2006-2008 Polaris Snowmobiles FS/FST Service Manual.

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This is a complete Service Manual in English for the 2006-2008 FS / FST Snowmobiles.
Color diagrams, high resolution images and full description for the procedures. Original Polaris service manual.

Models covered in this service manual:

Manual chapters:
2006 - 2008 FS / FST SERVICE MANUAL
 - FOREWORD
 - understanding manual safety labels and directions
 - TRADEMARKS
Model Specifications
 - 2006 FS Classic
 - 2006 FST Classic
 - 2006 FS Touring
 - 2006 FST Touring
 - 2006 FST Switchback
 - 2007 FST IQ
 - 2007 FST IQ LX
 - 2007 FS IQ Touring
 - 2007 FST IQ Touring
 - 2007 FST IQ Cruiser
 - 2007 FST IQ Switchback
 - 2008 IQ Turbo Dragon
 - 2008 IQ Turbo LX
 - 2008 Turbo Switchback
 - 2008 FS IQ Touring
 - 2008 FST IQ Touring
 - 2008 IQ Cruiser
General Information
 - VIN Organization
 - TUNNEL DECAL
 - 2006 Publication Part Numbers
 - 2007 Publication Part Numbers
 - 2008 Publication Part Numbers
 - Miscellaneous Publications
 - SAE
 - Metric
 - Decimal Equivalents
 - Conversion Table
 - Standard Bolt Specifications
 - GASOLINE VOLATILITY
Maintenance
 - Break-In Period Maintenance Interval
 - Maintenance Program
 - Engine Oil Level Check
 - Engine Oil and Filter Change Procedure
 - Airbox Oil Breather Foam Element
 - Spark Plug Servicing
 - Air Box Intake Boots
 - Engine Lubrication System Overview
 - FST Air Filter
 - Alternator Belt Inspection / Adjustment
 - Valve Lash Adjustment
 - Expansion Tank
 - Engine Coolant Removal
 - Adding Engine Coolant / Air Bleed
 - Cooling System Pressure Test
 - Engine Cooling System Overview
 - Oil Cooler Configurations
 - Drive Belt Deflection
 - Chaincase Chain Tension
 - Track Alignment
 - Track Tension
 - Track Lubrication
 - Lubrication Points
 - Driveshaft Bearing
 - Rear Suspension
 - Chaincase Oil Level
 - Chaincase Drain Plug
 - Handlebar Adjustment
 - Rider Select Adjustment
 - Throttle Lever Freeplay
 - Brake Lever
 - Brake Fluid
 - Brake Fluid Bleeding
 - Storage Procedures
EFI / Ignition Systems
 - System Overview
 - Safety Information
 - Bosch M7.4.4 System Specifications
 - Diagnostic Trouble Codes (DTCs)
 - ECU Connector Orientation
 - EFI - Engine Harness Repair Kits
 - Wiring Harness Connector Identification
 - ECU 100 Harness Connector (Gray Color)
 - ECU 200 Harness Connector (Brown Color)
 - ECU 300 Harness Connector (Black Color)
 - Engine RPM / Vehicle Speed Limit Modes
 - Turbo Boost Reduction Modes
 - Fuel Injection Circuit
 - Ignition Coil Circuit
 - Throttle Position Sensor Circuit (TPS)
 - TPS Baseline Adjustment
 - TPS Idle Speed Adjustment
 - Throttle Plate Synchronization
 - Ambient Pressure Sensor Circuit (FST Only)
 - Intake Manifold Pressure / Temperature Sensor Circuit
 - Boost Pressure Sensor Circuit (FST Only)
 - Coolant Temperature Sensor Circuit
 - Crank Position Sensor (CPS) Circuit
 - Camshaft Phase Sensor Circuit
 - Knock Sensor Circuit (FST Only)
 - Wastegate Solenoid Pulse Valve Circuit (FST Only)
 - Wide Band Lambda Sensor Circuit
 - Idle Air Control Actuator Circuit
 - Roll Over Sensor Circuit
 - Diagnostic Communications Circuit
 - Digital Wrench Diagnostic Cable Connection
 - Ignition Switch Jumper Tool
 - Fuel Rail / Intake / Exhaust Cylinder Head Components
 - Posi-Lock Fuel Hose Connectors
 - 2006 Fuel Tank / Fuel Supply
 - 2006 Fuel Pump Supply / Return Fittings
 - 2006 Pump / Sender Specifications
 - 2006 Fuel Pump Replacement
 - Drop-in Fuel Tank / Fuel Supply
 - Drop-in Fuel Supply / Return Fittings
 - Drop-in Pump / Sender Specifications
 - Fuel Pump Replacement (Drop-In Style)
 - Fuel Tank Pressure Test
 - Fuel Pressure Test
 - FS Induction System
 - FST Induction System
 - FST Airbox
 - Turbocharger Assembly
 - FST Boost / Vacuum Reference Hose System
 - Wastegate Solenoid Pressure Testing
 - Wastegate Actuator Pressure Testing
 - Turbocharger Inspection
 - Charge Air Cooler (Intercooler) Inspection
 - Boost / Vacuum Reference Hose System (FST)
 - FS Exhaust System
 - FST Exhaust
 - Troubleshooting
 - Ignition Switch Jumper Tool
 - Digital Wrench Diagnostic Cable Connection
 - Digital Wrench Overview
 - Digital Wrench Operating Requirements
 - Updating Digital Wrench
 - Version / Fileset Identification
 - Engine Controller Reprogramming
 - Data Display Screenshots - Engine OFF
 - Data Display Screenshots - Engine at Idle
 - Service Reports
 - Performance Issues with No Diagnostic Codes
 - Fuel System Minimum and Maximum Adaptation
 - Multiple Diagnostic Codes
 - Wire Harness Diagnostics
Engine Removal and Installation
 - Before You Begin
 - Suspending Engine
 - Engine Removal
 - MAG-Side Engine Mounting
 - PTO-Side Engine Mounting
FS / FST Engine
 - Engine Specifications
 - Fastener Torque Specifications
 - Cylinder Head / Crankcase Torque Patterns
 - Special Tools
 - Components
 - Valve Cover Assembly
 - Valve Train Assembly
 - Bed Plate / Scavenge Oil Pump Assembly
 - Oil Filter Assembly
 - Water Outlet Manifold Assembly
 - Water Pump Assembly
 - High Pressure Oil Pump Assembly
 - Chain Tensioner / Chain Guide Assembly
 - Crankcase Assembly
 - Piston Assembly
 - Valve Assembly
 - Crankshaft / Balance Shaft Assemblies
 - Front (MAG-END) Gear Cover Assembly
 - MAG Engine Mount / Alternator Bracket
 - Starter Motor Assembly
 - Valve Cover
 - Bedplate / Scavenge Pump
 - Water Outlet Manifold-Thermostat Assembly
 - Water Pump Assembly
 - MAG Gear Cover Assembly / Water Pump Driveshaft Removal and Installation
 - Flywheel Removal and Installation
 - High Pressure Oil Pump
 - Gear Train
 - Cylinder Head / Valve Train
 - Crankcase / Crankshaft / Pistons / Balance Shaft
 - Connecting Rod Bearing Oil Clearance Inspection
 - Bearing Replacement Guide
 - Crankshaft Main Bearing Oil Clearance Inspection
 - Bearing Replacement Guide
 - Crankcase / Crank Train / Piston Assembly
 - Timing Chain Installation / Locating TDC
Final Drive and Brake Systems
 - Optional Parts
 - Speed Chart
 - Drive Chain Deflection Adjustment
 - Chaincase Oil Level
 - Chaincase Oil Drain
 - Chaincase Disassembly
 - Jackshaft Removal
 - Jackshaft Installation
 - Driveshaft Removal
 - Driveshaft Installation
 - Overview
 - Compensation Port
 - GENERAL GUIDELINES
 - BRAKE FLUID REPLACEMENT & BLEEDING
 - BRAKE LINE REPLACEMENT
 - REMOVAL
 - ASSEMBLY
 - PAD REPLACEMENT
 - BRAKE DISC REPLACEMENT
PVT System
 - Overview
 - Drive Spring
 - Clutch Weight
 - Neutral Speed
 - Engagement RPM
 - Shift Out Over-Rev
 - Shift Out RPM
 - Driven Spring
 - Back-Shifting
 - Final Gearing
 - 1:1 Shift Ratio
 - Low / High Ratio
 - Driven Helix / Ramp
 - Special Tools
 - Drive Clutch Springs
 - Spring Free Length
 - Drive Clutch Weights
 - PERC Team LWT Driven Helixes (24 Fin)
 - Non-PERC Team LWT Driven Helixes (24 Fin)
 - Non-PERC Team Driven Helixes (12 Fin)
 - Team Ramp Angles
 - Team Driven Springs
 - Drive Belts
 - Belt Inspection
 - Drive Clutch Bolt Torque
 - Belt Wear / Burn Diagnostics
 - Drive Belt Removal - Team Driven Clutch
 - Drive Belt Installation - Team Driven Clutch
 - Adjusting Belt Deflection - Team Driven Clutch
 - Clutch Alignment / Offset
 - Offset Adjustment
 - Identification
 - Drive Clutch Removal
 - Drive Clutch Disassembly
 - Roller Removal
 - Roller Installation
 - Clutch Assembly
 - Spider Indexing
 - Drive Clutch Installation
 - Components
 - Driven Clutch Removal
 - Driven Clutch Installation
 - Driven Clutch Disassembly
 - Driven Clutch Assembly
Front Suspension / Steering
 - Inspection
 - Camber / Toe Specifications
 - Springs
 - Adjustable Shocks
 - Ryde FX Air 2.0 Shock
 - Rebuildable IFS Shock Specifications
 - 7043141 Piston Valve Specifications
 - 7043245 Piston Valve Specifications
 - Front Suspension
 - Steering Linkage
 - Steering Mount
 - Handlebar Post - Rider Select
 - Setup and Adjustments
 - Alignment Bar Specifications
 - Camber
 - Rod Ends
 - Rod End Engagement
 - Camber Adjustment
 - Handlebar Centering
 - Toe Adjustment
 - Spindle Removal
 - Spindle Assembly
 - Spherical Bearing Replacement
 - Upper / Lower Control Arm Removal
 - Upper / Lower Control Arm Installation
Rear Suspension
 - Rear Suspension Type by Model
 - Suspension Mounting Fastener Torque
 - IQ Rear Suspension Shock Rod
 - IQ Rear Track Shock Pivot Orientation
 - Operation
 - Weight Transfer
 - Coupling
 - Torsion Spring Adjustment
 - IQ 121 Pivots / Rear Idler
 - IQ 121 Rail Assembly
 - IQ 121 Front / Rear Torque Arms
 - M-10 128 Pivots / Rear Idler
 - M-10 128 Rail
 - M-10 128 Front / Rear Torque Arms
 - M-10 136 Pivots / Rear Idler
 - M-10 136 Rail
 - M-10 136 Front / Rear Torque Arms
 - IQ 136 Comfort Pivots / Rear Idler
 - IQ 136 Comfort Rail Assembly
 - IQ 136 Comfort Front / Rear Torque Arms
 - IQ 136 Coupled Pivots / Rear Idler
 - IQ 136 Coupled Rail Assembly
 - IQ 136 Coupled Front / Rear Torque Arms
 - IQ 144 Pivots / Rear Idler
 - IQ 144 Rail Assembly
 - IQ 144 Front / Rear Torque Arms
 - Adjustment Procedures
 - Rear Suspension Ride Height
 - Scissor Stop Adjustment
 - Limiter Strap Adjustment
 - Torsion Spring Adjustment
 - IQ 121 Heavy Torsion Spring Installation
 - M-10 OVERVIEW
 - M-10 ADJUSTMENTS
 - M-10 TERMINOLOGY
 - M-10 ADJUSTMENTS
 - M-10 FRA INITIAL SET UP REFERENCE
 - M-10 REAR SPRING PRELOAD
 - M-10 SKI PRESSURE
 - Wear Limit
 - Removal
 - Break-In
 - Removal
 - Installation
 - Specifications
 - Front Track Shock (FTS) Valving
 - Rear Track Shock (RTS) Valving
 - Shock Rebuilding Tools
 - Ryde FX™ Shock Valve Part Numbers
 - Fox™ Shock Valve Part Numbers
 - Valve Shim Arrangement
 - Piston Orientation
 - Ryde FX Air 2.0 Shock Disassembly
 - Ryde FX Air 2.0 Shock Assembly
 - Ryde FX Remote Reservoir Shock Disassembly
 - Ryde FX Remote Reservoir Shock Assembly
 - RYDE FX MONO-TUBE SHOCK DISASSEMBLY
 - RYDE FX MONO-TUBE SHOCK ASSEMBLY
 - FOX PS-5 DISASSEMBLY
 - FOX PS-5 ASSEMBLY
 - Assembly Illustration
 - Rear Suspension
Chassis
 - Assembly Illustration
 - Hood / Plastic Repair
 - Assembly Illustration
 - Assembly Illustration
 - IQ Fixed Seat Assembly
 - IQ Removable Seat Assembly
 - IQ Touring Seat Assembly
 - IQ Raw Seat Assembly
 - Seat Cover Replacement
 - Assembly (Typical)
 - Replacement
 - Decal Removal
 - Decal Installation
Chassis Electrical System
 - System Overview
 - Battery / Charging System Specifications
 - Battery Preparation
 - Battery Preparation
 - Testing Procedures
 - OPEN CIRCUIT VOLTAGE TESTING (OCV)
 - LOAD TEST
 - OFF SEASON STORAGE
 - Relay Overview
 - Relay Panel Wire Routing
 - Fuse Overview
 - Fusible Links
 - Circuit Breaker
 - Diodes
 - External Relays (Relays Located Outside of the Main Relay Panel)
 - EFI / Ignition Relay Circuit
 - EFI Relay Circuit
 - Ignition Relay Control Circuit
 - Ignition Relay Power Circuit
 - Chassis Relay Circuit
 - Chassis Relay
 - Start Solenoid Relay Circuit
 - Start Solenoid Relay Control Circuit
 - Start Solenoid Grounding Relay Circuit
 - Fuel Pump Relay Circuit
 - Fuel Pump Relay Circuit
 - Charge Air Cooler (Intercooler) Fan Relay Circuit
 - Charge Air Cooler Relay Circuit
 - Engine Stop / Throttle Safety Stop Circuits
 - Throttle Safety System
 - Perc 4 Reverse System Circuits
 - Perc 4 Button Circuit
 - Forward / Reverse Limit Switch Circuits
 - Perc 4 Forward Reverse Controller Circuit
 - Multi-Function Display (MFD) Circuits
 - Multi-Function Display Power Circuit
 - Multi-Function Display Inputs / Outputs
 - Mode / Set Switch Circuit (Non-ACE)
 - Vehicle Speed Sensor Circuit
 - Power-Up / Power-Down Sequence Overview
 - Power-Up / Power-Down Troubleshooting
 - Cylinder Head Routings
 - Crankcase / Throttle Body Routings
 - LH Foot Rest Routings
 - Ambient Pressure / Wastegate Solenoid Routings
 - Overview
 - Checking Components
 - Troubleshooting
 - Operation
 - Feedback
 - Enable / Disable
 - Display Select
 - Suspension Position
 - ACE Important Notes
2006 FS / FST Chassis 1 of 2
 - 2006 FS / FST Chassis 1 of 2
 - 2006 FS / FST Chassis 2 of 2
 - 2006 FS / FST Engine 1 of 2
 - 2006 FS / FST Engine 2 of 2
 - 2006 FS / FST Hood
 - 2006 FS / FST System Diagram
 - 2007 FS / FST Chassis 1 of 2
 - 2007 FS / FST Chassis 2 of 2
 - 2007 FS / FST M10 ACE Chassis 1 of 2
 - 2007 FS / FST M10 ACE Chassis 2 of 2
 - 2007 FS / FST Engine 1 of 2
 - 2007 FS / FST Engine 2 of 2
 - 2007 FS / FST Hood
 - 2007 FS / FST System Diagram
 - 2007 FS / FST M10 ACE Suspension
 - 2008 FS / FST Chassis 1 of 2
 - 2008 FS / FST Chassis 2 of 2
 - 2008 FS / FST M10 ACE Chassis 1 of 2
 - 2008 FS / FST M10 ACE Chassis 2 of 2
 - 2008 FS / FST Hood Harness
 - 2008 FS / FST M10 ACE Suspension
 - 2008 FS / FST Engine 1 of 2
 - 2008 FS / FST Engine 2 of 2

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