDLE JET PILOT AIR JET VALVE SEAT PILOT JET MAIN JET Mikuni carburetors use a starter enricher system rather than a choke In this type of carburetor fuel and air for starting the engine are metered with entirely independent jets The fuel metered in the starter jet is mixed with air and is broken into tiny particles in the emulsion tube The mixture then flows into the plunger area mixes again with air coming from the air intake port for starting and is delivered to the engine through the fuel discharge nozzle in the optimum air fuel ratio The starter is opened and closed by means of the starter plunger The starter type carburetor is constructed to utilize the negative pressure of the inlet pipe so it is important that the throttle valve is closed when starting the engine Fuel Delivery The pilot system s main function is to meter fuel at idle and low speed driving Though its main function is to supply fuel at low speed it does feed fuel continuously throughout the entire operating range Fuel for the pilot jet is drawn from the float bowl mixed with air jet and delivered to the engine through the pilot outlet FUEL DELIVERY TERRAIN DOMINATION POLARIS 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc The mixture is regulated
52. etting down in warm weather As the weather turns colder it will be necessary to re jet upward to prevent engine damage When selecting the proper main jet always use the lowest elevation and temperature that is likely to be encountered CAUTION A Main Jet that is too small will cause a lean operation condition and may cause serious engine damage Jet the carburetors carefully for elevation and temperature according to the jetting charts in the Specifications Chapter of this manual or the models Owner s Manual Supplements 4 14 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Piston Throttle Valve THROTTLE VALVE intake side throttle valve controls the rate of engine air intake by moving up and down inside the main bore At small throttle openings air flow control is performed chiefly by the cutaway By controlling air flow the negative pressure over the needle valve is regulated in turn varying the fuel flow The throttle valves are numbered 1 0 1 5 2 0 etc according to the size of the cutaway in millimeters The higher the number the leaner the gasoline air mixture TERRAIN DOMINATION POLARIS Fuel Systems Jet Needle The jet needle tapers off at one end and the clearance between the jet needle andthe needle jet increases as the throttle valve opening gets wider The air fuel mixture ratio is controlled by the he
53. ever working with the TPS Use Digital Wrench when checking the TPS voltage Digital Wrench is the only tool that will read display the actual TPS voltage the engine management system uses to determine throttle plate angle Disconnect the throttle cable from the throttle lever If the throttle body idle air gap TPS voltage changes after removing the throttle cable from the throttle lever the throttle cable is too tight and must be readjusted by turning the inline adjuster clockwise Verify the throttle cable is not pulling on the throttle plate cam Turn the throttle cable inline adjuster clockwise to loosen the cable If the cable continues to pull on the throttle plate cam readjust the throttle cable threaded barrel on the throttle body All engine management sensors switches must be connected to obtain accurate TPS voltage readings After removing the air box reconnect the air temp pressure sensor and lay the airbox inside the engine compartment Use a fully charged 12V battery to power the engine management system TERRAIN DOMINATION POLARIS Throttle Position Sensor TPS Idle Base Setting Engine idle speed with the engine at operating temperature is 1700 200 RPM for all 2007 2011 600 700 800 CFI snowmobiles 2007 2011 600 700 800 CFI Engine Idle Speed Engine at operatin pen Bererure 1700 200 RP The throttle body idle base setting voltage can be verified using Digital Wrenc
54. fasteners can be accessed through a set of Status Connected holes in the TPS guard Click Continue to proceed A Idle Speed Screw B Lock Nut C Throttle Stop TERRAIN DOMINATION C POLARIS 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 4 45 Fuel Systems 10 If replacing the TPS replace it now with a new part 11 Open and close the throttle plates 2 to 3 times to ensure plates are completely closed 12 Digital Wrench will ask if the throttle plate synchronization requires adjustment Select OPTION 1 THROTTLE SYNC IS OK unless it is clearly evident that the throttle plates are out of synchronization Based on your examination of the Throttle Plates in the last step is the Throttle Plate Synchronization acceptable Unless the Throttle Synchronization Screw has been moved Throttle Synchronization is normally not necessary 72008 700 Swit Status Connected A CAUTION THROTTLE PLATE SYNCHRONIZATION MISADJUSTMENT MAY CAUSE SEVERE ENGINE DAMAGE 13 If throttle plate synchronization requires adjustment select OPTION 2 THROTTLES ARE OUT OF SYNC Digital Wrench will outline the steps required to re synchronize the throttle plates 4 46 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 14 Digital Wrench will now perform the TPS BASE SETTING procedure To do this slowly rotate
55. h 1 Connect Digital Wrench to the vehicle Confirm the throttle lever free play is set to specification and the throttle cable is not pulling on the throttle plate cam 2 Click on the DATA GRID ICON to view the current sensor readings 3 Locate the TPS VOLTAGE reading and compare it to the specification for the vehicle Verify SENSOR REFERENCE VOLTAGE is 4 9 5 0 VDC NOTE Verify all sensors switches are plugged into the wiring harness TPS Voltage 0 947 Volts Exhaust Temperature 32 0 Deg F Intake Air Temperature 72 7 Deg F Engine Temperature 70 5 Deg F Barometric Pressure 29 1 Chassis Voltage 0 00 Volts Vehicle Speed Sensor Reference Voltage 4 990 Volts TPS Idle Base Setting Voltage Using Digital Wrench MODEL SPECIFICATION 600 700 CFI Engine 94 96 VDC 800 CFI Engine 93 95 VDC 4 Slowly move the throttle lever in and out The TPS voltage should change smoothly without any erratic jumps or gaps 4 43 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Fuel Systems NOTE Utilize the sensor graph function to view the TPS voltage return signal voltage as a line graph Doing so will reveal erratic operation Charts and Meters POLARIS 128 129 130 131 132 133 Time Seconds 134 135 72008 700 CFIIQ Switchback Status Connected 5 If erratic jumps or gaps are encountered inspect the
56. ice Manual 2010 Polaris Sales Inc TERRAIN POLARIS DOMINATION Fuel Systems DC CFI Diagnostic Trouble Codes DTCs MFD P TROUBLE CODE SPN FMI CODE BLINK DESCRIPTION CODE Throttle Position Sensor Unrealistic Transition 10 P0120 TPS signal changes too rapidly to be correct Throttle Position Sensor Voltage High 51 3 P0123 1 TPS signal is above 4 39 VDC Throttle Position Sensor Voltage Low 4 P0122 TPS signal is below 0 7 VDC Engine Coolant Temperature Sensor Voltage High 3 P0118 Sensor signal is above 4 8 VDC Engine Coolant Temperature Sensor Voltage Low 4 P0117 Sensor signal is below 0 1 VDC 110 2 600 IQ Widetrak Only Code is set occurrences accumulated Coolant Temperature Too High 16 dc counted in ECU whenever engine temperature hot lamp is illuminated awe 600 IQ Widetrak Only Code is set and occurrences accumulated Engine Overhsat Shutdown Misfire 0 counted in ECU whenever ECU enables engine overheat misfire mode Intake Air Temperature Circuit Voltage High 3 P0113 Sensor signal is above 4 9 VDC 105 Intake Air Temperature Circuit Voltage Low 4 P0112 Sensor signal is below 0 19 VDC 3 Barometric Pressure Sensor Voltage High 3 P0108 Sensor signal is above 3 23 VDC 108 Barometric Pressure Sensor Voltage
57. ide Once this is flush lock the locking screw Replace the carburetor covers If removed reinstall the fuel vent throttle and choke hose and cable connections Verify and set throttle cable free play 4 21 Fuel Systems CLEANFIRE FUEL INJECTION System Overview There are two CFI engine management systems used on 2007 2011 Polaris snowmobiles CFI4 DC CFI The primary difference between the CFI and DC CFI Systems is how each system handles stator voltage In a CFI system 100 of the stator AC voltage is converted to DC voltage In contrast DC CFI systems only covert the engine management and select accessory circuits to DC voltage The head lamps brake lamps and hand thumb warmers are supplied with AC voltage Broken down by component the detailed differences are included in the text below ECU ALL The ECU controls the ignition fuel injection angles chassis battery relays and supplies the MFD gauge with tachometer water temp PERC HOT DET diagnostic information Ay CAUTION CFI 4 DC CFI 2 DC CFl 2 2 ECUs cannot be interchanged Serious engine damage may occur e Stator CFI 4 The stator consists of a lighting charge coil ignition exciter coil fuel injector charge coil and two independent external crank position two and five pulse coils DC CFI Stator lighting charge coil split into two independent circuits one for DC power Chassis and o
58. ight of the E ring inserted into one of the five slots provided in the head of the jet needle This needle example is a 9DH01 57 The first number is the approximate overall length in 10mm increments of the jet needle The 9 indicates the needle is approximately 90mm but less that 100mm in length The letters on the jet needle indicate the angle of both tapers The first letter designates the taper angle of the top section closest to the grooves and the second letter designates the angle of the bottom taper The taper angles are graduated in 15 15 minute increments The jet needle marked 9DH01 57 would have a top taper of 1_0 and a bottom taper of 2 0 The number following the letters on the jet needle is the serial number and it varies with individual jet needles TERRAIN DOMINATION The last number 57 indicates that the outside diameter is 2 57mm The smaller the O D the richer the mixture 9DH01 57 Leaner Richer Straight Portion DESIGNATOR DESCRIPTION 9 Overall length in 10mm increments D Taper of the top section of the needle H taper of the bottom section of the needle 01 Serial number Outside diameter O D of the 57 straight portion Needle Jet The needle jet works in conjunction with the jet needle lt gt POLARIS 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 4 15 Fuel Systems Throttle Opening
59. ins 1 to 2 Temperature Crankshaft Position Sensors CPS The 5 tooth crank position sensor picks up all 5 flywheel teeth and determines the following Judge direction of rotation forward and backward gnition advance angle control Injector drive angle control Excess advance ignition control at reverse MAG PTO cylinder detection The 2 tooth crank position sensor picks up 2 flywheel teeth It detects the crank angle and obtains minimal information of the crank angle when control enters into limp home mode The sensors must be in the correct position or the engine will not run A sheared flywheel key will cause the engine to not start or to shut off misfire Crankshaft Position Sensor Air Gaps Hard engine starting erratic reverse operation and poor engine performance can occur if the CPS air gap s are outside specification Tf 1WO TOOTH CPS KS o lt Z gt Q9 H H 22 2 AY SILI 1 LIFT 4 FIVE TOOTH CPS if E Y P lt O em a HE SKE tgs NN d CA Mew N LIRE I7 N NL J N gt Yyf 97 1 ANT Dn 7 NOTE The sensor bases are not slotted Only minor deflection adjustments can be made 2400 82000 3400 82000 Pins 1 to 4 Pressure Pins 3 to 4 Pressure 4 36 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales
60. larisdealers com change 2 L he SERVICE AND WARRANTY drop d 2 Ew e ee 1 Start the Digital Wrench software 3 Click on DIGITAL WRENCH UPDATES 2 Locate the version ID on the title screen 4 The next screen is the Digital Wrench portal website 2007 600 700 CFI IQ RMK SB Dragon Foes EE PEE a el KIR ET i r i 3 Click on the SPECIAL TESTS icon toolbox 4 Click on ENGINE CONTROLLER REPROGRAMMING 5 Locate the fileset version number The following selections can be made on the update website Home Digital Wrench Home Page TERRAIN DOMINATION C POLARIS 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 4 57 Fuel Systems Engine Controller Reprogramming Select the Proper ECU Program from the List Below MATCH THE ENGINE SIZE AND INJECTOR COLOR AS INSTALLED CHOOSING THE WRONG COMBINATION WILL RESULT IN POOR ENGINE PERFORMANCE AND POSSIBLE DAMAGE File Set Version v1 0 2007 600 CF1 Blue Tyee z 2007 6 800 CFI Red meon Pr 4011812 4011814 n Select File 2 Integrity Check New File New Fite E Continue Cancel Engine Controller Reprogramming Reflash NOTE New service replacement ECUs programmed as no start and must be reflashed for the engine and fuel injector code 1 Verify the most current update is downloaded and loaded into Digital Wrench See Versi
61. n cold conditions A cold engine requires more fuel to start than a warm engine because the fuel mixture tends to condense on the intake and cylinder walls rather than vaporize as it would in a engine at operating temperature Mikuni VM carburetors use plunger type starting system When the choke lever is engaged a spring loaded plunger is pulled away from the starting circuit orifice allowing additional fuel to be drawn out of the float bowl along with the fuel drawn through the pilot jet system Because the starting system provides fuel not metered by the pilot or main jet systems it is important to verify the plunger properly closes when not needed A starting system that is stuck open or improperly set will cause rich running and heavy plug fouling Likewise a plunger that is stuck closed or does not open far enough will make starting a cold engine difficult Float System The float system is designed to maintain a constant height of gasoline during operation When the fuel flowing from the fuel pump into the float chamber through the needle valve reaches the constant fuel level the floats rise When the buoyancy of the float and the fuel pressure of the fuel pump balance the needle valve sticks fast to the needle seat preventing further delivery of gasoline thereby holding the standard level of gasoline The fuel level in the bowl assists in controlling the amount of fuel in the fuel mixture Too high a level allows more f
62. nd the needle jet increases as the throttle valve opening gets wider The air fuel mixture ratio is controlled by the height of the E ring inserted into one of the five slots provided in the head of the jet needle Needle Jet The needle jet works in conjunction with the jet needle TERRAIN DOMINATION POLARIS Fuel Systems VM CARBURETOR DISASSEMBLY INSPECTION ASSEMBLY VM Carburetor Disassembly 1 Remove the throttle slide cap spring and throttle slide Extract the retainer to remove the needle and throttle cable plug Cap dm Gasket Spring Retainer Plate E Clip Jet Needle Slide Valve 2 Remove the choke plunger Inspect the plunger for wear and replace if required Inspect the plunger seat for damage or foreign material Plunger Seat 3 Check the choke plunger and cable movement Plunger must move up and down in bore without binding 4 Remove the float bowl Inspect the choke fuel supply passage TERRAIN DOMINATION gt POLARIS 5 Remove the float pin then remove the inlet needle and seat assembly 6 Inspect the needle tip for abnormal wear and tear Replace if required 7 Remove the pilot and main jets 8 Thoroughly clean the carburetor body with carburetor cleaner Blow dry with compressed air Verify all air fuel and choke passages are clean Always wear eye
63. ne for AC power Lighting 4 22 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Flywheel CFI 4 The CFI flywheel contains the magnets for energizing the stator windings as well as two independent encoder ribs The set of two encoder ribs are spaced 180 degrees apart from each other and provide RPM information required at engine start up A set of five encoder ribs is responsible for crank angle detection speed and direction information DC CFI Same as the CFI 4 with the exception that the flywheel is forged and the fan cover is removed from flywheel Regulator Rectifier CFI 4 Converts VAC to VDC for the chassis and battery electric start circuits Regulates voltage to 14 5 VDC Also supplies fuel pump boost power when engine RPM is 700 RPM or less DC CFI Supplies power to the ECU fuel pump boost power MFD and accessory DC power points DC CFI models utilize a separate regulator for the AC circuit similar to carbureted models to regulate AC voltage to 14 3 VAC and battery charge voltage to 14 7 VDC Capacitor ALL The capacitor suppresses voltage spikes and ensures consistent voltage throughout the CFI chassis RED WHT circuit or DC CFI RED RED WHT circuits Chassis Relay CFI 4 The chassis relay is activated by the ECU at approximately 950 RPM Below 950 RPM all power supplied by the regulator rectifier RED circuit is used to power the ECU and fuel pump DC CFI The ch
64. ngine operation The engine of a vehicle is operated under a wide range of conditions from idling with the throttle valve remaining almost closed to full load or maximum output with the throttle valve fully opened In order to meet the requirements for the proper mixture ratio under these varying conditions a low speed fuel system or pilot System and a main fuel system are provided in Mikuni type carburetors The Mikuni carburetor has varying operations depending upon varying driving conditions It is constructed of a float system pilot system main system and starter system or initial starting device Float System The float system is designed to maintain a constant height of gasoline during operation When the fuel flowing from the fuel pump into the float chamber through the needle valve reaches the constant fuel level the floats rise When the buoyancy of the float and the fuel pressure of the fuel pump balance the needle valve sticks fast to the needle seat preventing further delivery of gasoline thereby holding the standard level of gasoline The fuel level in the bowl assists in controlling the amount of fuel in the fuel mixture Too high a level allows more fuel than necessary to leave the nozzle enriching the mixture Too low a level results in a leaner mixture since not enough fuel leaves the nozzle Therefore the predetermined fuel level should not be changed arbitrarily TERRAIN DOMIMATION POLARIS Fu
65. nol fuel fuel selector wires unplugged 4 injector CFI engines Premium non ethanol fuel fuel selector wires plugged together 2 injector CFI engines 87 89 91 w 10 ethanol fuel 24 ohm resistor plug installed 2 injector CFI engines Premium non ethanol fuel 160 ohm resistor plug installed STEP 2 DIGITAL WRENCH DW Using 1 Is DW the most current version Check the DW update site http polaris diagsys com modules php name Downloads to review and Digital download any available updates Wrench 2 Connect DW to the vehicle Are there any trouble code s Document all of the trouble code s both historic and current Use guided diagnostics to troubleshoot current trouble code s Once repairs are made and trouble code s are cleared do any return Start the engine and confirm trouble code s to not re appear If trouble code s re appear continue to troubleshoot issue using guided diagnostics and Service Manual 3 Review the ECU information for the vehicle Does the ECU map match the vehicle s configuration fuel injector color and part number If not reflash the ECU using the correct color coded map part number that matches the fuel injector color part number installed on the engine 4 Is the vehicle subject to any Service Bulletins or Team Tips where revised ECU reflash files have been made available If so verify the Service Bulletin or Team Tip has been performed if required and the ECU information matches the revised refl
66. oate u Qs S hein aod tr ya 4 9 PILOT SET TP 4 9 MAIN JE Tere 2 u ua uev eget u 4 9 JET FING GUIDELINES amp ead Sk ee D ie i edo 4 10 PISTON THROTTLE VALVE fe ec tees 4 10 rider Men rete um 4 10 JET NEEDLE rs u Tua oat oath Pd oret Sm canta te 4 10 NEEDEE JET ur au u oe BPS es eee at eee Lek es ee eh et 4 10 VM CARBURETOR DISASSEMBLY INSPECTION ASSEMBLY 4 11 VM CARBURETOR DISASSEMBLY 4 11 FLOAT ARM ADJUSTMENT 4 12 NEEDLE AND SEAT LEAK TESTING 4 12 MIKUNI TM CARBURETOR 4 12 FUNGTI N Saa ee DE SE E ache 4 12 F OAT SYSTEM arera etie Ma rer E 4 12 FUEL METERING y decet dene a Susu ctu condor rece dee G 4 13 FUELE DEL VERY u n Valya eo O Tu e us oS Sk ew R ew 4 13 PIO TET sine s up e A shes bande brah el E EU ON EE ee a eigo 4 13 EBEISGREW C sso s ran oe Seca tb ek abe En Soa ee p ee rat 4 13 MAIN SEM za here tee cet nM 4 14 JET TING GUIDELINES 1r L u t a ds ew eed ee PS aD 4 14 PISTON THROTTLE 4 14 IRL ok eh ee
67. on Identification on page 4 57 Connect the communication cables to the snowmobile connectors See CFI Digital Wrench Connections on page 4 56 Start Digital Wrench Select the model year and machine using the CHANGE VEHICLE TYPE button Click on the SPECIAL TESTS icon Click on ENGINE REPROGRAMMING Select the engine model and color of the injectors installed on the engine Record the 7 digit injector part number Click CONTINUE CONTROLLER NOTE All fuel injectors on the engine must share the same color code The most current reflash files will be located at the top of the list and will not have SUPERSEDED in the file name Files with SUPERSEDED in the file name denote older calibrations 4 58 7 On CFI models locate the program enable mode change jumper connector Insert the Reflash Enable Jumper tool SPX PN PS 50361 Click CONTINUE REFLASH ENABLE JUMPER TOOL SPX PART NUMBER PS 50361 NOTE DC CFI models do not feature a program enable jumper JUMPER BLACK TWO PIN PLUG pn m If the Reflash Enable Tool is not available use a short piece of insulated wire to make the connection Do not allow the jumper wire to touch the exhaust pipe or any CAUTION other grounded metal component ECU damage will occur 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 8 Arequest code will be generated R
68. onnect the power up cable to the EXTERNAL POWER connector NOTE To verify the 12 volt battery and power up cable are working connect the cable to the DC power up connector If working correctly the MFD gauge should illuminate TERRAIN DOMINATION POLARIS Fuel Systems Updating Digital Wrench Downloads Listing of current filesets and Digital Wrench downloadable updates Updates are released for Digital Wrench via the Internet The Digital Wrench update website can be found by Forums Member generated knowledge base accessing the dealer Internet site at www polarisdealers com Search Website search engine Topics Vehicle specific Digital Wrench information 5 Locate the version of Digital Wrench currently running on the PC or laptop 6 Locate and click on the update pack required Save the file to the PC or laptop s desktop 7 Locate the update file on the desktop Double click and select RUN on the icon to install the update 8 Delete the file after performing the update NOTE Delete the update file from the desktop when finished Version Identification l Knowing what Digital Wrench fileset versions NOTE Only authorized Polaris dealers and installed will help determine which updates are required distributors can access the dealer Internet website NOTE Version and fileset versions are subject to 1 Log on to www po
69. ousing 2 Firmly press the tool into the housing while carefully pulling the male hose out 3 Reconnect the fuel hoses by coating each hose end with a light film of two stroke engine oil 4 Carefully install the male end of the hose into the center of the female housing Firmly push the hoses together until the male nozzle fully seats behind the spring tabs 5 Grasp both hoses and gently pull to verify positive engagement Fuel Tank Pressure Test 1 Connect a Mity VAC hand pump to the fuel tank vent fitting 2 Connecta eight inch piece of 5 16 fuel hose and two gear clamps across the fuel supply and return fittings at the fuel pump flange 3 Pressurize the tank to 5 PSI NOTE Fuel tank deformation will occur when the tank is pressurized A WARNING Do not over pressurize the fuel tank past 6 PSI 4 39 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Fuel Systems NOTE Using a hand pump to pressurize the fuel tank may take a very long time The installation of an in line Schrader Valve PN 2872602 and the use of a low pressure pump bicycle tire pump is recommended Schrader Valve Added To fuel tank vent fitting 4 Once the tank is pressurized saturate the area around the PFA gasket with a mixture of water and mild detergent 5 f any bubbles form re check the PFA nut torque If bubble formation continues the PFA gasket will have to be replaced or t
70. ponent torque specifications when assembling the fuel pump components qar iS om c Q v 4 e T A Ground Wire Hex Nut 10 In Lbs 1 1 Nm B Pump Flare Nut 15 18 Ft Lbs 20 24 Nm C Angle Fittings 50 In Lbs 6 Nm TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual gt PELARIS 2010 Polaris Sales Inc 4 50 Fuel Systems 2007 700 CFI Fuel System RETURN FUEL HOSE SUPPLY FUEL HOSE BRACKET FUEL FILTER SY 44 e VENT FITTING FUEL RAIL VENT HOSE FUEL INJECTORS FUEL PUMP ASSEMBLY FUEL CAP GAUGE 10 FT LBS 14 FUELTANK 4 6 FTLBS 5 5 8 Nm THROTTLE BODY TPS FOAM PADS C POLARIS 9922854 2007 2011 IQ Service Manual 4 5 51 2010 Polaris Sales Inc Fuel Systems Drop In Pump Fuel Supply Typical FUEL RETURN HOSE FUEL SUPPLY HOSE FILTER BRACKET FUEL FILTER CAP FUEL RAIL o FUEL LEVEL GAUGE ON SOME MODELS FUEL INJECTORS HARNESS NOT SHOWN 10 FT LBS 4 6FTLBS FUELTANK 55 8Nm BN THROTTLE BODY VENT HOSE FOAM PADS FOAM PADS FUEL PUMP NUT FUEL ASSEMBLY TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc gt POLRHRIS 4 52 Fuel Systems 600 IQ Widetrak Fuel Supply FUEL PUMP ASSEMBLY PFANUT FUEL CAP VENT
71. protection when using compressed air A CAUTION 9 Assembly is the reverse of disassembly 4 11 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Fuel Systems Float Arm Adjustment Proper float arm adjustment in critical to carburetor performance 1 Invert carburetor assembly 2 Carefully bend the float arm tang contacting the inlet needle so the float arm legs are parallel with the float bowl mating surface Needle and Seat Leak Testing A leaking needle and seat can cause hard starting and poor runability issues 1 Invert the carburetor assembly Verify the float arm is properly adjusted 2 Attach a Mity Vac pressure pump to the fuel inlet fitting 3 Apply approximately 5 PSI of pressure and wait for at least one minute The needle and seat should hold the pressure indefinitely If the pressure drops rapidly replace the needle and seat assembly 4 12 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc MIKUNI TM CARBURETOR Function The function of a carburetor is to produce a combustible air fuel mixture by breaking fuel into tiny particles in the form of vapor to mix the fuel with air in a proper ratio and to deliver the mixture to the engine A proper ratio means an ideal air fuel mixture which can burn without leaving an excess of fuel or air Whether the proper mixture ratio is maintained or not is the key to efficient e
72. se a lean operation condition and may cause serious engine damage Jet the carburetors carefully for elevation and temperature according to the jetting charts in the Specifications Chapter of this manual or the models Owner s Manual Supplements Piston Throttle Valve INTAKE SIDE throttle valve controls the rate of engine air intake by moving up and down inside the main bore At small throttle openings air flow control is performed chiefly by the cutaway By controlling air flow the negative pressure over the needle valve is regulated in turn varying the fuel flow 4 10 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc The throttle valves are numbered 1 0 1 5 2 0 etc according to the size of the cutaway in millimeters The higher the number the leaner the gasoline air mixture Jet Needle Needle Jet The jet needle and needle jet have the most effect between 3 8 and 3 4 throttle opening Some mixture adjustment can be accomplished by changing the location of the E clip on the needle Moving the clip down raises the needle in the jet passage and enriches the mixture Moving the clip up lowers the needle in the jet passage and leans the mixture Letter and number codes are stamped into the needle and the jet indicating sizes and tapers taper of needles only of each Jet Needle The jet needle tapers off at one end and the clearance between the jet needle a
73. side of the nosepan y 246 i an Follow these steps to connect the diagnostic and power up cables to the snowmobile 1 Assemble the Smart Link cables and module as shown in the illustration 2 Open the hood and locate the connectors Remove the protective cap from the Digital Wrench connector 3 Connect the vehicle interface cable to the Digital Wrench connector 4 Using the power up cable part number PS 47296 A and a fully charged 12 volt battery connect the power up cable to the ECU POWER UP connector NOTE To verify the 12 volt battery and power up cable are working connect the cable to the chassis power up connector If working correctly the headlights should illuminate 4 56 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc DC CFI Digital Wrench Connections The access point for the ECU power up and Digital Wrench connectors is located in the front left side of the nosepan Bu B o AC DC POWER POWER TEST TEST Follow these steps to connect the diagnostic and power up cables to the snowmobile 1 Assemble the Smart Link cables and module as shown in the illustration 2 Open the hood and locate the connectors Remove the protective cap from the Digital Wrench connector 3 Connect the vehicle interface cable to the Digital Wrench connector 4 Using the power up cable part number PA 46355 and a fully charged 12 volt battery c
74. stems FUEL TANK PUMP SERVICE Fuel Tank Front Flange Type Fuel Pump A WARNING PROPOSITION 65 WARNING Snowmobile engines discharge fuel and exhaust which contain chemicals known to the State of California to cause cancer and birth defects or other reproductive harm onto the snow on which they operate Keep this engine properly tuned and avoid unnecessary idling and spillage during fueling Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored or used Do not overfill the tank past the bottom of the filler neck If you get gasoline in your eyes or if you swallow gasoline see your doctor immediately Never start the engine or let it run in an enclosed area Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time If you spill gasoline on your skin or clothing immediately wash it off with soap and water and change clothing 1 Remove the fuel from the fuel tank Store the fuel in an appropriate fuel holding container 2 Remove the following components Seat Assembly Console Loosen fasteners then lift console away from tank and set to the side Air box 3 If electric start is installed disconnect the negative cable the positive cable from the battery 4 Relieve the fuel pressure See Fuel Rail Bleeding Pressure Testing on page 4 38 5 Unplug the fuel
75. t be caused by faulty Fuel Injector Voltage Too Low P2147 wiring ECU or stator MAG Ignition Coil Circuit Malfunction P0351 9 Failure within the primary circuit Can be caused by faulty wiring ignition coil or ECU PTO Ignition Coil Circuit Malfunction P0352 5 Tooth CPS Signal Missing P0335 10 Engine is running but there is no signal from the 5 tooth CPS Can be caused by a faulty stator wiring or ECU Engine is running but the pulses from the 5 tooth CPS are incorrect Can be caused by a faulty n stator wiring harness or there is no 2 tooth CPS signal If there is no 2 tooth CPS signal the engine CFS Signal Intermittent will not run but the P0336 code will set because the ECU receives extra 5 tooth signals without any 2 tooth signals 5 VDC Sensor Supply Voltage Low P0643 Sensor supply voltage is below an acceptable limit Can be caused by faulty wiring or ECU Chassis Voltage High P0563 sd System voltage is too high Can be caused by faulty wiring or regulator rectifier Chassis Voltage Low P0562 System voltage is too low Can be caused by a faulty wiring or regulator rectifier Ignition Voltage Circuit Malfunction P0350 Engine is running but a problem is found with the ignition coil power circuit Can be caused by faulty wiring or ECU Chassis Relay Coil Open Circuit P1611 The chassis relay control circuit is open Can be caused by faulty wiring or a faulty relay 4 26 9922854 2007 2011 IQ Serv
76. t Code PJGMICPJFMNE Authorization Key RAGCEOLAHLBK 3 3 Enter Authorization Key 4 Prepare Vehicle S Reprogram 6 Verify Success 2008 700 CFI IQ Switchback Touring Status 16 The reflash process will begin Verify all connections are properly made Do not touch anything during the process 17 Verify the reflash was a success by comparing the software ID number listed under the CUSTOMER AND VEHICLE IDENTIFICATION button with the number recorded in step 6 Note the Request Code below and obtain an Authorization Key from the Dealer Web Site Enter the Authorization Key in the Proper Field to Customer and Vehicle Identification Vehicle Information Customer Information ECU Part Number 5201 Software Part 1011367 4 59 Fuel Systems TROUBLESHOOTING Flowchart STEP 1 DOCUMENT THE BASICS Preliminary 1 VIN Checks 2 Vehicle Miles 3 Issue s 4 Vehicle Engine Modifications Required info for Polaris to perform proper diagnostic assistance 5 Check unit against Unit Inquiry for any outstanding Service Bulletins or Team Tips 6 Type of fuel in the fuel tank Fuel Selector Status Select models only excludes 700 RMK and 600 Touring The fuel selector jumper wires or resistor plug must be set as outlined below based off of the type of fuel in the tank 4 Injector CFI engines 87 89 91 w 10 etha
77. ter replacing the injectors the ECU must be re flashed so the fuel calibration map matches the new color coded fuel injectors Ay CAUTION ALWAYS CHECK THE INJECTOR PART NUMBER TO VERIFY ENGINE APPLICATION REGARDLESS OF COLOR CODE NEVER RUN THE ENGINE WITH DIFFERENT COLOR CODED FUEL INJECTORS SEVERE ENGINE DAMAGE WILL OCCUR ALWAYS VERIFY THE ECU CALIBRATION FILE MATCHES THE FUEL INJECTOR COLOR CODE 1 Depressurize the fuel rail See Fuel Rail Bleeding Pressure Testing on page 4 38 2 Remove the panduit straps as shown NOTE The engine must be removed from the engine compartment to access the lower two fuel injectors 3 Remove the hex screws securing the fuel rail it to the cylinders TERRAIN DOMINATION gt POLARIS 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 4 f replacing a lower injector remove the two bottom screws bolts from the lower fuel rail 5 Remove the failed injector s NOTE Make sure that the green bushing comes out with the injector If it does not look inside the injector bore BLUE OR BLACK O RIN BROWN OR GREEN O RING B GREEN BUSHING 6 Measure from the end of the injector as shown below 3 76 2mm and cut the injector off 3 76 2mm 7 Strip the harness end injector wire covering 25 375 6 35 9 525 8 Crimp the ends of the new injector firmly on to the wire harness
78. the TPS until the specified TPS BASE SETTING VOLTAGE is established TPS Base Setting Loosen the TPS Screws and Rotate the TPS until the Base Setting is between 0 69 and 0 71 Volts y Tighten the Screws to 31 in Ib 3 5 N m and verify the voltage is still within specifications 2008 700 CFIIQ Switchback Status Connected TPS BASE SETTING VOLTAGE ALL 600 700 800 ENGINES 693 698 703 708 VDC NOTE The nominal TPS Base Setting is 698VDC 15 When the correct TPS base setting voltage is established the CONTINUE button will turn from RED to GREEN When this occurs carefully tighten the TPS screws to 31 In Lbs 3 5 Nm Verify the voltage has not changed 16 Open and close the throttle plate 2 3 times and verify the voltage is still within specification 17 Click on the green CONTINUE button Digital Wrench will perform the IDLE SET ADJUSTMENT Idle Set Adjustment Turn Screw A until the TPS Voltage is 600 700 CFI Between 0 94 and 0 96 Volts 800 CFI Between 0 93 and 0 95 Volts Then Tighten the Lock Nut B and verify the voltage is still within specifications 0 952 o a 7 2008 700 CFI IQ Switchback Status Connected TERRAIN DOMIMATION POLARIS Fuel Systems 18 To set the idle voltage slowly turn the set screw A clockwise until the IDLE SET VOLTAGE established IDLE SET VOLTAGE ALL 600 700 CFI ENGINE
79. uel than necessary to leave the nozzle enriching the mixture Too low a level results in a leaner mixture since not enough fuel leaves the nozzle Therefore the predetermined fuel level should not be changed arbitrarily Idle Speed Adjustment The idle speed adjustment screw sets the height of the throttle slide inside of the mixing chamber Turning the screw in clockwise raises the throttle slide and raises engine RPM Turning the idle speed screw out counter clockwise lowers the throttle slide and lowers engine RPM Always set the idle speed after the engine reaches operating temperature TERRAIN DOMINATION POLARIS 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Air Screw The air screw controls the amount of air that is mixed with the fuel drawn out of the float bowl The more air allowed to mix with the fuel the leaner the fuel mixture Turning the screw in clockwise reduces the amount of air while turning the screw out counter clockwise increases the amount of air Pilot Jet From idling to low speeds the fuel supply is metered by the pilot jet There are several air bleed openings in the sides of the pilot jet which reduce the fuel to mist The number stamped on the jet is an indication of the amount of fuel in cc s which passes through the jet during a one minute interval under a given set of conditions Main Jet When the throttle opening becomes greater and the area bet
80. ve 3 23 VDC Can be caused by a faulty wire connection or faulty TMAP 4 Barometric Pressure Sensor Voltage Low P0107 Sensor signal is below 1 25 VDC Can be caused by a faulty wire connection of faulty TMAP Exhaust Temperature Sensor Circuit Voltage High P0546 Zea Sana is above 4 9 VDC for at least 2 minutes and the engine has been running at or above 5 nhhi Exhaust Temperature Sensor Circuit Voltage Low P0545 is below 0 06 VDC for at least 2 minutes and the engine has been running at or above Detonation Sensor Circuit Voltage High P0328 Engine speed is above 6000 RPM and the sensor signal is above 4 3 VDC for at least 2 seconds 6 Detonation Sensor Circuit Voltage Low P0327 Engine speed is above 6000 RPM and the sensor signal is below 1 23 VDC for at least 2 seconds Exhaust Valve Solenoid Circuit Malfunction P1477 8 Solenoid control circuit is OPEN Can be caused by faulty wiring solenoid or ECU MAG Crankcase Injector Circuit Open P0261 MAG Cylinder Port Injector Circuit Open P1261 OPEN circuit or short to ground Can be caused by faulty wiring injector stator or ECU PTO Crankcase Injector Circuit Open P0264 PTO Cylinder Port Injector Circuit Open P1264 7 Engine is running but the voltage is above the acceptable limit be caused by faulty Fuel Injector Voltage Too High P2148 wiring ECU or stator Engine is running but the injector voltage is below the acceptable limi
81. ween the needle jet and jet needle increases fuel flow is metered by the main jet The number on the jet indicates the amount of fuel which will pass through it in one minute under controlled conditions Larger numbers give a greater flow resulting in a richer mixture Main jets are screwed directly into the needle jet base MAIN JET 4 9 Fuel Systems Jetting Guidelines Changes in altitude and temperature affect air density which is essentially the amount of oxygen available for combustion In low elevations and cold temperatures the air has more oxygen At higher elevations and in higher temperatures the air is less dense Verify the production setting for your specific model All carburetors must be re calibrated if operated outside the production temperature and or altitude range The main jetinstalled in production is not correct for all altitudes and or temperatures Refer to the jetting cart in the Specifications Chapter of this manual for correct jetting for altitude temperature ranges NOTE It is the owner s responsibility to ensure that the correct jets are installed in the machine for a geographical area Be very careful when jetting down in warm weather As the weather turns colder it will be necessary to re jet to prevent engine damage When selecting the proper main jet always use the lowest elevation and temperature that is likely to be encountered CAUTION A main jet that is too small will cau
82. wiring at the sensor and ECU connector Inspect the harness terminal pin inside the ECU connector 6 If no wiring problems are found inspect the TPS Verify the TPS is securely mounted to the throttle body If it is loose it will have to be re adjusted by following the Digital Wrench TPS Replacement Procedure 7 Replace the TPS if steps 5 and 6 do not resolve the issue Follow the Digital Wrench TPS Replacement Procedure Idle Speed Adjustment CFI Engines Normal throttle body component wear and tear may cause changes in idle speed over the lifetime of the vehicle The idle speed screw can be adjusted to compensate for these changes 1 Determine if the TPS or throttle plate synchronization screw have ever been replaced adjusted If this determination cannot be made then idle speed screw adjustment can only be performed by following the Digital Wrench TPS Replacement Procedure 2 Start and run the engine in a well ventilated area or drive the vehicle until the engine engine compartment are at normal operating temperature 3 Note the engine idle speed If the idle speed is within specification no adjustment is required If the idle speed is outside of specification continue with step 4 4 Stopthe engine and open the hood 5 Remove the air box assembly Verify the throttle lever free play is set to specification and the throttle cable is not pulling on the throttle plate cam 6 Locate the idle speed screw A and jam nut

Download Pdf Manuals

Related Search

Related Contents

Manuel d`utilisation    impianticondizionamento/scheda SIGNO  3 - Hospira  Samsung ATIV NP910S5J-K03BE notebook  Célébrité Fort-EQ  JAEA-Research-2010-014:3.11MB  PDF document - AutomationDirect Technical Support  GSK983Ta User Manual  

Copyright © All rights reserved. Failed to retrieve file