2007 Polaris 500 XC SP Owners Manual
2007 Polaris 500 XC SP Manual
2007 Polaris 500 XC SP manual content summary:
- 2007 Polaris 500 XC SP | Owners Manual - Page 1
- 2007 Polaris 500 XC SP | Owners Manual - Page 2
For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 Phone (763) 417-8650 Fax (763) 542-0599 Part No. 9920437 Rev 02 Printed in USA - 2007 Polaris 500 XC SP | Owners Manual - Page 3
WARNING Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. WARNING The engine exhaust from this product - 2007 Polaris 500 XC SP | Owners Manual - Page 4
operation of your vehicle, be sure to follow the instructions and recommendations in this owner's manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master - 2007 Polaris 500 XC SP | Owners Manual - Page 5
and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A. 2007 340 LX/550 LX/Supersport/500 XC SP Owner's Manual P/N 9920437 2 - 2007 Polaris 500 XC SP | Owners Manual - Page 6
of important identification numbers that should be recorded in the owner's manual. TABLE OF CONTENTS Safety ...6 This section describes safe vehicle in your snowmobile's regular maintenance. Polaris Products...Troubleshooting ...Warranty ...Maintenance Log ...Index ... 125 126 131 142 144 3 - 2007 Polaris 500 XC SP | Owners Manual - Page 7
) Engine Serial Number: _____ (right front side of engine crankcase) Key Number: _____ Important Notes for Owners and Drivers After reading this manual, store it in the snowmobile for convenient reference. It should remain with the snowmobile when the snowmobile is sold. Follow the maintenance - 2007 Polaris 500 XC SP | Owners Manual - Page 8
of our environment, including wildlife and vegetation. Snowmobile clubs and other organizations are working together to protect our environment. Please support their efforts and operate your snowmobile with consideration for the protection and preservation of our environment. Noise Level One of the - 2007 Polaris 500 XC SP | Owners Manual - Page 9
symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for injury. WARNING The safety alert to the vehicle. NOTE A note will alert you to important information or instructions. 6 - 2007 Polaris 500 XC SP | Owners Manual - Page 10
Operator Safety SAFETY Follow the recommended maintenance program beginning on page 74 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals. WARNING Driving a snowmobile requires your full - 2007 Polaris 500 XC SP | Owners Manual - Page 11
while warming up the track. A loose track or flying debris could cause serious injury or death. We recommend having your dealer perform all track service and alignment procedures. Stay Clear of Engine Never attempt adjustments with the engine running. Turn off the ignition, raise the hood, make the - 2007 Polaris 500 XC SP | Owners Manual - Page 12
Operator Safety Riding Position SAFETY Operating a snowmobile requires skill and balance for proper control. Rider positions may vary with experience and the features available on some snowmobiles, but under many conditions, the proper position is to be seated with both feet on the running boards - 2007 Polaris 500 XC SP | Owners Manual - Page 13
your snowmobile at all times Spare Drive Belt Extra Set of Spark Plugs Tow Rope Extra Oil Fuel Deicer Winter Survival Kit Trail Map Owner's Manual First Aid Kit 10 - 2007 Polaris 500 XC SP | Owners Manual - Page 14
Operator Safety Disabled Operators SAFETY Safe operation of this rider-active vehicle requires good judgement and physical skills. Operators with cognitive or physical disabilities have an increased risk of loss of control, which could result in serious injury or death. Rider Capacity Your - 2007 Polaris 500 XC SP | Owners Manual - Page 15
SAFETY Operator Safety Driver Awareness Slow down when traveling near poles, posts, or other obstacles. Be especially alert if you're snowmobiling after dark. Always be on the alert for wire fences. Single strands are especially dangerous, since there may be a great distance between posts. Guy - 2007 Polaris 500 XC SP | Owners Manual - Page 16
and avalanche conditions, contact local law enforcement in your area, or visit either the American Avalanche Association online at www.americanavalancheassociation.org or the U.S. Forest Service National Avalanche Center at www.avalanche.org. 13 - 2007 Polaris 500 XC SP | Owners Manual - Page 17
may interfere with the steering of your machine, resulting in serious injury or death. Keep the underhood area free of snow and ice. Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If difficulty - 2007 Polaris 500 XC SP | Owners Manual - Page 18
Operator Safety Driving Downhill SAFETY When riding downhill, shift your weight to the rear of the machine and reduce your speed to a minimum. Apply just enough throttle to keep the clutch engaged, allowing the engine's compression to help slow the machine and keep it from rolling freely downhill. - 2007 Polaris 500 XC SP | Owners Manual - Page 19
SAFETY Operator Safety Driving in Hilly Terrain WARNING Climbing a hill or crossing the face of a slope may result in loss of balance and machine roll-over, causing serious injury or death. Use caution and good judgement when driving in hilly terrain. Use extra caution when operating in hilly - 2007 Polaris 500 XC SP | Owners Manual - Page 20
of failure is extremely remote, don't defeat the purpose of the safety guard by removing it. Clutches Do not attempt to service the clutches. All clutch service must be performed by your dealer. The clutch is a complex mechanism that rotates at high speeds. Each clutch is dynamically balanced - 2007 Polaris 500 XC SP | Owners Manual - Page 21
SAFETY Operator Safety Inadequate Snow Conditions Moveable hood closures are included on some Polaris snowmobiles. They are normally left open and are located on the front upper and lower hood openings. If operating in deep snow or in extreme cold conditions (below -20_ F), Polaris recommends - 2007 Polaris 500 XC SP | Owners Manual - Page 22
Operator Safety Driving Responsibly SAFETY Every snowmobile handles differently, and even the most docile conditions may become dangerous if operators drive improperly. If you're new to snowmobiling, acquaint yourself with the machine and with what it will and won't do under various conditions. - 2007 Polaris 500 XC SP | Owners Manual - Page 23
SAFETY Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when temperatures become dangerous for riding. WINDCHILL CHART (_F) Wind Speed 40 in MPH Calm 5 10 15 20 25 30 35 40 45 50 55 60 40 36 34 32 30 29 28 28 27 26 26 25 25 Actual Thermometer - 2007 Polaris 500 XC SP | Owners Manual - Page 24
the decals depicted in this manual differ from the decals on your snowmobile, always read and follow the instructions of the decals on the snowmobile belt guard removed. Never run engine with drive belt removed. Never service clutches yourself -- see your dealer. Airbox Warning This warning decal - 2007 Polaris 500 XC SP | Owners Manual - Page 25
SAFETY Safety Decals and Locations Track Warning The track warning decal is on the rear of the tunnel: WARNING Stay clear of track. Do not sit on seat back. Entanglement with the track or a fall from seat back may result in severe injury or death. + "No Passenger" Warning Some snowmobiles are - 2007 Polaris 500 XC SP | Owners Manual - Page 26
up. • Avoid sharp turns. • Shift to or from reverse only when stopped. • Apply throttle slowly. SAFETY + NOTE: For more information, see Owner's Manual. If electric reverse: • Machine stopped and engine at idle, push yellow button on LH control to reverse. Flashing light on dash indicates reverse - 2007 Polaris 500 XC SP | Owners Manual - Page 27
stop. • To maintain vehicle control on ice or hard-packed surfaces, you should have a proper balance of ski carbides to track studs. See Owner's Manual for proper use of traction products. • Repeated stops from high speed may cause fading or sudden loss of braking ability. • Parking brake may relax - 2007 Polaris 500 XC SP | Owners Manual - Page 28
FEATURES 3 2 1 4 6 5 7 8 9 14 12 11 10 13 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Hood Headlight Windshield Handlebar Seat Storage Compartment Taillights Rear Bumper Snow Flap Track Suspension Ski Nosepan Front Bumper 25 - 2007 Polaris 500 XC SP | Owners Manual - Page 29
as a reverse indicator light, electronic fuel gauge, temperature light and electric shock control gauge. Not all models come with these features. Refer to your Owner's Manual Supplement for the features on your machine. 4 3 5 6 7 8 2 1 9 10 26 - 2007 Polaris 500 XC SP | Owners Manual - Page 30
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Fuel Filler Cap Ignition Switch Brake Lever Speedometer Tachometer Engine Stop Switch Throttle Control Hood Hold Down Straps Recoil Starter Handle Choke Headlight Dimmer Switch Parking Brake Handlebar Grip Warmer Switch Thumbwarmer Switch - 2007 Polaris 500 XC SP | Owners Manual - Page 31
THE PERFECT FIT Front Suspension Adjustments Independent Front Suspension (IFS) Break in the suspension for about 150 miles (240 km) before making any fine-tuning adjustments. Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions. We - 2007 Polaris 500 XC SP | Owners Manual - Page 32
Front Suspension Adjustments Independent Front Suspension (IFS) THE PERFECT FIT WARNING Always verify ski alignment before making adjustments to the IFS. See page 114 to check alignment. If the skis are misaligned, see your dealer, as the camber adjustment may also be affected. For the best ride, - 2007 Polaris 500 XC SP | Owners Manual - Page 33
THE PERFECT FIT Shock Damping Front Suspension Adjustments Adjustments to the compression stiffness of Indy Select shocks can be made by turning the adjustment screw located near the base of the shock (+). This adjustment is the easiest to perform and it should be considered first. A clockwise - 2007 Polaris 500 XC SP | Owners Manual - Page 34
Front Suspension Adjustments Spring Preload Increasing spring preload will increase ski-to-ground pressure. Decreasing spring preload will decrease ski-toground pressure. When adjusting, be sure the springs on both the left and right sides of the machine are at the same adjustment. To increase front - 2007 Polaris 500 XC SP | Owners Manual - Page 35
THE PERFECT FIT Rear Suspension Adjustments Rider weight, riding style, trail conditions, and vehicle speed all affect suspension action. Each rear suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions. However, all suspension designs - 2007 Polaris 500 XC SP | Owners Manual - Page 36
Rear Suspension Adjustments Suspension Performance Tips THE PERFECT FIT • Rider weight usually determines the position at which the spring preload should be set. However, this may vary with riding style. With a little experimentation, each rider can find a preferred setup. These adjustments are - 2007 Polaris 500 XC SP | Owners Manual - Page 37
THE PERFECT FIT EDGE Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method) To set up the EDGE rear suspension torsion spring preload, measure the distance between the ground and rear bumper. This is measurement X. Take the first measurement with no rider and with the rear - 2007 Polaris 500 XC SP | Owners Manual - Page 38
EDGE Rear Suspension Adjustments Torsion Spring Tension THE PERFECT FIT To adjust rear torsion spring tension, rotate the three-position cam using the engine spark plug tool. Different rate torsion springs are available if a firmer ride is desired. See your dealer for more information. Soft - 2007 Polaris 500 XC SP | Owners Manual - Page 39
THE PERFECT FIT Rear Shocks EDGE Rear Suspension Adjustments Indy Select Rear Shock Some snowmobiles are equipped with the Indy Select rear shock, which allows for adjustments to the compression valving by turning the adjustment screw located near the base of the shock. Locate the adjustment screw - 2007 Polaris 500 XC SP | Owners Manual - Page 40
EDGE Rear Suspension Adjustments Suspension Coupling THE PERFECT FIT On all Polaris snowmobile rear suspensions, there are two torque arms that control the movement of the rail beam. Prior to the advent of suspension coupling, these torque arms could move independently of each other. Rear - 2007 Polaris 500 XC SP | Owners Manual - Page 41
THE PERFECT FIT EDGE Rear Suspension Adjustments Rear To Front Coupling and the Rear Rear Scissor Stop (RRSS) The rear rear scissor stop (RRSS) couples the movement of the rear torque arm with the front torque arm and limits the amount of independent movement between the rear torque and the front - 2007 Polaris 500 XC SP | Owners Manual - Page 42
. Rearward Upper Position (optional hole location - This setting will increase weight transfer. NOTE: Your dealer can help you with initial setup and additional setup instructions to help you achieve your optimum ride. Scissor Stop Tool THE PERFECT FIT Stock Medium/High Rearward Upper 39 - 2007 Polaris 500 XC SP | Owners Manual - Page 43
THE PERFECT FIT Handlebar Angle Handlebar Adjustments Follow these steps to adjust handlebar angle at the handlebar block. 1. Remove the handlebar cover (1) to expose the handlebar and the four adjuster block bolts (2). 2. Using a 7/16I (11 mm) wrench, loosen the four nuts (3) on the bottom of the - 2007 Polaris 500 XC SP | Owners Manual - Page 44
, clutches, fuel systems, and exhaust systems. NOTE: Exhaust systems are critical safety areas that must use approved Polaris parts. Please see your Polaris dealer for service. 41 - 2007 Polaris 500 XC SP | Owners Manual - Page 45
THE PERFECT FIT Traction Products Studs Before equipping your machine with traction products, be aware of the laws in your area pertaining to the use of traction products. See your dealer about installing studs and/or carbides. Many tracks with deep lug designs cannot be studded, but your dealer - 2007 Polaris 500 XC SP | Owners Manual - Page 46
Traction Products nCarbide Skags THE PERFECT FIT A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain. Use carbide skags with studded tracks to help maintain proper vehicle - 2007 Polaris 500 XC SP | Owners Manual - Page 47
THE PERFECT FIT Traction Products Wear Strips To avoid excessive tunnel wear, tunnel wear strips must be installed whenever track studding is used. See your dealer for more information. Some models are manufactured with tunnel wear strips or wear strip coolers installed. Wear strips are designed for - 2007 Polaris 500 XC SP | Owners Manual - Page 48
Pre-Ride Checklist PRE-RIDE INSPECTIONS Inspect all items on the checklist for proper operation or condition before each use of the snowmobile. Procedures are outlined on the referenced pages. Look for a checkmark (n) on the referenced pages to locate the pre-ride inspection items. Item Drive Belt - 2007 Polaris 500 XC SP | Owners Manual - Page 49
and Understand Your Owner's Manual Read the Owner's Manual completely and refer to it often. The manual is your guide to safe and enjoyable lever freeplay, DO NOT start the engine. Have the throttle serviced immediately. n Throttle Safety Switch Test the throttle safety switch system before - 2007 Polaris 500 XC SP | Owners Manual - Page 50
indicates low brake fluid level or air in the hydraulic system. Refer to the brake bleeding information on page 97 or see your dealer for service. 1/2I (1.3 cm) Lever Feel If the brake lever feels "spongy" when squeezed, check the brake fluid level and condition. Add fluid as needed. See page - 2007 Polaris 500 XC SP | Owners Manual - Page 51
the console will light up if the parking brake lever lock is set while the engine is running. It will also be lit when the service brake is in use. If the parking brake light does not come on when the parking brake or - 2007 Polaris 500 XC SP | Owners Manual - Page 52
Before Starting the Engine Parking Brake Lever Lock PRE-RIDE INSPECTIONS Lock Release To release the lock, squeeze the brake lever tightly and release it. The lock will return to the unlock position. WARNING If the parking brake lever lock is partially or entirely engaged while riding, the brakes - 2007 Polaris 500 XC SP | Owners Manual - Page 53
may interfere with the steering of your machine, resulting in serious injury or death. Keep the underhood area free of snow and ice. Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If difficulty - 2007 Polaris 500 XC SP | Owners Manual - Page 54
Before Starting the Engine n Hood Latches PRE-RIDE INSPECTIONS The hood of the snowmobile protects the operator from moving parts as well as aiding in sound emission control and other functions. Under no circumstances should your snowmobile be operated with the hood open or removed. Always ensure - 2007 Polaris 500 XC SP | Owners Manual - Page 55
PRE-RIDE INSPECTIONS n Engine Stop Switch Start the Engine and Check Check the auxiliary shut-off switch for proper operation. Push the switch down to stop the engine. Pull it up to allow restarting. n Ignition Switch Make sure the engine stops when the ignition switch is turned to OFF. n Tether - 2007 Polaris 500 XC SP | Owners Manual - Page 56
Starting the Engine WARNING OPERATION Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start your snowmobile without checking all components to be sure of proper operation. See Before Starting the Engine beginning on page 46. 1. Turn the - 2007 Polaris 500 XC SP | Owners Manual - Page 57
OPERATION Engine Break-In No single action on your part is as important to long, trouble-free machine life as proper break-in of a new or rebuilt engine. Premix the first tank of fuel with one pint of Polaris injection oil - 2007 Polaris 500 XC SP | Owners Manual - Page 58
Engine Break-In Oil Injection System OPERATION Always check and fill the oil tank when refueling. See page 60. CAUTION Serious engine damage can occur without the proper lubrication. Check the oil tank level often during the first tank of fuel. If the oil level doesn't go down, contact your - 2007 Polaris 500 XC SP | Owners Manual - Page 59
behind it while warming up the track. Do not use excessive throttle during warm-up or when the track is free-hanging. Use a stable rear support. WARNING Use of traction products such as studs, ice growsers, etc. will increase the possibility of track damage and/or failure. This could cause loss - 2007 Polaris 500 XC SP | Owners Manual - Page 60
Fuel Valve Turn the fuel valve clockwise to OFF to shut off the fuel supply. Turn the valve counter-clockwise to ON to turn the fuel supply on. OFF OPERATION ON Fuel WARNING Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling - 2007 Polaris 500 XC SP | Owners Manual - Page 61
than 87 octane fuel. Do not use fuel containing more than 10% ethanol (including E85) NOTE: Some engines require premium fuel. See your Owner's Manual Supplement. Premium Fuel Switch If your Polaris snowmobile is equipped with a key function to adjust the timing on the machine as you change fuels - 2007 Polaris 500 XC SP | Owners Manual - Page 62
Fuel OPERATION Fuel Reserve Capacity (Mechanical Gauge) There are approximately two gallons of fuel left in the tank when the mechanical fuel gauge reads RES. Fuel System Deicers If you use non-oxygenated fuel, Polaris recommends the regular use of isopropyl-based fuel system deicer. Add one to - 2007 Polaris 500 XC SP | Owners Manual - Page 63
OPERATION Oil n Low Oil Indicator Light The low oil indicator light will alert the operator if the oil level is low. Visually check for oil in the bottle. Add oil before further operation of the snowmobile. CAUTION Operating the snowmobile without adequate engine lubrication can result in serious - 2007 Polaris 500 XC SP | Owners Manual - Page 64
Carburetion OPERATION Proper carburetor adjustment is critical. A lean mixture (too much air, too little fuel) may result in piston burning, bearing failure, or complete engine failure. A rich mixture (too much fuel, too little air) may foul plugs and cause generally poor engine performance. A - 2007 Polaris 500 XC SP | Owners Manual - Page 65
and may cause serious engine damage. Jet the carburetors carefully for elevation and temperature according to the jetting charts in your Owner's Manual Supplement. NOTE: It's the owner's responsibility to ensure that the correct jets are installed in the machine for a geographical area. Be very - 2007 Polaris 500 XC SP | Owners Manual - Page 66
n Engine Stop Switch Push down on the engine stop switch (+) to ground out the ignition and stop the engine quickly. Pull the switch up to the ON position to allow restarting. OPERATION + n Throttle Safety Switch The throttle safety switch is designed to stop the engine whenever all pressure is - 2007 Polaris 500 XC SP | Owners Manual - Page 67
may cause the safety switch to activate, preventing the engine from starting. If this occurs, return the machine to an authorized Polaris dealer for service. If an emergency exists and it's necessary to start the engine, the throttle safety switch and engine stop switch may be disconnected from the - 2007 Polaris 500 XC SP | Owners Manual - Page 68
Emergency Stopping OPERATION The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 63 for more information about the engine stop switch and throttle safety switch. SYSTEM Ignition Switch Brake Choke Engine Stop Switch Throttle Safety Switch Tether - 2007 Polaris 500 XC SP | Owners Manual - Page 69
OPERATION Emergency Starting Your machine is equipped with a tool kit containing essential tools for emergency use. Snowmobiles equipped with electric start have a recoil for emergency starting. On non-electric-start models, if the recoil starter system fails, an emergency start strap is provided - 2007 Polaris 500 XC SP | Owners Manual - Page 70
Reverse Operation WARNING OPERATION Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. Damage will occur to the chaincase or transmission if shifting is attempted when the engine is operating above idle speed Shift to or from reverse - 2007 Polaris 500 XC SP | Owners Manual - Page 71
OPERATION Reverse Operation Electronic Reverse (PERCt) Electronic reverse will activate only if the engine RPM is below 4000. If your machine is running at an altitude of over 6000 feet, adjust the ignition setting as described below. Always make sure the vehicle is stopped and the engine is - 2007 Polaris 500 XC SP | Owners Manual - Page 72
Reverse Operation Electronic Reverse (PERCt) OPERATION Disengaging Reverse 1. Stop the snowmobile and leave the engine idling. 2. Push the yellow reverse button for one second and release. The engine will slow and begin to rotate forward. The light on the instrument panel will shut off. 3. Apply - 2007 Polaris 500 XC SP | Owners Manual - Page 73
OPERATION Daily Storage At the end of each ride, park the snowmobile on a level surface and support it at the rear with an appropriate track stand. The track should be suspended approximately 4I (10 cm) off the ground. Remove the key and cover the machine. 70 - 2007 Polaris 500 XC SP | Owners Manual - Page 74
Towing OPERATION For your safety, do not attempt to use a tow hitch until you've read the following warnings and understand the proper hitch functions. WARNING Objects towed with a rope have no braking power and can easily collide with the rear of the snowmobile or other objects, resulting in - 2007 Polaris 500 XC SP | Owners Manual - Page 75
and it comes on, you must take your snowmobile to a qualified dealer for diagnostic service. Specifications and adjustments for engine tune-ups are located in the Service Manual, which is available to your qualified service technician. Reverse (if equipped) must not be engaged during engine tune-ups - 2007 Polaris 500 XC SP | Owners Manual - Page 76
specified maintenance is performed, including the emission-related maintenance outlined in these sections of the manual. You must inspect the air intake system on your snowmobile prior to each use ( that you contact an authorized Polaris dealer to perform any service that may be necessary. 73 - 2007 Polaris 500 XC SP | Owners Manual - Page 77
MAINTENANCE Polaris Recommended Maintenance Program To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform service checks as outlined in this manual. Record maintenance and service in the Maintenance Log beginning on page 142. The recommended - 2007 Polaris 500 XC SP | Owners Manual - Page 78
Periodic Maintenance Interval Table MAINTENANCE The following chart is a guide based on average riding conditions. You may need to increase frequency based on riding conditions. When inspection reveals the need for replacement parts, always use - 2007 Polaris 500 XC SP | Owners Manual - Page 79
MAINTENANCE Item Periodic Maintenance Interval Table See Page Frequency 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi. (3200 km) PreSeason BRAKES Hose Routing Hose Condition Fluid Leaks Brake Pads Brake Disc Parking Brakes Brake System Brake Fluid Pilot Air Screws Carburetor ( - 2007 Polaris 500 XC SP | Owners Manual - Page 80
Drive Shaft Bearing Jackshaft Bearings Skags (Wear Bars) Ski Saddle/Spindle Bolts Ski Pivots Ski Spindle Steering Arm(s) Upper / Lower Steering Post Support Bracket Drive Chain Tension Hood Latches Battery Fluid Level Rear Wheel Idler Bolts Idler Bolt Jam Nut Rear Suspension Pivot Shafts Camber - 2007 Polaris 500 XC SP | Owners Manual - Page 81
the front ski pivots at the fittings as shown. Grease the jackshaft and driveshaft clutch side bearings. Use an aerosol lubricant on the steering post support bracket. Grease the steering post lower pivot. Grease the rear suspension pivot shafts (raise the rear of unit). + + + + + 78 - 2007 Polaris 500 XC SP | Owners Manual - Page 82
Lubrication EDGE Rear Suspension MAINTENANCE + + + + + 79 - 2007 Polaris 500 XC SP | Owners Manual - Page 83
MAINTENANCE Lubrication Jackshaft Bearing Loosen the driven clutch retaining bolt and pull the clutch outward to expose the bearing and grease fitting. Inject grease into the grease fitting in the flangette until grease purges from inside or outside the bearing seal (may take only two pumps). Push - 2007 Polaris 500 XC SP | Owners Manual - Page 84
Lubrication Throttle Cable Lubricate the throttle cable lightly with grease or oil. With the engine off, turn the handlebars to the left and lubricate liberally as shown. MAINTENANCE + Choke and Choke Cable Lubricate the choke slide and cables lightly with oil or grease. Before turning the engine - 2007 Polaris 500 XC SP | Owners Manual - Page 85
MAINTENANCE Lubrication n Chaincase Oil Check the chaincase oil level at the intervals outlined in the maintenance charts beginning on page 74. Change the chaincase oil after the first 500 miles (800 km), then every 1000 miles (1600 km) or seasonally. Maintain the oil level between the "safe" marks - 2007 Polaris 500 XC SP | Owners Manual - Page 86
the engine is operated in conditions more severe than intended for that plug. Always use the spark plugs recommended for your snowmobile. See your Owner's Manual Supplement Use recommended spark plugs with the proper gap. Torque spark plugs to 18-22 ft. lbs. (24-30 Nm). Always carry spare spark - 2007 Polaris 500 XC SP | Owners Manual - Page 87
be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetor/throttle - 2007 Polaris 500 XC SP | Owners Manual - Page 88
Intake Filters CAUTION MAINTENANCE Operating the snowmobile with the intake filters removed may cause carburetor icing. The result will be poor fuel economy or carburetor malfunction. Always reinstall the intake filters before operating the snowmobile. The intake foam filter (+) limits snow - 2007 Polaris 500 XC SP | Owners Manual - Page 89
in the bottom of the oil tank. After changing the oil filter, bleed the oil injection system of all trapped air. See your dealer for instructions, or have your dealer perform the filter change and bleeding operation for you. NOTE: The direction of the arrow indicates the direction of flow through - 2007 Polaris 500 XC SP | Owners Manual - Page 90
Carburetor Water/Sediment Trap Service MAINTENANCE Most Polaris snowmobiles contain patented carburetor from anything that may cause the fuel to ignite, such as open flames, sparks, heaters, trouble lights, cigarettes, etc. Review the gasoline warnings found on page 57. Plug Cleaning Procedure - 2007 Polaris 500 XC SP | Owners Manual - Page 91
MAINTENANCE Carburetor The number stamped in the end of the main jet indicates the jet size. The jet installed at the time of manufacture is not necessarily correct for your elevation. It's your dealer's responsibility to make sure the correct main jet is installed. CAUTION Operating the snowmobile - 2007 Polaris 500 XC SP | Owners Manual - Page 92
cool completely. Open the hood and inspect the muffler and pipes for cracks or damage. Check for weak or missing retaining springs or damper/support grommets. WARNING Hot exhaust system parts can cause serious burns. Allow adequate time for the exhaust system to cool. Never perform this procedure - 2007 Polaris 500 XC SP | Owners Manual - Page 93
MAINTENANCE Cooling System The cooling system on liquid cooled models consists of the following major components: Coolant bottle Water pump Cylinders Heads Inlet and outlet manifolds Pressure cap Heat exchangers 90 - 2007 Polaris 500 XC SP | Owners Manual - Page 94
Cooling System Coolant MAINTENANCE The coolant supplied in the system at the factory is a 50/50 mixture of ethylene-glycol and distilled water, which will provide adequate freeze protection under most conditions. If the vehicle will be stored or operated at extremely low temperatures, greater - 2007 Polaris 500 XC SP | Owners Manual - Page 95
coolant maintains its ability to protect the engine, drain the system completely every two years and add a fresh mixture of antifreeze and distilled water. This service must be performed when the engine is cold. Ask your Polaris dealer to check the coolant when he performs the fall tune-up on your - 2007 Polaris 500 XC SP | Owners Manual - Page 96
Cooling System Bleeding the Cooling System MAINTENANCE WARNING Steam and hot liquids will cause serious burns to your skin. Never bleed the cooling system or remove the pressure cap when the engine is warm or hot. Use of a non-standard pressure cap will not allow the recovery system to function - 2007 Polaris 500 XC SP | Owners Manual - Page 97
MAINTENANCE Drive Chain Tension Check drive chain tension weekly and before each long trip. To obtain correct chain tension: 1. Rotate the driven clutch counterclockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the brake lever firmly. 2. - 2007 Polaris 500 XC SP | Owners Manual - Page 98
Brakes n Hydraulic Brake Inspection MAINTENANCE Inspect the brake lever reserve before each use of the snowmobile. See page 47. Brake pads must be replaced when the brake pad material becomes thinner than the backing plate (approximately 1/16I). A kit is available for replacing brake pads. See - 2007 Polaris 500 XC SP | Owners Manual - Page 99
MAINTENANCE Brakes Brake Fluid On some models, the brake fluid level can be seen through a plastic sight glass in the brake reservoir. If the fluid is sufficient, the sight glass will be black. If the sight glass is any color other than black, add brake fluid. On all other models, frequently check - 2007 Polaris 500 XC SP | Owners Manual - Page 100
Brakes MAINTENANCE Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause spongy brake lever action. Bleed the system before operating the snowmobile. WARNING Operating the vehicle with a spongy brake lever can result in loss of brakes, which could cause an accident and - 2007 Polaris 500 XC SP | Owners Manual - Page 101
MAINTENANCE Lights Headlight Adjustment The headlight may be adjusted for vertical aim using the following procedure. 1. Place the snowmobile on a level surface with the headlight approximately 25 feet (7.6 m) from a wall. 2. Measure the distance from the floor to the center of the headlight and - 2007 Polaris 500 XC SP | Owners Manual - Page 102
Lights MAINTENANCE NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Headlight Bulb Removal 1. Pinch the ends of the spring (1) together and lift until it releases from the spring retainer. 2. Lift the - 2007 Polaris 500 XC SP | Owners Manual - Page 103
MAINTENANCE Clutch System Periodically inspect clutch sheaves for damage, wear or belt residue. To maintain optimum performance, clean with non-oil based cleaners such as isopropyl alcohol. WARNING If you become aware of higher than normal clutch engagement or an unusual vibration or shift pattern, - 2007 Polaris 500 XC SP | Owners Manual - Page 104
crucial to maintaining optimum performance. See your Owner's Manual Supplement for the recommended offset between the drive and driven change the shift pattern, resulting in poor performance. See your dealer for service and adjustments. NOTE: A worn belt will continue to function, but will - 2007 Polaris 500 XC SP | Owners Manual - Page 105
of excessive wear: frayed edges, missing cogs, cracks and excessive looseness. Replace the belt if any of these conditions exist. See Belt Troubleshooting on page 130. For improved drive-away during extremely cold temperatures, remove the belt and warm it to room temperature. Reinstall it before - 2007 Polaris 500 XC SP | Owners Manual - Page 106
Clutch System Drive Belt Removal MAINTENANCE CAUTION Do not attempt to remove the drive belt after operating in reverse. The snowmobile must be stopped after forward motion to prevent damage to components during belt removal. 1. 2. 3. 4. 5. Stop the engine after operating in a forward motion. - 2007 Polaris 500 XC SP | Owners Manual - Page 107
MAINTENANCE Clutch System Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. NOTE: To ensure satisfactory belt life, install belts so they operate in the same direction of rotation by positioning the identification numbers so that you can read them. If - 2007 Polaris 500 XC SP | Owners Manual - Page 108
Clutch System n Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position. Place a straight edge (1) on the belt and apply downward pressure while measuring at point 2. This measurement should be 1 1/4I (3.2 cm). MAINTENANCE 1 2 Drive Belt - 2007 Polaris 500 XC SP | Owners Manual - Page 109
MAINTENANCE Clutch System Torque Stop If your snowmobile is equipped with an engine torque stop, periodically check torque stop clearance. With clutches in proper alignment, the torque stop clearance should be .010I-.030I (.25-.75 mm) from the engine case. Adjust if necessary, and lock the jam nut. - 2007 Polaris 500 XC SP | Owners Manual - Page 110
MAINTENANCE Maintain the proper chain tension as outlined on page 94. For maximum performance, arrange for a fall service tune-up with your Polaris dealer. His experienced and trained service technician will keep your machine in peak operating condition. Tool Kit A tool kit is included with each - 2007 Polaris 500 XC SP | Owners Manual - Page 111
, which could cause serious injury or death. Never operate with a damaged track. Never rotate a damaged track under power. 1. Using a hoist, safely lift and support the rear of the snowmobile off the ground. 2. Rotate the track by hand to check for damage. 3. Carefully examine the track along the - 2007 Polaris 500 XC SP | Owners Manual - Page 112
Track Track Lubrication MAINTENANCE WARNING Operating with insufficient lubrication between the rail slide and track guide clips can cause track failure, loss of vehicle control and loss of braking ability, which can result in serious injury or death. Avoid operating for - 2007 Polaris 500 XC SP | Owners Manual - Page 113
adjustments should be made only after the track is warmed up and limber. 1. Turn the engine off. 2. Lift the rear of the machine and safely support it off the ground. 3. Place the recommended weight or downward pressure on the track at the specified distance (see chart) ahead of the center of - 2007 Polaris 500 XC SP | Owners Manual - Page 114
Track Track Tension If the track needs adjustment: 5. Loosen the rear idler shaft bolt. 6. Loosen the locknuts. Slack Adjusting Screw Measurement MAINTENANCE Locknut Track S Shaft Bolt 16I(40 cm) 10 lbs. (4.54 kg) 7. Tighten or loosen the track adjusting screws to provide equal adjustment on - 2007 Polaris 500 XC SP | Owners Manual - Page 115
check that the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail. 1. Safely support the rear of the machine with the track off the ground. 2. Start the engine and apply a small amount of throttle until the track turns slowly - 2007 Polaris 500 XC SP | Owners Manual - Page 116
Steering System Steering Inspection and Adjustment MAINTENANCE Each week, or before a long ride, check all steering system fasteners and tighten if necessary. + + + + + + + 113 - 2007 Polaris 500 XC SP | Owners Manual - Page 117
MAINTENANCE Steering System Ski Alignment WARNING Improper ski alignment or adjustment may cause loss of steering control, resulting in serious injury or death. Do not attempt to change the ski alignment or camber adjustment. See your Polaris dealer. With the handlebars in a straight ahead - 2007 Polaris 500 XC SP | Owners Manual - Page 118
when worn to half their original diameter. NOTE: Carbide skags must be replaced if any abnormal wear or chipping is found. Skag Replacement 1. Raise and support the front of the machine so the skis are approximately 6I (15.2 cm) from the ground. 2. Remove the attaching nuts and pry the skag - 2007 Polaris 500 XC SP | Owners Manual - Page 119
reduce your snowmobile's reliability and cause needless repairs and down time. Before beginning any snowmobile trip, a visual inspection will uncover potential problems. Check the following items on a weekly basis or before any long trip: n Check suspension mounting bolts for tightness. n Check rear - 2007 Polaris 500 XC SP | Owners Manual - Page 120
Extended Storage MAINTENANCE Off-season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components. See page 125 for the part numbers of Polaris products. Cleaning and Preservation Proper storage starts with - 2007 Polaris 500 XC SP | Owners Manual - Page 121
except the driven clutch shaft bushing as outlined in the Master Repair Manual. See your dealer. Engine and Carburetor Protection Proper preparation of the Clean or a fuel conditioner/stabilizer to the fuel tank. Follow the instructions on the container, running the engine for five minutes to get - 2007 Polaris 500 XC SP | Owners Manual - Page 122
1. Transfer unused fuel from the fuel tank to an approved fuel container using a siphon pump. Do not re-use fuel after storage. 2. Securely support the front of the snowmobile with a jack stand so the machine is elevated and the engine is tilted rearward. 3. Remove the spark plug(s). 4. Rotate - 2007 Polaris 500 XC SP | Owners Manual - Page 123
the battery as outlined on page 124. Track and Suspension Moderate track tension should be maintained during summer storage. The machine should be supported off the ground to allow the track to hang freely. Transporting the Snowmobile Whenever the snowmobile is transported: 1. Turn the fuel valve - 2007 Polaris 500 XC SP | Owners Manual - Page 124
Battery Battery Fluid MAINTENANCE A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. Maintain the fluid level between the upper and lower level marks. WARNING Battery electrolyte is poisonous. It contains acid! Serious burns can result from contact with the - 2007 Polaris 500 XC SP | Owners Manual - Page 125
MAINTENANCE Battery Battery Connections Keep battery terminals and connections free of corrosion. When cleaning is necessary, remove the corrosion with a stiff wire brush. Wash terminals and connections with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and - 2007 Polaris 500 XC SP | Owners Manual - Page 126
Battery Battery Installation MAINTENANCE WARNING Batteries contain gases that can explode. If the battery vent tube is pinched or kinked, battery gases could accumulate. Whenever removing or installing the battery, disconnect the negative (black) cable first and reinstall the negative cable last - 2007 Polaris 500 XC SP | Owners Manual - Page 127
MAINTENANCE Battery Battery Storage When your snowmobile is placed in storage for one month or more Remove the battery. Charge it to the proper level. Store it in a cool dry place. Check and/or charge monthly. Before using the battery, take it to your dealer for testing and recharging. Batteries - 2007 Polaris 500 XC SP | Owners Manual - Page 128
POLARIS PRODUCTS Part No. 2870791 2871098 2871097 2871240 2871721 2871722 2872347 2874438 2874439 2874443 2873105 2872951 2871312 2871322 2871423 2871329 2871323 2871534 2871326 2870652 2872189 2872893 2870505 2872889 2872890 Description Engine Lubricants Fogging Oil (12 oz. Aerosol) Premium 2- - 2007 Polaris 500 XC SP | Owners Manual - Page 129
TROUBLESHOOTING Engine Troubleshooting Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise. Problem Erratic engine operating RPM during acceleration or load variations Probable Cause Solution Drive clutch binding • Disassemble drive - 2007 Polaris 500 XC SP | Owners Manual - Page 130
Engine Troubleshooting Problem Noise in drive system Broken drive clutch components Bearing belt Excessive belt/ sheave clearance Loose torque stop Sticky clutch Engine doesn't turn Seized engine TROUBLESHOOTING Probable Cause Solution • SEE YOUR DEALER. • SEE YOUR DEALER. • Inspect and replace - 2007 Polaris 500 XC SP | Owners Manual - Page 131
TROUBLESHOOTING Problem Engine turns but fails to start Engine Troubleshooting Probable Cause Solution Faulty ignition is too small will cause seizure resulting in loss of power. This indicates a major engine problem that must be repaired before operating. SEE YOUR DEALER. • Replace the plug(s). • - 2007 Polaris 500 XC SP | Owners Manual - Page 132
EDGE Suspension Troubleshooting Problem Rear suspension bottoms too easily TROUBLESHOOTING Solution • Increase torsion spring preload • Increase rear shock compression damping by turning screw clockwise • Increase torsion spring wire diameter (see your dealer) • Check for binding - 2007 Polaris 500 XC SP | Owners Manual - Page 133
Drive Belt Troubleshooting Belt Wear/Burn Diagnosis Causes Driving at low RPM Insufficient warm-up Solutions • Drive at higher RPMs. Gear the machine down. Check belt deflection. • Warm - 2007 Polaris 500 XC SP | Owners Manual - Page 134
of purchase 5. Details of trouble experienced 6. Length of time and conditions of operation 7. Previous correspondence Use the page provided near the front of your Owner's Manual to record the identification numbers of your snowmobile and its engine. Polaris Customer Service United States: 1-763-417 - 2007 Polaris 500 XC SP | Owners Manual - Page 135
1. Polaris snowmobile owner reports theft. A. In addition to notifying the proper law enforcement officials, the owner must call Polaris Customer Service. B. Owners must provide their name, address, telephone number and the model and serial number of stolen machines. 2. 3. Polaris warranty will - 2007 Polaris 500 XC SP | Owners Manual - Page 136
preparation and setup of your snowmobile is very important in ensuring trouble-free operation. Purchasing a snowmobile in the crate or without any damages that occur during trailer transit or as a result of unauthorized service or parts. In addition, this warranty does not cover physical damage to - 2007 Polaris 500 XC SP | Owners Manual - Page 137
dealer is YOUR responsibility). Polaris recommends that you use your original selling dealer; however, you may use any Polaris Servicing Dealer to perform warranty service. Please work with your dealer to resolve any warranty issues. Your dealer will contact the appropriate personnel at Polaris if - 2007 Polaris 500 XC SP | Owners Manual - Page 138
to perform the required vehicle Pre-Delivery Inspection, perform all applicable service bulletins and have the consumer sign the PDI form prior to delivery products for lubrication and maintenance as directed by the Owner's manual is highly recommended. Should a failure occur during the warranty - 2007 Polaris 500 XC SP | Owners Manual - Page 139
• Each repair visit after the first twelve months of standard warranty coverage is subject to a $50 deductible. • The free Second Year Engine Service Contract applies to the first 5,000 miles or two (2) calendar years from date of purchase, whichever comes first. Tampering with the odometer shall - 2007 Polaris 500 XC SP | Owners Manual - Page 140
oil. • Piston seizures, unless caused by a defective engine component. • Failures caused due to improper adjustments. • Failure due to unauthorized service. • Failures due to lack of service as required in the owner's manual or Polaris updates. This includes off-season storage as listed in the owner - 2007 Polaris 500 XC SP | Owners Manual - Page 141
Polaris Industries. Dealers may not give authorization for export. You should consult an authorized dealer to determine this vehicle's warranty or service bulletin coverage if you have any questions. This policy does not apply to vehicles registered to government officials or military personnel on - 2007 Polaris 500 XC SP | Owners Manual - Page 142
must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle. Outside the Country where your vehicle - 2007 Polaris 500 XC SP | Owners Manual - Page 143
WARRANTY Snowmobile Engine Emissions Limited Warranty This snowmobile engine emissions limited warranty is in addition to the Polaris standard limited warranty for snowmobiles. Polaris Industries Inc. warrants that at the time it is first purchased, this emissions-certified snowmobile engine meets - 2007 Polaris 500 XC SP | Owners Manual - Page 144
for performing the scheduled maintenance identified in the owner's manual. Polaris can deny an emissions warranty claim if any snowmobile. Polaris recommends that you contact an authorized Polaris dealer to perform any service that may be necessary. It is a potential violation of the Clean Air - 2007 Polaris 500 XC SP | Owners Manual - Page 145
LOG Present this section of your manual to your dealer each time your snowmobile is serviced. This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 150 mi. (240 km - 2007 Polaris 500 XC SP | Owners Manual - Page 146
MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 143 - 2007 Polaris 500 XC SP | Owners Manual - Page 147
117 Coolant...91 Coolant Level...92 Cooling System ...90-93 Cooling System, Bleeding ...93 Cooling System, Flushing ...92 Customer Service...131 H Handlebar Adjustments ...40 Headlight Adjustment ...98 Headlight Bulb Installation ...99 Headlight Bulb Removal ...99 High Temperature Indicator Light - 2007 Polaris 500 XC SP | Owners Manual - Page 148
Products ...42-44 Transporting the Snowmobile...120 Troubleshooting, Drive Belt ...130 Troubleshooting, Engine...126-128 Troubleshooting, Suspension ...129 Tune-Up ...107 S Identification Numbers ...4 Water/Sediment Trap Service...87 Wear Strips ...44 Weight Transfer ...39 Windchill ...20 145
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