Snowmobile Polaris IQ (2007-2008 year). Manual - part 19

3.16

Maintenance

BRAKE SYSTEM MAINTENANCE

Brake Lever Travel

The gap between the brake lever and handlebar grip should be
equal to or more than 1/2

″

 (1.27cm) when depressing the brake

lever.

If the gap is less than 1/2

″

 (1.27cm), the brake system should be

inspected and bled of any air within the fluid.

Brake Fluid

Inspect the reservoir to be sure it contains the correct amount of
fluid. Use only Polaris DOT 4 high temperature brake fluid.
Change fluid every 2 years or whenever the fluid is dark or
contamination is suspected.

NOTE: A low brake fluid level can be indicated
through the sight glass on the cover. If the fluid is

low this sight glass will glow a brighter. color.

THROTTLE AND CHOKE CABLE 
ADJUSTMENTS

Throttle Lever Free Play - Non CFI

Throttle lever free play must always be at a specified clearance
(A) 0.010

″

-0.030

″

 (0.25-0.80 mm) between the throttle lever

(B) and the throttle block (C). This clearance is controlled by the
throttle cable (D).

If adjustment is needed follow these steps: 

1.

Check the idle RPM and verify it is within the specified
range.

2.

Shut off engine.

3.

Locate the throttle cable that is attached to the carburetors
and adjust the throttle free play by adjusting the barrel nut
(E) and lock nuts (F).

WARNING

Do not over fill the master cylinder. Fluid expansion 

could cause brakes to lock, resulting in serious injury or 
death. Once a bottle of brake fluid is opened, use what 

is necessary and discard the rest. Do not store or use 

a partial bottle of brake fluid. Brake fluid is hygroscopic, 

meaning it rapidly absorbs moisture from the air. This 

causes the boiling temperature of the brake fluid to 

drop, leading to early brake fade and the possibility of 

serious injury

1/2” (1.27cm)

FULL

LOW

= In. / mm. 

Throttle Lever Free Play: 0.010"-0.030" (.25-.8mm)

CAUTION

When adjusting throttle lever free-play, always verify the
engine RPM does not rise with bars in the full low and full up-
right Rider Select positions (if applicable) and while turning
the handlebars to the full left and full right positions.

CAUTION

After any idle speed adjustments are made, the throttle 
lever clearance and the oil pump adjustment must be 
checked and adjusted.

A

B

C

D

E

F

3.17

Maintenance

3

4.

Once you achieve the proper free play of  0.010

″

-0.030

″

(.25-.80mm), tighten the lock nuts.

5.

Verify the oil pump index marks are within specification.

6.

Check the idle RPM and verify it is within the specified
range.

NOTE: If the idle speed screw is adjusted inward
and the cable sleeve is not adjusted to take up the
throttle lever clearance, the engine may misfire or
kill upon initial throttle opening.

Throttle Lever Free-Play - CFI Models

The inline adjuster should only be used to set free play and to
remove cable slack that occurs if the cable has stretched over
time.

NOTE: Never use the in-line adjuster to adjust
engine idle speed and never adjust the cable so that
the throttle plate cam on the throttle body no longer
rests against the idle air gap screw.

Turning the in-line adjuster inwards (clockwise) will increase
throttle lever free-play.

Turning the in-line adjuster outwards (counter-clockwise) will
decrease throttle lever free-play.

After setting the throttle lever free play, always verify the oil
pump adjustment is set correctly.

Choke Adjustment

1.

Flip the choke toggle to the “OFF” position.

2.

Loosen locknuts (1) on the carburetor.

3.

Turn sleeve adjusting nut (2) counter-clockwise until the
choke toggle shows no free play when pulled, then rotate
it clockwise until there is between 1/8 - 1/4in (3.2-.6.4mm)
free play (3).

NOTE: Verify the cable does not lift the plungers
when checking the free play.

4.

Tighten adjustment locknut (2).

CAUTION

When adjusting throttle lever free-play, always verify the
engine RPM does not rise with bars in the full low and full up-
right Rider Select positions (if applicable) and while turning
the handlebars to the full left and full right positions.

= In. / mm. 

Throttle Lever Free Play: 0.010

″

-0.030

″

 (.25-.8mm)

ADJUSTER

LOCK NUT

1

2

3

1/8 - 1/4in. (3.2-6.4mm)

3.18

Maintenance

STEERING / SUSPENSION 
MAINTENANCE

Handlebars

Periodically inspect the torque of the handlebar clamp fasteners.

1.

To adjust the handlebar angle, remove the handlebar cover
to expose the clamp.

2.

Loosen the four clamp fasteners. Slightly pry the upper
clamp up with a flat blade screwdriver.

3.

Adjust handlebars to desired position. Verify the wiring
harness, brake hose, and throttle cable do not kink.

4.

Secure the front clamp fasteners first to specification.
Finish by securing the two rear clamp fasteners to the same
torque setting.

5.

If equipped, reinstall the handlebar cover.

Rider Select Steering U-Joint

The rider select steering U-joint should be lubricated with
Polaris fogging oil (PN 2870791).

= T 

Handlebar Clamp Fastener Torque

16 Ft.Lbs. (21 Nm)

STEERING POST

CLAMPS

APPLY FOGGING OIL

3.19

Maintenance

3

Ski / Ski Skag Fasteners

Periodically inspect the ski-to-spindle fasteners for proper
torque.

Inspect ski skags and skag fasteners for abnormal wear and tear.
Replace skags when carbide edge is worn away.

Always use new Nylock nuts and secure hand tight.

Track Tension

Track tension is critical for maintaining correct suspension
operation. If the track tension is too loose it may cause the track
to slip or “ratchet”. If the track is too tight it will wear down the
rail slides, reduce top speeds, cause rear suspension vibration
and cause track and rear suspension durability problems.

1.

Lift the rear of the machine and place a jack stand or secure
the rear of the machine so that the track is off of the
ground.

2.

Start the engine and slowly let the engine turn the track
over. This will warm up the track for a correct
measurement.

3.

Shut off the engine.

4.

Place a 10 lb. (4.54kg) weight at point (A). Point (A) is 16”
(41cm) ahead of the rear idler shaft (E).

5.

Measure the distance (D) between the rail slider and the
track. This measurement should fall with in the
measurement range for the appropriate vehicle, see chart o
this page.

6.

If adjustment is needed, loosen up the lock nuts (B) on each
side.

7.

Loosen up the idler shaft bolts (F).

8.

Turn each adjuster bolt (C) clockwise to tighten track. Turn
the adjuster bolt counterclockwise to loosen track tension.

9.

Torque the lock nuts (B) and idler shaft bolts on each side
to 35 ft-lb (48 N-m).

= T 

Ski-to-Spindle Fastener Torque

36 Ft.Lbs. (49 Nm)

WASHERS PROVIDED

FOR BLOW MOLDED SKIS

SUSPENSION

MEASUREMENT

IQ 121

136 Coupled

136 Comfort

7/8

″ - 1-1/8″

(2.2 - 2.9cm)

M-10 128

7/8

″ - 1-1/8″

(2.2 - 2.9cm)

M-10 136

3/4

″ - 1.0″

(1.9 - 2.5cm)

IQ RMK / Switchback

3/8

″ - 1/2″

(1 - 1.3cm)

o

B

C

A

D

16”(41cm)

E

TRACK

F