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2002 DEEP SNOW SERVICE MANUAL

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4. CARBURETION AMBIENT TEMPERATURE Type IA E REI RHE aat TM 40 w TPS Below 30 F 30 to 10 F 10 to 10 F 410 to 430 F 430 to 450 F Above 450 F Main J Bl ouest 390 Altitude Below 34 C 34 t0 23 C 23 0 12 C 12tb 1C 1w 10 C Above 410 C PilotJet 45 JetNeedle 9DG 3 57 2 E in d SE E ps Es Needle l t i cerea P 8 825 S001200 POOR 500 2 See 220 2b Cutaway 2 0 2000 4000 4 4 4 8 2 2 Fuel Screw 2 0 Turn Meters 1200 1800 490 470 450 430 410 390 Air Screw 1 0 Turn ieee 12000890 A 43 B 2 2 Valve Seat 18 l 6000 8000 BO EE SCH Se E oy Fuel Octane R M 2 Key Switch Adj 2400 3000 a a m SC E 91 Premium 8000 10000 B ES 2 12 2 2 89 Regular 3000 3700 360 340 330 320 300 290 Throttle Gap 10000 12000 2 2 2 2 E Under Cutaway 0 102 2 6mm E StarterJet 145 NU NON Pilot Air J et SRI N A refers to the clip position from top or jet needle Exhaust Valve Spring Pink Low Elevation Exhaust Valve Spring P urple W hite CLUTCH CHART CLUTCH DRIVE DRIVEN DRIVEN Chaincase Chaincase Type epe P 85 SES as Ge Clutch Driven Gearing Gearing BEE iinet trated aot 3211080 mj m MERE HH Has NGA ikasa 3 EE Feet 9 3000 1054 Green SCH TAT HYVO ide Angle Overall
5. Gp POLARIS FUEL SYSTEM CARBURETION O The main system is designed to deliver fuel between low speed and high speed operation This system is made up ofthe 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 KA Throttle Valve system works in conjunction with the needle jet sys 3 et Needle tem By pass During low speed driving there is very little clearance Pilot Outlet 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 2 Under full throttle opening the cross sectioned area of MG Pilot J et clearance between the jet needle and the needle jet 7 Needle J et becomes greater than the cross sectioned area of the det Main J et main jet Thus the main jet is now controlling the amount of fuel flow Main J et 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 CCs which will pass through it in one minute under controlled conditions Larger numbers give a greater flow resulting in a richer
6. 90 ft Ibs 124 nm 1 26 Gp POLARIS GENERAL INFORMATION d MODEL 800 EDGE RMK 144 151 156 MODEL NUMBER SO2NM8CS ENGINE MODEL 52188 8070PL8C ELECTRICAL CAPACITIES Flywheell D Kokusan 4010629 FuelTank 11 8 gallons 44 7 liters CDI Marking 4010522 Oil Tank 3 5 quarts 3 3 liters Alternator Output 280 Watts Coolant 4 3 quarts 4 1 liters Ignition Timing 29 BTDC 4000RP M 500 Chaincase Oil 11 fl 02 325cc 0 2146 BTDC 5 4510mm BTDC Spark Plug Gap Champion RN57YCC 0 025 0 64mm Voltage Regulator LR7 Electric Start Option LR7 Full wave voltage regulator Magneto Pulses 6 SUSPENSION CHASSIS CHAINCASE Body Style EDGE Sprockets Chain 144 151 21 41 74P Front Suspension EDGE CRC 156 19 39 72P FrontShocks Nitrex or Ryde FX IER Reverse 45 Option IFS Spring Rate 1004 in Brake Pads Type 81 Large Front Spring Preload Nitrex 3 4 Thread Adjust Chaincase Center Dist 7 05 17 91cm Ryde FX IFP 3 13 16 Thread Adj Driveshaft Sprockets 2 Drivers Wide Front Vertical Travel 7 2 7 6 18 3 19 3cm Brake Type Polaris HPB Liquid Cooled Rear Suspension EDGE RMK Rear Axle Travel 144 17 43cm 151 17 5 44 5cm 156 18 46cm Front Track Shock Nitrex or Ryde FX IFP Rear Track Shock Selector Ryde FX I
7. Idler Wheel Rear Track Shock ront Track Shock Front Torque Arm N Wa A NAN SS PE OCL e N SEND y gt E NIPA ei Rail Bumper Slide Rail SUSPENSIONS EDGE RMK Exploded view Rear Torque ARm Front Torque Arm gt POLARIS 7 12 SUSPENSIONS Suspension Adjustment The EDGE RMK and XTRA Lite suspension has been designed and set up to deliver a soft ride under average riding conditions Rider weight riding styles trail conditions and vehicle speed each affect suspension action The suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of condi tions It should be noted however that suspension adjustments involve a compromise or trade off A machine set up to perform well in the moguls would not suit the preference of a groomed trail rider Adjustable Features and Adjustment Options SRear torsion spring preload S Optional coil springs for front track shock and spring preload washers or threaded collar S Optional torsion springs SFront limiter strap S Optional coil springs for IFS shocks SAdjustable Compression damping on Ryde FX or Indy Select rear track shock Adjustment Procedures It is a good idea to break the suspension in for approximately 150 miles 240 km and re grease all suspension parts before fine tuning adjustments are made All settings will vary from rider to rider depending on rider weight vehic
8. 44 48 ft lbs 60 66 3 Nm A ENGINES Torque Sequences EC55 Engines CYLINDER HEAD O sib G 0 ae CYLINDER BASE o oU e 9e Ig CRANKCASE TWIN CYLINDER Fuji E 3 2 omestic 500 omestic omestic Gs POLARIS 3 3 A ENGINES Torque Sequence Domestic 600 700 800 E Aen ZI 15 DD o VO DO CYLINDER HEAD Domestic Twins 600 700 800 CRANKCASE Domestic Twins 600 700 800 SES Ww S Uo Y Domestic Twins 600 700 800 ENGINES O Engine Removal Typical 1 On some models it may be necessary to remove the hood for easier access to engine components or to prevent damage 2 Disconnect battery ground from battery if applicable Shut off fuel E Ground Cable Pa o 6 BN 3 Remove fuel pump or CDI from airbox if applicable 4 Remove airbox A ENGINES Engine Removal Typical Cont 5 Free recoil rope from chassis NOTE Be sure to tie a knot in recoil rope upon removal so rope doesn t wind up into recoil housing 6 Loosen clamps at carburetor mounting flange Pull carbs from adaptors and secure out of the way Note routing of all cables and hoses for reassembly 7 Disconnect oil pump control cable 8 Disconnect and plug oil supply line TIP A bolt or spare water trap plug can be used to plug the oil line from the oil reservoir 3 6 Gp POLARIS ENGINES O Engine Removal Typical Cont 9 Remove drive b
9. If shock eyelet is removed for damper rod replacement clean threads of eyelet and damper rod thoroughly with Loctitet Primer N Apply Loctitet 262 to threads before assembly Gp POLARIS 7 35 SUSPENSIONS Ryde FX t Valve Washer Part Numbers Foxt Part Numbers can be found on pg 7 26 Polaris Thickness Diameter 1700080 0 004 700 1700081 0 006 700 1700082 0 008 700 1700083 0 010 700 1700084 0 012 700 1700085 0 015 700 1700086 0 004 800 1700087 0 006 800 1700088 0 008 800 1700089 0 010 800 1700090 0 012 800 1700091 0 015 800 1700092 0 004 900 1700093 0 006 900 1700094 0 008 900 1700095 0 010 900 1700096 0 012 900 1700120 0 015 900 1700121 0 006 1 000 1700122 0 008 1 000 1700126 0 010 1 000 1700127 0 012 xm 1 000 1700128 0 0152 i 1 000 1700129 0 006 1 100 1700130 0 008 1 100 1700131 0 010 1 100 1700132 0 012 1 100 1700133 0 015 1 100 1700134 0 006 1 250 1700135 0 008 1 250 1700136 0 010 1 250 1700137 0 012 1 250 1700138 0 015 1 250 1700139 0 006
10. 10 Apply thread sealant install brake line and tighten snug 11 Mount the master cylinder and switch pack to the handlebars making sure the wires are not pinched or twisted NOTE Startall four screws prior to tightening Tighten top two screws first followed by bottom two Do not over tighten This will create a gap approximately 050 100 between LH control and master cylinder at the bottom ofthe assembly There should notbe a gap at the top when correct tightening torque sequence has been followed Torque to 24 28 in lbs 2 7 3 2 Nm Master Cylinder Control Torque 24 28 in Ib 2 7 3 2 Nm BRAKES FINAL DRIVE Es 12 Tighten brake line connector at outlet to 1 ft lbs plus two turns Brake Line Torque 1 ft Ib 1 4 Nm plus 2 turns 13 Fill reservoir with clean D O T 3 brake fluid Polaris DOT 3 Brake Fluid PN 2870990 14 Bleed brakes as outlined on pages 8 10 and 8 11 Check entire system for leaks and fill reservoir to fluid level line 15 Install master cylinder reservoir cover and gasket Torque screws to 15 18 in lbs 1 7 2 0 Nm Cover Screw Torque 15 18 in Ib 1 7 2 0 Nm Es BRAKES FINAL DRIVE Lever and or Pivot Pin Removal 1 For ease of service remove master cylinder assembly as outlined on pages 8 11 and 8 12 2 Squeeze the lever handle and actuate the parking brake lever enough distance for the head of the pivot pin to clear the park brake le
11. Drive Clutch Bolt Torque Large ID Shaft 3 4 40 45 ft Ibs 55 2 62 1 Nm Drive Clutch Bolt Torque Small ID Shaft 14mm 7 16 50 ft lbs 69 Nm NOTE Re torque clutch to specification after first period of operation such as a test ride 5 20 Gp POLARIS DRIVE DRIVEN CLUTCHES Spider Indexing NOTE S pider indexing affects clutch balance and belt to sheave clearance Read procedures carefully before proceeding 1 Before disassembling drive clutch mark spider cover moveable sheave and stationary sheave in line with a permanent marker as shown 2 Disassemble drive clutch as described starting on page 5 13 Take care to note the amount and thickness of the shim washers under the spider 3 Add or remove spider washers as required to achieve desired belt to sheave clearance S Forexample If beltto sheave clearance is 020 too large removing one 020 shim will position the movable sheave closer to the fixed sheave reducing belt to sheave clearance by 020 NOTE The following washers are available for fine tuning Washers PN 5210754 050 PN 5210753 032 PN 5210752 020 4 Install spider washer s and spider aligning Xs Notice as the spider seat location is changed the sheave marks made before disassembly no longer align There are two ways to bring the sheave marks into alignment S Vary the amountand thickness of spacer washers Washer thickness may vary slight
12. 1 375 Compression Distance in Driven Clutch Spring Data Part Number Description Free Load at Load at Moment at Moment at Length 2 50 Ibs 1 375 67 Rota 150 Rota Ibs tion in Zs tion in Zs a we us sofa 9 a 1 a ow us 38 9 7 mer aora um 35 wf DRIVE DRIVEN CLUTCHES P 85 Drive Clutch Do not lubricate drive clutch components Washer mut Roller a a Weight w B ushing rH po Vi m i Weight P in Clutch Assembly Less weights spring Fixed Sheave Replacement clutches come complete and balanced without clutch weights and clutch spring The clutch cover spider and sheaves cannot be purchased separately as replacement parts DRIVE DRIVEN CLUTCHES P 85 Driven Clutch Do not lubricate driven clutch components except inside of ramp helix hub to reduce fretting and corrosion Stationary Sheave Driven Cap Driven Plate Driven Bushing Adjustment Cam mg m e Washer Pin Button Screw Moveable Sheave v Clutch Assembly Replacement driven clutches come complete with ramp and spring The moveable and station ary sheaves cannot be ordered as separate service parts DRIVE DRIVEN CLUTCHES The Polaris drive system is a centrifugally actuated variable speed belt drive unit The drive clutch driven clutch and belt make up the torque converter system Each clutch comes from the factory with the proper i
13. Wash the shock body in parts cleaner then dry with compressed air to remove sand and dirt WARNING When using compressed air to dry com ponents protective eyewear should be worn to avoid risk of injury Remove bearing sleeve and or bushings from lower shock mount eyelet Secure the lower mount of the shock in a vise The use of soft jaws is recommend to prevent damage or marks to the shock PICTURE 2 CAUTION It is important that the gas shock be re tained in the vise by the lower mount Any other meth od of securing the shock body during these proce dures may deform the shock body cylinder Remove the small button head screw from the pres sure valve assembly PICTURE 3 Depressurizing shock A Internal Floating Piston Shocks P N 7041990 Using a slotted screwdriver loosen the pressure valve assembly counter clockwise two full revolutions al lowing the gas pressure to fully escape pastthe pres sure valve assembly O ring SUSPENSIONS B Emulsion Shocks P N 7041992 With the shock inverted and the piston rod fully extended secure the lower mount of the shock in a vise Allow a couple of minutes for the gas pressure to separate from the oil and rise to the top Using a rag as a shield to prevent spraying gas and oil place rag over top the pressure valve assembly and slowly loosen the valve assembly with slotted screw driver three full revolutions allowing all the gas pressure to escape past the pre
14. 12 7mm up from bottom of skirt DOMESTIC ENGINES Measure 3 8 10 0mm up from bottom of skirt Piston to Cylinder Clearance Refer to specifications in chapter 1 for specific models Piston Ring Installed Gap Refer to specifications in chapter 1 for specific models Important Always verify piston to cylinder clearance and piston ring installed gap prior to assembling an engine O ENGINES Crankcase Inspection Bearing Fit Any time crankshaft bearing failure occurs and the case is to be reused Polaris recommends check ing the bearing fitinto the case halves using the fol lowing procedure 1 With case halves cleaned press a replacement bearing into each of the main bearing journals to determine a basic amount of press fit NOTE Do a comparison check of all journals by manually forcing the bearing into the bearing seats noting if any are noticeably loose or tight Normal hand installation will be an indication of the recommended interference fit If the bearing falls out of the case when the case is inverted orif the crankcase bearing surface is severely galled or damaged the case should be replaced Crankcase Bearing Interference Fit C 3 0006 015mm C 4 001 025mm Crankshaft Main Bearing Inspection 1 Clean crankshaft thoroughly and oil main and connecting rod bearings with P olaris Premium 2 engine oil Carefully check each main bearing on the shaft NOTE Due to extremely clos
15. 15 Assemble engine mount straps to crankcase Engine Mount Strap Torque 44 48 ft Ibs 60 66 Nm 16 Lubricate main bearing oil holes with Polaris Premium 2 Cycle or Premium Gold engine oil and rotate crankshaft to distribute oil evenly 17 Install a new C clip in both pistons inside with gap facing down Be sure clip is fully seated in groove 18 Lubricate and install new connecting rod small end bearing in rod 19 Install piston with arrow facing exhaust ring locating pins should be facing intake Warming the piston may help to ease installation of pin 20 Install remaining C clip with gap down Be sure both clips are fully seated in the groove 21 Install new base gasket Be sure gasket surface is clean and free of nicks burrs or scratches 22 Lubricate and install piston rings on piston with mark on end of ring facing upward Up Straight Edge 7 IA 23 Place piston support under skirt and lubricate pistons and cylinders thoroughly 24 Align ring end gaps with locating pins and compress rings Install cylinder carefully with a gentle front to rear rocking motion Install cylinder base nuts loosely Do not tighten them at this time Repeat Steps 22 25 for other cylinder Keystone Piston Ring Piston Ring Cutaway CAUTION Do not twist or force cylinder during installation 25 Install new cylinder head O rings and install cylinder head Make sure O rings are properly s
16. IL 11 Set IFP tool to specified depth with a dial caliper as shown IFP Tool PN 2871351 Fox Shock Maintenance Assembly Cont 12 13 14 15 Place a shop towel over the end of IF P tool and slowly push IFP to specified depth With the IFP set and the bleeder screw removed slowly stroke shock to force air through piston oriface Move the shock body slowly to prevent aeration of the oil Allow all air to purge through the bleeder screw hole Install the bleeder screw with a new O ring and tighten securely using the flats on the tool to prevent the IFP from turning Pour out excess oil It is not necessary to completely clean all oil from the nitrogen chamber a small amount of oil will lubricate the IFP Verify the proper IFP depth to within x 025 63mm with a dial caliper Be sure to measure to the flat portion of the IFP notto the tapered outer edge Reinstall body cap with a new O ring and tighten by hand Mount shock with body cap end down in the soft jaws of a vise Torque bearing cap to 8 10 ft Ibs 11 14 Nm This will also tighten the body into the body cap CAUTION Do not over tighten or damage to the bearing may result Bearing Cap Torque 8 10 ft Ibs 11 14 Nm Gb POLARIS SUSPENSIONS 7 33 SUSPENSIONS Fox Shock Maintenance Assembly Cont 16 Install pressurizing valve with new O ring and tighten 17 18 19 securely Setth
17. Jam Nut Torque P85 models only 235 ft Ibs 324 3 Nm Jam Nut Tool PN 2870338 Weight Pin Nut Torque 30 In Lbs 3 4 Nm DRIVE DRIVEN CLUTCHES Assembly Cont 5 Install spring and cover Torque cover bolts evenly to specification CAUTION Carefully align bushing with shaft during installation of coverto prevent bushing damage Maintain alignment by tightening cover bolts evenly and carefully Spider Cover Bolt Torque 90 in Ibs 10 3 Nm Installation l Slight galling or scoring of the bore taper can usually be corrected using a tapered reamer P lace reamer in a vise and lubricate with cutting oil Clean taper by manually rotating clutch clockwise Tapered Reamer PN 2870576 2 Check crankshaft taper for galling or scoring If necessary clean taper evenly with 200 grit emery cloth 3 Both clutch taper and crankshaft taper should be clean and dry NOTE Do not use harsh cleaners which may cause clutch taper to corrode during use This will cause diffi culty when removing clutch in future Clean clutch taper with lacquer thinner or isopropyl alcohol Gp POLARIS 5 19 DRIVE DRIVEN CLUTCHES Installation Cont 4 Slide clutch fully onto crankshaft taper 5 Install retaining bolt with any spacers washers or O rings See appropriate parts manual for type and placement of retaining bolt components 6 Torque retaining bolt to specifications Hold clutch with strap wrench
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19. 3900 RPM Cylinder Head Torque Cylinder Base Nut Torque Crankcase Torque 8mm 1 24 18 22 ft lbs 25 30 Nm 30 34 ft Ibs 41 47 Nm 20 24 ft lbs 28 33 Nm Cylinder Head Mark 3021022 0 014 0 020 0 36 0 51mm Flywheel Torque90 ft Ibs 124 Nm Gp POLARIS GENERAL INFORMATION d MODEL 700 EDGE RMK 136 144 151 MODEL NUMBER SO2NJ 7CS SO2NK7CSA SO2NK7CS SO2NL7CS ENGINE MODEL 52190 7070PL7C ELECTRICAL CAPACITIES Flywheel I D Kokusan 4010629 FuelTank 11 8 gallons 44 7 liters CDI Marking 4010553 Oil Tank 3 25 quarts 3 1 liters Alternator Output 280 Watts Coolant 4 3 quarts 4 1 liters Ignition Timing 18 BTDC 2500RP M 500 Chaincase Oil 11 fl 0z 325cc With TPS Unplugged 0 0815 BTDC 2 0705mm BTDC Spark Plug Gap Champion RN57YCC 0 025 0 64mm Voltage Regulator LR7 Electric Start Option LR7 Full wave voltage regulator Magneto Pulses 6 SUSPENSION CHASSIS CHAINCASE Body Style EDGE Sprockets Chain 21 41 74P HYVO 136 Front Suspension EDGE 19 39 72P HYVO 144 151 Front Shocks Nitrogen Cell Reverse ssa Option IFS Spring Rate 1004 in Brake Pads Type 81 Large Front Spring Preload 3 4 Thread Adjust Chaincase Center Dist 7 05 17 91cm Front Vertical Travel 7 2 7 6 18 3 19 3cm Driveshaft Sproc
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21. Do not lubricate bushings or premature wear will result DRIVE DRIVEN CLUTCHES P 85 Driven Clutch Movable Sheave Large Bushing Removal NOTE The P 85 driven moveable has a split bushing Note the position of this split during bushing removal See Ill 1 Note position of split Moveable Sheave Bushing Inspection Replace the cover bushing if more brass than Teflon is visible on the bushing 1 Inspect bushing and replace if excessively worn 2 Insert bushing removal tool Item 6 into sheave Bushing centering split on tool NOTE The split must be removal tool touching the tool See Ill 1 3 Install main adapter as illustrated Install bridge Item 7 onto puller with legs pointing toward clutch See Ill 2 4 From the outside insert thumb through center of sheave Using downward pressure hold bushing removal tool tightly in place 5 With back side toward vise slide sheave onto puller 6 Install nut onto puller rod and hand tighten Slowly align clutch with bridge and turn puller barrel to increase tension if needed 7 Turn sheave counterclockwise until bushing is removed and sheave comes free 8 Remove nut from puller and set aside 9 Remove tool and bushing from puller Discard bushing 10 Remove bridge and adapter from puller DRIVE DRIVEN CLUTCHES P 85 Driven Clutch Movable Sheave Large Bushing Installation NOTE The P 85 driven moveable has a split bushing The bus
22. Gp POLARIS Filter Filter is located before the check valve MAINTENANCE TUNE UP fed Filter Lift Lock Lever To Bleed Remote Filler Neck Bleed at 600 RPM Caution Increase RPM Slowly when lever lock is up to avoid loss of coolant Manifold Bleed Screw Fill Surge Tank 2 11 MAINTENANCE TUNE UP When performing the following checks and adjustments stay clear of all moving parts to avoid serious personal injury Track Maintenance Never make this maintenance check with the engine running as se rious personal injury can result Using a hoist safely lift and support the rear of the snowmobile off the ground Rotate the track by hand to check for any possible dam age To inspect track rods carefully examine the track along the entire length of each rod bending the track and inspecting for breakage The three most common places where breakage occurs are shown in the illustration If any rod damage is found the track should be replaced Broken track rods are a serious hazard since they can cause a ro tating track to come off the machine Never operate or rotate a torn or damaged track under power Serious personal injury or death may occur Track Alignment Track alignment affects track tension Misalignment will cause ex cessive wear to the track hifax and slide rail A periodic check should be made to see that the track is centered and running evenly on the slide rails NOTE If exc
23. How to Adjust Rear Suspensions a 7 20 Rear SUSPENSION 5prings vuevserxadupesesax exer Yd 1 21 IFS Springs Xtra 10 Xtra Lite EDGE RMK 7 22 Stock Shock Valvihg x23 Bree ada e ER ER i Se od 7 23 7 24 FOXE QVOIVIOW ead atte e aate E hg 7 25 Foxt Valving Part Numbers iiis Za re xa kA 7 26 Foxt Mee Ee aa PREPARES 7 27 7 35 Ryde FXt Valving Part Numbers aa 7 36 Ryde FXt Maintenance 7 37 7 44 Troubleshooting BEER 7 45 7 47 SUSPENSIONS Refer to Specifications Section in Chapter 1 for Suspension Type Model Application Rear Suspension Operation The primary function of the rear suspension is to provide a comfortable ride in all types of riding conditions It separates the rider from the ground while allowing for complete vehicle control The rear suspension also must provide weight transfer and maintain track tension The rear suspension has many adjustable features for fine tuning to achieve optimum comfort The suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions Itshould be noted however that suspension adjustments involve a compromise ortrade off A machine setup to perform well in the moguls would not suit the preference of a groomed trail rider Weight Transfer The shifting of weight from the skis to the track is called weight transfer As engine torque is ap plied to the drive axle the torque is
24. Make sure skis are aligned properly straight forward with rider on machine Make sure spindles and all steering components are free turning Make sure skags are straight on skis Check hi fax and replace if worn Reduce ski pressure Dincrease front track spring preload DR educe IFS spring preload if shims have been added DR educe rear torsion spring preload Front end pushes Check for worn skags Check for binding suspension shafts and grease all pivot points Increase IFS spring preload by adding shims Steering is heavy Check ski alignment Check skags and skis for damage Reduce ski pressure Dncrease front track spring preload DR educe IFS spring preload if shims have been added DR educe rear torsion spring preload Setting up for deep snow operation Change worn hi fax Lower front and rear torque arms see P erformance sec tion at the back of this manual SUSPENSIONS Suspension Troubleshooting XTRA 10 Style ron Rear suspension bottoms too easily Increase torsion spring preload Increase rear shock compression valving by turning screw clockwise if equipped with optional Indy Select shock or refer to optional valving on Suspension Wall chart for Fox equipped models Change RRSS to highest setting Rides too stiff in rear Check for binding suspension shafts and grease all pivot points Decrease torsion spring preload adjustments Decrease rear shock compression valving by turning screw counterclo
25. Overall Snowmobile Length 116 295cm Overall Snowmobile Height 45 114cm Maximum Snowmobile Width 43 5 110 5cm OPTIONAL REAR TORSION SPRINGS STD 405 Sq Diameter x 77 L H 7041655 067 R H 7041655 067 d GENERAL INFORMATION MODEL sanan INDY 500 RMK MODEL NUMBER SO2SR5AS ENGINE MODEL 52186 5044PL5A JETTING CHART AMBIENT TEMPERATURE C A R B U R E TIO N f Below 30 F 30_to 10_F 10 to 410 F 410 to 430 F 430 to 50_F Above 50_F f Altitude Below 34 C 34 to 23 C 23 to 12C 12to 1C 1to 10 C Above 10_C TyDe we cid tata ade TM38 Mikuni MainJet 270 0 600 440 220 MO 390 380 370 PilotJet 45 0 2000 43 8 18 8 3 8 Jet Needle 9FH4 57 2 AN SEH 380 370 350 340 320 Needle et P 6 NE Lui m E NAA AH CEN Cutaway iii ee ena 1 5 Notched Feet 4000 6000 e P 2 e P Fuel Screw 0 5 Turns SS 300 290 280 270 260 250 Valve Seat 1 5 Viton 2 2 2 2 2 Fuel Octane R M 2 87 Non Oxygenated SE 280 210 260 250 240 230 89 Oxygenated Throttle Gap 3000 3700 260 250 240 230 220 210 10000 12000 2 2 2 2 2 2 Under Cutaway 0 130 3 3mm StarterJet 155 Pilot Air Odia 0 7 Long refers to the clip position from top of jet needle CLUTCH TVDe sese Ros gota P 85 CLUTCH CHART Be
26. PE 9 Ter Fuel Screw G S etNeedie C Main Pilot et F Ol Jet py Starter J et B gt N 3 E Plunger f SE f Pilot Air J et A CS amp Seat d Asm H Needle J et D C Float Body Hl 1 g The part numbers for main jets and pilot jets are the same as Mikuni VM round slide carburetors The advantages ofthe TM flatslide system include improved throttle response and a significant reduction in throttle effort due to rack style carbs and the use of cable cam The following are the main components of TM carburetors and the functions of each PilotAir et A The pilotairjetcontrols the amountof air entering the engine in the idle circuit The pilotair jetsize is imprinted on it Bigger pilot air jets allow more air to enter leaning the idle mixture If engine loads up at idle first try turning fuel screw in If not correct try larger pilot air jet Starter et B The starter jet s function is to meter fuel entering the engine when choked Larger numbered starter jets pass more fuel therefore more fuel will enter the system when jetting to a larger size Like the pilot air jet the jet size is imprinted J etNeedle C The jetneedle performs the same functions as on Mikuni VM carburetors However the needles in the TM 38 carburetors are longer and are not interchangeable with VM needles To raise or lower the needle remove the top cap D and loosen the 2 5mm allen screw holding the needle in place Reach inside w
27. PVT Drive Belt Inspection and Maintenance 2 15 Headlight Inspection and Replacement 2 16 HandlebarAdJustfie nbus bee RP OPE Dt ES 2 17 Brake Systems Inspection and Adjustment 2 18 Throttle Lever Freeplay Adjustment 2 19 General Cleaning and Lubrication Recommendations 2 20 2 22 1500 Mile 2400 km Maintenance Inspection _14 17 18 19 20 15 _16 E Check cylinder head and base area for signs of exhaust or coolant leaks Re torque cylinder heads amp cylinder base nuts cold Check compression and record readings Check ignition timing EA observed BTDC ES corrected BT DC Inspect recoil starter rope Check drive to driven clutch offset belt removed Remove clutches disassemble amp inspect all wear surfaces Clean sheaves repair clutch as necessary reassemble clutches and torque to specifications Check belt condition Check and adjust belt deflection Inspect rubber engine mounts Torque engine mounting plate to chassis fasteners Adjust engine torque stop if equipped 0 10 0 30 Carburetor Inspections A Adjust choke plungers B Adjust pilot air screw C Synchronize carburetor slide valves at idle and off idle D Adjust engine idle RPM E Adjust throttle lever free play F Synchronize oil pump lever G Inspect Choke Throttle Cables H Inspect vent lines for wear or kinking Remove chaincase
28. Place caliper on bench with piston down 7 Remove piston from caliper using a caliper piston pliers commercially available or by covering the piston with a shop cloth and applying compressed air to the hydraulic inlet port CAUTION Use only enough air to remove piston Too much pressure may damage piston or bore 8 Using a small wooden or plastic stick work piston seal out from its groove in the piston bore CAUTION To avoid scratching bore or burring edge of seal groove do not use a metal tool such as a screwdriver 9 Discard old seal BRAKES FINAL DRIVE Es Hydraulic Brake Cleaning and Inspection Check all parts for wear or damage and replace as required Always replace caliper piston seal and dust seal where applicable 1 Clean all parts with denatured alcohol and wipe dry with a clean lint free cloth 2 Using compressed air blow outthe drilled passages and piston bore Be sure piston seal groove is thoroughly clean and free from corrosion or brake fluid build up 3 Inspect piston bore for scoring pitting or corrosion A corroded or deeply scored casting should be replaced Lightscores and stains may be removed by polishing with a crocus cloth only Use finger pressure and rotate the crocus cloth in the cylinder bore Do not slide the cloth in and out of the bore under pressure Do notuse any other kind of abrasive cloth 4 Check piston to see if it is pitted scored or worn If so d
29. SUSPENSIONS WARNING When using compressed air to dry components protective eyewear should be worn to avoid risk of injury Place the shock piston rod upper mountin bench vise begin piston and valve removal Arrange parts removed in the sequence of disassembly Items to inspect Piston rod for straightness nicks or burrs Cylinder Head Assembly DU Bearing Seals and Scraper clean inspect or replace Inside of shock body for scratches burrs or excessive wear Teflon piston and F P wear band for cuts chipped or nicked edges or excessive wear O rings for nicks cuts or cracks Valve discs for kinks or waves Hard line and fittings for leaks kinks worn of loose threads Should any of these items be in question replacement is recommended ASSEMBLY Place the piston rod upper mountinto the vise Reassemble damper rod assembly in the reverse order of disassembly S pecial attention should be paid to the order of the Rebound and Compression disc shim stacks ensuring that they are in the same order prior to disassembly Tighten the lock nut to 15 20 ft lb of torque CAUTION DO NOT OVER TORQUE If excessive torque is applied damage to the piston and valves will occur Secure the lower mountofthe shock in a vise The use of softjaws is recommend to preventdamage or marks to the shock CAUTION Itis importantthatthe gas shock be retained in the vise by the lower mount Any other meth od of securing the shock body d
30. Seat Gasket He NAY i d5 Drain Plug e 5 Gp POLARIS 4 7 O FUEL SYSTEM CARBURETION Altitude Compensating Carburetor System ACCS Do not change calibration setting or serious engine damage may result ACCS valves cannot be interchanged between models When replacing a faulty valve be sure the identification number stamped on the valve body is correct FUEL SYSTEM CARBURETION O Altitude Compensating Carburetor System ACCS The Altitude Compensating Carburetor System ACCS is designed to automatically compensate for changes in altitude This allows the snowmobile to operate in changing elevations without having to change jets although extreme temperatures may require re jetting for optimum performance Refer to the jetting compensation chart in the specifications sections A vacuum line is connected to the float bowl The ACCS valve is connected to this line via the 4 way manifold Atlow altitude the ACCS valve supplies atmospheric pressure to the vacuum line and the float bowl see Ill 1 At high altitudes the bellows expand moving the plunger to the left and closing off some of the passageways through the ACCS valve see Ill 2 This prevents atmospheric pres sure from reaching the floatbowl allowing the vacuum line to reduce the pressure in the float bowl This reduces the amount of fuel sup plied through the carburetor preventing the mixture from becoming too rich NOTE
31. The venturi shape can be adjusted for each engine s breathing characteristics by using a different valve cutaway angle A number will be stamped into the bottom of the valve e g 2 5 indicating the size of the cutaway The higher the number the steeper the angle Leaner mixture Throttle Valve et Needle By pass Pilot Outlet Pilot J et Needle J et Main J et Leaner Richer Throttle Valve The throttle valve controls the rate of engine air intake by moving up and down inside the main bore Atsmall 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 Da according to the size of the cutaway The higher the ES number the leaner the gasoline air mixture Cutaway Tel FUEL SYSTEM CARBURETION The jet needle and needle jet have the most effect be tween 3 8 and 3 4 throttle opening Some mixture adjust ment can be accomplished by changing the location ofthe E clip on the needle Moving the clip down raises the needle in the jet passage and richens 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 jetindicating sizes and tapers needles only of each J et Needle Needle J et Fig 1
32. This oil change is necessary to avoid any chance of corrosion which could be caused by moisture contamination For competition use shocks should be disassembled inspected and serviced more fre quently When performing maintenance on Fox Shocks use Gas Shock Recharging Kit P N 2200421 Itconsists of the necessary valves pressure gauge and fittings to deflate and pressurize the shocks The Body Holder Tool Inter nal Floating Piston IFP and Shock Rod Holding Tool are notincluded in the Recharging Kit and must be ordered separately Refer to your Victor Specialty Tool catalog for part numbers Gas Shock Recharging Kit PN 2200421 Extreme caution should be observed while handling and working with high pressure service equipment Wear a face shield safety glasses and ear protection during service of these shocks Care should be observed while handling the inflater needle and pressure gauges Maintain your equipment and keep it in good condition If injury should occur consult a physician immediately Extreme cleanliness is of utmost importance during all disassembly and reassembly operations to prevent any dirt or foreign particles from getting into the shocks Keep the parts in order as they are disassembled Note the direction and position of all internal parts for reas sembly Bleed Screw 1 Body WA Ca SE EE o ER kakai Cam Shock Body 5 Retaining Ring bA Spring Retainer Body e CO E DIA Damper Rod gt
33. Turn clutch cover counterclockwise on puller rod until bushing is removed 9 Remove nut from puller rod and set aside 10 Remove bushing and bushing removal tool from puller Discard bushing P 85 Drive Clutch Cover Bushing Installation 1 On Garmax style bushings PN 3576516 apply Loctite 680 retaining compound P N 2870584 to the outer surface of the bushing Do not lubricate bushings or premature wear will result 2 Working from inside of cover insert bushing and bushing installation tool into center of clutch cover 3 With main adapter on puller insert cover onto puller rod placing outside of cover toward vise 4 Install nuton rod and hand tighten Turn puller barrel to apply more tension if needed 5 Turnclutch covercounterclockwise on puller rod until bushing is seated 6 Remove nutfrom puller rod and take installation tool and clutch cover off rod 7 Squeezing ends ofsnapring gently fitring into clutch cover P 85 Drive Clutch Movable Sheave Bushing Removal 1 8 9 10 DRIVE DRIVEN CLUTCHES Piston Pin Inspect bushing and replace if excessively worn Puller Item 1 Install handle end of piston pin puller PN 2870386 securely into bench vise and lightly grease puller threads Remove nut from puller rod and set aside Install main adapter Item 8 onto puller See Ill 1 Main Adaptor Working from inside of moveable sheave insert removal tool Item 1 into center o
34. compressed air 2 Apply 3 Bond 1215 sealant to upper crankcase half NOTE se only 3 Bond 1215 sealant Curing time and film thickness are critical for proper bearing clear ance 3 Bond 1215 PN 2871557 120 Gram Tube 3 Setcrankshaft in lower crankcase Lubricate seal lips with Premium All Season Grease Make sure seals are positioned properly with lip and spring facing inward toward crankshaft Install snap rings with gap facing upward toward upper case half NOTE When installing a crankshaft on a 800 twin en gine apply Loctitet 609 to the PTO bearing surfaces and bearing seats Allow for 12 to 24 hours for the Loc titet to cure before running the engine 3 42 Gp POLARIS ENGINES O Assembly Cont 4 If studs were removed or new crankcase installed apply Loctite 242 to threads of studs and screw in until bottomed Tighten securely 5 Measure installed length of stud bolt This is the length necessary to allow cylinder installation Lower Crankcase Stud Height 121 124 mm 4 76 4 88 from crankshaft parting line 6 Install crankcase halves together Torque bottom crankcase bolt to specification in the proper sequence found in the beginning of this chapter 7 Install new O rings on water manifold Grease O rings and install manifold au oral I 8 Install pistons and rings Make sure C clips are firmly seated in grooves NOTE Keystone ring bevel must be up Marking
35. necessary 9 28 Gp POLARIS ELECTRICAL Notes 9 29 CHAPTER 10 WIRING DIAGRAMS A Alignment Bar Specifications 6 6 Battery Charging 9 11 Battery Filling 9 11 Battery Storage 9 11 Battery Testing 9 10 Belt D eflection 5 31 Belt Inspection 2 15 Belt to Sheave Clearance A djustment 5 35 Belt to Sheave Clearance Inspection 5 35 Belt Wear Burn Diagnostics 5 30 Belt Wear Burn Diagnosis 5 30 5 43 Brake A ssembly 8 23 8 24 Brake Bleeding 2 18 Brake Bleeding Fluid Change 8 9 8 10 Brake Cleaning and Inspection 8 23 Brake Fluid Replenishment 2 18 Brake L ever and Pin Replacement 8 16 8 17 C Camber A djustment 6 11 Camber A djustment CRC 6 16 6 17 Camber D efinition All IFS 6 7 Carbide Placement 6 18 Carburetor L eak Testing N eedle and Seat 4 23 Chaincase Oil L evel 2 8 Chaincase Specifications 8 1 Choke A djustment 4 32 Clutch Alignment A djustment 5 34 Clutch A lignment Inspection 5 34 Clutch Offset A djustment 5 33 Clutch O ffset nspection 5 33 Connecting Rod Big End Inspection 3 51 Connecting Rod Small End Inspection 3 51 Coolant L evel 2 11 Cooling System 3 62 Cooling System Bleeding 2 11 3 62 Cooling System D iagram 3 64 3 65 3 66 Crankcase Inspection 3 50 Crankshaft Bearing Inspection 3 50 Crankshaft Indexing 3 54 3 55 Crankshaft Truing 3 52 Cylinder Cleaning 3 48 Cylinder D eglazing 3 47 Cylinder H ead Ins
36. position Slide ski forward so spindle is behind ski saddle A Apply soapy water solution to the rear portion of the rubber ski stop Install ski stop on top of ski saddle with large portion forward Push ski back to slide spindle into place From outside of ski install bolt and castle nut Torque to 36 ft lbs Install cot ter pin and bend both legs PLASTIC SKI INSTALLATION Install metal support onto ski stop Install ski stop with tall portion toward rear of ski Install cotter pin and bend both legs as far forward in the ski as possible If adjustments are neces sary re torque screws to 18 20 ft lbs 2 48 2 76 kg m Ng L Ensure retainer is pushed Lo E SC BODY AND STEERING Ski Spindle Finbar SE Ski ANA TIN E Ss TERN E Ski Saddle Rubber Ski Stop Forward E RMK models with this type of ski stop will not require the use of the metal support The 90 flat portion of stop should face toward the front of the ski NG L Long saddle skis with this type FE of ski stop will require the metal AA A G support The 90 flat portion of stop ps 7 should face toward the front of the Z sA ski N Install Ski to spindle From outside of ski install bolt washers and castle nut Torque to 36 ft lbs 4 97 kg m NOTE On RMKs the side of the ski with the lip goes refully r machin to the inside Carefully lower machine SD POLARIS 6 2
37. 0787 TEE 0938 E SD e EE 3 mm 3 1181 1 8 casas 1250 EE 1406 IL e EE 4 mm 3 1575 11 64 cts emt 1719 TU WEE 945 EE 5 mm 1969 IE AA 2031 1 325 2 casa Ka uiuo quise Sela 2188 tree EE 6 mm 2362 1 4 enn 25 Lo ee pe etis LODO cst s 7 mm 2 2756 9 32 Sese coeno tat 2813 19 62 nees mee eie Na naat 2969 E EH 8 mm 2 3150 LUIS iia coc 3281 LU AA Aa EE 9 mm 2 3543 LIA E a 3594 Oriana delas 375 25 047 E ee Orito 10 mm 3937 1332 icons 4063 24 04 i v xaX xixka 4210 E LER 11 mm 2 4331 TILG a 4375 29 04 ee palng teme canes 4531 15 32 ir a 4688 een 12 mm 2 4724 31 64 KEE 4844 l2 cxx Dis sve LEES 13 mm 5118 CEL AA 5156 UE 5313 Ch AA AA 5469 ies 14 mm 2 5512 QING inna 5625 EE EE 15 mm 2 5906 19 32 Ze 5938 39 64 cce E 6094 KI D c eee 16 mm 6299 AV OA EE 6406 21 32 Lis 10003 cara 17 mm 6693 43 04 riceve e 6719 11 167 re 6875 ASA PAA AA O3 Totes 18 mm 7087 EE 7188 ve RE EE 19 mm 7480 Mi io 75 e 7656 TEE Aa 20 mm 7874 KEEN 7969 iia reas 9125 1 ka te dotes 21 mm 3 8268 OD E 8281 LU ts 8438 e ODO teg Bina 22 mm 8661 HEEN 875 KEE 0900 EE 23 mm 3 9055 29 327 Dami oa ial ed s aa a 9063 59 64 EELER 9219 15 16 esas E EE 24 mm 9449 UA aaa 9531 31 32 x cesitewe ze tuis 9088 ioco as deese ces 25 mm 2 9843 0 0 e RENE 9844 d GENERAL INFORMATION SAE Tap Drill Sizes 3 27 64 29 64 31 64 33 64 17 32 37 64 21 32 11 16 49 64 13 16 7 8 5
38. 136 144 151 MODEL NUMBER SO2NJ 7CS S02NK7CSA SO2NK7CS SO2NL7CS ENGINE MODEL 52190 7070PL7C JETTING CHART CARBURETION 3 d AMBIENT TEMPERATURE Type Ka KA EE EE KA TM 40 w TPS M ikuni Altitude Below 20 30 to 10F 10 to 10 F 10 to 430 F 30_to 50_F Above 50_F M ain J et TEASE SE 350 elow 34 to 23 C 23 to 12 C 12 to 1_C 1 to 10_C Above 10_C Plotters dd 45 cu o 280 260 230 Go SS Jet Needle 9DGJ 2 57 2 0 2000 P a B B 8 8 Needle Jet P 8 825 600 1200 470 450 430 410 390 380 Cutaway 2 0 O Ye 8 8 8 8 p AirScrew 1 0 Turns Meters rr Ze SC KE x p o Valve Seat 8 Ex 410 390 370 350 340 320 Fuel Octane R M 2 Key Switch Adjustable B B m a i n Throttle G ap 2400 3000 380 360 340 320 310 290 8000 10000 Under Cutaway 0 984 2 5mm T ie ii E SE 145 IAN EE ANAN MN Pilot AirJet 0 9 Long FuelScrew 2 0 Turns out SEM l E xhaust Valve S pring O ra nge refers to the clip position from top of jet needle Low Elevation Exhaust Valve Spring Green Yellow CLUTCH CLUTCH CHART TYPE cua anakan da P 85 DRIVE DRIVEN Belt DEER T 3211080 Altitude shit Clutch ciutch Driven od E Belt Width Projected 1 438 36 53mm Weight Spring Spring Helix 1369 1447151 T o Side Angle Overall 2
39. 3000 and a bright headlight indicates a good lighting coil Voltage below 10 volts at 3000 indicates excessive system loads poor flywheel magnets lighting coil problems or wires harness problems Check for partially grounded shorted yellow wire Reconnect the yellow regulator wire and increase the RPM If the headlight was bright with the regulator disconnected and dim when connected at the same RPM the regulator or regulator ground is at fault 9 16 Gp POLARIS ELECTRICAL 2 Pulse and 6 Pulse Alternators The difference between a 2 pulse and 6 pulse alternator system is the number of AC sine waves created by the alternator in one revolution of the crankshaft Forexample ona 6 pulse system the alternator will create 6 pulses or 6 complete AC sine waves in one crankshaft revolution The tachometer reads these sine waves therefore giving you accurate RPM readings Refer to the following text for applications Polaris Snowmobiles Polaris Domestic twin cylinder engines ccc cee eee eee 6 pulse 900 F ibWir cylinider sio ia e 6 pulse 6 Pulse Tachometers Tachometers for snowmobiles will have an identification marking on the back side For example The tachometer for a 600 RMK will have 6 pulse or 6P written on it 2002 Flywheels The flywheels used on model year 2002 snowmobiles will not work correctly if used on earlier build models The 2002 flywheel is calibrated specifically for 2002 CDI
40. 8 ue 2 Fuel Octane R M 2 Key Switch Adj 60 8000 380 2 pr Pu Pu EH Premium 91 Regular 87 Non O xy emil 2 2 e e e Throttle Ga Under C LS TER 0 102 2 6mm amen Y 310 a 2 Starter GE eso pus 140 XY P ilot Air J et SE de N A i refers to the clip position from top of jet needle Exhaust S pring Green White Low Elevation Exhaust Valve Spring Pink CLUTCH CHART CLUTCH DRIVE DRIVEN EE P 85 Ren KA EE E ER 3211080 maaalala ET Belt Width Projected 1 438 36 53mm Feet 0 3000 Bushed Green Blue B HYVO Side Angle Overall 28 B00 4400 i 0 39 72P Outside Circumference 48 375 122 87cm 13000 6000 Blu 3 HYVO Center Distance 11 5 4500 2100 Ra R3 Oe Shift Weights 10 56 Bushed Sec Primary Spring Black Green 7000 30 Ra 3 wo Secondary Spring Silver Blue 2700 3350 EA 9 39 72P Driven Helix R 32 3 9000 11000 Blue HYVO 3350 4000 10 Black sive R 32 9 39 72P 11000 13000 Bushed Green Blue 3 HYVO E Production Setting ENGINE Pit Deco tol Liquid Cooled Case Reed w TPS Displacement 593cc Fuel Pump Manuf Walbro BOLE kinatha hte dka Bech dol 2 9930 3 041 77 25mm Fuel Pump Mark N A STOKE asd ott sto ea aeo 2 520 64mm Oil Pump Manuf Mikuni Piston Cylinder Clearance 0 0044 0 0058 0 11 0 15mm Oil Pump Mark 2540097 Service Limit Piston Marking Piston Ring Marking
41. A 280 Watt Charging System NOTE Always verify timing of engine at room temperature only 68 F 20 C Refer to ignition timing procedure on page 9 9 Acceptable Variance Flywheel Flywheel Lines Rotation Stationary Pointers NOTE Acceptable variance is usually one line on either side of the dial indicated timing mark Timing Procedure All Models ELECTRICAL NOTE Always check ignition timing with the engine at room temperature only 20 C 68 F Refer to the timing specification charts at the beginning of this section to determine the proper ignition timing 1 2 for the engine you are working on Use a dial indicator to place the piston in the proper timing position and mark the flywheel at this point follow procedure on page 9 4 Connect an accurate tachometer and a good quality timing light to the engine according to manufacturer s instructions Disconnectthe TPS Throttle P osition Sensor connector from carburetors on models with TP S Start engine and increase RPM to the point specified in the timing specifications in Chapter 1 Hold the throttle to maintain specified timing RPM Pointthe timing light atthe timing inspection hole With your head positioned so there is a straight line between your eye the stationary pointer and the crankshaft center line note the relative position between the marked flywheel line and the stationary pointer If the stationary pointer is aligned with th
42. INSPECTION NEE 3 61 Oil Pump Operation Adjustment 00 c cca 3 62 3 65 EEN e woven quie ege 3 66 3 70 Recoil Disassembly and Assembly 3 71 Keelen RE EE EK ER 3 72 3 73 ENGINES O When tightening bolts nuts or screws a torque pattern should be followed to ensure uniform equal tension is applied to allfasteners Proper torque application prevents fasteners from loosening or breaking in critical service It also minimizes wear and eliminates premature or needless repair costs Following uniform torque application sequence patterns ensures optimum performance from precision machined close tolerance assemblies Engine Torque Specifications The most common units of torque in the English system are ft Ib and in Ib In the Metric system torque is commonly expressed in units of kg m or Nm Newton Meters Multiply foot pounds by 1383 to obtain kg m Move decimal point one place to the right to obtain Nm from kg m Cylinder Head Cylinder Crankcase Crankcase Flywheel Base Nuts 8 mm 10 mm 550 Fan Cooled 18 19 5 ft Ibs 24 28 ftlbs 16 6 18 ftlbs N A 60 65 ft Ibs Twin Cylinder 25 27 Nm 33 39 Nm 22 25 Nm 83 90 Nm EC55 IM a 24 ft a a 34 ft Es Di 24 ft E E ft een SN70 25 30 Nm a2 4 Nm Q8 33 Nm 36 41 Nm 124 Nm SN80 Torque head bolts prior to torquing cylinder base nuts Apply Loctitet 242 All 6mm Crankcase Bolts 108 in lbs 12 4 Nm All 7 16 14 Engine Mount Strap Bolts
43. Ifthe spring was removed reinstall it by spiraling counterclockwise toward the center 2 Lubricate center shaft and spring with grease Premium All Season Grease PN 2871423 14 oz 3 Wind rope in a counterclockwise direction around outside of reel as viewed from ratchet side of reel 4 Pass end of rope through rope guide and slide reel down onto shaftand spring NOTE Make sure reel tab engages hook on end of spring 5 Reinstall ratchet pawl onto reel face NOTE Ratchet spring must hold ratchet in retracted position 6 Reinstall friction plate with one end of friction spring in hole on end of ratchet pawl 7 Reinstall flange nut and torque to 5 ft Ibs 6 9 Nm 8 Pull recoil rope to full extension and align notch on outside edge of reel with housing rope guide hole 9 Using a needle nose pliers or hooked wire pulla loop of rope through the notch into center of housing 10 Holding side of rope loop attached to reel wind reel counterclockwise until coil bind is felt Then unwind reel between one and two turns 11 Pull loop to outside of housing by pulling on rope handle 12 Allow rope to fully retractand check for normal recoil and ratchet operation Gp POLARIS 3 71 ENGINES Engine Troubleshooting PROBLEM PROBABLE CAUSE Will not start hard starting Low compres sion No spark Engine idles but no acceleration Engine runs but fails to reach maximum RPM Engine runs but fails
44. Inspect coolant filter annually for contamination and replace if necessary COOLANT BOTTLE Check Valves tapered side points in flow direction Check Valve Flow Bleeding the Cooling System Pressure Caps Ifthe cooling system should become low in the tank and or fillerneck the system should be bled of any trapped airus ing the following procedure 1 Allow the system to cool completely F ill the reservoir with coolant to the maximum indicated mark With pressure cap removed add coolant and fill to the top of the filler neck Install the pressure cap with the lever lock up in its release position and run the engine at low idle RPM 600 100 to allow all air to purge and preventtrapped air which can lead to overheating Reset idle to specified RPM after bleeding Bleeding the Cooling System Surge Tanks If the cooling system should become low in the surge tank the system must be bled of any trapped air using the fol lowing procedure Ii 2 Allow the system to cool completely F ill the surge tank with coolant to the maximum indicated mark Startthe engine and loosen the bleed screw on the top of the water pump until trapped air has been purged Tighten the bleed screw Loosenthe bleed screw atthe end andtop ofthe water outlet manifold until trapped air has been purged Tighten the bleed screw Recheck the surge tank coolant level and add coolant again if necessary
45. Installa tion Tool 600 700 800 RMK domestic engines 8 9mm PN 2872389 Impeller Nut Torque 10 ft Ibs 14 Nm A ENGINES Disassembly Cont 16 Remove reed cover reed stuffers and reeds TE Mm Kl ES e zs i ES en Kb ing L E A e Reed Valve Inspection 17 Measure air gap between fiber reed and reed block as shown The air gap should not exceed 015 4 mm If clearance is excessive DO NOT attempt to reverse the reeds to reduce the air gap Always replace them if damaged Check each fiber reed for white stress marks or missing material Replace if necessary Reed Pedal Clearance 015 38 mm max Exaggerated for illustration 18 Remove cylinder head Note condition and placement of both cylinder head O rings 19 Loosen cylinder base nuts and remove cylinders Disassembly Cont 20 Carefully remove C clip holding piston pin in place 21 Remove piston pin using piston pin puller and adaptor Piston Pin Puller PN 2870386 Adaptor PN 5130971 22 Remove water manifold by removing both retainer brackets 23 Remove bottom crankcase bolts and separate crankcase halves Gp POLARIS ENGINES O sta A 3 LETT Zs FU d 3 41 A ENGINES Disassembly Cont 24 Remove snap rings and crankshaft seals 25 Clean thoroughly to remove all grease oil dirt and old sealant Assembly 1 Clean all parts with solvent and dry with
46. Nut 9 Add 9 oz 11 oz on models equipped with reverse of Polaris chaincase oil to the chaincase Verify proper level with dipstick Polaris Synthetic Gearcase Lube PN 2871477 Gallon PN 2871478 12 ounces 10 Torque jackshaft bearing set screws to specification if so equipped Driveshaft and J ackshaft Bearing Set Screw Torque 80 in Ibs 9 2 Nm 11 Lubricate bearings with Polaris Premium All Season grease Polaris Premium All Season Grease PN 2871423 8 34 Bearing Seal O Ring KG Mag em at A Snap Ring Gp POLARIS BRAKES FINAL DRIVE Es Final Assembly Cont 12 Reinstall clutch offset washers on jackshaft and install driven clutch Using the clutch alignment tool adjust driven clutch to achieve proper offset Clutch Alignment Tool P90 PN 2870914 P85 PN 2870426 P90 Offset 21 32 P90 Electric Start Off set 1 28 straight edge P85 Offset 5 8 P85 Electric Start Off set 1 straight edge 13 With proper offset achieved the driven clutch must float on the jackshaft This is done by adding or subtracting spacer washers PN 7555734 to the clutch retaining bolt When properly adjusted the driven clutch will have 020 100 5 2 5 mm float CAUTION Incorrect float can cause jackshaft bearings to be side loaded resulting in premature bearing failure 14 Torque driven clutch retaining bolt to specification Driven
47. REX 5 20 Spider Ind xiligi uoo Lice ate x dex ERE DEAE 5 21 Driven Clutch Removal veo ero RD ERR er Rd 5 22 Driven Clutch Disassembly st ices mancare eraot s 5 23 5 24 Driven Clutch Assembly ek ERR Ee ARS 5 25 5 27 Driven Clutch Installation de cise Seege Eer 5 28 Drive Belt Part Numbers Applications 5 29 Drive Belt Inspeccion PE SER ey E Bad ALAN Data 5 30 Drive Belt Delen Kama maaga tinder Rx hREY ES 5 31 Drive Belt Deflection Measurements 5 32 Clutch Offset Inspection and Adjustment 5 33 Clutch Alignment and Inspection 5 34 Drive Belt to 5heave Clearance ccc cece eens 5 35 Clutch Bushing Replacement 5 36 5 41 Drive Driven Clutch Troubleshooting 5 42 5 43 Belt Wear Troubleshooting 2 22 ge ERE e 5 44 DRIVE DRIVEN CLUTCHES All drive clutch maintenance disassembly and assembly must be performed only by an authorized P olaris dealer who has attended current model Dealer Service Seminars has received a certificate of completion and displays the Polaris Servicing Dealer decal Because ofthe critical nature and precision balance incorporated into the drive clutch itis absolutely essential that no attempt at clutch disassembly and or repair be made without factory authorized tools and service procedures Essential Drive Clutch Tools Refer to the Service Tool Catalog PN 9914681 for photos and descriptions of all tools
48. Replace the belt if you no tice any loose cords broken cracked or missing cogs and variations in width If the water pump belt fails seri ous engine damage could result Nominal thickness of a new belt should be approximately 345 8 75mm Check belt tension by rotating crankshaft 1 8 turn at a time The tension should be equal at all points of rota tion l Aweightis neededto testbelt deflection Constructa weight out of wire and weights such as thick washers Usethe illustration to assist you The finished weight should weigh 2 Ibs 2 Measure the belt deflection using the following procedure a Hang weight midway between pulleys Weight must hang free and not rest on any part of ma chine b Laya straight edge or straight piece of stiff materi al steel is suggested across the top of both pul leys The straight edge should measure approxi mately 1 8 x 8 x 1 c Measure the gap between the belt and the straight edge at the point where the weight is hanging d Measured distance must be between 1 and 25 f the measured distance is more than the specification try another waterpump belt NOTE Do not use tools to assemble belt on pulleys Damage can occur which could shorten belt life Before installing new belt check pulley teeth remove all foreign material dirt and oil Never install a used belton a differ ent engine Install belt so writing on the belt can be read from the right side of the machi
49. SUSPENSIONS Fox Shock Maintenance Disassembly Cont 5 If body of shock starts to unscrew from body tighten and try again To keep body from turning it may be necessary to use Body Clamp Tool clamped lightly around body in soft jaws of vise as shown NOTE Position body clamp atleast 1 1 2 below bearing cap Shock Body Clamp Tool PN 2871071 6 Pullshock rod and piston straight out to avoid seal or valve damage Be prepared to catch piston ring when removing the damper rod valve piston 7 Remove shock from vise and dispose of used oil properly in suitable container Setshock body aside 8 Mount damper rod in soft jawed vise Loosen valve nut and clean the valve piston and valving washers with electrical contact cleaner Dry thoroughly with compressed air Tighten nut and torque to 12 ft Ibs 17 Nm Valve Nut Torque 12 ft Ibs 17 Nm SUSPENSIONS Fox Shock Maintenance 9 If bearing cap and or seals are to be replaced remove nut washer and valve piston with valving washers and set aside Keep washers in order and note orientation of slots in piston for proper re installation The side with the greater number of slots must face the damper rod nut toward IFP Seal Replacement 1 Remove bearing cap from damper rod Inspect seals o ring and bushing inside cap Inspect cap O ring and replace if torn or damaged 2 Using a small screwdriver or scribe pry upper seal main sea
50. T he ACCS valve is calibrated specifi cally for the model it was intended There are no adjustments for the valve and itshould not be tampered with in any way Gp POLARIS High Atmospheric P ressure D Bellows compress D Fuelflow increases Vacuum from Venturi To Float Bowls p d Sealed Plunger Bellows Low Altitude High Atmospheric P ressure ACCS System Low Atmospheric Pressure D Bellows expand D Fuelflow decreases Vacuum from Venturi To Float Bowls Cc Plunger This Sealed gt end Bellows fixed High Altitude Low Atmospheric Pressure ACCS System 4 9 Tel FUEL SYSTEM CARBURETION Explanation of Gasoline Volatility One of the sometimes misunderstood properties of gasoline is its volatility or ability to vaporize at different ambi ent temperatures and altitudes during the year When gasoline is blended it is given a Reed Vapor Pressure RVP number which reflects its ability to vaporize or mix with air at a given temperature range Gasoline vapor pressure is measured by putting a sample of fuel inside a closed container and applying a specified amount of heatto the container for a certain amount of time RVP will vary from about 7 0 PSI during the summerto approximately 13 5 P SI during the colder months Service stations selling a large volume of fuel will normally have the correct blend to work well at
51. Tighten jam nut while holding adjuster bolt 7 The chain is now tensioned Release brake lever lock Drive Chain Tension Chaincase cover removed To obtain correct chain tension 1 Remove drain plug F and drain oil into a suitable container Dispose of properly 2 Remove the chaincase cover 3 While putting a slight reverse tension on the chain by turning brake disc as indicated by the arrow A there should be approximately 1 4 3 8 6 1 cm deflection on the chain at point B Refer to illlustration 1 4 The chain is adjusted by loosening the adjusting bolt locknut C and turning adjusting bolt D until correct chain deflection is obtained Lock the adjusting bolt locknut C while holding a wrench on the adjusting bolt D to prevent it from turning Reinstall the chaincase cover and drain plug Add Polaris synthetic chaincase lubricant PN 2871478 through the dipstick opening to the level described above NOTE Clean the magnetic plug E every 500 miles 800 km and whenever checking or changing lubricant MAINTENANCE TUNE UP Suspension Lubrication To maintain rider comfort and to retard wear of the pivot shafts the suspension pivot shafts should be lubricated with P olaris Premium All Season Grease PN 2871423 at 500 miles 800 km initially 1000 miles 1600 km and before summer storage each year The riding characteristics ofthe snowmobile will be affected by lack of lubrica tion of these shafts NOTE A
52. Tighten jam nuts and re check adjustment Shift Lever Actuator Chaincase Cover Assembly MAINTENANCE TUNE UP Cleaning And Preservation Of Hood Chassis And Trim Proper storage starts by cleaning washing and waxing the hood chassis upholstery and plastic parts Clean and touch up with paint any rusted or bare metal surfaces Ensure that all corrosive salt and acids are removed from surfaces before beginning preservation with waxes and rust inhibitors grease oil or paint Ifthe machine is equipped with a battery disconnectthe battery cables and clean the cables and battery posts Fill battery to proper level with distilled water and charge to full capacity Remove and store the battery in a cool dry place The machine should be stored in a dry garage or shed out of the sunlight and covered with a fabric snowmobile cover Do not use plastic to cover the machine moisture will be trapped inside causing rust and corrosion problems Controls And Linkage All bushings spindle shafts and tie rod ends should be coated with a light coat of oil or grease Throttle controls and cables should be lubricated Force a small amount of lubricant down cables Electrical Connections Separate electrical connector blocks and clean corrosive build up from connectors Lubricate or pack connector blocks with Nyogelt grease and reconnect Replace worn or frayed electrical wire and connectors Nyogelt Grease PN 2871329 Clutch And D
53. a crankshaft straightness is of utmost importance Runout must be as close to zero as possible NOTE Maximum allowable runout is 0041 1 mm Gp POLARIS ENGINES O HIGH 004 1mm HIGH 004 1mm A B SUPPORT CRANKSHAFT A CU AT THESE TWO BEARINGS HIGH 002 05mm AHIGH 005 13mm A HIGH 002 05mm A A HIGH 005 13mm 3 57 A ENGINES Crankshaft Indexing Polaris crankshafts are pressed together or indexed so the connecting rod journal center lines are 180 twins or 120 triples apart from each other It is sometimes necessary to check multi cylinder crank shafts to verify that one cylinder has not been forced out of position relative to the other cylinder or cylinders Causes for out of index crankshafts include but are not not limited to S Hydrolock from water or fuel S Impactto drive clutch from foreign object or acci dent S Abrupt piston or other mechanical failure S Engine lock up due to drive belt failure Following is a method of checking CAUTION Disconnect battery ground cable and all spark plug high tension leads ground high tension leads to engine Dis connectlanyard from engine stop switch before proceed ing with the following steps l Securely fasten a degree wheel on the flywheel or PTO end of crankshaft Use a large degree wheel for more accuracy and make sure it is mounted concentrically with the crankshaft cent
54. and lower sprockets and chain at the same time Finger tighten the top sprocket nut and turn in bottom sprocket bolt until snug NOTE OnHyvot sprockets the beveled side goes toward the chaincase bearing 6 Install chain tensioner Finger tighten adjustment bolt 7 Install brake caliper assembly in chaincase CAUTION On models with hydraulic brakes make sure caliper piston is fully retracted into caliper to prevent brake binding from preload of pads On models equipped with mechanical brakes make sure cam is fully re tracted 8 Torque caliper mounting bolts to specification Caliper Mounting Bolt Torque 28 30 ft Ibs 38 6 41 4 Nm Es BRAKES FINAL DRIVE Track Installation 1 Tip machine back onto left side Insert suspension rear first into the track 2 Move the suspension back and forth until front torque arm mounting bolts can be started Tighten finger tight 3 Rotate the suspension until the rear mount bolts can be installed in the same manner as the front NOTE For ease of installation turn the front rear scis sor stops FRSS to low position This allows the rear torque arm to move forward more to line up holes 4 Torque suspension mounting bolts to specification 5 Return front rear scissor stops FRSS to original position 6 Install suspension springs FRSS Front Rear Scissor Stop XTRA 10 Shown 7 Align track outlined in suspension section and
55. at any time to achieve the best possible ride in any condition NOTE W henever shocks are replaced or reinstalled for any reason the adjustment screw should be located to ward the inside of the suspension Access to the adjuster is not possible if reversed Fox Shocks should be installed with the charge fitting up Threaded Adjust Collar Adjustment Screw SUSPENSIONS How to Adjust Rear Suspension Ifthe suspension is bottoming tighten the compression screw clockwise in 1 2 turn increments until the bottom ing stops or on Ryde FX equipped suspensions turn the adjusting lever towards the FIRM or SOFT settings Backing off 1 4 turn counter clockwise at this point should give you the best possible ride ensuring use of the full travel of the suspension The opposite procedure should be used if the suspension is too stiff upon initial set up If bottoming continues after the screw is turned in full clockwise the torsion spring should be adjusted using the adjustment block Back the screw out to the original starting position after torsion spring preload has been in creased Riding conditions are ever changing Keep in mind the Indy Select Ryde FX shocks can be adjusted atany time to achieve the best possible ride in any condition NOTE W henever shocks are replaced or reinstalled for any reason the adjustment screw should be located to ward the forward right side of the suspension Access to the adjuster is not possib
56. attractiveness of design PTO End Power Take Off drive clutch side 1 Pan Head Screw Provides a low large diameter head but with characteristically high outer edges along the outer edge ofthe head where driving action is mosteffective Slightly differenthead contour when supplied with P hillips Recess See dotted line Piston Clearance Total distance between piston and cylinder wall Piston Erosion Piston dome melts Usually occurs atthe exhaustportarea Possible causes 1 lean fuel air mixture 2 improper spark plug heat range 3 Poor fuel Pre Ignition A problem in combustion where the fuel air mixture is ignited before normal spark ignition Piston looks melted atarea of damage Possible causes 1 incorrectspark plug heat range 2 spark plug not properly torqued 3 glowing piece of head gasket metal burr or carbon in the combustion chamber 4 lean fuel air mixture 5 Incorrect ignition timing Primary Circuit This circuitis responsible for the voltage build up in the primary windings ofthe coil In the CDI system the parts include the exciter coil the trigger coil the wires from stator plate to CDI box and to the low resistance primary windings in the ignition coil Primary Clutch Drive clutch on engine Primary Compression Pressure built up in the crankcase of a two stroke engine GENERAL INFORMATION d psi Pounds per square inch Pushing When the front of the vehicle does not steer as much as the driver des
57. caliper Caliper assembly must fit freely onto disc and chaincase 10 Replace 3 8 bolts washers and rope guide Torque to specification Caliper Bolt Torque 25 30 ft Ibs 34 5 41 4 Nm 11 Actuate brake several times to set brake pads to proper operating position 12 Check for proper fluid level in master cylinder and replace cover Torque cover bolts to specification Reservoir Cover Torque 15 18 in Ibs 1 7 2 0 Nm 13 Inspect entire system for leaks and repair if necessary 14 Field testatlow speeds and verify proper brake action If pads drag on disc check caliper and pad assembly Es BRAKES FINAL DRIVE Hydraulic Caliper Disassembly Carrier Bracket Attaching Bolts Carrier Bracket Piston Piston Seal Spring Clip Stop Light Switch Brake Pads Brake Line 9 Bleeder Screw 10 Caliper 11 Rope Guide The rider s safety depends on cor rect installation Follow proce dures carefully Qo curas ey pes Refer to the exploded view above while performing the following steps 1 Remove bracket bolts 2 Disconnect brake line Drain brake fluid into appropriate container and dispose of properly 3 Disassemble on a clean bench 4 Open RE screw and drain brake fluid from caliper assembly into appropriate container Dispose of properly CAUTION Protect eyes from brake fluid at all times 5 Slide brake assembly out of bracket and remove old pads and clips 6
58. couple of minutes for all air bubbles to rise to the top 7 40 Gp POLARIS With the cylinder head assembly pushed down against the piston carefully insert the piston rod and assembly into the cylinder Slightly oscillating the piston rod to allow piston to enter shock body bore A light coating of oil on the piston wear band will ease installation PICTURE 17 Slowly push the piston rod and assembly into shock body until the cylinder head assembly bot toms on the cylinder counterbore Slight up and down movement may be required to allow all air to pass through piston assembly NOTE During installation some shock oil will overflow Wrap a shop cloth around shock body to catch possible oil overflow F ast installation of the piston rod and assembly may displace the floating piston from its original position This must not oc cur if the damper is expected to perform as de signed Using an open face spanner wrench tighten cylin der head securely into the shock cylinder PIC TURE 18 Pressurize the shock through the pressure valve with nitrogen gas to the specified pressure PIC TURE 19 If using R ydeF X inflation tool Refer to Procedures for use of replaceable inflation needle instruction manual found in the RydeF X inflation tool case NOTE After being compressed the piston rod should fully extend from the shock body once the shock has been pressurized Install the small button head screw in the pressur
59. cover flush chaincase inspect and adjust chain refill with new chaincase oil Change primary fuel filter and oil filter Check fuel and oil line condition and routing Inspect fuel and oil tank vent lines routing Inspect airbox fit air filter Clean or replace Change shock oil Fox annually before storage V E S Variable Exhaust System if applicable A Disassemble and clean components ACCS A Inspect vent lines Polaris Service Technician Authorized Dealer Date MAINTENANCE TUNE UP 21a 1 99 E 24 25 26 Im 28 29 30 _31 32 33 _34 ER _36 37 38 39 _40 41 _21b Brakes Hydraulic A Check brake fluid level B Check for proper hose routing tighness of banjo bolts and line fasteners C Check for system fluid leaks D Visually inspect pads for wear damage or looseness E Check security and surface condition of brake disc F Flush brake fluid and change every two years Brake Mechanical A Check cable conditions routing B Check brake pad and brake disc condition and mounting C Adjust brake to proper specifications Check auxiliary shut off switch amp perform throttle safety switch tests Inspect brake light tail light oil light and all electrical accessories Inspect Hi Lo beam operation and aim headlight check fasteners Liquid cooled models A Check coolant level and specific gravity B Check water pump drive belt co
60. d MODEL INDY 500 SKS EUROPEAN MODEL NUMBER E025S5AE ENGINE MODEL 52209 5044PL5A ELECTRICAL CAPACITIES Flywheel I D 4010523 FuelTank 11 8 gallons 44 7 liters CDI Marking 4010584 Oil Tank 3 quarts 2 8 liters Alternator Output 280 Watts Coolant 5 quarts 4 7 liters Ignition Timing 12 BTDC 22500 RPM Chaincase Oil 11 fl oz 325cc 0 0327 BTDC 0 8294mm BTDC Spark Plug Gap Champion RN2C 0 028 0 7mm Voltage Regulator LR7 Electric Start O ption LR7 Full wave voltage regulator Magneto Pulses 6 SUSPENSION CHASSIS CHAINCASE Body Style Gen Il Sprockets Chain 18 41 68P HYVO Front Suspension Indy XC 10 Reverse oo o o Option FrontShocks Indy Select Brake Pads Type 81 Large IFS Spring Rate 100 in Chaincase Center Dist 7 05 17 91cm Front Spring Preload 3 4 Thread Adjust Driveshaft Sprockets 2 Drivers Wide Front Vertical Travel 9 6 24 4cm Brake Type Polaris HPB Rear Suspension XTRA 10 EURO Rear Axle Travel 9 5 24 1cc Front Track Shock Nitrogen Cell Spring Rate 190 in variable Rear Track Shock Indy Select RearSprings 405 sq 77 Track Type 15 x136 x1 25 38 1x345 44x3 175cm Track Tension 3 8 1 2 1 1 3 cm slack with 10 4 54kg weight 16 40 64cm ahead of rear idler shaft
61. engaging slot in shaft with drive gear Apply Loctite 242 to bolts and torque evenly to 78 in lbs 9 Nm End Play 008 016 203 406 mm Optional Shims PN 3083671 006 15mm PN 3083672 012 3mm PN 3083673 024 6mm Oil Pump Mounting Bolt Torque Loctitet 242 Blue 78 in Ibs 9 Nm ENGINES O Oil Pump Adjustment Procedure Roundslide Carburetors 1 Synchronize carburetors as outlined in chapter four Set engine idle speed as outlined in each model s specification chart listed in chapter one 2 Adjust throttle cable freeplay to 010 030 25 8mm See figure 1 010 030 25 8 mm Figure 1 3 Verify that carburetor slides leave their respective resting positions upon opening within 01 to 03 of throttle cable movement not throttle lever movement See figure 2 4 Verify that the oil pump alignment lines are aligned at the point where the carburetor slides begin to raise from their resting positions Note Marks may not line up without throttle engagement See figures 3 and 4 5 Torque cable locknuts to 10 20 in Ibs NOTE Use a mirror when aligning the oil pump marks whenever the oil pump is difficult to view Mikuni Flatslide Carburetors l Verifythatcarburetor slides are within 1 16 of each other when passing the top of the carburetor throat See figure 2 2 Set engine idle speed as outlined in the specifications listed in chapter one 3 Adjust
62. engine spark plug tool The block provides three spring tension positions This adjustmentis easier if the long spring leg is lifted over the roller and replaced after the block is properly positioned Always maintain equal adjustment on both sides A 7 16 RRSS low position shown RRSS high position shown FRSS medium position shown Scissor Stop Block Position Medium Ba Soft Tension Long End to Front Medium Tension Short End Up Firm Tension Long End Up Gp POLARIS Front Suspension Setup and Adjustments Spring preload is one of the adjustment options which affects ride Preload is the amount of pressure at which the spring is held The longer the installed length of the spring the less the amount of pre load the shorter the installed length of the spring the more the amount of pre load An increase in IFS shock spring pre load will result in an increase in ski pressure To adjust front spring preload on threaded adjust models grasp the spring and turn in a clockwise direction as viewed from the bottom of the shock to increase the preload Turnin a counter clockwise direction to decrease preload In the adjacent illustration high preload and low preload posi tions are depicted When adjusting be sure springs on both the left and right sides of the machine are at the same adjustment Forthe best ride the spring preload should be as low as possible Set the preload to use
63. filters fuel lines vent lines fuel pump impulse hose air box exhaust system and finally the carburetors The following troubleshooting information assumes that the general mechanical condition of the engine pistons rings bearings etc is good When the fuel air mixture is diagnosed as improper due to spark plug readings clean the carburetor and blow its passages clear with compressed air Use the spark plug firing end condition as a guide for further determination of whether the mixture is too rich or too lean Use the throttle lever to determine at what degree of throttle valve opening the problem exists CONDITION SYMPTOMS Mixture Too Rich Black spark plug tip plug fouling Heavy exhaust smoke Engine runs worse after warm up Engine loads up Mixture Too Lean S park plug electrodes white Fluctuation in engine speed Power loss Engine overheats Cylinder scoring Holing pistons Backfiring detonation Throttle diagnostic opening check points Poor Fuel Mileage Incorrect ignition timing Improper track tension too tight Incorrect carburetor jetting Fuel leaks lines fittings fuel pump Needle and seat leaks Plugged exhaust Carburetor vent line problems Clutching incorrect for conditions worn belt Troubleshooting Tips 0 1 4 Throttle S Pilot air screw misadjusted Pilot jet of wrong size loose or obstructed Obstruction of pilot jet Pilot jet loose Choke plunger not seating rich Ca
64. finished surfaces 2 Remove the handlebar protector pad from the outlet end of the handlebar master cylinder to access the brake fluid line connector Remove handlebar cover strips Remove two screws Remove holding clip in front of cover Remove handlebar pad 3 Loosenthe connector approximately 1 4 to 1 2 turn Loosen and remove the four switch pack and handlebar master cylinder mounting screws Put screws aside for later installation Es BRAKES FINAL DRIVE 5 Remove master cylinder from switch pack and handlebar CAUTION Remove switch pack wires from the master cylinder housing with extreme care and note where they are routed for later installation 6 Remove master cylinder cover screws and cover P our out the fluid in the reservoir into a container Unscrew the brake fluid line from the master cylinder outlet using a shop cloth to catch the remaining fluid Drain the fluid from the brake line into the aforementioned container and discard the fluid Inspection NOTE Due to the critical nature of these parts and pro cedures be sure you have thoroughly read and under stand Hydraulic Brake Operation page 8 8 1 Thoroughly clean all brake parts with isopropyl alcohol and either wipe dry with a clean lint free cloth or lightly blow dry with an air hose Examine all parts carefully for signs of excessive wear damage or corrosion Replace any parts found to be damaged Check park lever spring
65. for breakage Replacing Cartridge Subassembly 1 Remove master cylinder assembly as described previously 2 To remove the lever from the housing squeeze the lever handle and actuate the parking brake lever enough distance for the head of the pivot pin to clear the park brake lever 3 Squeeze the two spring tabs on the end of the pivot pin at the same time pushing the pivot pin up through the hole Remove the pivot pin and the lever BRAKES FINAL DRIVE Es 4 Lift the housing tab on the outlet end of the housing to release the cartridge assembly allowing the cartridge to be pushed out the back of the housing 5 Clean housing bore with alcohol Inspect bore for scratches dents cuts or digs that might cause a leak Replace housing if severe damage is found 6 Paint housing bore and cartridge o rings with D O T 3 brake fluid Polaris DOT 3 Brake Fluid PN 2870990 7 Align slots in cartridge with tabs in housing bore and insert cartridge Push cartridge through until outlet end of cartridge snaps into place Es BRAKES FINAL DRIVE 8 Install the lever and pivot pin by actuating the parking brake lever enough distance for the head of the pivot pin to clear the park brake lever 9 Align the lever pivot hole with the housing pivot hole Squeeze the two spring tabs on the end of the pivot pin at the same time pushing the pivot pin down through the pivot hole until the pivot pin snaps into place
66. grease gun kit complete with grease and adaptors is available to lubricate all fittings on Polaris snowmobiles Order PN 2871312 Suspension Lubrication Polaris Premium Grease PN 2871423 Grease Gun Kit PN 2871312 XTRA Lite Style L LUBRICATION POINTS XTRA Lite Grease all fittings XTRA 10 Style Grease at fittings L LUBRICATION POINTS Forward MAINTENANCE TUNE UP EDGE RMK Style Nr M S mi Ch AN e d A A Na EN ra ree S H rj D Pe Le i DA IT y Q ts PS d e e NE Si DAY 7 e N Ame TAR AW 3 S Forward 2 10 Never remove the pressure cap when the engine is warm or hot If the pressure cap is to be removed the engine must be cool Severe personal injury could result from steam or hot liquid Use ofa non standard pressure cap will not allow the recovery system to function properly If the cap should need replacement install the correct P olaris cap with the same pressure rating R efer to the appropriate parts manual Coolant Level Coolant level in the reservoir or surge tank must be maintained between the minimum and maximum levels to prevent overheating and serious engine damage Recommended Coolant Use a 50 50 or 60 40 mixture of antifreeze and distilled water depending on the freeze protection required for your area Do not use tap water in the system or reduced cooling or filter contamination may result Replace coolant every 2 years or if contaminated
67. near ring end gap faces upward Straight Edge 7 E Piston Ring Cutaway Keystone Piston Ring A ENGINES Assembly Cont 9 Lubricate pistons rings upper rod bearing and cylinders with two stroke oil and install cylinders Align ring end gaps with locating pins and compress rings Install cylinder carefully with a gentle front to rear rocking motion Loosely install cylinder nuts 10 Install new cylinder head O ring and install cylinder head Make sure O ring is properly seated in groove Make sure O rings are properly seated in grooves es 11 Torque cylinder base bolts in proper sequence Refer to specifications in the beginning of this chapter 12 Torque head bolts in proper sequence Refer to specifications in the beginning of this chapter Assembly Cont 13 Reassemble water pump carefully installing seal 14 Install crankcase seal to ignition water pump housing from inside toward outside until bottomed on housing Spring and seal lip must face inward toward crankshaft 15 Apply 3 Bond sealant to pump housing crankcase mating surface and carefully install onto crankcase Tighten water pump to engine hose clamp and torque bolts to specification Ignition Water Pump Housing Torque 22 Ft Ibs 30 4 Nm 16 Align timing marks and install stator Gp POLARIS ENGINES O 3 45 A ENGINES Assembly Cont 17 Install flywheel and torque flywheel n
68. open filling the float bowl in the carburetor When the float level in the carburetor reaches its standard level the needle valve will close prevent ing more fuel from entering the carburetor even though the fuel pump continues to try to provide the carburetor with fuel Maintenance The impulse operated diaphragm fuel pump does not require any specific scheduled maintenance However the following procedures should be observed Operation S The pump may be checked for operation by re moving 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 S The pump and impulse line must be disas sembled and cleaned of foreign material in the event of piston or other internal engine part fail ures which produce fragments Inspection S Disconnect impulse line from pump Connect Mity Vac to impulse fitting or line and apply 4 6 PSI pressure Diaphragm should hold pres sure indefinitely S Thediaphragms and check valves must be care fully examined for cracks holes or other dam age Ifin doubtas to the condition of any internal parts replace all diaphragms check valves and gaskets O FUEL SYSTEM CARBURETION Fuel spillage will occur during this installation Gasoline is extremely flammable and explosive under certain conditions Do not smoke or allow open flames or sparks in or near the a
69. outdoors or in a well ventilated area 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 Do not fill the tank neck If you get gasoline in your eyes or if you swallow gasoline see your doctor immediately If you spill gasoline on your skin or clothing immediately wash it off with soap and water and change cloth ing Never start the engine or let it run in an enclosed area Gasoline powered engine exhaust fumes are poi sonous and can cause loss of consciousness and death in a short time JetPart Numbers The following chart lists main and pilot jets and the part number of each that are presently available gt PPP BB Mikuni Mikuni PILOTJETNO PARTNO PILOTJETNO PART NO 25 4 un d es 3130064 60 paman 3130071 30 EE 3130065 KE 3130066 MO rs 3130067 db cr etx 3130068 KI 3130629 ias 3130070 Mikuni Mikuni HEX HEAD HEX HEAD MAIN JET NO PARTNO MAIN JET NO PARTNO LIRE 3130099 250 s baad 3130128 510N 3131400 B5 co haw wigs vus 3130100 200 sce 3130129 520N 3131401 90 cnr 3130101 KARTEN 3130130 530N paa kasi 3131402 EE 3130102 PAE 3130131 540N 3131408 TOO pana ties 3130103 SEI ie as 3130132 KE EE 3131409 LOD sese 3130104 EIER 3130133 560N ugs 3131410 LOS ne 3130105 310 nep Rotes 3130134 T15 get 3130106 NEEN 3130135 The N series jets have the same T20 ve en 3130107 330
70. overall handling characteristics of snowmobile suspensions Rider weight riding style course conditions and the condition of suspension components are some ofthe things that you have to consider when tuning a suspension On new machines or whenever new suspension parts are installed the sled should be ridden for at least one tank of fuel to allow moving parts in the shocks and suspension to wearin The shock springs will also take their initial set and the setup will be more accurate REAR SUSPENSION SET UP This chart is only a guideline to be used for initial suspension set up Your set up may vary based on your dasired riding style es A E Tu cim WITHOUT RIDER WITH RIDER SETTING INITIAL TORSION SPRING PRELOAD SAG METHOD To set up the EDGE AMK rear suspension torsion spring preload measure the distance between the ground and rear bumper see illustration This measurement should be taken with na rider and the rear suspension at full extension This measurement rom the ground te the rear bumper is dimension X NOTE SAG measurements should be taken with suspension moving freely in a warm shop or after a short warmup ride Rear of machine may need to be lifted slightly to achieve full extension of rear suspension Next have the rider drop down hard an the seat and bounce up and down several times working the rear suspension With the rider seated measure the distance between the ground and the rear bumper at the exact
71. papuswwo33Y ION ZHN AI Tro ros es Tear Tos p Tren ron sar sr enn E aY Ds sss Iss rvs rer ror ser sss ris owe oo enr ovr var re prc prar peur ru qr c jm YNOH Yad SITIW Nda ueysyoer Saa ZZ ZZ aaa v z S zr vos o oz OL 02 oz ww uw es eo an UN 02 oz UN sn aa eo UN un oz oz un EN 99 s9 un 99 s 99 un s9 Bo s9 UN 99 99 UN uw es s s9 uw se 99 en EZR AAR AG 2 100 0 eter we pe E ae eee owe EN E EE Wad autdug ogey Wdy 3 3 Gp POLARIS Es BRAKES FINAL DRIVE popueului029M JONSYN UNOH ad SITIW Wd yeysyoer 04 Pan as es 9 an ss ww o pajas 9 sw 9 os SN S9 moss Wag suisug ogey Wd Gp POLARIS 8 4 BRAKES FINAL DRIVE Es HYVOt Sprocket Part Numbers Top Sprockets For 3 4 HYVOt Drive Systems 18T 3221085 20T 3221087 22T 3221089 SC e HYVOt Drive Chain Chain Length Pitch Part Number 3224070 me Bottom Sprockets For 3 4 HYVOt Drive Systems Standard Bottom Sprockets Reverse Sprockets Geen 0 Er EECHER Aa 1 mr jas S HYVO Lightweight Cut Metal Gears are also avaiable Please look these PartNumbers up in your High Performance Manual PN 9917367 or the Quick Reference Manual PN 9914898 BRAKES FINAL DRIVE Sprocket Chain Combinations 7 05 Center Distance Chain C
72. than 4 ohms Turn the Hi Lo S witch back to the Lo beam position and the meter should again read an open circuit OL Seat Harness Troubleshooting 1 Remove the taillight lens 2 Remove the two taillight bulbs and the brakelight bulb 3 Separate the seat harness from the main harness by unplugging the connector at the right rear of the tank 4 With the multitester dial seton ohms 2 connect either meter test lead to the brown seat harness wire 5 Touch the other tester lead to first the yellow wire and then the orange wire Observe the readings Readings other than an open circuit O L indicate a shorted harness or bulb socket NOTE The bulb sockettangs sometimes short to ground with the bulb removed 6 Check between the yellow and orange wires in the same manner to check for a short between the brake and running lights If damaged wiring is found remove the seat 7 Tip the seat over and remove the right side seat cover staples Locate and repair the harness problem 8 Reinstall the staples and re check the seat harness 9 18 High Low Switch Gp POLARIS ELECTRICAL Ignition Switch Testing Non Electric Start 1 Set the multitester dial to the ohms Q position Connect one of the tester leads to either of the switch terminals and the other tester lead to the other switch terminal 2 With the switch off the reading should be less than 4 ohms With the switch on the reading mustbe an open circuit
73. the case 3 Set battery aside and allow it to cool and stabilize for 30 minutes 4 Add electrolyte to bring the level back to the upper level mark on the case NOTE This is the last time that electrolyte should be added If the level becomes low after this point add only distilled water 5 Charge battery at 1 10 of its amp hour rating Example 1 10 of 9 amp battery 2 9 amps 1 10 of 14 amp battery 1 4 amps 1 10 of 18 amp battery 1 8 amps recommended charging rates 6 Check specific gravity of each cell with a hydrometer to ensure each has a reading of 1 270 or higher Battery Testing There are three easy tests which can determine battery condition Whenever the complaint is related to either the starting or charging systems the battery should be checked first Lead acid batteries should be keptatoras near full charge as possible Ifthe battery is stored or used in a partially charged condition hard crystal sulfation will form on the plates reducing their efficiency and possibly ruining the battery Open Circuit Voltage Test OCV Battery voltage should be checked with a digital multitester Readings of 12 6 orless require further battery testing and charging Specific Gravity Test A tool such as the battery hydrometer P N 2870836 can be used to measure electrolyte strength or specific grav ity As the battery goes through the charge discharge cycle the electrolyte goes from a heavy more acidic state at full cha
74. the shock damper rod for limiting For example If standard full shock travel IFP depth is 835 and 6 spacers are added to reduce shock travel by 1 5 inches multiply 029 x 6 to calculate the amount to subtract from IFP depth 835 174 661 025 New IFP Depth Fox Shock Maintenance Disassembly 1 Remove spring and bushings from shock eyes Thoroughly wash shocks in a parts washer or with soap and water to remove dirt and other debris Dry thoroughly with compressed air Position and clamp body cap of shock in softjaws aluminum or brass of vise Remove Allen screw from pressure valve With valve outlet pointed in a safe direction insertred tip of safety needle assembly into recess in shock pressure valve Depress safety pin on safety needle and push gauge and needle assembly slowly toward shock inserting needle Be sure to push needle completely into shock valve Release nitrogen in a safe direction away from everyone by turning T handle clockwise if equipped or by depressing Schrader valve pin CAUTION Itis possible for some residual pressure to remain in the shock regardless of the gauge reading Always com pletely remove valve from body cap before further disas sembly of shock 3 Remove valve and sealing O ring from body cap 4 Extend shock shaft by pulling up on shock eyelet Using a 1 25 mm wrench loosen shaft bearing cap Gp POLARIS SUSPENSIONS 7 21
75. to the engine through the pilot outlet The mixture is regulated to some degree by adjusting the airscrew When the air screw is closed the fuel mixture is made richer as the amount of air is reduced When the air screw is opened the mixture is made more lean as the amount of air is increased Pilot et 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 inter indicstor val under a given set of conditions Number Pilot Air Screw The pilot air screw controls the fuel mixture from idle to low speeds The tapered tip ofthe air screw projects into the air passage leading to the pilot jet air bleeds By turning the screw in or out the cross sectional area of the air passage is varied in turn varying the pilot jet air supply and changing the mixture ratio FUEL SYSTEM CARBURETION O Throttle valve cutaway effectis most noticeable at 1 4 throttle opening The amount of cutaway is pre determined fora given engine to maintain a 14 1 air fuel ratio at part throttle A steep angle would indicate a fairly lean mixture because there is less resistance to air flow A flat angle would provide a much richer mixture because there is more resistance to air flow
76. two 3 8 hex bolts and washers from bracket Remove rope guide NOTE Do not disconnect brake line 3 Lift bracket and brake assembly off vehicle Remove all dirt from caliper assembly using brake cleaner and clean shop cloths 4 Usea drop cloth to protect surfaces from brake fluid spillage Remove reservoir cover from master cylinder assembly Using a large hardwood dowel ora C clamp vise grip on the center ofthe old pads apply pressure toward the caliper piston Compress piston back into caliper assembly Apply pressure slowly to prevent excessive spillage from master cylinder assembly NOTE Pushing the piston back into the bore will cause the fluid level to rise in the reservoir and possibly overflow Remove excess fluid and discard CAUTION Piston must not be forced back into the caliper at an angle or bore damage may occur 5 Slide caliper and brake pads out of bracket Discard old pads and clips NOTE Pad and holders must be replaced as a set BRAKES FINAL DRIVE Es Friction Pad Replacement Cont 6 Place new pads with friction material facing each other into housing Hold in place using clips See illustration on page 8 20 7 Slide brake assembly into bracket until both clips snap into grooves in bracket Clean brake mount on top of chaincase 9 Separate pads for installation over disc If brake assembly does notslide easily overthe disc with loose pads the piston is not compressed far enough into the
77. 00 ESOOO is listed in degrees only convert to either Hs lon LOO 0 ke NOTE 000 0 G900 0 2000 0 1900 0 2000 0 19000 Z000 0 G00 0 2000 0 2900 0 SIHONI WW sauoN ww S3HONI ww S3H NI WW S3HONI WW INOYLS WIN 89 e ificat INOYLS WW 02 dou WW 91 INOULS WW v9 QOY WIN GL INOYLS WW 09 OY NW OCT INOYLS WW 9 SS JOY WW EOL INOYLS WW S9 dou WW SZ Qou WW 9EL iming marl STA YM 009 onsauiog 005 onsawog Ot onsawog iming spec 004 onsawog CSI A Noun 009 ansawog 008 3nsawag Wdz ve 24 ignition t Degrees to Piston Position BTDC Conversion Chart If the list for correct engine indicatorto verify t ecve o zi698 cocco eveza e oreo tesis ee 16064 e Les e AECH besoo ee tozzo 9z695 ze esses 08610 zezos oe voaro B602 ez eco oort e si9ro orolt zz oosro Orge oz 06c 0 Zocst pezio eooze vz terio oo00 e ez Eege zz D R e Ka LESCL 88600 86092 iz 65477 86800 20922 oz ogez 7 11800 i902 6t nod 6e200 gesgi 69641 zsooo ergot zi 86631 81500 829p1 or zop 60s0 0 zieet st ecec vrvoo sagi vi essot escoo vzz60 er 90060 zeo o rezso zi ses 0 szeoo 926590 n saz90 zeeoo 02250 or 62050 8t00 oyo 6 9kopo 9vioo eooc
78. 0484 Bb 3130319 6CGY6 3130652 GEO Zaang CR 3130378 IR ER 3130470 Needle J et Part Numbers Mikuni NEEDLE JET NO PARTNO NEEDLE J ET NO PART NO P 4 159 3130162 P 6 247 s cet kan 3130655 P 2 166 3130460 P 8 247 3130382 P 4 166 3130348 Q 0 247 3130414 P 4 166 3130499 Q 2 247 3130165 P 6 166 3130160 Q 4 247 3130603 P 8 166 3130421 Q 8 247 3130485 Q 2 166 3130376 R 0 247 cca 3130477 0 4 169 3130166 P 0 286 3130607 0 4 169 3130409 P 2 286 3130608 0 6 169 3130358 0 4 286 3130635 0 6 169 3130469 0 6 480 3130429 0 8 169 3130453 0 8 480 3130683 0 8 171 3130035 P 2 480 00 3130675 P 0 225 3130579 P 4 480 onanan 3130639 P2255 scaig 3130608 Q 6 480 3130618 P 2 259 3130161 P 8 513 3130510 P 0 247 3130671 P 2 247 3130672 P 4 247 3130641 4 2 Go POLARIS FUEL SYSTEM CARBURETION O Mikuni TM 38 TM 40 J et Part Numbers DESCRIPTION PARTNUMBER DESCRIPTION PARTNUMBER jeWedes reas cone Tagen arr riatar e 17 EE JetWeede EGDHULS 3130796 Jr J 1 1 3131258 1 2 3131259 Jet Jet JetNeedle 8 9C B01 50 313079
79. 1 300 1700140 0 008 1 300 1700141 0 010 1 300 1700142 0 012 1 300 1700143 0 015 1 300 Tool Part numbers 7 36 Gas Fill Tool and Gague Incl 5 needles Gas Fill Needles replacement pack Gas Fill Gague replacement Lower Retainer Wrench IFP Positioning Extraction tool Cylinder Head Wrench Wear Band Tool Arvin Shock Body Holder PS45259 PS45259 1 PS45259 2 PS 45260 PS45261 PS45262 PS45263 PS45629 Gp POLARIS SUSPENSIONS Ryde FX Shock Maintenance Procedures for the proper disassembly and assembly of RydeFX gas charged IFP and emulsion mono tube shock absorbers Polaris PN 7041990 7041992 7042059 WARNING Before servicing a gas shock itis important that all the gas pressure be discharged from the unit Refer to the instructions listed below forthe proper procedure of discharging the gas pressure from a shock Protective eyewear should be worn to avoid risk of injury while servicing RydeFX gas charged mono tube shocks Remove the shock from the vehicle S If shock incorporates spring re move spring and collateral retain ers NOTE Before unscrewing pre load springs measure the compressed length of the installed spring and mark position for reinstallation PICTURE 1 CAUTION When removing the spring from a shock that utilizes a fixed lower retainer the use of a proper spring compressor should be used to avoid risk of bodily injury
80. 12 ft Ibs 17 Nm Shock rods must pivot freely after torquing L LUBRICATION POINTS XTRA 10 L LUBRICATION POINTS XTRA LITE Grease at fittings Grease at fittings Forward w Ba Both sides SUSPENSIONS Rear Suspension Exploded View XTRA Lite Front track shock spring preload washers PN 5210953 AG py Rear Torque Arm SUSPENSIONS XTRA Lite Rear Suspension Torsion Springs Rear Track Shock Carrier Wheel Rail Bumper Front Track Shock Front Torque Arm SN Torsion Spring P d Sg Front Track w ag NY Su X S pring NN Bogie Wheel Rear Torque Arm Rail Tip Bumper Bogie Wheel Rear Track SHOCK Slide Rail SUSPENSIONS XTRA 10 Rear Suspension Rear Limiter Front Track Shock Strap ERA Rear Track Shock Limiter Strap Pivot Arm Pivot Arm Shaft Shaft Rear Torsion Spring Carrier Wheel Rear Track Shock Rear Torsion Spring Limiter Slide Rail Front Track Shock gt POLARIS 7 10 SUSPENSIONS EDGE RMK Torque Specifications Suspension Mounting and Lubrication Points 3 8 suspension mounting bolts a 35 40 ft lbs 49 55 Nm Shock rod bolts do not over torque Shock rods must pivot freely after torquing 12 ft Ibs 17 Nm Vru s 3 NAN SEB IN NN ks Y gt e EA CA y I gt N y SAN 1 e gt S d N Vereen Sy NI lc MARS 131 e NG y Torsion S pring
81. 15 Install the flywheel and insert the lock washer 16 Torque the flywheel nut During the procedure use a flywheel holding wrench to prevent the flywheel from rotating Flywheel Holding Wrench PN 8700229 Flywheel Nut Torque 60 65 ft Ibs 83 90 Nm 17 Reinstall the flywheel cover and CDI module 3 24 Gp POLARIS ENGINES O Engine Assembly Continued 18 Insert the vibration dampener into the cooling fins between the intake ports Reinstall the two fan shrouds making sure that they interlock before fastening tightly 19 Using a new o ring reinstall the oil pump Oil Pump Mounting Screw Torque 48 72 in Ibs 5 5 8 3 Nm 20 Install each carburetor and torque the carburetor mounting clamps Reinstall oil lines on the oil pump Gb POLARIS 3 25 A ENGINES Engine Disassembly Assembly Domestic 500 600 Engine NOTE Inspect all parts for wear or damage during disassembly Replace all seals O rings and gaskets with Genuine Polaris parts during assembly Refer to pages 3 47 3 56 for gen eral inspection procedures Disassembly 1 Remove carburetor mount adaptors reed cages stuffers and oil pump Note position of stator wire guide Measure air gap between fiber reed and reed block as shown The air gap should not exceed 015 4 mm If clearance is excessive DO NOT attempt to reverse the reeds to reduce the air gap Always replace them if damaged Check each fiber r
82. 28 z ilver z S E Outside Circumference 46 625 dido 24 Green us Ki wo Na Center Distance 11 50 MEETS NER o EE A ad 5000 7000 Green Blue 3 HYVO HYVO S hift Weights cji NONG 10 60 Bushed 2100 2700 SS Black Silver R 31 41 74p 19 39 72P Primary Spring Black Green 7000 9000 Green Blue 8 HYVO HYVO Secondary Spring E Silver Blue Gen 10 58 Edd A R 21 41 74P 19 39 72P Driven Helix poesia R 11 3 3300 3900 10 56 nem anan na SC SR G INE 11000 13000 Green Blue 3 HYVO HYVO EN Ke Liquid Cooled Case Reed w TPS Fuel Pump Manuf Walbro Displacement 794cc Fuel Pump Mark N A BOG eas paka A 3 3464 85mm Oil Pump Manuf Mikuni STOKE lee ghet AA od 2 7559 70mm Oil Pump Mark 2540053 Piston Cylinder Clearance 0 006 0 0074 0 15 0 188mm Cylinder Head Mark 3021294 Service Limit N A Piston Marking 3021184 Piston Ring Marking N A Piston Ring End Gap 0 016 0 022 0 41 0 56mm Head ccs Uninstalled 46 47cc Head ccs Installed 33 33cc Operating RPMz200 8000RPM Idle RPM 200 1500 RPM Engagement RPM 300 4000 RPM Cylinder Head Torque 18 22 ft lbs 25 30 Nm Cylinder Base Nut Torque 30 34 ft Ibs 41 47 Nm Crankcase Torque 8mm 29 24 ft lbs 28 33 Nm Crankcase Torque 10mm 26 30 ft lbs 36 41 Nm Flywheel Torque
83. 3 O BODY AND STEERING Torsion Bar Removal 1 Remove trailing arm assembly 2 Using a small pin punch tap out the rivet mandrels in the center of the torsion bar support rivets 3 Using a 1 4 bit drill out the center portion of the rivets 4 Punch outthe rivet body 5 Remove support and torsion bar 6 Repeat procedure for second torsion bar Torsion Bar Installation l Rivetsupport in place using Polaris PN 7621449 rivets NOTE These high strength Q rivets are the only replacement rivets recommended for this application Torsion Bar Support Rivets PN 7621449 2 Reinstall torsion bar 3 Reinstall trailing arm assembly 4 Check camber and toe adjustments BODY AND STEERING Handlebar Torque and Sequence 1 2 Remove handlebar cover Using a 7 16 11 mm wrench loosen four nuts on bottom of adjuster block NOTE Turn handlebar to left or right for access to back nuts Adjust handlebar to the desired height Be sure that handlebars brake lever and throttle lever operate smoothly and do not hit the fuel tank windshield or any other part of the machine when turned fully to the left or right IMPORTANT When adjusting the handlebar be sure the serrations in handlebar and adjuster block match be fore torquing 4 Torque the handlebar adjuster block bolts to specification following sequence shown The gap Elte should be equal at front and rear Handlebar Adjuster Block
84. 3 8 1 cm drive extension loosen the radius rod end jam nut Remove the lower radius rod boltfrom the spindle requiring the most camber correction Adjustthe opposite side next 3 Toadjustcamber change lower radius rod length until alignment bar measurement is within specified range for each spindle Refer to charts on page 6 8 forcamber specifications On models with neutral camber 0 the bar should slide freely through both spindles tolerance CAUTION Radius rod ends must remain parallel to the bulkhead Bulkhead after rod end jam nuts are tightened to specified il torque See illustration at right 4 Tighten all jam nuts Torque radius rod attaching bolts to specification Rod end parallel to mounting surface when jam nut is tight After camber adjustment is complete be sure to measure set up width outlined on page 6 9 and compare to specifica tions listed on page 6 8 Do not attempt to set suspension wider than the specified maximum set up width If set up width exceeds maximum adjust upper and lower radius rods equally to maintain camber adjustment Radius Rod Attaching Bolt Torque Radius Rod End J am Nut Torque 7 16 inner top 35 40 ft Ibs 48 55 Nm 1 2 inner bottom 40 50 ft Ibs 55 69 Nm g BODY AND STEERING Handlebar Centering 5 With alignment bar installed through spindles on 0 camber models center handlebars by adjusting drag link length Fig I On models w
85. 3 Nm Cylinder Base Nut Torque 30 34 ft lbs 41 47 Nm Crankcase Torque 8mm 20 24 ft Ibs 28 33 Nm Crankcase Torque 10mm N A Flywheel Torque 90 ft lbs 124 Nm GENERAL INFORMATION d MODEL asana INDY 500 RMK MODEL NUMBER SO2SR5AS ENGINE MODEL 52186 5044PL5A ELECTRICAL CAPACITIES Flywheell D Kokusan 4060223 FuelTank 11 8 gallons 44 7 liters CDI Marking 4010259 Oil Tank 3 quarts 2 8 liters Alternator Output 280 Watts Coolant 5 quarts 4 7 liters Ignition Timing 22 BTDC 3000RPM 1 5 Chaincase Oil 9 fl oz 266cc 0 1139 BTDC 0 0175 2 8927mm BTDC 0 48mm Spark Plug Gap Champion RN2C 0 025 0 64mm Voltage Regulator LR7 Electric Start Option LR7 Full wave voltage regulator Magneto Pulses 6 SUSPENSION CHASSIS CHAINCASE Body Style Gen Il Sprockets Chain 18 41 68P HYVO Front Suspension Indy X 10 38 CRC Reverse Option Front Shocks Nitrogen Cell Brake Pads Type 81 Large IFS Spring Rate 100 in Chaincase Center Dist 7 05 17 91cm Front Spring Preload 1 8 Thread Adjust Driveshaft Sprockets 2 Drivers Wide Front Vertical Travel 8 05 in 21cm Brake Type Polaris HPB Rear Suspension XTRA Lite 136 Rear Axle Travel 12 30 5cm Front Track Shock Nitrogen Cell Spring Rate 200 in vari
86. 7 37 60 95 50cm 13 16 3 4 2 08 80cm Widetrak LX At Normal Ride 41 Indy Xtra Height S port Tour Sport Tour E S 39 10 99 31cm 0 4 5 16 0 80cm Sport Tour Euro 42 5 Indy Xtra Ng 0 50 Classic Touring Trail Touring 49 44 102 72cm 0 5 16 0 80cm 42 5 X 10 CRC 600 Classic Touring Lite IFS 340 Deluxe 340 Touring 40 18 102 06cm 1 2 5 16 1 22 80cm 42 5 XC 10 CRC 700 SKS 500 700 Euro SKS 40 73 103 45cm 7 8 x 5 16 2 29 80cm 800 XCR 40 85 103 76cm 3 4 5 16 1 96 80cm WIDTH NOTE Width is measured in inches from the center of the spindles near the grease fitting for the ski mount bolt located at the base of the spindle The tolerance on this measurement is 1 4 TOE ADJUSTMENT NOTE Toe is measured in inches with the machine on the ground and resting at normal ride height not full rebound Measure at a point 10 254mm forward of the ski mount bolt and 10 behind the ski mount bolt preferably on the centerline of carbide skags Note Measurements to points on the skis may be inaccurate NOTE Camber measurement is taken in inches from top of alignment bar to the top of ski mount hole in the spindle bushing removed BODY AND STEERING Prior to performing steering alignment the suspension should be inspected for damage or wear and replacement parts installed as required See inspection on page 6 6 A maximum set up width is listed in the c
87. 7 Pilot Air J et 13 3131260 et Needle J8 8BEY01 3131250 Pilot Air et 14 3131261 Tat Needle 8 9DFH06 57 3131253 Pot ArTet 15 et Needle J 8 9DFHO7 60 3131268 Pilot Air J et 1 6 3131263 J et Needle J 8 9DFH10 57 3131313 Pilot Air et 17 3131264 JetNeedle 8 9DG101 60 3131377 Pilot Air J et 1 8 3131265 et Needle J 8 9DGJ 02 57 3131378 Pilot Air J et 1 9 3131266 JetNeede J8 EFHO1 60 3131207 EE 20 wNeede G SEFYUL G 3131202 PistonValves PiotAi es Shor Piston Valve 15 Piot Air et o5 msorr PistonValve 20 amo Poar oe 3130774 PistonValve 25 prono Poa 07 33075 Piston vale 30 Poari 08 3130776 Piston valve E Poran 03 prom PistonValve 40 33053 O Pie 10 mor NewMainJets Poa 1 peo menje SION Poa gt 12 pooo menje SON Poa 777 013 rore MainJet 530N EE E CC N Series main jets are designated N for the flow characteristics 3130783 The 510N flows the same as the 540 main jet The 520N flows the same as the 560 main jet The 530N flows the same as the 600 main jet 3130785 For Example You should NOT substitute a 530 Main e Jet for a 530N a regular 530 will have a leaner effect Pilot Air J et 1 8 3130786 than the 530N Piot Airjet 19 3530787 seee Pilot Air J et 2 0 3130788 Starterjet 130 3130805 Pilotair ets Long Starter et Hs 3130767 Pal 05 pors Starer set HO 3130768 Pone 05 nsus sweet e sor poaa 07 su
88. 72436 2 5 Gal 2 2871958 11 oz Cartridge 12 2871326 Carbon Clean Plus 1202 12 2872607 2872926 2871954 2871955 2871956 Gallon 55 Gallon Drum 2872435 802 12 2872952 2871323 2871534 2870995 2872279 2870990 2870791 2871517 2871518 2871312 2871322 2871423 2871460 2871592 2871285 2870505 Synthetic Chaincase Lubricant 2 5 Gallon 2871593 TC W3 Lube Value Pack 4 Value pack Premium Antifreeze 60 40 P remix Gallon 6 Premium Brake Fluid DOT 3 Premium Fogging Oil spray Premium Fogging Oil liquid with spout Premium Fogging Oil liquid Barre 1202 12 Pump for 16 30 55 gal drums Flex Spout fits gal and 2 5 gal jugs Isopropyl 10 oz 24 2871966 2871965 2871964 WAX AND POLISH Restore polish scuff remover Reflect Wax Final Finish Renew vinyl rubber protector RACING FUELS Premium Antifreeze 60 40 P remix Quart 12 2871589 Revival Detailing Kit 6 Kit 12 12 oz 12 12 oz 12 12 oz 2873019 2872980 2872981 2873019 2872982 2872983 2 2 Gp POLARIS MAINTENANCE TUNE UP Air Filter Maintenance The intake foam filter limits snow ingestion into the intake system When operating in loose powder snow check top of foam filter periodically to remove any accumulation of snow CAUTION Do not operate machine with the intake filters removed This can cause carburetor icing resulting in poor fuel economy or carburetor malfunction Key Components A Intake Foam Fi
89. 8 0 900 0 62 Black Silver R 8 21 4174P 19 39 72P Outside Circumference 46 625 0 3000 Bushed Green Blue 8 HYVO HYVO Center Distance 11 5 900 1500 0 60 Black Siver R 8 21 4174p 19 39 72P Shift Weights 10 56 Bushed E E E pig d i 1500 2100 0 58 Black Silver R 8 21 4174P y P Primary Spring Black Green NE KE iver Rt SE Ha Secondary Spring Silver Blue Feet 5 19 39 72 Dri Heli R 8 43 2100 2700 0 56 Black Silver R 8 21 4174 riven HelX 7000 9000 Bushed Green Blue 43 HYVO HYVO 2700 3350 0 54 Black Silver R 8 21 4174P 19 39 72P 9000 11000 Bushed Green Blue 3 HYVO HYVO 3350 4000 0 AL Black Silver R 8 21 41 74P 9 39 72P 11000 13000 Bushed Green Blue 3 HYVO HYVO CL Production S etting ENGINE TYPE aa Eed ha mhaba ded e Liquid Cooled Case Reed w TPS Displacement 701cc Fuel Pump Manuf Walbro BOIG bad aia a 3 1889 81mm Fuel Pump Mark FPA 4 Stroke ciere ens 2 6772 68mm Oil Pump Manuf Mikuni Piston Cylinder Clearance 0 0043 0 0057 0 11 0 14mm Oil Pump Mark 03A Service Limit aaua 0058 Piston Marking 3021041 Piston Ring Marking N A Piston Ring End Gap Head ccs Uninstalled 37 2 50cc Head ccs Installed 33 5 34 5cc Operating RPM 200 8100 RPM Idle RPM 200 1500 RPM Engagement RPM 300
90. 8 Oz 2870601 Metal Polish go 2870632 DOT 3 Brake FlUid 24 3 rex tas iaa Rees 2870990 FOGGING Oil uc Wan Land Waaa Kish Than deat 2870791 Nyogelt Grease a 2871329 FOX SHOCK Olan lol recen fer e e ER e 2870995 Premium All Season Grease 14 oz 2871423 Premium All Season Grease 302 2871322 Premium 60 40 Anti Freeze Coolant 2871323 Premium Carbon Clean Fuel System Additive 2871326 Polaris Battery Tender 2 0 0 cece eee eee 2871076 Carbon Clean Fuel System Additive 2871326 T 9 Metal Protectant 0 ccc cee eee eee eee 2871064 Crankcase Sealant 3 Bond 1215 2871557 1 8 Gp POLARIS GENERAL INFORMATION d ACS Alternator control switch ACV Alternating current voltage Air Gap Spark Test A good check for ignition voltage and general ignition system condition S park should arc 3 8 1 cm minimum from end of high tension lead to ground Several testers are available commercially Alternator Electrical generator producing alternating current voltage Bore Diameter of cylinder BTDC Before Top Dead Center Bump Steer When skis toe in and toe out through suspension travel CDI Capacitor Discharge Ignition Ignition system which stores voltage generated by the stator plate exciter coil in a capacitor or condenser in CDI box Atthe proper momenta voltage generated by the stator plate pulser coil cl
91. 870975 Apply approximately 5 PSI pressure and wait for one minute The needle and seat should hold pressure indefinitely If the pressure drops rapidly replace the needle and seat assembly and or sealing washers Tel FUEL SYSTEM CARBURETION Throttle Synchronization Procedure 1 Remove air box noting position of throttle cable junction block Reposition throttle cable and junction block in same position when air box is reinstalled Throttle Cable Synchronization Throttle Gap 2 Referring to specification section in chapter 1 select correct diameter Throttle Gap synchronization drill gauge for your engine Back out idle screws about three turns 4 Slightly lift throttle slides with throttle lever and insert tool or drill gauge under throttle slide Allow throttle slides to return 5 Loosen lock nut and turn throttle cable adjuster on top of carburetor in clockwise or out counterclockwise as required until a slight drag can be felt on the gauge or tool 6 Securely tighten throttle cable synchronization lock nut 7 Repeat steps 3 through 5 on remaining carburetor ldle Gap Synchronization 8 Referring to chart in the Specifications section chapter 1 select correct diameter Idle Gap drill gauge for the engine 9 Slightly lift throttle slides with throttle lever and insert idle gap drill gauge under throttle slide Allow throttle slides to return 10 Turn idle adjustment screw in as required until only
92. 9 64 63 64 8 36 1 3 64 310 24 1 7 64 310 32 KE 1 11 64 12 28 1 11 32 1 4 20 127 64 1 4 28 19 16 5 16 18 1 43 64 5 16 24 i 1 25 32 3 8 16 E 1 59 64 3 8 24 2 1 4 4 1 2 2 1 32 7 16 14 2 1 2 4 2 1 4 EECH 2 3 4 4 212 34 2 3 4 Tepsize bilSize Decimal Equivalent Nearest Fraction 3x 50 3x 4x 4x 5x 5x 6 x 1 00 7 x 1 00 8 x 1 00 8x1 25 9 x 1 00 9x 1 25 10 x 1 25 10 x 1 50 11 x 1 50 12 x 1 50 12 x 1 75 GENERAL INFORMATION d PB Im ees RO RUE ERIT SR EA Gan Pa Fo mg ph Cubic inches cu in x 16 387 Cub cen metes c US quarts US qt Imperial quarts Imp qt US quarts US qt Liters 1 05 qus US a US gallons US gal Liters l EUS gas US ga Pounds force per square inch psi Kilopascals kPa Kilopascals kPa Pounds force per square inch psi Kilopascals kP a Kilograms force per square cm Kilograms force per square cm Kilopascals kPa C to F 9 C 40 5 40 F F to C 5 CF 40 9 40 C kg d GENERAL INFORMATION Description Part Number Chaincase Lubricant Ouart cece ees 2871280 Chaincase Lubricant Gallon 2870464 Chaincase Lubricant 2 5 Gallon 2872281 Fuel System Deicer Isopropyl aa 2870505 Loctite Primer T 6 Oz Aerosol 2870585 Loctite RC 680 10cc Retaining Compound 2870584 Loctite Chisel Gasket Remover 1
93. A tool catalog update is available through the Polaris parts department The part number is 9915235 Description P art Number Offset Alignment Tool 21 32 1 7 cm P 90 Clutches 2870914 Offset Alignment Tool 5 8 1 6 cm P 85 Clutches 2870426 T Handle Drive Clutch Puller Large Shaft ID 2870506 Drive Clutch Puller 550 Fuji Engines 2872084 Strap Wrench EE 2870336 Replacement Strap for 2870336 an 2870389 Spider Spanner Nut Driver Jam Nut 0004 2870338 Spider Removal Installation Tool 2870341 Holding Fixture eos Aree an URS KG AG 2871358 Holding Fixture Tab easain nenii eaea E eee 5130518 Tapered Reamer 2870576 Spider Button Tool nh 2870985 Clutch Bushing Rebuild Tool Kit P 85 P90 2871025 P 85 Drive Clutch Compression Tool 2870984 Driven Clutch Puller P 90 ccc cece eee ees 2871056 Torque Wrench 250 ft Ip Commercially Available Torque Wrench 0 200 in Ip Commercially Available Clutch Compression Tool 8700220 Clutch Holding Wrench 0 0 c cece eee 9314177 SEP BUON TOON ia 8716010 SLP Clutch Sheave Clamp Tool 8716020 DRIVE DRIVEN CLUTCHES TOC B Modified A 7581 Gram weignt 3g Gram Weight 37 59 Gg SET 41 591 Gram Weight 47 59 1 PN 5630063 PN 5630080 Ken Gram Weight 4991 Gram Weight 51 Gram Weight 5391 Gram Weight 32 58 1 PN 5630225 PN 5610088 PN 5630174 PN 5630227 M1 M
94. AL DRIVE Es 2 Rotate the straight spring arm counterclockwise while tilting the park lever down and inserting the pivot post into the pivot hole Pivot Hole 3 Release the straight arm of the spring and push the park lever pivot post down into position 4 With a small screwdriver push the straight spring arm down until it snaps into the notch in the housing 5 Fill reservoir Replace the master cylinder cover and screws Torque screws to 15 18 in lbs 1 7 2 0 Nm Cover Screw Torque 15 18 in Ib 1 7 2 0 Nm Es BRAKES FINAL DRIVE The caliper assembly is mounted on the chaincase which allows ease of brake pad and caliper service Measure brake pads from the back of the backing plate to the surface of the friction material as shown in illustration NOTE Replace pads when worn beyond service limit Brake Pad Thickness Minimum Pad Thickness 250 6 35mm Service Limit 250 6 35mm Friction Pad Replacement Carrier Bracket Attaching Bolts Carrier Bracket Piston Piston Seal S pring Clip Stop Light S witch Brake Pads Brake Line Bleeder Screw 10 Caliper 11 Rope Guide The rider s safety depends on cor rect installation Follow proce dures carefully ODADUAWNE CAUTION Protect eyes from brake fluid 1 Clean any dirt from mount bracket and bolts Brake cleaner may be used to aid in cleaning of components 2 Witha 9 16 socket remove
95. BURETION Altitude coor ee a ae E E TYPE se oia ei es TM40 Mikuni Main J CE kayat Dina 420 0 600 450 440 420 400 390 370 PilotJet 38 02009 18 18 43 e 2 2 Jet Needle 9DFH10 57 3 SH 420 ao a Ta 360 mo CU ECKE P Meters 400056000 400 390 370 350 340 320 Sai AN e Pao a ce Feet x 3 3 3 2 2 1 Air Screw N A 1800 2400 380 360 340 330 310 290 Valve Seat 1 8 GH 8 LE id 2 n E Fuel Octane R M 2 e SE EU 350 340 320 300 290 270 ag Ga P gt SE www T Y ME we ee a Starter et 145 XXX Pilot Air eL uocis 1 1Long st refers to the clip position from top of jet needle Exhaust Valve Spring Green Yellow CLUTCH Type P 85 CLUTCH CHART Belt 3211065 DRIVE DRIVEN Belt Width Projected 1 438 3 63cm Altitude Saiten ich clutch Driven Chaincase R2ircase Side Angle Overall 28 Weight Spring Spring Helix Gearing XT Outside Circumference 48 375 122 87cm Meters 0 900 10 58 Black Silver R8 23 40 70P 23 40 70P Center Distance 12 50 Feet 0 3000 Bushed Green Blue 2 HYVO HYVO Shift Weights 10 58 Bushed 10 56 Black silver R8 23 40 70P Primary Spring Black Green EEN Blug 2 SEA paa Secondary Spring Silver Blue e El De Sr SEET Ree 2700 3700 10 AL Black Silver R8 21 41 70P 21 41 70P 9000 12000 Bushed Green Blue 2 HYVO HYVO Eb Production Setting ENGINE PY PCr sad al Liquid Cooled Case Ree
96. Bar BODY AND STEERING Camber Adjustment XTRA CRC and XC 10 CRC Cont 8 Using a 3 8 drive 11 16 1 7 cm crow foot wrench and 20 51 cm long 3 8 1 cm drive extension loosen the radius rod end jam nut and remove the lower radius rod bolt from the spindle requiring the most camber correction Adjust the opposite side next Change radius rod length until alignment bar slides freely through both spindles 9 When adjustmentis correct tighten jam nuts to 24 25 ft lbs 33 35 Nm Torque radius rod attaching bolts to 28 30 ft lbs 39 41 Nm CAUTION Radius rod ends must remain parallel to the mounting Bulkhead brackets after the rod end jam nuts are tightened to d the specified torque See illustration at right 10 Tighten all jam nuts Torque radius rod attaching bolts to specification Rod end parallel to mounting surface when jam nut is tight ll Re check set up width and compare to specifications Handlebar Centering CRC 12 With alignment bar in spindles and tie rod ends Handlebar Centering CRC disconnected center the steering rack by pointing the pitman arm and idler arm straight forward 13 Center the handlebars by adjusting drag link length Tighten jam nuts to 24 25 ft Ibs 33 35 Nm 14 The steering arms should be parallel to the ski centerline or slightly inward Adjust Drag Link 3 Pitman Arm and To Center Bars m Idler Arm Point Straight Forward 15 Re attach
97. Bearin Piston Ring Damping 8 e 8 1 Spring Retainer Slotted Qc Bumper f SUSPENSIONS 2002 Fox Optional Valving Listed By Shock Part Number Refer to the appropriate parts manual for a complete listing of Fox shock parts Fox Registered Trademark of FOX Shox Shock Travel Limiting Spacer 1 4 Part Number 5431355 Valve Washer Part Numbers Part No Description Part No Description 1500052 1 300 x 0 006 1500046 0 900 x 0 010 1500050 1 250 x 0 006 1500047 0 800 x 0 010 1500049 1 100 x 0 006 1500044 0 700 x 0 010 1500048 1 000 x 0 006 1500079 1 300 x 0 012 1500053 0 900 x 0 006 1500078 1 250 x 0 012 1500054 0 800 x 0 006 1500060 1 100 x 0 012 1500055 0 700 x 0 006 1500059 1 000 x 0 012 1500030 1 300 x 0 008 1500058 0 900 x 0 012 1500051 1 250 x 0 008 1500057 0 800 x 0 012 1500031 1 100 x 0 008 1500056 0 700 x 0 012 1500032 1 000 x 0 008 1500087 1 300 x 0 015 1500033 0 900 x 0 008 1500086 1 250 x 0 015 1500028 0 800 x 0 008 1500085 1 100 x 0 015 1500029 0 700 x 0 008 1500084 1 000 x 0 015 1500062 1 300 x 0 010 1500083 0 900 x 0 015 1500026 1 250 x 0 010 1500082 0 800 x 0 015 1500027 1 100x 0 010 1500081 0 700 x 0 015 1500045 1 000 x 0 010 Note Subtract 029 from IFP depth for each 1 4 inch spacer added to
98. Bolt Torque 11 13 ft Ibs 15 18 Nm Replace handlebar cover O BODY AND STEERING Gasoline is extremely flammable and explosive under certain conditions Do not smoke or allow open flames or sparks in or near the area where work is being performed If you should get gasoline in your eyes orif you should swallow gasoline see your doctor immediately If you should spill gasoline on your skin or clothing immediately wash if off with soap and water and change clothing Prolonged exposure to petroleum based products may cause paint failures Always protect finished surfaces and wipe up any spills immediately Two Piece Fuel Tank Seat Removal Remove tank cover by disconnecting snaps Remove vent line at front LH side of tank Remove gas cap and rubber grommet Remove air silencer box Disconnect fuel line from fuel pump and plug line to prevent fuel spillage from tank See photo one at right 6 Roll front tank hold down spring forward off tank saddle 7 If machine is equipped with a fuel gauge connector this should be unplugged 8 Remove two bolts holding rear of seat to tunnel prado tance 9 Slide seat rearward enough to gain access to taillight connector at RH side of fuel tank Unplug connector Slide seat off machine and set aside 10 Fuel tank can now be removed from chassis by disconnecting two springs at center of fuel tank One Piece Fuel Tank Seat Removal 1 Remove front tank retaining spring loca
99. C Driven clutch spring broken or installed match engine application in wrong helix location c Replace spring refer to proper d Drive belt too long installation location e Improper driven clutch setup d Install new belt and or adjust belt tension e Install correct parts and or ad just to match engine application and ma chine use Erratic engine operating RPM Drive clutch binding or driven clutch Disassemble drive clutch inspect shift during acceleration or load malfunction weights for wear and free operation variations Clean clutches install new belt Converter sheaves greasy belt slippage Clean and polish stationary shaft hub reassemble clutch without spring to determine problem area Replace ramp buttons Inspect moveable sheave for excessive bushing clearance replace Engine RPM above specified a Incorrect drive clutch spring too high a Install proper spring operating range spring rate b Install proper shift weights b Drive clutch shift weights incorrect for c Disassemble and clean clutch application too light inspecting shift weights and buttons C Drive clutch binding Reassemble without the spring to d Driven clutch binding determine probable cause e Converter sheaves greasy belt slippage d Disassemble clean and inspect f Improper driven clutch setup driven clutch noting worn sheave bushing and ramp buttons and helix spring location e Clean clutches install new belt f Install correct parts and or adj
100. Center Hose Gripper Cooler Center Hose Engine Out F ront pper NOTE When leak testing cooling system system pressure should not exceed 2 Ibs less than cap pres sure Refer to filling and bleeding procedure on page 3 61 REAR CROSSOVER EXCHANGER TUNNEL ROLL EXCHANGER o ENGINES Cooling System 700 800 RMK 151 and Longer only A Colant Flow Gripper De Icer Hose Gripper Brake Cooler Hose Tee Brake Cooler A Engine Out 9 De K a wB Cooler Center Hose Gripper R ear Closeoff Hose Gripper Center Cooler Hose Tee to Engine Hose Center Cooler Tee ENGINE BY PASS NOTE When leak testing cooling system system THERMOSTAT pressure should not exceed 2 Ibs less than cap pres sure Refer to filling and bleeding procedure on page COOLANT BRAKE oon BOTTLE 4 COOLER CENTER EXCHANGER TUNNEL ROLL EXCHANGERS REAR CROSSOVER EXCHANGER Recoil Disassembly CAUTION ENGINES O Wear eye protection when servicing recoil Spring can unwind suddenly and unexpectedly if dislodged 1 Remove recoil handle and allow rope to retract and spring to unwind completely 2 Remove retaining nut friction plate and ratchet pawl from reel face 3 Liftreel assembly straightup outof housing NOTE If spring tension is relieved and the reel is lifted straight out the spring will most likely remain in the housing however be sure to heed caution above Assembly 1
101. Clutch Retaining Bolt Torque 12 ft Ibs 16 6 Nm Es BRAKES FINAL DRIVE Final Assembly Cont 15 Reinstall air box adjusting box properly 16 Reinstall battery if so equipped Always attach ground cable last to prevent sparks 17 Replace exhaust system 18 Install hood if removed aligning with marks made during disassembly Ensure proper hood closure and readjust if necessary Hood Bolt Torque 8 10 ft Ibs 11 14 Nm 19 Test ride the unit to ensure all components are functioning properly before putting into service BRAKES FINAL DRIVE Es The following illustration indicates sprocket position with the P olaris Reverse Kitin the forward and reverse selec tion Reverse Installation Tips Refer to Illustration on page 8 38 S When installing pinion shaft be sure the chamfered end of pinion shaft is toward case cover S Install chain top sprocket bottom option sprocket and wide face pinion gear into case at the same time S When installing case cover be sure that shift fork has slipped into fork groove of reverse gear Forward Position Reverse Position Top Sprocket _m Se 5 7 psp Drive Chain Chain Pinion Gear Chain Pinion Gear Chain Pinion Gear Wide Face Narrow Face _ Narrow Face paa SE VN Chain Pinion Gear e Wide Face MN B i Spur Pinion G pur Pinion Gear 7 Spur Pinion Gear E e Shift Fork Groove Reverse Kit Option Sprocket R
102. DED 41 76 NOT RECOMMENDED 39 74 40 76 NOT RECOMMENDED 41 76 39 76 NOT RECOMMENDED 40 76 pulo D POLARIS 8 7 Es BRAKES FINAL DRIVE Hydraulic Brake System Overview The Polaris snowmobile hydraulic brake system consists of the following components or assemblies brake lever master cylinder hydraulic hose brake caliper slave cylinder brake pads and a brake disc which is secured to the drive line When the hand activated brake lever A is applied it contacts a piston B within the master cylinder As the master cylinder piston moves inward it closes a small opening called a compensating port C within the cylinder and starts to build pressure within the brake system As the pressure within the system is increased the piston D located in the brake caliper moves outward and applies pressure to the moveable brake pad This pad contacts the brake disc moves the caliper in its floating bracketand pulls the stationary pad into the brake disc As the lever pressure is increased the braking effect is increased The friction applied to the brake pads will cause the pads to wear As the pads wear the piston within the caliper self adjusts and moves further outward Brake fluid level is critical to proper system operation A low fluid level allows air to enter the system causing the brakes to feel spongy Compensating Port Located within the master cy
103. E Itis not necessary to increase RPM The reading can be obtained at idle Usage S Testing stator coil power output GNG TAB Opa LES ELECTRICAL Multimeter Usage A Amps DC used to check battery charge rate system draws etc Used to check the current flow to and from the battery Test Method 1 Make sure red lead is in the 10A terminal of the meter and the black lead is in the Com terminal of the meter 2 Disconnect battery ground wire s from battery terminal 3 Connect red meter lead to battery terminal 4 Connect black meter lead to harness ground wires and cable CAUTION Do not operate electric starter if equipped or meter damage may occur Usage S Testing key off current draw S Testing key on current draw S Testing charging system break even RPM S Testing DC current flow direction is battery charging NOTE When using the DC Amp settings the red test lead must be moved to the 10A socket on the front of the instrument ELECTRICAL Ignition Timing A Maximum Advance Depending on Model TIMING ADVANCE DEGREES 1000 2000 3000 4000 5000 6000 7000 8000 AM RPM Ja NOTE Always verify timing of engine at room temperature only 68 F 20 C and at the proper RPM To obtain the best ignition timing accuracy and reduce the chance of error the ignition timing specification is given ata lat portion of the advance curve This flat portion on the curve
104. FIER R C BR 6 d i BK M SEN R B STARTER R W S LONTEIONPSHEIGH Poy STARTER RELAY A A CHASSIS GND 1 COLOR CODE EAS SAA A R RED i BRN BROWN i ENGINE GND BLK BLACK 1 Y YELL LI 1 1 D Remove starter motor and disassemble S ee page 9 14 for exploded view Mark end covers and housing for proper reassembly Remove pinion retaining snap ring spring and pinion gear Remove brush end bushing dust cover Remove housing through bolts Slide brush end frame off end of starter NOTE The electrical input post must stay with the field coil housing Slide positive brush springs to the side pull brushes out of their guides and remove brush plate Clean and inspect starter components NOTE Some cleaning solvents may damage the insulation in the starter Care should be exercised when selecting an appropriate solvent The brushes must slide freely in their holders If the commutator needs cleaning use only an electrical contact cleaner and or a non metallic grit sandpaper Replace brush assembly when worn to 5 16 8 cm or less Starter Housing and Field Coil Inspection l Using a digital multitester measure resistance between starter input terminal and insulated brushes The reading should be 3 ohms or less 2 Measure resistance between insulated brushes and field coil housing The reading should be infinite 3 Inspect insulated brush wire and field coil insulation for damage Repair or replace components a
105. FP Spring Rate 170 in All Models RearSprings 359 sq 47 All Models Track Type 15 x144 x2 0 38 1x365 76x5 08cm or 15 x151 x2 0 38 1x383 40x5 08cm or 15 x156 x2 0 38 1x396 24x5 08cm Track Tension 3 8 1 2 1 1 3 cm slack with 10s 4 54kg weight 16 40 64cm ahead of rear idler shaft Overall Snowmobile Length 144 Track 119 75 304 2cm 151 Trackz 123 5 314cm 156 Track N A Overall Snowmobile Height 48 5 123cm Maximum Snowmobile Width 47 25 120cm OPTIONAL REAR TORSION SPRINGS 347 Sq Diameter x 47 359 Sq Diameter x 47 375 Sq Diameter x 47 L H 7042081 067 L H 7042068 067 L H 7042079 067 R H 7042082 067 R H 7042069 067 R H 7042080 067 re CHAPTER 2 MY MAINTENANCE AND TUNE UP General Maintenance Inspection Sheet Z4 Recommended Maintenance Products 2 2 Air Filter Maintenance 254v2oed 1 DA MER RAS et 2 3 Sediment Trap Oil Fuel Filter Maintenance 2 4 ACCS Maintenance cesta 2 5 General Lubrication EE 2 6 Water Pump Belt Tension NN exe x EN ez E x 2 7 Chaincase Oil Drive Chain Maintenance 2 8 Suspension Lubrication 22 323 220 kaki x eat DRY Ee YI 2 9 Cooling System Inspection and Maintenance 2 11 General Track Inspection and Maintenance 2 12 Spark Plug Inspection uu uo Na a YER e wc 2 14
106. IN is the model year of the vehicle Example W 1998 X 1999 etc Refer to the listing below 1 2001 2 2002 3 2003 d GENERAL INFORMATION Standard Torque Specifications The following torque specifications are to be used as a general guideline when torque value is not specified There are exceptions in the steering suspension and engine areas Always consult the torque chart and the specific manual section for torque values of fasteners DUE Bolt Size Threads In Grade 2 Grade 5 Grade 8 MM Thread Torque in Ibs Nm 10 pA 2I WEE AS 5 saba maang na 60 6 9 10 32 voe Es 31 3 6 49 5 6 68 7 8 Torque ft Ibs Nm 14 SE E KA ENEE e CSN E 12 16 14 20 2 M ES NEE TO TA Sun ess 14 19 5 16 EE TT T5 eebe LAR EE 25 35 5 16 EE 12 LE n verres 19 26 29 40 3 8 WO sins sac ara rara 20 2 T geg and vce ica maa 30 40 aaa aca aa za 45 62 3 18 24 23 32 sees 35 48 50 69 7 16 IT RAA 30 40 zz tcr sua cha 50 69 sss 70 97 7 16 ZO KNA GEI 55 A EE 80 110 12 1342 AN 50 69 0 alas 75 104 110 152 12 LO naawa 55 16 aaa eaten a 90 124 120 166 To convertft lbs to Nm multiply foot pounds by 1 356 To convert Nm to ft lbs multply Nm by 7376 GENERAL INFORMATION d EE 0156 EE 0312 cR 1 mm 0394 EE 0469 UNE 0625 ji DOT s eee Et 2 mm
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108. OL 3 Check the resistance between each of the switch Ignition S witch terminals and the switch body With the switch still in the on position there must be an open circuit OL reading Readings other than those listed indicate a defective switch Ignition Switch Testing Electric Start Models NOTE Refer to the appropriate model and year wiring diagram for ignition switch wire colors and connections 1 Disconnect wires Set the multitester dial to the ohms Q position 2 With the key in the off position check the resistance between the G Ground brown terminal and the M Mag black terminal This reading mustbe less than 4 ohms 3 Turn the key to the on position The multitester should now read an open circuit OL Off On Start 4 Move the tester lead from the G terminal to the switch housing and re check the reading It should also be an Bm open circuit OL f 5 Place one of the tester leads on the B Battery red terminal and the other tester lead on the S Starter blue terminal With the key in the on position there must be an open circuit OL reading 6 Turn the key to the start position The reading should be f Blk less than A ohms Readings other than the ones listed indicate a defective switch M Ignition S witch Electric Start ELECTRICAL Coolant Temperature Indicator Testing Ground the Black W hite wire Circuit with the engine running to t
109. P olaris for repairing hoods Hoods for 2001 model snowmobiles are made of Thermoplastic Olefin TPO and cannot be repaired If a hood is broken it must be replaced For small cracks you may drill a small hole on both ends of the crack to limit spreading Gp POLARIS 6 29 9 BODY AND STEERING Taillight Assembly Replacement 1 After removal of seat cover drill out three rivets from top of taillight 2 Remove taillight assembly and wire harness 3 Install new taillight assembly and rivet into place 4 Connect taillight wire harness NOTE Taillight harness wires must be routed away from any possible contact with seat cover staples to prevent electrical shorts 5 Pullseatcover tightly and evenly into position and re staple to seat pan 6 Inspect cover for a wrinkle free finish before reinstalling on the snowmobile BODY AND STEERING Nosepan Replacement Procedure Gen Il XTRA 10 IMPORTANT When installing a replacement nosepan the open circles representrivets installed from inside the nosepan through the bottom The filled in circles representrivets installed from the under side of nosepan through to the top NOTE The rivet for polyethylene nosepans is PN 7621467 NOTE Rivet holes may require drilling into the bulkhead Non tipped in trailing arm style NOTE 1 When transfer drilling holes do not force pan into a position which is not uniform with the other side Use the same method to drill both s
110. POLARIS he Way Out INDY TRAIL RMK INDY 500 RMK INDY 500 SKS EURO 600 EDGE RMK INDY 700 SKS EURO SKS ZOO EDGE RMK 800 EDGE RMK PO 2002 DEEP SNOW SERVICE MANUAL em PART NUMBER 9917366 Printed in U S A N N LI m m U o c O 2 o m JJ lt O m gt Z gt POLARIS The Way Out LIVE THE RIDING EXPER WORK TO MAKE IT BE DEEP SNOW SERVICE MANUAL Foreword This manual is designed primarily for use by Polaris snowmobile service technicians in a properly equipped shop Persons using this manual should have a sound knowledge of mechanical theory tool use and shop procedures in order to perform the work safely and correctly The technician should read the textand be famil iar with service procedures before starting the work Certain procedures require the use of special tools Use only the proper tools as specified Cleanliness of parts and tools as well as the work area is of primary impor tance All references to left and right side of the vehicle are from the operator s perspective when seated in a normal riding position This manual includes procedures for maintenance operations componentidentification and unit repair along with service specifications for the Polaris Indy 500 Euro 700 SKS Trail RMK 500 RMK 600 EDGE RMK 700 EDGE RMK 800 EDGE RMK snowmobiles A table of contents is placed at the beginning of each chapter and an alphabetic index is provid
111. Piston Ring End Gap Head ccs Uninstalled 0059 0 15mm 3021088 N A 0 012 0 018 0 30 0 46mm 36 0cc Head ccs Installed 29 0cc Operating RPM 200 8000 RPM Idle RPM 200 1500 RPM Engagement RPM 300 N A RPM Cylinder Head Torque 18 22 ft Ibs 25 30 Nm Cylinder Base Nut Torque 30 34 ft lbs 41 47 Nm Crankcase Torque 8mm 20 24 ft lbs 28 33 Nm Crankcase Torque 10mm 26 30 ft lbs 36 41 Nm 1 20 Cylinder Head Mark 3022057 Gp POLARIS GENERAL INFORMATION d MODEL 600 EDGE RMK MODEL NUMBER SO2NJ 6ES ENGINE MODEL S2187 6044PL6E ELECTRICAL CAPACITIES Flywheel I D 4010629 Fuel Tank 11 8 gallons 44 7 liters CDI Marking 4010554 Oil Tank 3 25 quarts 3 07 liters Alternator Output 280 Watts Coolant 4 3 quarts 4 07 liters Ignition Timing 24 9 3500RPM 500 Chaincase Oil 11 fl 02 325cc With TPS Unplugged 1350 BTDC 3 43mm BTDC Spark Plug Gap Champion RN57YCC 0 025 0 64mm Voltage Regulator T1 Electric Start Option Magneto Pulses 6 SUSPENSION CHASSIS CHAINCASE Body Style EDGE RMK Sprockets Chain 19 39 72P HYVO Front Suspension EDGE RMK Reverse saa Option Front Shocks Nitrex Brake Pads Type 81 Large IFS Spring Rate 100 in Chaincase Center Dist 7 92 20 12cm Fro
112. Remove two upper flangette attaching bolts Es BRAKES FINAL DRIVE Rear Suspension Removal Cont 6 Removethree bolts nuts and washers securing angle drive and bearing flangettes Remove and discard adaptor key 7 Remove four suspension mounting bolts 8 Place a protective mat on floor and tip machine onto left side 9 Remove rear suspension by pulling rear of track outward and sliding suspension forward Lift out rear of suspension first NOTE Unhookthe reartorsion springs to relieve pressure on the torque arm for ease of removal Loosen rear shaft bolts and adjuster bolts slide rear shaft forward for ease of removal Chaincase Removal 1 Remove third jackshaft flangette attaching bolt Tip machine back to upright and support rear with jack stand 2 Remove chaincase cover attaching bolts and remove cover 3 Remove cotter pin and nut 4 Loosen chain adjustment bolt and remove chain tensioner assembly 5 Remove bottom sprocket attaching bolt chain and sprockets 6 Remove two bolts securing caliper carrier bracket to chaincase NOTE Inspect brake pad condition and replace if worn to less than 1 2 the original thickness See Brake Pad Re placement in this chapter 7 Remove three chaincase to bulkhead attaching nuts and bolts The front bolt is a through bolt rear and bottom bolts are carriage bolts NOTE On some machines it may be necessary to remove the rear exhaust bracket prior to l
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115. The TPS comes set from the factory and should not need adjustment However upon removal of the TPS you must mark the TPS position on the carburetor and replace itin the exact same position as removal Polaris has developed a TPS test kit for aid in setting the Throttle Position Sensor to specification TPS Testing l Illustration at right shows the TPS sensor kit PN 2201519 H Black Pink 2 Make sure your 9 volt battery is in good condition by inserting the black volt meter probe from your Fluket meter in the black terminal and the red probe into the pink terminal Voltage should read 4 99 to 5 01 volts If not try a new 9 volt battery 3 Remove the connector from the TPS ELECTRICAL TPS Testing Continued 4 Install test harness connector on TPS 5 Insert red voltmeter lead into yellow terminal and black lead to black terminal Slowly open throttle and check for smooth voltage change NOTE The fluke meter will change scales and show O L momentarily when throttle is opening 6 Voltage at yellow terminal should be 4 0 to 4 2 volts at Wide Open Throttle for domestic engines and 3 77 volts for Fuji engines 800 XCR If not the TPS must be adjusted to this specification TPS Volts at Wide Open Throttle Polaris Domestic Engines 4 0 to 4 2 volts TPS Volts at Wide Open Throttle Fuji 800 XCR Engine 3 77 Volts ELECTRICAL TPS Adjustment 1 Loosen the two sc
116. The jet needle tapers off at one end and the clearance be tween the jet needle and 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 The chart at right shows the variation of fuel flow based on the height of the E ring Needle J et Fig 2 The needle jet works in conjunction with the jet needle to regulate fuel flow rate An air bleed opening in the side of the needle jet brings in air measured by the air jet This air initiates the mixing and atomizing process inside the needle jet Mixing is augmented by a projection at the needle jet outlet called the primary choke The letter number code stamped on the jet indicates jet inside diameter Throttle Opening vs Fuel Flow Fig 3 In a full throttle condition the cross sectioned area be tween the jet needle and the needle jetis larger than the cross sectioned area of the main jet The main jet therefore has greater control over fuel flow Small Medium Large Clearance f Clearance Clearance Closed One half Full Throttle Throttle Throttle Fig 3 4 16 Throttle Valve J et Needle By pass Pilot Outlet Fuel flow Pilot J et Needle J et Main J et 15 50 75 100 Fig 1 Throttle Valve Opening Air Bleed Opening FF
117. Volts AC Vp position Disconnect the alternator to main harness connector at engine Connect one of the tester leads to the yellow alternator wire and the other lead to the brown alternator wire NOTE On floating alternators the yellow red stator wire should connect to the brown stator wire If it does not the system will not have a ground and will not operate Start the engine While observing the voltage reading increase the engine speed to about 3000 RPM Readings of between 15 and 45 VAC are considered normal Short Circuit Current AC Amp Test 1 2 3 4 5 Turn multitester dial to Ap Connect red lead to 10A terminal Connect black lead to Com meter terminal Disconnect lighting charge coil wires from system Connect meter leads to coil wires leading to stator coils Start and idle engine Readings should be above 5 amps Referto Amps AC on page 9 2 Regulated Voltage Connect the alternator to main harness connector Insert one of the tester leads along the side ofthe yellow regulator wire connector between the insulation and the terminal Ground the other tester lead Start engine and observe headlight output Increase engine RPM If the headlights seem dim above 3500 RPM let the engine return to idle and disconnect the yellow wire from the regulator Carefully observe the voltage reading Do notallow voltage to increase above 14 0 volts Slowly increase RPM Voltage above 12 volts at 2500
118. When possible do not go in deep snow when towing RPM another machine Use fast effective throttle to en gage the clutch Not all machines are intended for pulling heavy loads or other machines Spinning track while vehicle is stuck high RPM low Lower the gear ratio Remove windage plates from vehicle speed high ambient temp Example 8000 driven clutch If possible move to better snow condi RPM 10mph vehicle speed 60 mph indicated on tions and reduce RPM Avoid riding in very high am speedometer bient temperatures Ice and snow piled up between track and tunnel Break loose snow and ice under tunnel Allow longer overnight or after stopping for a long period of time than normal warmup Allow belt to warm sufficiently enough to re freeze the snow and increase grip ability on clutch sheaves Use fast effective throttle when engaging clutch Poor running engine Maintain good state of tune including throttle and tc choke synchronization Check for fouled spark i09 MS BAKE Clay plug s Check for foreign material in carbs Make sure no water or ice in fuel tank lines or carbure tors Loading machine on trailer Use caution when loading machine Carbide skags may gouge into trailer and prevent drive train from spinning freely Use enough speed to drive com pletely onto trailer If machine cannot be driven com pletely onto trailer it may need to be pulled or pushed to avoid belt wear burning Clutch malfunction Chec
119. YCC 0 025 0 64mm Voltage Regulator LR7 Electric Start Option LR7 Full wave voltage regulator Magneto Pulses 6 SUSPENSION CHASSIS CHAINCASE Body Style Gen ll Sprockets Chain 23 40 70P HYVO Front Suspension Indy XC 10 Reverse oo o Option Front Shocks Indy Select Brake Pads Type 81 Large IFS Spring Rate 100 in Chaincase Center Dist 7 05 17 91cm Front Spring Preload 3 4 Thread Adjust Driveshaft Sprockets 2 Drivers Wide Front Vertical Travel 9 6 24 4cm Brake Type Polaris HPB Liquid Cooled Rear Suspension XTRA 10 136 XTRA 10 European Rear Axle Travel 9 5 in 24 1cm Front Track Shock Nitrogen Cell Spring Rate 200 in variable Rear Track Shock Indy Select RearSprings 359 sq 77 Track Type 15 x136 x1 25 38 1x345 44x3 175cm Track Tension 3 8 1 2 1 1 3 cm slack with 10 4 54kg weight 16 40 64cm ahead of rear idler shaft Overall Snowmobile Length 116 295cm Overall Snowmobile Height 45 114cm Maximum Snowmobile Width 48 122cm OPTIONAL REAR TORSION SPRINGS 700 SKS 347 Sq Diameter x 77 359 Sq Diameter x 77 405 Sq Diameter x 77 L H 7041627 067 L H 7041629 067 L H 7041655 067 R H 7041628 067 R H 7041630 067 R H 7041656 067 d GENERAL INFORMATION MODEL 700 EDGE RMK
120. a slight drag can be felt on the gauge 11 Repeat steps 8 through 10 for remaining cylinders 12 Verify proper throttle lever free play and adjust if necessary by loosening cable adjuster locknuts and turning adjusters out equally until throttle lever freeplay is correct Throttle Free Play 0 010 0 030 25 76mm 4 24 MIKUNI Center of slide under cutaway See chart for size Ce du AO mp IL A Forward Gp POLARIS FUEL SYSTEM CARBURETION O CAUTION Wear eye protection when using compressed air or cleaning solvents Review all fuel system warnings found on page 4 1 before proceeding Carburetor Removal Disassembly and Inspection 1 Remove carburetor rack from engine Before disassembling clean outside of carburetor thoroughly with solvent CAUTION Do not use compressed air to dry at this time The float chamber could become pressurized resulting in damage to the floats or inlet needle and seat Do not soak carburetors in carb cleaner Clean only with aerosol cleaner 2 Remove top caps 3 Remove four screws on funnel 4 Turn throttle shaft so slide opens all the way NOTE You may have to turn out slide stop screw for slide to move farther up body 5 With slide fully open pull funnel out bottom first O FUEL SYSTEM CARBURETION Disassembly Cont 6 From top of carb loose
121. a baffle inside the airbox This pro vides a more consistent pressure difference between the carburetor venturi and the float bowl as the vacuum inside the airbox changes For example if the airbox foam filter becomes restricted with snow when riding in pow der the airbox vacuum increases Without airbox venting the pressure difference would increase substantially choking or flooding the engine With airbox venting the pressure difference remains the same creating a slightly leaner mixture to compensate for reduced air flow Vent Line Routing Opposite Carb to Handlebar TeeFitting Atmospheric Pressure Direction Through Valve Some Models Have Interconnecting Lines Between each Carb TeeFittings Are Orientated Vertically Air Box Some models have airbox venting O FUEL SYSTEM CARBURETION Fuel Delivery System Typical The fuel system contains many components which directly affect fuel mixture and driveability When performing diagnosis or carburetor maintenance the entire fuel delivery system should be inspected The illustration below shows parts of the system requiring periodic maintenance to ensure there is no fuel or air leaks present Fuel filters should be replaced at least once per season More often if any contamination is suspected Fuellines should be replaced every other season More often if they becom
122. able Rear Track Shock Indy Select RearSprings 347 sq 77 Track Type 15 x136 x1 5 38 1x345 44x3 81cm Track Tension 3 8 1 2 1 1 3 cm slack with 10 4 54kg weight 16 40 64cm ahead of rear idler shaft Overall Snowmobile Length 116 295cm Overall Snowmobile Height 45 114cm Maximum Snowmobile Width 43 5 110 4cm OPTIONAL REAR TORSION SPRINGS STD ERRE _ O O 347 Sq Diameter x 77 375 Sq Diameter x 77_ L H 7041627 067 L H 7041631 067 R H 7041628 067 R H 7041632 067 d GENERAL INFORMATION MODEL iiis INDY TRAIL RMK MODEL NUMBER SO2SR5BS ENGINE MODEL EC55PM024 JETTING CHART AMBIENT TEMPERATURE C A R B U R E TIO N Below 30 F 30_to 10 F 10 to 10 F H0 t 430 F 30 to 50 F Above 450 F Altitude Below 34 C 34 to 23 C 23 to 12C 12 0 1C 1 HOC Above 40 C TYPE EEN VM34SS Mikuni w ACCS 0 600 300 290 280 270 260 250 MainJet 270 0 200 B E 8 E 38 3 AAA 35 a ee a Si x 260 250 t Needle rodeos 6DEH11 3 NET E 20 286 o 200 20 Needle Jet Q 0 480 Feet 4000 6000 8 8 ES 8 8 8 Cutaway 3 0 CINE 290 280 270 260 250 AirScrew 1 5 Turns m B ZS B 5 m Valve Seat 1 5 Viton duae 300 290 280 270 260 250 Fuel Octane R M 2 87 Non Oxygenated is E X i Throt
123. abrasive brush O ENGINES Variable Exhaust System V E S V E S Assembly 1 Insert exhaust valve into valve housing Re place housing gasket 2 Install washer beveled side out and bellows 3 Apply Loctitet 262 to threads of valve and install valve cap Torque to specification Valve Cap Torque 6 Ft Ibs 8 3 Nm 4 Install spring valve cover and adjuster nut Torque exhaust valve cover bolts to specifica tion Valve Cover Bolt Torque 4 Ft Ibs 5 5 Nm 3 48 Gp POLARIS ENGINES O Variable Exhaust System V E S 5 Install V E S assembly onto cylinder and torque V E S housing bolts to specification Setspring adjuster screw to desired specification V E S Housing Bolt Torque 9 Ft Ibs 12 Nm V E S Adjustment The RPM at which the exhaust valves open and close can be tuned by turning the spring adjuster in or out for the desired valve characteristics l Turning spring adjuster in S Creates more spring pressure S Allows exhaust valve to open at slower rate S For applications such as drag racing 2 Turning spring adjuster out S Creates less spring pressure S Allows exhaust valve to open at faster rate S For applications such as trail riding Riders can fine tunethe VES to suittheir riding con ditions and power delivery characteristics Base setting is with adjuster screw flush with housing CAUTION Do notturn spring adjustertoo far The spring adjuster is turne
124. age to snap ring grooves lift crankshaft straight upward and out of lower case i ET la i T as sf e vi P LIT IT ki H A 14 If pump shaft removal is necessary remove retaining pin from crankcase using a diagonal cutter or similar tool 15 Tap out the drive shaft using a center punch and hammer Locate the center punch in the centering hole on the oil pump end of the shaft Be careful not to damage the bearing This will remove the oil seal and the mechanical seal from the crankcase A ENGINES Assembly Oil Pump Side 1 Insertbushing into case on oil pump side of case Press in until firmly seated in case 2 Install the bearing washer to the oil pump end of the shaft S Lubricate shaft insert shaft through the case on water pump side into the bushing on oil pump side 3 Lubricate and install bearing washer and brass bushing onto the shaft on waterpump side NOTE If front bushing is replaced it may be necessary to drill a retaining pin hole in the new bushing If there is no hole in the bushing S Measure depth ofthe retaining pin hole in the old bushing S Using the retaining pin hole as a guide carefully drill a hole in the new bushing to the same depth and diameter as the hole in the old bushing Be careful not to enlarge the retaining pin hole or z GENO AP e s Align hole in bushing S Install new retaining pin 1 with weep hole and 4 Lubricate and install oil seal with seal l
125. all times throughoutthe year in their local area When the weather is very cold gasoline must be able to vaporize very quickly in order for an engine to start and warm up properly If summer blend fuel is being used in the winter little or no vaporization will occur Droplets will form causing flooding and very hard starting If winter blend fuel is being used during the summer months it may cause vapor lock boiling fuel inside the fuel lines fuel pump or carburetor This will cause warm engine driveability problems and hard starting when warm Some states are limiting the Reid Vapor numberto 9 0 PSI yeararound to help meetevaporative emissions stan dards Warm Weather Low Vaporization Rate Maximum Reid Vapor Ambient Air Temp Range 8 sees sr uer ers ar ar Cold Weather High Vaporization Rate Add 2 4 F for each 1000 feet above seal level FUEL SYSTEM CARBURETION Tel Float Chamber Venting Fuel flows through a carburetor by creating a pressure difference between the venturi and the floatbowl The greater the pressure difference the greater the fuel flow On some models the float bowl is vented to the handle bars This provides consistent atmospheric pressure for a consistent fuel flow If the vent lines become kinked plugged or exposed to fluctuating pressures under hood the pressure difference will change causing erratic fuel flow Polaris has airbox venting on some models The vent lines are connected to
126. arings on drive shaft S If bearings are loose internally or rough they should be replaced S If bearings are loose on the shaft the shaft must be replaced BRAKES FINAL DRIVE Es Chaincase Assembly 1 Apply Loctite 680 to outer race of new bearing and press into position Press on outer race only or bearing damage may result Loctite 680 PN 2870584 2 Reinstall snap rings 3 Press new seals in until outer edge is flush with chaincase shoulder New seals must be installed from outside of case with lip side in 4 Install chaincase NOTE Do not tighten chaincase bolts at this time Jackshaft Installation l Replace seal sleeves and O Rings with new and grease 2 Install jackshaft installation tool on the threads of the jackshaft J ackshaft Installation Tool PN 2870974 13 Tooth J ackshafts PN 2871296 15 Tooth J ackshafts 3 Insert jackshaft through bearing in chaincase 4 Install jackshaft alignment tool and secure with castle nut and flat washer Tighten jackshaft nut securely to ensure positive bearing and jackshaft seating to chaincase NOTE Use ofa standard nutand flat washer for this align ment process will simplify the process as well as preserve the locking features of the lock nut for reassembly Jackshaft Alignment Tool PN 2870399 13 Tooth J ackshafts PN 2871535 15 Tooth J ackshafts Es BRAKES FINAL DRIVE J ackshaft Installation Cont 5 If shaft is not
127. as the ability to retard ignition timing whenever engine temperature exceeds a given set of parameters at specific RPM ranges Because of the three inputs the temperature indicator light and ignition timing depend on there is no one given specification to when the temperature warning light or ignition limiting function will activate Coolant Temperature Sensor Testing Temperature Sensor Temperature esistance 20 C 68 F 43222500 100 C 212 F 192230 ELECTRICAL Insulat Ofideswitth 2 9 Auxiliary Kill S witch Contacts Ignition P rimary Conductor Plungers Outward Idle S witch Engine Ground Throttle Control Cutaway The speed control assurance consists of two series connected switches If one or both switch plungers are posi tioned inward the circuit is open and the engine will run At idle with the throttle lever properly adjusted the bottom switch circuit is open and the plunger is inward The top switch circuit is closed and the plunger is outward The speed control circuit is open allowing the engine to run As the throttle lever is actuated to an off idle position the top switch circuit is opened plunger in and the bottom switch circuit is closed plunger out The speed control circuit is still open allowing the engine to run In the event the carburetor or controls malfunction and allow the throttle cable to become slack the circuit will close both switch plungers out grou
128. ase Acceptable gearing chain combinations are listed below for the 7 05 center distance chaincase Refer to page 8 1 for chaincase center distance by model Combinations listed as not recommended should not be installed EE E TI of Teeth of Teeth NOT RECOMMENDED NOT RECOMMENDED NOT RECOMMENDED NOT RECO NDED NOT RECO NOT RECO NOT RECO NOT RECO NOT RECO NOT RECO NOT RECO NOT RECO NOT RECO NOT RECO NOT RECO AA sR COED PPT wi a464i prae aaa CA a a eee 50 189 D JNPTRECONMERDED CO CC 8 6 Go POLARIS BRAKES FINAL DRIVE Sprocket Chain Combinations 7 92 Chain Case Acceptable gearing chain combinations are listed below for the 7 92 center distance chaincase Do not use this chart for models with 6 625 or 7 05 chaincase Referto page 8 1 for chaincase center distance by model Combinations listed as not recommended should not be installed of Teeth of Teeth 35 70 NOT RECOMMENDED 37 70 39 72 NOT RECOMMENDED 40 72 41 72 35 70 NOT RECOMMENDED 37 70 39 72 40 72 41 72 35 70 37 72 NOT RECO 39 72 40 72 41 74 NOT RECO 35 70 37 72 NOT RECO 39 72 40 74 NOT RECO 41 74 35 70 37 72 39 74 NOT RECOMMENDED 40 74 41 74 35 72 NOT RECOMMENDED 37 72 39 74 NOT RECOMMENDED 40 74 41 74 35 72 37 72 39 74 40 74 41 76 NOT RECO 35 72 37 74 NOT RECO NDED 39 74 40 76 NOT RECOMMEN
129. aulic Caliper Removal Installation 8 22 8 24 Drive System Removal Installation 8 25 Rear Suspension Removal cece cece ees 8 25 8 26 Chaincase J ackshaft Driveshaft Removal 8 27 8 28 Chaincase J ackshaft Driveshaft Installation 8 29 8 31 Track Installation EE 8 32 Final Assembly a oon Pe RBS E 8 33 8 36 Reverse Maintenance Adjustment 8 37 8 38 Chaincase IEN 8 39 BRAKES FINAL DRIVE 2002 Tracks Length x Width Lug ae Indy 700 SKS 15 x 136 Indy 600 EDGE RMK 15 x 136 Indy 700 EDGE RMK 15 x136 15 x144 15 x151 Indy 800 EDGE RMK 15 x144 15 x151 15 x156 2002 Chaincases Chaincase Version Indy 500 SKS 7 05 17 91cm Indy 700 SKS 7 05 17 91cm Indy Trail RMK 7 05 17 91cm Indy 500 RMK 7 05 17 91cm Indy 600 EDGE RMK 7 92 20 12cm Indy 700 EDGE RMK 7 92 20 12cm Indy 800 EDGE RMK 7 92 20 12cm Es BRAKES FINAL DRIVE pepusuiuu029 JON YN jew sur esr zr ear e eur see rer sr soe s owe ps rar sc ss se rw ew rm fee MNOH Yad SITIN Wadi euer sr sz ww pus vr v2 9N S wN s v v ww amp S NN vx we DDL zz 22 un oz 02 oz un zz zz zz un oe 00 oz tm amuy coz Wad oursug h le sz onew yamno eet yd ones WdH Gp POLARIS 8 2 BRAKES FINAL DRIVE Es
130. base only and install into wire harness Insert bulb into housing Carefully flip spring back into housing placing it around wire harness Squeeze spring together until itis over spring retainerandrelease Verify headlight aim Removing and Installing Halogen Bulbs High Beam 1 2 3 4 Remove wire harness Grasp bulb firmly and twist it 1 2 turn counterclockwise Remove bulb from housing and replace with new bulb P lace bulb and housing back inside hole and turn housing 1 2 turn clockwise to lock into place Reinstall wire harness to housing 2 16 Lamp Center Height 2 5 1 cm Headlight Adjustment Knob Wire bd p Pd 7 Bulb S pring Gp POLARIS Taillight Bulb Replacement MAINTENANCE TUNE UP 1 Remove 5 Phillips screws from taillight lens 2 Working from front to back carefully pry lens away from housind and remove Pull bulb straight out from socket and insert new bulb Reinstall lens Handlebar Adjustment 1 Remove handlebar cover Socket Screws 2 Using a 7 16 11 mm wrench loosen four nuts on bottom of adjuster block NOTE Turn handlebar to left or right for access to back nuts 3 Adjusthandlebar to the desired height Be sure thathandlebars brake lever and throttle lever operate smoothly and do nothitthe gas tank windshield or any other part of the machine when turned fully to the left or right 4 Torque the handlebar adjuster block bolts to spe
131. bearing to achieve proper offset Most models require the driven clutch to float on the jackshaft After adjusting offset add or remove shim washers from the retaining bolt to provide a 030 060 75 1 5mm of float on jackshaft This will prevent side loads on the jackshaft bearing NOTE On models with driven clutch snap ring retainer the clutch is mounted firmly on the shaft without float NOTE When checking electric start models use a straight edge as shown in Ill 2 If alignmentis off loosen the engine mounts and shift engine as required to obtain the proper offset and alignment Driven Clutch Bolt Torque 12 ft Ibs 16 6 Nm Gp POLARIS DRIVE DRIVEN CLUTCHES Offset Non Electric Start Models A ogapat 5 8 offset All models with P85 driven clutch NOTE Up to 060 1 5mm air gap allowed at point B Up to 125 is acceptable on new machines Offset Alignment Tool Offset Electric Start Models NOTE Up to 060 1 5mm air gap allowed at point B 125 on new machines Straight Edge f P85 Electric Start 1 00 B SECH VEA EM 5 33 DRIVE DRIVEN CLUTCHES Clutch Alignment Inspection NOTE Drive clutches are purposely misaligned slightly forward to compensate for the engine shifting on it s mounts Under load the engine will pull back slightly so both clutches are in alignmen
132. beltis installed check belt deflection Install so part numbers are easily read from left side of machine Center Distance MAINTENANCE TUNE UP Headlight Adjustment The headlight can be adjusted for vertical aim using the following pro cedure 1 Place the snowmobile on a level surface with the headlight approximately 25 7 6 m from a wall 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall 3 Start the engine and turn the headlight switch to high beam 4 Observe the headlight aim The mostintense partof the headlight beam should be aimed 2 5 1 cm below the mark placed on the wallin Step 2 NOTE Rider weight mustbe included on the seat 5 If necessary the headlight aim can be adjusted by turning the adjustment knob located inside the hood just below the headlamp opening Turn knob in or out as needed for proper aim Removing Halogen Bulbs Low Beam NOTE Do not touch a halogen bulb with bare fingers Oil from skin leaves a residue causing a hot spot which will shortend the life of the lamp 1 Pinch ends of spring together and lift until it releases from spring retainer 2 Lift spring carefully around wire harness and flip to outside of housing 3 With wire harness attached to bulb withdraw bulb from housing 4 Grasp bulb by metal base and carefully separate bulb from harness Installing Low Beam Bulb 1 2 3 4 5 Hold bulb by metal
133. boxes and will not fit on earlier snowmobiles if installed on earlier snowmobiles the flywheel may cause CDI failure The 2002 flywheel will be stamped with two red dots and 14 ONLY this means that this flywheel will only work with 14 degree CDI boxes These flywheels were used on the 2001 440 Pro X and the 2001 700 XC SP with Exhaust Valves ELECTRICAL Headlight Bulb Filament Continuity Test 1 2 3 Turn the Multitester dial to the ohms Q position Disconnect the wire harness from the headlight bulb Viewing the back of the bulb with the terminal blades at the 9 12 and 3 o clock position connect the black multitester lead to the 9 o clock blade Touch the red tester lead to the 12 o clock terminal and then to the 3 o clock terminal noting the resistance value of each A reading of between 2 and 5 ohms is good An open reading indicates a bad element Hi Lo Beam Switch Testing l 2 Set the multitester dial to the ohms 9 position If the Hi Lo switch has not been removed from the machine disconnect the switch to harness plug in connector With the Hi Lo switch in the Lo beam position check the resistance between the yellow and the green switch wires The reading should be less than 4 ohms Turn the Hi Lo switch to the Hi beam position and the multitester should indicate an open circuit OL reading Move one of the tester leads from the green to the red switch wire The multitester should now read less
134. cal using a clean soft rubber squeegee to prevent scratching of decal surface 5 If decal has a pre mask carefully remove No 1 Roloc and holder 3M PN 048011 15408 NOTE Ifthe decal being applied needs to be stretched around a radius follow these recommendations 6 Fasten a straight edge to tail end of decal 7 Pull or stretch remaining portion of decal around radius and into position NOTE A small amountof heat applied to the decal will aid in forming it to the radius The mass of the decal which was secured in previous steps will hold itin position while pulling 8 Again apply soapy water solution to top of decal and remove trapped air using a clean soft rubber squeegee Use care to prevent scratching the decal surface 9 Apply a small amount of heat to the decal to fasten it securely 10 Carefully remove excess decal material Problem Machine darts from side to side Tie rod hits trailing arm Steering has excessive freeplay Front end bounces or sags BODY AND STEERING Possible Cause Somon Incorrect ski toe alignment Incorrect camber Loose or worn steering compo nents or fasteners Cracked or broken skis skags or carbides Steering arm installed incorrectly Tie rod ends worn Steering bellcrank bushing worn or loose Drag link worn or loose Steering post loose Steering post bushings worn Tie rod ends worn Spindle bushings worn IFS shock spring preload too so
135. ced every other season NOTE After changing the oil filter the oil injection system must be bled of all trapped air See your dealer for instructions or have your dealer perform the filter change and bleeding operation for you Oil Filters 44CAUTION The in tank fuel filter 1 and fuel lines should be inspected regularly Special attention should be given to the system s fuel line condition af ter periods of storage Normal deterioration from weather and fuel compounds can occur Do not use pliers or a similar tool to remove fuel lines Damage could occur Do not kink the fuel line Damage could occur Ifa fuel has been dam aged or kinked replace it MAINTENANCE TUNE UP ACCS Altitude Compensating Carburetor System Maintenance Some models are equipped with Polaris ACCS The ACCS is de signed to compensate automati cally for changes in altitude without having to change carburetor jets ACCS does not require peroidic maintenance See your dealer for ACCS service or adjusment NOTE Tampering or adjustments tothe ACCS may cause severe en gine damage A Airbox B Vent Line Attachment C ACCS Valve MAINTENANCE TUNE UP Lubricate the following fittings with Polaris Premium All Season grease annually or approximately every 1000 miles 1600 km Remove weight from the component being greased to permit better penetration and flushing of the joint S Spindles left and right S Rear suspen
136. centered tap shaft with a soft faced hammer until centered This will align the upper chaincase bearing in the chaincase bore 6 Once correct jackshaft alignment has been achieved install lock nuts on chaincase mounting bolts and torque to specification Remove alignment tool from chaincase 7 Install jackshaft flangette gasket and bolts Align grease hole A in bearing with hole or fitting in flangette B to within 100 to ensure greasability Torque nuts to specification Do notlock setscrews on retainer ring if so equipped Chaincase Mounting Bolt Torque Flangette Nut Torque 28 30 ft Ibs 38 6 41 4 Nm 15 17 ft Ibs 20 7 23 5 Nm Driveshaft Installation l Tip machine back on its left side Set track into machine making note of correct direction of travel Mosttracks have an arrow pointing which direction the track turns BRAKES FINAL DRIVE Es Driveshaft Installation Cont 2 Insert driveshaft through bearing hole in bulkhead Place inner driveshaft bearing flange bolts in the bulkhead 3 Insert chaincase side of driveshaft through bottom chaincase bearing 4 Tip machine upright Replace speedometer key with a new one and install angle drive Torque nuts to specification Speedometer Angle Drive Mounting Nut Torque 15 17 ft Ibs 20 7 23 5 Nm 5 Link together the upper and lower chaincase sprockets with the chain Install both the upper
137. ch is not uniform with the other side Use the same method to drill both sides 2 Rivetholes across from one another in unison g BODY AND STEERING Decal Removal 1 Before removing old decal itis importantto note its position by marking it in several locations 2 Remove old decal completely NOTE A small amountof solvent will aid in removing the old decal 3 The decals are UV based If heat will not remove decal gently buff area with a mild abrasive Use 3M Scotch Brite Graphics Removal Discs with a No 1 Roloc and holder or an equivalent low RPM buffing disc CAUTION Maintain 2500 3500 RPM to prevent damage to hood caused by excessive heat 4 Removeanyremaining decal adhesive with a citrus based cleaner or equivalent non solvent based Cleaner 3M Scotchbrite Graphics Removal Disc 5 Thoroughly clean area where the new decal will be 3M PN 048011 16855 installed using a solution of mild soap such as dishwasher liquid and clean water NOTE Use approximately four ounces soap to one gallon water Decal Installation l Apply a solution of mild soap mixed with clean water to the area where the new decal is to be applied Do not wipe off 2 Carefully remove decal backing and apply new decal 3 Ifdecaldoes nothave a pre mask apply additional soapy water solution to top of decal after it is in position 4 Holding decal in position remove all trapped air and soapy water solution from under de
138. chnologies Loctite Registered Trademark of the Loctite Corporation STA BIL Registered Trademark of Gold Eagle FOX Registered Trademark of Fox Shox Nyogel Trademark of Wm F Nye Co Fluke Registered Trademark of J ohn Fluke Mfg Co Mity Vac Registered Trademark of Neward Enterprises Inc Ammco Registered Trademark of Ammco Tools Inc Torx Registered Trademark of Textron Hilliard Trademark of the Hilliard Corporation pi RH D KH www E Suz ano rmac zu EN CHAPTER 1 GENERAL INFORMATION Publication Part Numbers Service Manuals 1 1 Model Number Identification o o oooo o 1 2 Vehicle Identification Number VIN 1 3 Standard Bolt Torque Specifications 1 4 Decimal Equivalents EE 1 5 Tap Drill Size Chas EE 1 6 Units of Measure Chart gtt eee ees 1 7 Recommended Shop Supplies 1 8 Glossary EE EE 1 9 1 11 General PrecautbIiS ii 1 12 Beie RAT 1 13 Indy 500 SKS Euro Specifications 1 14 1 15 Indy 500 RMK Specifications 1 16 1 17 Indy Trail RMK Specifications Age a n AE 1 18 1 19 600 EDGE RMK Specifications 7 32 M wid ds 1 20 1 21 Indy 700 SKS Euro Specifications 1 22 1 23 700 EDGE RMK Specifications sese oe dtm hrs 1 24 1 25 800 EDGE RMK Specifications x43 e tee er 1 26 1 27 GENERAL INFORMATION d 2002 Publication Numbers Supplement Manual M
139. cification Maintain an equal gap at front and rear of block 5 Replace handlebar cover Handlebar Adjuster Block Bolt Torque 11 13 ft Ibs 15 18 Nm Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosen ing of the handlebars resulting in loss of control MAINTENANCE TUNE UP Replenishing Brake Fluid Remove brake fluid master cylinder reservoir cover Add P olaris brake fluid as required to bring the level up to the top of the fluid level mark on the inside ofthe reservoir B The proper fluid level 1 4 5 16 is 1 4 5 16 6 8 cm below the lip of the reservoir opening NOTE On some models the brake fluid level can be seen through the plastic reservoir The fluid should be maintained be tween the minimum and maximum marks on the reservoir for those models Inspect the reservoir to be sure it contains the correct amount of fluid Use only Polaris DOT 3 high temperature brake fluid Change fluid every 2 years or whenever the fluid is dark or con tamination is suspected Master Cylinder Fluid Level Polaris DOT 3 High Temp Brake Fluid 1 4 5 16 6 8 cm below lip of PN 2870990 reservoir opening Do notover 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
140. cknut A 6 Repeat steps 4 and 5 for remaining carburetor s Choke Lever Freeplay 1 8 1 4 3 6 cm 1 8 1 4 3 6 cm Freeplay 4 32 Choke Toggle Position Full On Contents of Lever Kit Gp POLARIS FUEL SYSTEM CARBURETION O The fuel pumps on all Polaris engines are basically the same The differences are in the size and location of the pumps Pumps may be mounted to the engine or to the chassis Inthe two cycle engine the pressure in the crankcase changes with the up and down stroke of the piston The amplitudes of pressure vary according to the RPM and degree of throttle opening Whether idling or at full throttle the pressure built up in the crankcase has enough amplitude to operate the pump When the piston is on the upstroke crankcase pressure in that cylinder becomes less positive The diaphragm in the fuel pump moves toward the engine causing a negative pressure or suc tion in the pump chamber This causes the inlet valve from the fuel supply to open and permits fuel to enter the chamber This same suction causes the outlet valve to the carburetor to close so that fuel cannot return form the carburetor Whenthe piston begins its downward stroke the pressure from the crankcase becomes positive causing the fuel pump dia phragm to move in the opposite direction and reversing the pressure in the fuel pump chamber This causes the inlet valve in the pump to close and the outlet valve to
141. ckwise if equipped with optional Indy Select shock or refer to optional valving on Suspension Wallchart for Fox equipped models Set RRSS to lowest position or totally remove Machine darts from side to side Make sure skis are aligned properly straight forward with rider on machine Make sure spindles and all steering components are free turning Make sure skags are straight on skis Check hi fax and replace if worn Reduce ski pressure Dncrease front track spring preload requires shims Reduce IFS spring preload by adjusting cam DR educe rear torsion spring preload D engthen front limiter strap Front end pushes Check for worn skags Check for binding suspension shafts and grease all pivot points Increase IFS spring preload by adjusting cam or adding washers Shorten front limiter strap Steering is heavy Check ski alignment Check skags and skis for damage Reduce ski pressure Dincrease front track spring preload DR educe IFS spring preload by adjusting cam DR educe rear torsion spring preload Setting up for deep snow operation Change worn hi fax Lower rear torque arms see Performance section at the back of this manual Increase front limiter strap length Based on rider preference RRSS may be removed to increase weight transfer SUSPENSIONS Suspension Troubleshooting EDGE RMK Suspension Troubleshooting Only perform one change al a time Problem Solution Rear suspension Check the sag dimen
142. cle Fuji 3A 340 F C Piston Port Fuji 4A 440 F C Cylinder Reed Fuji 4B 488 L C Piston PortFuji 4C 440VES L C Case Reed domestic 4D 440 F C Piston Port 4E 488 F C Piston Port Fuji 5A 497 L C Case Reed 2 Cyl domestic 5B 544 F C Cylinder Reed 5C 500 VES L C Case Reed 2 Cylinder domestic 6D 600 700 L C Case Reed 2 Cylinder domestic 6E 600 440 VES L C Case Reed 2 Cylinder domestic 7A 700 L C Case Reed 2 Cylinder domestic 7C 700 VES L C Case Reed 2 Cyl domestic 8A 800 VES L C Case Reed 3 Cylinder Fuji 8B 800 L C Case Reed 2 Cylinder domestic 8C 800 VES L C Case Reed 2 Cyl domestic TUNNEL DECAL MODEL NO MADE IN U S A VIN NO THIS VEHICLE CONFORMS TO ALL APPLICABLE U S FEDERAL AND STATE REQUIREMENTS AND CANADA MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE MFD DATE S North American Model U European Model POLARIS PATENT NOTICE Mfd by Polaris Industries Inc in Roseau MN under one or more of the following patents U S Patents 3 605 511 3 580 647 3 483 766 3 533 662 3 545 821 3 605 510 3 525 412 Patented Canada 882 491 71 883 694 71 864 394 71 Canadian Rd 34 573 71 34 572 71 1 227 823 87 7072133 3 613 810 3 867 991 4 793 950 5 038 881 5 172 675 5 090 386 5 050 564 5 050 559 5 048 503 5 056 482 5 099 813 5 074 271 5 191 531 3 613 811 These numbers should be referred to in any correspondence regard
143. conditions moderate track tension should be maintained during summer storage Rubber track tension should be maintained at the prescribed normal operating tension specified in this manual The rear of the machine should be supported off the ground to allow free hanging of track ll 2 Driveshaft Bearing MAINTENANCE TUNE UP Engine and Carburetor Fog engine with Polaris Fogging Oil aerosol type according to directions on can On models with carburetor vacuum fittings the fogging oil can be sprayed through the fitting Polaris Fogging Oil PN 2870791 Carbon Clean PN 2871326 Treat the fuel system with Polaris Carbon Clean If Polaris Carbon Clean is not used fuel tank fuel lines and carburetor should be completely drained of gasoline Battery Disconnect and remove battery Fill with distilled water Clean terminals and cables Apply dielectric grease Charge until specific gravity is at least 1 270 each cell If machine is to be stored for one month or longer fill and charge battery monthly using Polaris Battery Tender or a 1 amp trickle charger to maintain at 1 270 specific gravity Polaris Battery Tender PN 2871076 Exhaust System Atapproximately 2000 miles or in preparation of off season storage itis a good idea to check the exhaustsystem for wear or damage To inspect allow the engine and exhaust system to cool completely Open the hood and inspectthe muffler and pipes for cracks or damage Check for w
144. correct the sprockets will mesh fully when the lever is pulled and no grinding will occur indicating incomplete engagement If incomplete engagement is suspected perform the following steps 1 Move lever to forward position 2 Loosen jam nuts on linkage rod 3 Adjust linkage rod until endplay movement is 1 32 08 cm Do not adjust beyond this point 4 Tighten jam nuts and re check adjustment Reverse Linkage Rod End Play 1 32 08 cm Gp POLARIS BRAKES FINAL DRIVE Es Shift Lever Actuator Chaincase Cover Assembly 8 39 CHAPTER 9 ELECTRICAL Multimeter Usage uscar e at rcs 9 1 General Electrical ocasionar et 9 2 9 3 Ignition Timing Overview esee 9 4 9 5 Indy Trail RMK Electrical Exploded View 9 6 Indy 500 SKS 600 EDGE RMK Electrical Exploded View 9 7 700 800 EDGE RMK Electrical Exploded View 9 8 Timing Procedure er 9 9 Preparing a New Battery 9 10 Load TA 9 11 Dynamic Testing uto e EE 9 12 Statie TS PIDE ooa i ded a casi e oO do e C aa 9 13 Starter Assembly Exploded View 9 14 Unregulated Voltage 9 15 9 16 Regulated Voltage eis oec ve nO P ER 9 16 2 kO Pulse Alternators ce y re Ee Ra 9 17 2002 Flywheels saa 5525 KGG ERE KAMANG 9 17 Electrical Systems Testing 9 18 9 23 TPS Testing Adjustment 9 24 9 27 Troubleshooting sos
145. cylinder 2 or center cylinder Repeatsteps 4 and 5 Note the degree wheel indication when the dial indicator reads 100 ATDC It should be 180 or 120 2 from cylinder 1 Repeat procedure on PTO cylinder 3 where applicable Cylinder 3 should also be 120 2 from cylinder 1 Symptoms of an out of index crankshaft can include S Difficulty calibrating carburetor repetitive plug fouling on one cylinder with no other cause S Unexplained piston failure on one cylinder i e severe detonation broken ring lands piston holing S Excessive vibration of engine backfiring etc S Rough idle poor top speed A ENGINES Cylinder Head Inspection 1 Inspect each cylinder head for warping Replace cylinder head if warp exceeds service limit Cylinder Head Warp Service Limit 003 08mm Cylinder Measurement 1 Inspect each cylinder for wear scratches or damage If no damage is evident measure the cylinder for taper and out of round with a telescoping gauge or a dial bore gauge Measure the bore 1 2 from the top of the cylinder in line with the piston pin and 90 to the pin to determine if the bore is out of round Repeatthe measurements atthe middle ofthe cylinder and the bottom of the cylinder to determine taper or out of round atthe bottom Record all measurements Cylinder Taper Limit 002 Max Cylinder Out of Round Limit 002 Max 3 60 Gp POLARIS Piston Inspection Meas urement L C
146. d Twin Displacement 701cc Fuel Pump Manuf Walbro Bore Sac bea Dao adus 3 1889 81mm Fuel Pump Mark FPA 4 STOKE ac hhc beier ae 2 6772 68mm Oil Pump Manuf Mikuni Piston Cylinder Clearance 0 0044 0 0058 0 11 0 15mm OilPump Mark 03A Service Limit 0 0060 Cylinder Head Mark 3021022 Piston Marking 3021041 Piston Ring Marking N A Piston Ring End Gap Head ccs Uninstalled 37 5 50cc Head ccs Installed 33 5cc Operating RPM 200 8250 RPM Idle RPM 200 1500 RPM Engagement RPM 300 4000 RPM Cylinder Head Torque 18 22 ft Ibs Cylinder Base Nut Torque 30 34 ftlbs Crankcase Torque 8mm 20 24 ft lbs Crankcase Torque 10mm 26 30 ft lbs Flywheel Torque 1 22 0 014 0 020 36 51mm Gp POLARIS GENERAL INFORMATION d MODEL INDY 700 SKS EUROPEAN MODEL MODEL NUMBER S02557CS E02557CE ENGINE MODEL S2189 7070PL7C ELECTRICAL CAPACITIES Flywheel I D 4010523 Fuel Tank 11 8 gallons 44 7 liters CDI Marking 4010587 Oil Tank 3 quarts 2 8 liters Alternator Output 280 Watts Coolant 5 5 6 quarts 5 2 5 7 liters Ignition Timing 18 3000RP M 500 Chaincase Oil 9 11 fl oz 266 325cc 0 0815 BTDC 2 075mm BTDC Spark Plug Gap Champion RN57
147. d onto the I F P locator tool and adjust the top of the value indicator to the appropriate measurement PICTURE 12 NOTE Depending on which shock absorber is be ing worked on adjustthe piston location tool to the specified depth indicated in the shock specification chart Go POLARIS SUSPENSIONS i H H F SUSPENSIONS Apply a thin film of oil onto the floating wear band and O ring and install the floating piston into the top of the shock body positioning it below the counterbore PICTURE 13 Using the tool as a handle push the floating piston down into the shock body being careful not to damage I F P wear band and O ring until the val ue indicator knob comes in contact with the shock body The piston should now be located correctly PICTURE 14 Apply of light film of grease to the pressure valve port counter bore through 360 Degrees where the pressure valve assembly O ring meets Screw the pressure valve assembly into the valve port by hand with a slotted head screwdriver and tighten to 100 110 in Ib of torque PICTURE 15 Fill the shock body with shock oil A Internal Floating Piston Shocks Fill the shock body with shock oil to the bottom ofthe thread with in the cylinder B Emulsion Shocks P N 7041992 Fill shock body with 110cc of oil This will allow for the re quired air space to properly gas charge the shock with nitrogen gas NOTE After filling the shock body with oil allow a
148. d out to its maximum when the adjuster is flush with top of housing O ENGINES Polaris Variable Exhaust System Springs COLOR Load 1 0 In Load 630 In Free Length Wire Dia LBS LBS In x 0 4 z 0 5 7041786 01 01 RE RED WHITE 30 1 1854 GE 02 BEEN Gn BE 1 740 7041786 03 GREEN WHITE 1 930 Ware veuowmmme 58 88 1829 REECH 38 239 omo Pwewane so 88 zm emer PURPLEMANE 30 no 2m EE amo wu lao o 17 995 NG cai BAG veuow 3 38 3s y Mosa wam las a TE These springs will change the timing characteristics of the exhaust valve opening A heavier spring will keep the valve in the closed position longer while a lighter spring will allow the valve to open sooner NOTE If making any changes to the valve springs make sure to change all springs so that each valve spring is the same Exhaust Valve Springs for Low Elevation If you are setting up a RMK for low elevation use the springs for the XC SP s corrisponding to engine size 600 RMK 700 RMK 800 RMK Low Elevation Exhaust Valve Low Elevation Exhaust Valve Low Elevation Exhaust Valve S pring S pring S pring PINK GREEN YELLOW PURPLE WHITE Cylinder Honing ENGINES O The cylinder bore must be de glazed whenever new piston rings are installed A light honing with fine stones removes only a very small amount of material A proper crosshatch patter
149. d the remaining carbs are synchronizedto it Carburetorsynchronization is mea sured atwide open throttle Open the throttle to wide open The bottom ofthe slide should be flush with the top ofthe throttle bore see Ill 2 If itis not flush locate the wide open throttle stop screw J and tum it until the base carburetor is set flush Loosen the phillips head setscrew in the remaining carburetor s Turn the adjusting nut K thatsurrounds the setscrew until the throttle slide is setthe same as the base carburetor Tighten all setscrews and replace the top caps making sure gaskets are properly positioned b POLARIS 4 5 O FUEL SYSTEM CARBURETION Mikuni TM 38 TM 40 Exploded View E Top Cap Gasket e t Adjustment Screw gt Ring LA TA 1 AP Lever a TL O pe M A se Eed Funnel UL Cap 8 E Ring Je Guide y No Spring Bi Pilot et Ep liotje Ge EE eg e zi US Starter J et d Spring Jet Needle x Dg N 7 Float Needle amp Plunger d Seat Asm Float Bowl lt gt Drain Plug 4 6 Gp POLARIS FUEL SYSTEM CARBURETION O Mikuni VM 34SS Exploded View 5 Mixing Chamber Top 9 777 Including Gasket Inc Throttle Spring DU Plunger Cap S Plunger Spring E Ring S pring AN Oe EA Plate NN get Se S pring FI Packing o EE Stop Screw oat Arm i on gt T Pilot Tav b at oat Bin 4 P e s Ring Needle amp fa amp Main J et
150. dos Sek PHAT NAAN BUAYA KGG Nata 9 28 Multimeter Usage The easiest and most accurate method for testing modern electrical components is with a digital multitester Any good quality multitester will work However due to ease of opera tion and durability P olaris recommends the Fluke Model 73 PN 2870659 or Tektronix DMM155 See photo at right This instrument will provide a digital readout of the measured value of the test being performed Listed below are the dial symbols their meaning and what the dial setting can be used for Off 2 Instrument Off NI Volts AC measuring alternator output Usedto measure AC voltage in an electrical system AC volt age is produced from every coil on the stator plate when a magnet is passed by it Test Method 1 Connect black lead to Com meter terminal 2 Connect red lead to VQ meter terminal 3 Turn selector dial to V setting 4 Connect test leads parallel with test component The polarity of the leads is not important Usage S Test unregulated voltage output of a stator coil S Test regulated voltage to the lights and handwarm ers ELECTRICAL Red Lead here for Volts and Ohms Red Lead here for Amperes V Volts DC measuring battery voltage volt drop etc Used to measure DC voltage produced by a battery or rectifier Test Method 1 Connect black lead to Com meter terminal 2 Connect red lead to VQ meter terminal 3 Turn selec
151. duty to experience spark plug failure CAUTION A plug with a heat range which is too high may cause engine damage if the engine is operated in conditions more severe than that for which the spark plug was intended A new engine can cause temporary spark plug fouling even though the heatrange is correct due to the preserva tive which has been added during assembly of the engine to combat rust and corrosion Avoid prolonged idle speeds as plug fouling and carbonization will result Always use resistor type spark plugs NOTE Incorrect fuel mixture can often cause a spark plug to appear to be too dark or too light in color Before changing spark plug heat ranges be sure the correct jetting is installed in the carburetors and proper carburetor function is verified The spark plug and its condition is indicative of engine operation The spark plug firing end condition should be read afterthe engine is warmed up and the vehicle is driven athigher speeds Immediately check the spark plug for correct color Normal The insulator tip is gray tan or light brown There will be a 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 carburetion adjustments Wet Fouled The insulator tip is black A damp oily film cove
152. e valve assembly and tighten securely PICTURE 20 Reinstall sleeve and bushings in lower shock mount Gp POLARIS SUSPENSIONS 7 41 SUSPENSIONS Ryde FX 7041968 GENERAL REBUILD PROCEDURES WARNING Before servicing a gas shock it is important that all the gas pressure be discharged from the unit Referto the instructions listed below forthe proper procedure of discharging the gas pressure from a shock Protective eyewear should be worn to avoid risk of injury while servicing RydeF X gas charged mono tube shocks Remove the shock from the vehicle Account for inner sleeve in lower shock mount Wash the shock body in parts cleaner then dry with compressed air to remove sand and dirt WARNING When using compressed air to dry components protective eyewear should be worn to avoid risk of injury Remove inner sleeve and bushings from lower shock mount eyelet Secure the lower mount of the shock in a vise The use of soft jaws is recommend to prevent damage or marks to the shock CAUTION Itis importantthatthe gas shock be retained in the vise by the lower mount Any other meth od of securing the shock body during these procedures may deform the shock body cylinder Remove the small button head screw from the pressure valve located on top of reservoir Using a 9 16 wrench discharge all gas pressure from the shock by loosening the pressure valve as sembly three 3 full turns counter clockwise WARNING Nitrogen gas i
153. e brittle or swollen Fittings should be inspected for cracks or leaks Do not use pliers or other tools that may damage fuel lines when installing or removing fuel lines Test run and check the fuel system for leaks any time parts are replaced Verify that all lines are routed correctly and away from any moving parts Vent Lines Red Fuel Line Water C t Cunt Violet Fuel Line Vent Line Traps Fuel Lines B Cylinder Base Gasket Filter Fuel Line Impulse y Crank Weighted Pickup and Line Line Crank Check Seal Fuel filter on some models No filter on 2001 Seal Valves Impulse Fitting and earlier models at Crankcase NOTE Some models use fuel filters are located inside the fuel tank To inspect replace filter S Remove fuel cap S Using a long clean wire bend into a fish hook shape Pull the fuel line that is inside of the tank up through the filler hole S Inspect filter on end of fuel pick up line Replace if worn or clogged Red fuel line is the exterior line for outside the tank The violet line is the interior line for inside the fuel tank They cannot be interchanged NOTE The violetline used inside the tank will fade and turn clear after a relatively shorttime This does not affect the function or durability of the line When replacing fuel line be sure to use the correct color line for inside or outside the fuel tank Also be very careful not to bend fuel line to a p
154. e mark made in Step 2 or within the acceptable variance the timing is correct If the pointer is outside the variance the stator will have to be rotated either with crankshaft rotation to retard the timing or against rotation to advance it NOTE Rotate stator plate approximately the same distance as the marks must move NOTE In most cases the recoil starter housing recoil drive hub and flywheel must be removed to loosen the stator bolts and change the timing On some en gines the stator plate retaining screws can be ac cessed through the flywheel 8 Torque stator plate screws and flywheel nut to specified torque Apply Loctite 262 red to crankshaft flywheel taper if required Refer to the Specifications section for torque specifications and flywheel installation procedure for engine type Gp POLARIS Acceptable Variance Flywheel lywheel Lines Rotation Stationary Pointers NOTE Acceptable variance is usually one line on either side of the dial indicated timing mark Liquid Cooled 9 9 ELECTRICAL Preparing a New Battery for Service To ensure maximum service life and performance from a battery it must have proper initial servicing To service a new battery the following steps mustbe taken NOTE Do notservice the battery unless itwill be put into regular service within 30 days 1 Remove vent plug from vent fitting 2 Fill battery with electrolyte to the upper level marks on
155. e nitrogen tank pressure regulator to 200 205 PSI Insert the Fox Safety Needle and charge with nitrogen to 200 PSI Pullthe needle straight outward and remove from the pressurizing valve while holding the pressure hose on the fitting Do not insert the needle again to check pressure as the volume inside the gauge will reduce pressure in the shock As a final check push the damper rod through a full stroke The damper rod mustbottom outat full travel and then slowly rise to full extension Shaft movement must be smooth and consistent throughout the entire compression and rebound stroke without binding or loss of damping 7 34 Gp POLARIS SUSPENSIONS Fox Shock Maintenance Assembly Cont 20 To check for leaks submerge the shock in water and look for bubbles or oil seepage around the bearing and body caps 21 When reinstalling shocks on the machine torque only to required specifications If the shock is over tightened itwill notpivot possibly resulting in damage to shaft and seals 22 When installing IFS shocks tighten top mount first Pivot shock body into lower mount and determine if spacer washers are necessary to prevent twist or side loading of shock Suspension assemblies should always be moved through entire travel without springs to verify free movement and proper alignment of all components Shock Eyelet Replacement Top Shock Eyelet i Damper Rod Holding t Tool PN 2871352
156. e proper belt deflection S The top edges have been trimmed on some drive belts It will be necessary to project the side profiles and measure from corner to corner S Place a straight edge on each side of the drive belt S Place another straight edge on top of belt S Measure the distance where the side straight edges intersectthe top as shownin the illustra tion at right Inspect belt for loose cords missing cogs cracks abrasions thin spots or excessive wear Replace if necessary Inspect belt for hour glassing extreme circular wear in at least one spot and on both sides of the belt Hour glassing occurs when the drive train does not move and the drive clutch engages the belt Belt Wear Burn Diagnosis Belt Wear Burn Diagnosis Possible Cause Of Wear Or Burning Driving at or about engagement RP M for extended periods in all types of conditions Cold weather startups Towing another machine at or about engagement RP M rojected Belt Width ke N 7 Drive at higher RPM if possible Gear the machine down Make sure belt deflection is at 1 25 to achieve optimum starting ratio Be patient Warm up engine at least 5 minutes or until it readily responds to throttle input For the quickest most efficient driveaway in extreme cold weather take drive belt off machine and bring it in to a warm environment Break skis and track loose from the snow Engage throttle aggressively for short durations f
157. e tolerances the bearings must be inspected visually and by feel Look for signs of discoloration scoring or galling Turn the outer race of each bearing The bearings should turn smoothly and quietly The inner race of each bearing should fit tightly on the crankshaft The outer race should be firm with minimal side to side movement and no detectable up and down movement Replace any loose or rough bearings 3 54 Gp POLARIS Connecting Rod Big End Bearing Inspection 1 Measure connecting rod big end side clearance with a feeler gauge Clearance should be equal on all rods within 002 Rotate rod on crankshaft and check for rough spots Check radial end play in rod by supporting rod against one thrust washer and alternately applying up and down pressure Replace bearing pin and thrust washers if side clearance is excessive or if there is any up and down movement detectable in the big end bearing NOTE S pecialized equipment and a sound knowledge of crankshaft repair and straightening is required to per form crankshaft work safely and correctly Crankshaft repair should be performed by trained Polaris service technicians in a properly equipped shop Piston Pin Needle Bearing Inspection 1 Clean needle bearing in solvent and dry with compressed air Inspect needle cage carefully for cracks or shiny spots which indicate wear Replace needle bearings if worn or cracked and always replace them if piston damage has occur
158. e trigger pulse coil gap and compare to specification Stator Screw Torque 60 in Ibs 7 Nm Trigger Pulse Coil Gap Minimum 020 5mm Maximum 040 1 0mm Assembly Cont 36 Apply Loctitet 262 evenly to the flywheel mounting 37 38 39 40 41 taper on crankshaft Install woodruff key Install flywheel Apply Loctitet 242 to crankshaft threads Install washer and nut Use flywheel holder to hold flywheel and torque nut to specification found in beginning of this chapter Flywheel Holder PN 8700229 Install recoil hub and recoil housing Torque bolts to specification Recoil Hub and Housing Bolt Torque 108 in Ibs 12 5 Nm Install engine in chassis and align clutches Refer to General Inspection Procedures in this chapter to fill and bleed cooling system and oil pump Gp POLARIS ENGINES O 3 35 o ENGINES Engine Disassembly Assembly Domestic 700 800 Engines NOTE Inspect all parts for wear or damage during disassembly Replace all seals O rings and gaskets with Genuine Polaris parts during assembly Refer to pages 3 47 3 56 for gen eral inspection procedures Disassembly 1 Remove oil pump 2 Remove recoil housing 3 Remove recoil hub Inspect waterpump drive belt for missing cracked or broken drive cogs Replace if worn Replace if width is less than 25 6 35mm Measure the belt at 4 different points as shown Re p
159. eak or missing retaining springs or damper sup port grommets Exhaust system temperatures can exceed 900 F 500 C Serious burns may occur if this inspection is per formed without allowing adequate time for the exhaust system to cool Never perform this procedure with the engine running MAINTENANCE TUNE UP Notes 2 23 CHAPTER 3 ENGINES Engine Torque Specifications xax yr OY ek Ra 3 1 Engine Torque Sequences 2 5 d eed wg NANGGAD e esse 3 2 3 4 Engine Removal e Egger 3 5 3 8 Engine Installation zd wuts Ka KANIYA NARANASANG MAG Ba 3 9 3 12 550 Engine Disassembly and Inspection 3 13 3 19 550 Engine Assembly cus ss deno sav E Dn ka bahal patay 3 20 3 25 500 600 Engine Disassembly and Inspection 3 26 3 30 500 600 Engine Assembly 0 cece cece ene eee 3 31 3 35 700 800 Big Block Disassembly and Inspection 3 36 3 42 700 800 Big Block Assembly ssseeseeeeeeene 3 43 3 46 EV Maintenance 20 6e obo BANNA Viv a P od MGA 3 47 3 49 Optional EV SDFIIngs questi etd ate as a Ex D e e PARATANG LA 3 50 Cylinder HONING ess ev EE eas Baie EE 3 51 3 52 Piston Inspection ees rx RR ALAK AKA NAN OSEE RU EN 3 53 Crankcase Inspection EE 3 54 Connecting Rod InSpectlOlt aiu ces qe rm i EE 3 95 Crankshaft Wing nemore AE RITA BELINDA TIMORE E 3 56 3 57 Crankshaft Indexing seo ege de 3 58 3 59 Cylinder Head Inspections maa xe eee pean NINANG 3 60 PAStOD
160. eated in grooves Apply a light film of grease to hold O rings in place if necessary Assembly Cont 26 Install new cylinder head cover O rings and install cylinder head cover Make sure O rings are properly seated in grooves Apply a light film of grease to hold O rings in place if necessary 27 Loctite 242 to threads of head bolts and install 28 Torque head bolts to specification outlined in beginning of this chapter in proper sequence 29 Torque cylinder base nuts outlined in beginning of this chapter in proper sequence 30 Install washers and water pump impeller as shown and torque nut to 10 ft Ibs 14 Nm Impeller Nut Torque 10 Ft lbs 14 Nm Gp POLARIS ENGINES O Cylinder Head OO 00 DO 00 Cylinder Base Washer 10 3x14x1mm 10 ft Ibs Mechanical Washer Seal 325x 75x 063 3 33 A ENGINES Assembly Cont 31 Install water pump cover with new gasket Water Pump Cover Bolt Torque 9 Ft Ibs 12 5 Nm 32 Install new exhaust manifold gaskets and manifold Exhaust Manifold Bolt Torque 16 Ft Ibs 22 Nm 33 Install reed valves stuffers and carburetor adaptors Place stator wire guide on Mag side carburetor adaptor bolt 34 Install stator assembly aligning timing marks or Apply marks made upon disassembly Seal stator wires a d o Loctitet with high temperature silicone sealant Install and tighten stator screws to specification 35 Measur
161. ecal Removal Installation 6 34 Troubleshooting tai aou reae ai art Aero ad repe sas 6 35 BODY AND STEERING Steering Assembly Indy Trail RMK Torque Specifications A 28 30 ft lbs 38 41 Nm B 35 40 ft lbs 47 54 Nm C 40 45 ft lbs 45 62 Nm D 45 50 ft lbs 61 68 Nm E 55 60 ft lbs 76 83 Nm Apply Premium All Season Grease PN2871322 30z to all grease zerks located on suspension assemblies z Replace locking fasteners if removed g BODY AND STEERING Steering Assembly Indy 500 SKS European Torque Specifications 17 19 ft lbs 24 26 Nm 28 30 ft lbs 39 41 Nm 35 40 ft lbs 48 55 Nm 40 45 ft lbs 55 62 Nm 45 50 ft lbs 62 69 NM Apply Premium All Season Grease PN2871322 30z to all grease zerks located on suspension assemblies z Replace locking fasteners if removed BODY AND STEERING Steering Assembly Indy 700 SKS 700 SKS European Torque Specifications A 17 19 ft lbs 24 26 Nm B 28 30 ft lbs 39 41 Nm C 35 40 ft lbs 48 55 Nm D 40 45 ft Ibs 55 62 Nm E 45 50 ft lbs 62 69 NM Apply Premium All Season Grease PN2871322 30z to all grease zerks located on suspension assemblies o BODY AND STEERING Steering Assembly Indy 500 RMK Torque Specifications 17 19 ft bs 23 26 Nm 28 30 ft lbs 38 41 Nm 35 40 ft lbs 47 54 Nm 40 45 ft Ibs 55 62 Nm 45 50 ft lbs 61 68 Nm Apply Premium All Season Grease PN2871322 30z to all grease zerks located on susp
162. ect Yes No Verify the correct CDI module by comparing the CU code on the box to the information listed in the ignition data charts at the beginning of this section Is it the right module No Yes Check the resistance of the coils under the flywheel Compare these to values on wiring diagram Are they within limits No Yes Check the ignition switch wire harness throttle safety switches and kill switch for proper adjustment or short to ground Repair or replace as necessary All except 3 cylinders If the parts of the ignition system under the flywheel check OK the only remaining component is the coil CDI module assembly Replace the module with another with the same number See ignition data All 3 cylinders Disconnect and check the secondary ignition coil resistances Refer to the resistance values listed in wiring diagrams If the coil resistance values are within specs replace the CDI module Adjust the ignition timing by rotating the stator plate to correct the timing After adjusting the recommended RPM timing continue with operating RPM timing if poor performance exists Continue on with left column Check the ignition switch throttle safety switches kill switch and harness for damage which can cause intermittent shorting problems Correct the problem Replace the module with the correct part and readjust the ignition timing Check the wiring connecting the coils and or replace the coils as
163. ed atthe end ofthe manual for location of specific page numbers and service information Keep this manual available for reference in the shop area At the time of publication all information contained in this manual was technically correct However all materials and specifications are subject to change without notice Comments or suggestions about this manual may be directed to Polaris Sales Inc Service Publications Department 2100 Hwy 55 Medina Minnesota 55340 Deep Snow Snowmobile Service Manual PN 9917366 Copyright 2001 Polaris Sales Inc Printed in U S A UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS Throughout these instructions important information is brought to your attention by the following symbols N Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED A DANGER Failure to follow DANGER instructions will resultin severe injury or death to the operator bystander or person inspecting or servicing the snowmobile Failure to follow WARNING instructions could result in severe injury or death to the operator bystander or person inspecting or servicing the snowmobile CAUTION A CAUTION indicates special precautions that must be taken to avoid personal injury or snowmobile or prop erty damage NOTE A NOTE provides key information to clarify instructions Trademarks Polaris acknowledges the following products mentioned in this manual FLEXLOC Registered Trademark of SPS Te
164. ed either in the machine with the cables disconnected or on a piece of wood in a cool place NOTE Stored batteries lose their charge at the rate of 1 per day They should be fully recharged every 30 to 60 days during a non use period If stored during winter months the electrolyte will freeze at higher temperatures as the battery discharges The chart indicates freezing points by specific gravity 1150 1 100 1 050 Charging Procedure Charge battery with a charger no larger than 1 10 of the battery s amp hr rating foras many hours as need ed to raise the specific gravity to 1 270 or greater The gases given off by a battery are explosive Any spark or open flame near a battery can cause an explo sion which will spray battery acid on anyone close to it If battery acid gets on anyone wash the affected area with large quantities of cool water and seek im mediate medical attention Gp POLARIS 4a WARNING Battery electrolyte is poisonous It contains acid Serious burns can result from contact with the skin eyes or clothing ANTIDOTE EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegeta ble oil Call physician immediately EYES Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in closed space Always shield ey
165. eed for white stress marks or missing material Replace if necessary Reed Pedal Clearance 015 38 mm max Exaggerated for illustration 2 Remove cylinder head cover and inspect O rings and sealing surfaces for damage or debris Use new O rings upon assembly ENGINES O Disassembly Cont 3 Remove cylinder base nuts Note location of acorn nuts on exhaust side where applicable 4 Carefully remove cylinders while supporting pistons and connecting rods to prevent piston damage Refer to General Inspection Procedures in this chapter 5 Remove outer piston pin C clips using a scribe through access slot in piston 6 Place supportblock under piston and remove piston pins using pin puller Piston Pin Puller PN 2870386 Support Block PN 2870390 7 Remove water pump cover from front of engine A ENGINES Disassembly Cont 8 Remove recoil housing and drive hub 9 Remove flywheel using heavy duty flywheel puller Use drive clutch puller T handle or a wrench to hold puller Flywheel Puller PN 2871043 T Handle PN 5020326 10 Before removing stator plate note where ignition timing marks are located or scribe additional marks for reference upon reassembly 11 Mark or note location of engine mount straps and remove 3 28 Gp POLARIS ENGINES O Disassembly Cont 12 Remove bolts and separate case halves Keep bolts in order for assembly 13 To prevent dam
166. elect shock on some models Rear Suspension SRear torsion springs SFront rear scissor stop FRSS SRear rear scissor stop RRSS S Optional coil springs for front track shock and spring preload some models require washers S Optional torsion springs S Indy Select rear track shock on some models S Limiter straps front and rear SUSPENSIONS Adjustment Procedures It is a good idea to have customers break the suspension in for approximately 150 miles 240 km before fine tuning adjustments are made All settings will vary from rider to rider depending on rider weight vehicle speed riding style and trail conditions We recommend starting with factory settings and then customizing each adjustment individually to suit rider pref erence The machine should be methodically tested under the same conditions after each adjustment trail and snow conditions vehicle speed riding position etc until a satisfactory ride is achieved Adjustments should be made to one area at a time in order to properly evaluate the change The purpose of the front rear scissor stop FRSS is to control the bump attitude of the rear suspension As the front torque arm FTA hits the bump it forces the rear scissor to collapse a predetermined amount depending on the FRSS block position This accomplishes two important things it allows a lighter spring rate on the FTA because it can borrow spring rate from the rear torsion springs and it prepares the rear por
167. elt NOTE If drive clutch removal is necessary it may be done atthis time Refer to Chapter 5 clutches 10 Remove exhaust system 11 Disconnectcoolantsupply hoses as necessary atthe most convenient location on liquid cooled models Drain coolant into suitable container A ENGINES Engine Removal Typical Cont 12 Disconnect electrical connections from stator and starter motor where applicable 13 Remove two front and two rear engine mount bolts nuts that secure engine mount plate straps to chassis 14 Remove engine from chassis 3 8 Gp POLARIS ENGINES O Engine Installation Typical 1 Prepare chassis for engine installation by moving hoses and wiring out of the way 2 If model is equipped with a torque stop loosen locking screw and turn torque stop in to gain clearance when installing engine NOTE Torque stop must be adjusted properly after clutch alignment see chapter 5 clutches 3 Check condition of bonded rubber engine mounts Be sure mounts are tight before installing engine With engine mounting plate or mount straps installed on engine set engine on rubber mounts and loosely install mounting bolts and nuts 4 Install drive belt and clutch if removed and check clutch offset alignment Adjust torque stop where applicable Refer to chapter 5 clutches for torque stop adjustment procedure 5 Tighten engine mounting bolts to specification Engine Mounting Bolt Torq
168. embly must be replaced Test 2 Closed Circuit Kill The two speed control switches must make a complete cir cuit to kill the engine To check the switches pull the throttle leveroutaway from the throttle block With the switch plung ers outward and the auxiliary shut off switch in the ON posi tion the multitester must read less than 4 ohms resistance Inspect wires and repair if damaged or replace switch as sembly Test 3 Auxiliary Shut Off The multitester should read less than A ohms in the OFF position and an open circuit in the the ON position Inspect wires and repair if damaged or replace switch assembly Speed Control Assurance Replacement Auxiliary shut off and speed control assurance switches are connected and replaced as a unit from the back side of the throttle block 1 Remove the handlebar pad and or throttle block backing plate 2 Slide out the auxiliary shut off portion of the switch 3 Remove the two screws securing the two speed control assurance switches 4 Remove the switches noting their placement in the throttle block 5 Replace the assembly and check its operation ELECTRICAL Use the multitester ohmmeter to test the resistance of the fuel sender Poston ohms Range HEE The supply voltage to the gauge should be 13 5 VAC Fuel Gauge Q Pur Wh Brn ELECTRICAL TPS Throttle Position Sensor Some Polaris snowmobiles are manufactured with Throttle Position Sensors TPS
169. ension assemblies z Replace locking fasteners if removed BODY AND STEERING Steering Assembly EDGE RMK 600 700 800 Torque Specifications A 28 30 ft lbs 38 41 Nm B 35 40 ft Ibs 47 54 Nm E 54 66 ft lbs 75 91 Nm D 135 165 ft lbs 187 228 Nm Apply Premium All Season Grease PN2871322 30z to all grease zerks located on suspension assemblies z Replace locking fasteners if removed g BODY AND STEERING Inspection Prior to performing steering alignment inspect all steering and suspension components for wear or damage and replace parts as necessary Refer to steering assembly exploded views in this chapter for identification of components and torque values of fasteners While disassembling make notes of what direction a bolt goes through a part whattype of nutis used in an application in which direction do the steering arms go on weld up or weld down etc Some of the fasteners used in the IFS are special and cannot be purchased at a hardware store Always use genuine Polaris parts and hardware when replacing front end components Review steering adjustment guidelines on page 6 8 before making adjustments The following components must be inspected at this time NOTE Always follow rod end engagement guidelines found on page 6 7 Maximum setup width must be checked whenever front suspension components are adjusted or replaced Tie rods and tie rod ends Radius rods and radius rod ends Torsio
170. er Gauge Cylinder 1 2 1 3cm Piston Ring Piston Ring Cutaway Keystone Piston Ring 3 61 A ENGINES Oil Pump Operation and Troubleshooting Any time the engine is disassembled or repaired it is important that the oil supply from the pump to the engine be checked NOTE Banjo type or pressed in valves should open with 2 to 7 lbs of pressure Perform this testwith 40 1 premix in fuel tank 1 With engine in chassis oil reservoir full and pump bled remove two oil feed line banjo bolts A from their location on the manifold or carburetors NOTE Install new sealing washers upon installation on either side of the banjo check valve Loosely thread only the banjo bolts back into the manifold or carburetors Place oil feed lines with their check valves away from the clutch area Start the engine and let it idle at normal idle RPM Lift oil pump control lever up to its maximum flow position Drops of oil should be visible from the banjo check valves after the engine is idled one to two minutes with a drop occurring approximately every few seconds If oil does not flow from one of the check valves remove oil line from check valve and again idle engine If oil then flows the check valve is defective and must be replaced If oil does not flow with check valves removed from their feed lines the malfunction is one of the following S Inline filter blocked Air not bled from oil pump Feed lines leakin
171. er line Dial Indicator 2 Sharpen a coat hanger or section of welding rod and anchor itto a convenient spot Point the sharpened end at the outer perimeter of the degree wheel 3 Install a dial indicator into the magneto end cylinder spark plug hole front 1 The ignition timing is referenced by the magneto Degree end Wheel 4 Rotate the engine to bring the piston to top dead center TDC on the cylinder with the indicator installed 5 Locate TDC as accurately as possible by finding the center ofthe point where there is no piston movement Zero the dial indicator at this point Continue to rotate the crankshaft in the normal direction of rotation until the dial indicator reads 100 2 54mm after top dead center ATDC IMPORTANT Do not allow the crankshaft to move from this position ENGINES O 6 Bend the pointer or move the degree wheel until the pointer aligns with the 180 or 120 mark on the degree wheel Crankshaft Indexing Continued 7 With the pointer aligned make sure the degree wheel and pointer are secured and will not move out of position Re check accuracy of this location by repeating steps 4 and 5 The pointer should align with the 180 or 120 mark when the dial indicator reads 100 2 54mm ATDC IMPORTANT Do not move the degree wheel or pointer after the initial setting on the mag end cylinder simply read the wheel and dial indicator 8 Remove the dial indicator and install in
172. es when working near batteries KEEP OUT OF REACH OF CHILDREN 9 11 ELECTRICAL Dynamic Testing of the Electric Starting System Condition Starter fails to turn motor or motor turns slowly NOTE Be sure the engine crankshaft is free to turn before proceeding For this test a digital multitester must be used Meter connections are shown on page 9 15 With tester on VDC place tester black lead on bat 8 Remove battery test and or service Install a fully tery negative terminal and tester red lead on bat charged shop battery to continue the test tery positive terminal A Page 9 13 Reading should be 12 6V or greater Is it Continue with left column No Yes Disconnect red engagement coil wire from start sole With black tester lead on ground check for voltage noid Connect black tester wire to an appropriate at large relay in terminal circuit breaker in and out ground and red lead to red harness wire at solenoid terminals and across both sides red and red white F page 9 13 Rotate ignition key to the start posi of the ignition switch with switch on start Repair or tion Meter should read battery voltage Does it replace any defective parts No Yes Reconnect solenoid connect tester black lead to Clean battery to solenoid cable ends or replace battery positive terminal and red tester lead to sole cable noid end of battery to solenoid cable B Page 9 13 Turn key to start position The reading m
173. essive hi fax wear occurs due to poor snow conditions additional wheel kits are available l Safely support the rear of the machine with the track off the ground 2 Startthe engine and apply a small amount of throttle until the track turns slowly at least five complete revolutions Stop the engine 3 Inspecttrack alignment by looking through the track window to make sure the rails are evenly spaced on each side Ifthe track runs to the left loosen left locknut and tighten the left adjusting bolt If the track runs to the right loosen right locknut and tighten the right adjusting bolt 4 Afteradjustments are complete be sure to tighten locknuts and idler shaft bolts Torque to specification Idler Shaft Bolt Torque 35 40 ft Ibs 48 55 Nm 2 12 Track window Looking through track window make sure the rails are evenly spaced on each side Idler Shaft Bolt Gp POLARIS MAINTENANCE TUNE UP Track Tension Data EE me Com SCHEI EE 10 lbs 4 54 kg 16 ahead of rear idler shaft 3 8 1 2 1 1 3 cm When performing the following checks and adjustments stay clear of all moving parts to avoid serious personal injury Track Tension XTRA Lite Xtra 10 EDGE RMK 1 Turn the machine off 2 Liftthe rear of the machine and safely support it off the ground 3 Place a 10 lb 4 5 kg weight on the track at a point approximately 16 40 6 cm ahead of
174. est Power the light In Yel BIk W Engine Ground The indicator light is controlled by a temperature warning switch installed into the engine cooling system When engine coolant temperature reaches approximately 205 F the switch closes completing the circuit through the indicator light to ground The system should be tested periodically for proper operation Lamp Circuit Test 1 Remove wire from temperature sensing switch located under thermostat housing 2 With engine idling ground wire to engine The temperature warning lamp on the console should light If not replace the lamp assembly or inspect wiring for shorts or open circuit Temp Light Temperature Sensor Test The temperature warning switch is normally open 1 Setthe multitester on the ohms Q scale 2 Disconnect the lamp wire 3 Connectone test probe to the switch terminal and the other to engine ground The meter should show an open circuit OL This indicates a normally open switch If the switch were heated to approximately 205 F the contact in the switch would close and the reading would be less than 4 ohms CAUTION If attempting to heat the sensor to close the contacts heat only in a water bath Never subject the sensor to an open flame to attempt to close the contacts as sensor damage will result Coolant Temperature Sensor The temperature sensor works in conjunction with the throttle position sensor TPS and CDI controller The CDI h
175. et hone using honing oil anda coarse roughing stone Measure the new piston at room temperature see piston measurement and rough hone to the size of the piston or slightly larger Always leave 002 003 05 07 mm for finish hon ing Complete the sizing with fine grit stones to provide the proper cross hatch finish and required piston clearance Inspect cylinder for taper and out of round Taper or out of round on the finished bore should not exceed 0004 002mm EXAMPLE OF CROSS HATCH PATTERN NOTE Always check piston to cylinder clearance and piston ring installed gap after boring honing is complete Gp POLARIS 3 51 A ENGINES Honing Procedure 1 Wash cylinder with solvent Clamp cylinder in a soft jawed vise by the exhaust port studs 2 Place hone in cylinder and tighten stone adjusting knob until stone contacts the cylinder walls DO NOT OVERTIGHTEN Cylinders may be wet or dry honed depending on the hone manufacturer s recommendations Wet honing removes more material faster and leaves a more distinct pattern in the bore Using a 1 21 13 mm drill motor rotating at a speed of 300 500 RPM run the hone in and out of the cylinder rapidly until cutting tension decreases Remember to keep the hone drive shaft centered to prevent edge loading and always bring the stone approximately 1 21 1 3 cm beyond the bore at the end of each stroke Release the hone at regular intervals to inspect bore size and finish Port C
176. everse Kit Option Sprocket Drive Coupler fei BRAKES FINAL DRIVE Reverse System Maintenance Chain Retention Bracket Screw Pinion Gear Drive Washer Drive Coupler Washer Reverse Gear O Ring Compression S pring Es Drive Coupler Retainer Chain Tension Adjustment 1 Elevate the rear of machine and support so track is off the floor 2 Loosen adjuster bolt lock nut 3 Loosen adjuster bolt slightly about one turn out 4 Tighten adjuster to specified torque Adjuster Bolt Torque 20 in Ibs 2 3 Nm 5 Loosen adjuster bolt 1 2 turn 6 Hold adjuster bolt in position and tighten locknut securely 8 38 Gp POLARIS Oil Change 1 Change annually prior to off season storage Oil Level l Using Polaris chaincase lubricant maintain proper oil level Proper level is checked by removing dipstick 2 Wipe off any metal particles from the dipstick S mall amounts of particles will be common 3 Add lubricant until the level is in the safe zone on the dipstick 11 oz Do not mix or use other types of lubricant Polaris Chaincase Lube PN 2871280 Quart PN 2870464 Gallon PN 2872281 2 5 Gallon Adjustment Due to break in or replacement of components the re verse shift mechanism may require adjustment Adjust with the shifter in the forward position 1 Pull shift lever slowly while observing shift arm on transmission 2 Ifadjustmentis
177. f sheave With towers pointing away from vise slide sheave onto puller rod Hl 1 Install nut removed in step 2 onto end of puller rod and hand tighten Turn puller barrel to increase tension on sheave if needed Turn sheave counterclockwise on puller rod until it comes free Remove nut from puller rod and set aside Pull bushing removal tool and adapter from puller rod Remove bushing from tool and discard Remove retaining ring from inside adapter and set aside P 85 Drive Clutch Movable Sheave Bushing Installation l 2 w KON DO bal SONS UT cS Place main adapter Item 8 on puller Push new bushing into center of sheave by hand Insert installation tool Item 1 into center of sheave and with towers pointing toward vise slide sheave onto puller rod Install nut on puller rod and hand tighten Turn barrel to apply additional tension if needed Turn sheave counterclockwise until bushing is seated Remove nut from puller rod and set aside Remove sheave from puller Remove installation tool Insert retaining ring removed in step 9 and installation tool into center of sheave With towers pointing toward vise install sheave onto puller rod 11 12 13 14 15 Install nut on puller rod and hand tighten Turn barrel to apply additional tension if needed Turn sheave counterclockwise until ring is seated Remove nut from puller rod and set aside Remove sheave from puller Remove installation tool
178. ff the ground and suspension fully extended The maximum setup width specifications listed on page 6 9 are maximum width mea surements and are critical to ensure adequate thread engagement of steering tie rod and radius rod ends If the suspension is set too wide the torsion bar can come loose and interfere with steering Do not attempt to set the suspension wider than the specified Maximum Set Up Width Camber Adjustment XTRA CRC and XC 10 CRC 5 RemovelFS shocks and install appropriate travel location bars The travel location bars will locate the IFS at a given point of travel where the camber should be neutral 0 6 Disconnect tie rods from steering arms NOTE If toe adjustment is correct the spindles will not be horizontally aligned with the travel location bars installed Therefore the alignment bar will not slide through both spindles Disconnecting the tie rods will eliminate bind on the alignment bar and allow for more precise camber adjustment It may also be helpful to secure the tie rods so they don t interfere with inspection or adjustment 7 Determine which spindle requires the greatest amount of correction by installing the alignment bar through one side to the opposite spindle then remove the bar and install it through the other side to the opposite spindle LD M W W un Camber Adjustment Install appropriate Travel Location Bars Disconnect Haya e ED S AU Disconnect Remove to adjust radius rods Alignment
179. fficient lubrication Ex cessive wear may be due to improper alignment improp er track adjustment or machine operation on surfaces without snow Replace Hi F ax when worn to 3 8 95 cm on XTRA 10 and 7 16 1 1 cm on EDGE RMK and XTRA Lite style A suspensions 3 8 7 16 1 1 cm All XTRA 10 12 PN 5521452 Suggested Hi Fax Wear Limit XTRA Lite 7 16 1 1 cm 7 16 1 1 cm t 2002 Edge RMK PN 5521581 2002 Edge RMK HyFax will NOT fit on 2001 units EDGE RMK 7 16 1 1cm Hi Fax Removal 1 Remove suspension from machine NOTE Some models may allow Hi Fax to be removed by sliding it through track windows with the suspension mounted in the machine 2 Remove front Hi F ax retaining bolt 3 Use a block of wood or a drift punch and hammer to drive Hi F ax rearward off the slide rail 4 With Hi F ax material at room temperature install new Hi Fax by reversing steps 1 3 NOTE Lightly coat Hi Fax track clip area with a lubricant such as LPS2 or WD 40 to ease installation NOTE W ide Hi F ax should be narrowed on the leading sides to allow it to fit through narrow windows SUSPENSIONS Xtra 10 Xtra Lite Torque Specifications Suspension Mounting and Lubrication Points 3 8 top shock mounting bot 28 30 ft Ibs 39 41 Nm 3 8 suspension mounting bolts aa 35 40 ft Ibs 49 55 Nm 7 16 suspension mounting Dote 55 60 ft lbs 76 83 Nm Shock rod bolts do not over torque
180. from the engine the driven clutch becomes dominantand overrides the drive clutch The driven clutch downshifts into a ratio which will match the increased load Because the driven clutch can sense and shift into the proper ratio engine RPM will remain within the specified range Driven Clutch Adjustments The driven clutch has a provision for varying the torque required to change its ratio Itcan bereadjusted by relocat ing the spring in the helix which in turn increases or decreases the amount of load required to change the ratio Driven Clutch Typical P 85 DRIVE DRIVEN CLUTCHES Removal 1 Hold clutch with strap wrench Remove drive clutch retaining bolt grease puller thread and tip lightly and install puller into clutch Tighten puller with a wrench or strike t bar with a hammer until clutch is removed Strap Wrench PN 2870336 Clutch Puller PN 2870506 3 4 16 ID Clutch Clutch Puller PN 2872084 550 Fan 2 Slight galling or scoring of bore taper can usually be corrected using a tapered reamer Place reamer in a vise and lubricate with cutting oil Clean clutch taper by manually rotating clutch clockwise Do not ream taper more than required to remove galling or scoring Never use power tools to ream taper of drive clutch Tapered Reamer PN 2870576 CAUTION Never use an air impact wrench for installing or removing a drive clutch It will loosen the spider torque value and could cause engi
181. ft Improper shock charge or valving if so equipped Adjust to correct toe alignment Adjust to correct camber Tighten or replace Replace if necessary Index correctly in relation to spindle Replace if necessary Tighten or replace if necessary Tighten or replace if necessary Tighten as needed Replace if necessary Tighten as needed Replace if necessary Adjust spring tension on shocks Recharge service or replace shocks 4Some machines with a wide front end may experience darting while following narrower machines on a trail This is caused by the skis moving in and out of the narrower track left by the previous machine Gp POLARIS 6 35 Rear Suspension Theory of Operation 7 1 7 2 Suspension Overview and Setup 7 3 Shock TOUNINO DEE EE 7 4 Overall Suspension Setup aa 7 5 Hi Fax Removal Installation 7 6 Suspension Information Xtra 10 Xtra Lite 1 7 XTRA Lite Exploded VIEW 402 atrae deat roe as 7 8 XTRA Lite Rear Suspension cece eee ees 7 9 XTRA 10 Rear Suspension coe n ra y eri d 7 10 Suspension Information EDGE RMK 7 11 EDGE RMK Exploded VIEW use ENNER re nee 7 12 Suspension Adjustment s aeu ter n t cedo is 7 13 7 16 Front Suspension Adjustment ranana 7 17 Limiter Strap Adjustment 7 18 Compression Damping Adjustable Shocks 7 19
182. g Oil tank vent restricted or kinked nnn WN Defective pump 3 62 Pressed Apply Pressure Here To Test 9 Gp POLARIS ENGINES O The oil pump must always be bled following any service to the injector system or engine which allows the loss of oil and subsequent entrapped air during reassembly Oil Pump Bleeding 1 Fill oil reservoir with Polaris injector oil 2 Loosen bleed screw After a short time oil should flow from beneath the screw head to indicate the pump is free of air 3 Tighten bleed bleed screw securely Oil Pump Bushing End Play Adjustment Fuji Ifthe oil pump crankcase or any pump drive component is replaced inspect the drive gear bushing end play us ing the following procedure 1 Assemble oil pump drive gear assembly Be sure the bushing is fully seated in the crankcase 2 Measure distance from oil pump mounting surface to bushing Call this measurement A O ENGINES Oil Pump Bushing End Play Adjustment Fuji continued 3 Measure distance from oil pump mounting flange surface to end of seal flange as shown Call this measurement B 4 Subtract measurement B from A to determine total bushing end play 5 Measure thickness of existing shims and subtract from total bushing end play determined in step 3 6 Add or subtract shims as required to provide specified end play 7 Lightly grease a new O ring and install iton the pump Install pump
183. g Chaincase Side Angle Overall 28 Weight Spring Spring Helix Gearing Outside Circumference 47 625 Meters 0 900 10 56 Dark Blue a R32 18 41 68P Center Distance 12 00 Feet 0 3000 Bushed White aven ee HYVO Shift Weights 10 56 Bushed soso 10AL Almond Siver R32 1641688 Primary Spring Dark Blue White iila E rl de pring SC ee ege silver R2 ee 2700 3700 10M5 Almond i R32 18 41 68P Production Setting ENGINE Type cops deste E Liquid Cooled Case Reed Twin Displacement 500cc Fuel Pump Manuf N A El 2 116 70 5mm FuelPump Mark N A EE 2 520 64mm Oil Pump Manuf Mikuni Piston Cylinder Clearance 0 0045 0 0063 0 11 0 16mm Oil Pump Mark 2540051 Service Limit N A Cylinder Head Mark 3021048 Piston Marking 3021038 Piston Ring Marking N A Piston Ring End Gap 0 012 0 018 30 46mm Head ccs Uninstalled 27 5x 50cc Head ccs Installed 25cc Operating RPMz200 8000 RPM Idle RPM 200 1500 RPM Engagement RPM 300 4200 RPM Cylinder Head Torque 20 24 ft lbs 28 33N m Cylinder Base Nut Torque 30 34 ft lbs 41 47 Nm Crankcase Torque 8mm 20 24 ft lbs 28 33 Nm Crankcase Torque 10mm N A Flywheel Torque 90 ft Ibs 124 Nm 1 14 Gp POLARIS GENERAL INFORMATION
184. ged of air Close bleed screw and tighten securely 5 Fill reservoir bottle until coolant level is between the minimum and maximum fill marks 6 Replace pressure cap 7 Start engine and test for leaks Domestic Twins Cooling System 500 RMK 500 SKS Euro Hose tee to bottle Hose tee to brake cooler NOTE When leak testing cooling system system pressure should not exceed 2 Ibs less than cap pres sure Refer to filling and bleeding procedure on page 3 61 Gp POLARIS ENGINES O Hose brake cooler to rear extrusion SS LE Lo THERMOSTAT P BY PASS COOLANT BOTTLE CENTER S EXCHANGER 7 TUNNEL EXCHANGERS REAR CLOSEOFF EXCHANGER Euro Only Y 3 67 O ENGINES Cooling System 700 SKS Euro Hose tee to bottle Bypass Hose Not Shown Hose brake cooler to rear extrusion Hose tee to brake cooler ose bulkhead to rear extrusion NS Protective conduit Hose engine out to bottom close off Hose tee to pump in THERMOSTAT BOTTLE NOTE When leak testing cooling system system pressure should notexceed 2 Ibs less than cap pres BRAKE COOLER sure Refer to filling and bleeding procedure on page 3 61 TUNNEL EXCHANGERS ENGINES O Cooling System 600 RMK ER Close off Gripper De Icer Cooling Extrusions Hose Brake Cool Hose Gripper Brake er Bypass Cooler S Hose Bottle Pump E Cooler Center 3 outlet 4 Hose Cooler
185. gher 36 52mm horsepower engines Drag Racers Good for lower horsepower trail riding pe 1 MEA 12 E 47 Du Double cog CVT MEA 52mm E 1 438 E 50 ee 625 Double cog CVT version of PN 3211078 36 52mm 3211078 1 438 11 50 46 625 Standard Drive Belt 36 52mm Belt dimensions given are nominal dimensions There is a variance for all critical dimensions Clutch set up must be inspected when a new belt is installed and If necessary clutch set up must be adjusted The drive belt is an important component of the converter system In order to achieve maximum efficiency from the converter drive belt tension deflection clutch offset and alignment must be adjusted properly General Belt Selection Guidelines NOTE R efer to appropriate parts manual for proper belt Production belt is recommended unless tuning for a specific application CVT S Increased service life for high horsepower and extended high speed running S Need 1 2 grams heavier drive clutch weight S Good for prolonged high speed running S Good for aggressive riders Standard Compound S More aggressive at low speeds S Reduced heat and drive clutch sheave wear S Used for short higher horsepower runs Drag Racing S Good trail belt for lower horsepower engines DRIVE DRIVEN CLUTCHES Drive Belt Inspection 1 Measure belt width and replace if worn severely G enerally belt should be replaced if clutches can no longer be adjusted to provid
186. ghtness nicks or burrs Cylinder Head Assembly DU Bearing clean in spect or replace Inside of shock body for scratches burrs or excessive wear Teflon piston and I F P wear band for cuts chipped or nicked edges or excessive wear O rings for nicks cuts or cracks Cap and rod seals for nicks cuts or cracks Valve discs for kinks or waves Compression bumpers ski shocks only for chipping cracking or being missing Should any of these items be in question replace ment is recommended ASSEMBLY Place the piston rod upper mountinto the vise Re assemble damper rod assembly in the reverse or der of disassembly Special attention should be paid the order of the Rebound and Compression disc shim stacks ensuring that they are in the same order prior to disassembly Tighten the lock nut to 15 20 ft lb of torque PICTURE 10 CAUTION DO NOT OVER TORQUE If exces sive torque is applied damage to the piston and valves will occur Secure the shock body by its lower mount in vise The use of soft jaws is recommend to prevent damage or marks to the shock PICTURE 11 CAUTION Itis importantthatthe gas shock be re tained in the vice by the lower mount Any other method of securing the shock body during these procedures may deform the shock body cylinder Note The next points on IFP are notapplicable for emulsion shocks P N 7041992 Proceed to as sembly of the pressure valve on next page Thread the positioning hea
187. given an the set up decal and adjust torsion spring blocks accordingly or install optional torsion springs to achieve correct sag dimensions Increase IFS preload by turning spring collar to the right clockwise Move limiter strap on front torque arm to high position Fig 2 Steering is heavy Check skags and skis for damage Check for binding front suspension and steering components grease all pivot points elevate front of machine Check the sag dimension given on the set up decal and adjust torsion spring blocks accordingly or install optional torsion springs to achieve correct sag dimensions Decrease IFS preload by turning spring collar to the left counter clockwise Machine darts from Make sure skis are aligned properly see your owners manual side lo side Check for binding front suspension and steering components grease all pivot points elevate front of machine Make sure skags are straight on skis Install e z steer skags See rear suspension sel up decal located under hood CHAPTER 8 BRAKES FINAL DRIVE Track and Chaincase Specifications 8 1 Jackshaft RPM Charts dao stata Pra BANA 8 2 8 4 HYVO Sprocket Part Numbers 8 5 Sprocket Chaincase Combinations 8 6 8 7 Hydraulic Brake Overview 8 8 Brake Bleedi g EE 8 9 8 10 Master Cylinder Removal Installation 8 11 8 19 Brake Pad Replacement cria di a8 8 20 8 21 Hydr
188. h friction material facing each other into housing Hold in place using clips Slide brake assembly into bracket until both clips snap into grooves in bracket Separate pads for installation over disc Place brake assembly over disc and push bracket into chaincase Replace 3 8 bolts rope guide and washers Torque to specification Caliper Bolt Torque 25 30 ft Ibs 34 5 41 4 Nm Perform brake bleeding procedure as outlined after S ystem Rebuild page 8 10 8 11 BRAKES FINAL DRIVE Es Drive System Disassembly The Type 3 drive system is used on all models except the WideTrak This system consists of a right side mounted chaincase with right side mounted brake assembly Rear Suspension Removal l Mark hood hinges for ease of alignment when reassembling Remove hood to prevent damage air silencer exhaust system and battery if so equipped Place drip pan under chaincase and remove drain plug Dispose of used chaincase oil properly 2 Turn fuel valve off 3 Remove drive belt and driven clutch Note position of washers for controlling drive to driven Offset A and washers to control clutch free floating B 4 Loosen jackshaft bearing lock set screws if equipped NOTE Some models are equipped with set screw or Skwez loct style jackshaft bearings Some models are equipped with press fit bearings which have no locking device Press On Bearing Set Screw Bearing Skwez loc Bearing 5
189. hamfering Remove the sharp edges at the bottom and top of each port whenever boring or honing is performed Make sure there are no sharp edges IMPORTANT Cleaning the Cylinder After Honing Itis very important that the cylinder be thoroughly cleaned after honing to remove all grit material Wash the cylin derin a solvent then in hot soapy water Pay close attention to areas where the cylinder sleeve meets the alumi num casting transfer port area Use electrical contact cleaner if necessary to clean these areas Rinse thor oughly dry with compressed air and oil the bore immediately with Polaris Premium 2 Cycle Lubricant NOTE Always check piston to cylinder clearance and piston ring installed gap after boring honing is complete ENGINES O Piston Measurement Whenever cylinders are honed or bore clearance is checked it is important to measure piston diameter properly to arrive at its major dimension Measurements should be taken with piston at room temperature and at rightangles to the pin as shown Determine the largest diameter within this area and refer to the chart below for clearance specifications Cylinder bore must be straight and concentric Refer to honing information outlined in this chapter for specific procedures Refer to the specifications section in chapter 1 for Target Clearance when re boring cylinder or S ervice Limit specifications to determine if piston requires replacement FUJI ENGINES Measure 1 2
190. hart on page 6 8 Maximum set up width is the maximum allowable dis tance between ski spindle centers with front end of vehicle off the ground and suspension fully extended The Maximum Set Up Width specifications are maximum width measurements and are critical to ensure adequate torsion bar engagement with the trailing arm If the suspension is settoo wide the torsion barcan come loose and interfere with steering Do not attempt to set the suspension wider than the specified Maximum Set Up Width Spindle Centering Set Up Width 1 OY Bi A Make sure the track is properly aligned Refer to Maintenance Chapter for procedure This will be used as a reference point for final toe out measurement Support the front of the machine 1 2 2 5 5 1 cm off the floor Remove skis and ski pivot bushings Disconnect adjustable torsion bar linkage where applicable Measure spindle to chassis centering as shown and record measurement Both spindles should be an equal distance 1 8 3 mm from the center of the chassis after adjusting camber width and toe alignment This measurement is controlled by adjusting radius rod length Measure set up width and record This measurement is controlled by adjusting radius rod E length and must not exceed the Maximum Setup Spindle To Chassis Width listed in the appropriate table at the front of Centering this section after all steering adjustments are Left Right 1 8 complete See ill
191. he driver to make adjustments to the compression valving by turning the screw located near the base of the shock Adjustment Locate the adjustment screw near the base of the shock NOTE This adjustment is easiest to make with the machine tipped on its side Be sure to shut off the fuel supply before tipping the machine to prevent fuel spillage and flooding of the carbure tors By turning the screw clockwise a small screwdriver or dime work well the compression valving is increased stiffening the ride To soften the ride reduce the compression by turning the screw counter clockwise A great dealof ride performance is accomplished with a mere 1 2 to 1 turns There are approximately 3 fullturns of adjust ment available How to Adjust IFS Ifthe suspension is bottoming tighten the compression screw clockwise in 1 2 turn increments until the bottom ing stops Backing off 1 4 turn counter clockwise atthis point should give you the best possible ride ensuring use of the full travel ofthe suspension The opposite procedure should be used ifthe suspensionis too stiff upon initial set up If bottoming continues after the screw is turned in full clockwise the compression spring should be adjusted with the threaded adjustment collar Back the screw out to the original starting position after the compression spring has been adjusted Riding conditions are ever changing Keep in mind the compression damping adjustable screw can be adjusted
192. he primary ignition components and lighting coils Stroke The maximum movement of the piston from bottom dead center to top dead center Itis characterized by 180 of crankshaft rotation Surge Tank The fill tank in the liquid cooling system TDC Top Dead Center Piston s most outward travel from crankshaft Transfer The movement of fuel air from the crankcase to the combustion chamber in a two stroke engine Trigger Coil Pulser coil Generates the voltage for triggering closing the thyristor and timing the spark in CDI systems Small coil mounted at the top of the stator plate next to the ignition generating coil or on the outside of the flywheel V Regulator Voltage regulator Maintains maximum lighting coil output at approx 14 5 ACV as engine RPM increases Venturi An area ofair constriction A venturi is used in carburetors to speed up airflow which lowers pressure in venturi to below atmospheric pressure causing fuel to be pushed through jets etc and into the venturi to be mixed with airand form a combustible air fuel mixture Volt The unit of measure for electrical pressure of electromotive force Measured by a voltmeter in parallel with the circuit Watt Unit of electrical power Watts amperes x volts d GENERAL INFORMATION In order to perform service work efficiently and to prevent costly errors the technician should read the text in this manual thoroughly familiarizing him herself with procedures before beginn
193. heck piston for scoring or cracks in piston crown or pin area Excessive carbon buildup below the ring lands is an indication of piston ring or cylinder wear 2 Measure piston outside diameter at a point 10 mm 3 8 up from the bottom of the skirt at a 90 angle to the direction ofthe piston pin domestic engines For Fuji engines measure 1 2 12 7mm up from the bottom of the piston skirt Record the measurement for each piston NOTE The piston must be measured at this point to pro vide accurate piston to cylinder clearance measurement 3 Subtract this measurement from the minimum cylinder measurement recorded previously If clearance exceeds the service limit the cylinder should be re bored and new pistons and rings installed Piston Ring Installed Gap 1 Position ring 1 21 1 3 cm from the top of the cylinder using the piston to push it squarely into place Measure installed gap with a feeler gauge at both the top and bottom of the cylinder NOTE A difference in end gap indicates cylinder taper Thecylinder should be measured for excessive taper and out of round Replace rings if the installed end gap ex ceeds the service limit NOTE Always check piston ring installed gap after re bor ing a cylinder or when installing new rings NOTE Piston rings are installed with marking or beveled side up Gp POLARIS ENGINES O O 90 to pin FUJI ENGINES Measure 1 2 12 7mm up from bottom of skirt Feel
194. helix down with a softfaced hammer Remove snap ring and washer 3 Allow sheaves to return and force the helix out Before removing helix note driven clutch spring position Remove helix 4 Inspect helix ramps and movable buttons and for wear or damage P 85 buttons can be removed by applying heatto the button housing or drill button with an 1 8 drill bit The ramp buttons should be replaced when worn See Maintenance section for inspection intervals Gp POLARIS 5 23 DRIVE DRIVEN CLUTCHES Disassembly Cont 5 Remove driven clutch spring Both spring tabs should line up If not spring is fatigued and should be replaced 6 Slide moveable sheave off and inspect sheave surfaces for wear or grooving Note size and number of shim washers between sheaves 7 Note condition of moveable sheave bushing Install helix into bushing It should slide freely without binding See page 5 39 for bushing replacement 8 Polish helix with a fine emery cloth to remove any sharp edges or build up which may cause sticking 5 24 Tabs Aligned Gp POLARIS DRIVE DRIVEN CLUTCHES Assembly 1 Install appropriate washer s on fixed shaft Optional Thin Adjustment Washer P 85 048 PN 7555899 2 Slide moveable sheave on fixed shaft 3 Install driven clutch spring Be sure spring tab is seated in hole in moveable sheave Refer to specifications in front of this section for driven spring set
195. hing is held in place after installation by screws 11 Insert bushing PN 3569803 into clutch and tap lightly with a soft face hammer 12 Install adapter number two Item 10 onto puller See IL 4 13 Slide clutch sheave onto puller with back side away from vise 14 Turn puller barrel until rod extends past back side of sheave 15 Insert large installation tool for DU bushing onto rod 16 Install nut onto puller rod and hand tighten Tum puller barrel to increase tension as needed Adapter 17 Turn clutch sheave counterclockwise until bushing is Number Two seated 18 Remove nut from puller rod and set aside 19 Remove installation tool and slide clutch sheave from puller NOTE The screws hold the bushing in place DRIVE DRIVEN CLUTCHES Drive Driven Clutches Troubleshooting SYMPTOMS PROBABLE CAUSE REMEDY Harsh drive clutch engage Drive belt worn too narrow Replace ment Excessive belt to sheave clearance with Perform belt to sheave clear new belt high performance version with ance adjustment with shim out detent shift weight washers beneath spider Drive belt turn over Wrong belt for application Replace Clutch alignment out of spec Adjust alignment offset Engine mount broken or loose Inspect adjust or replace Driven clutch sheaves have excessive Measurement should be tak runout are bent or damaged en 25 in from outer circum ference on sheave face Max imum all
196. hness or loose bushing Also inspect to see if roller and bushing are separating Bushing must fit tightly in roller Replace roller and pin if roller fails to roll smoothly flat spots or if bushing is loose 5 14 Direction of rotation Gp POLARIS DRIVE DRIVEN CLUTCHES Spider Roller Removal 1 Remove spider buttons using button removal tool Remove shims if any are installed and note location Spider Button Removal Tool PN 2870985 2 Place spider on a vise or in an arbor press Using a pin punch drive out the roller pin Roller Installation 1 Startareplacementroller on each leg driving a pin in 100 125 25 32 cm beyond the first land of the spider leg A Remove any aluminum burrs from pin protruding from spider 2 Install one washer onto pin Gp POLARIS 5 15 DRIVE DRIVEN CLUTCHES Roller Installation Cont 3 Place roller on pin as it protrudes from first land 4 Place a second washer on other side of roller 5 Install service tool as shown 6 Place spider on a vise anvil and drive roller pin through to second land of spider CAUTION Use care to start the pin straight Aluminum burrs could pass through into the roller bushing causing itto bind and stick Also use care to make sure the roller remains aligned when the pin is driven through The roller bushing could be damaged causing premature wearand roller fail ure Spider Button Shimming 1 Determ
197. i mc 1 125x EAN e o To wep oon 8 1250x010 Compre Compress Stack Stack orice o o ome 070 m IR Rebound Rebound SE SE uu qn mi eR 700x010 700x010 Ene a bako Rear Track Shock Valving 3 Compress Stack 2C 1 100x 006 1C 1 250x 006 orice 009 1 250x 012 1 250x 012 1 100x 015 Rebound T 000x 012 Stack 900x 012 TR 800x012 700x012 SUSPENSIONS Ryde FXt Shock Chart Front Track Shocks Front Track Shocks Extended Collapsed e Shock Rod y Shock PN Length in Length in Stroke in IFP Depth in Shaft P art Rear Track Shocks Rear Track Shocks Extended Collapsed e Shock Rod e Shock PN Length in Length in Stroke in IFP Depth in Shaft P art IFS Shocks Extended Collapsed Shock Rod 8 Shock PN Length in Length in Stroke in IFP Depth in Shaft P art IFP position is measured from the top if the Cylinder or Reservoir to the top if the IFP IFP DEPTH EE EE mana I s I n T j fi AN H RNS A a Sep eX i A h Hika d Een es ay EGLO OL LL PELE 4 919507 0 074 4742 75 IFP DEPTH PXXZYXXZYXXZYXXZYXXZYXXCYEXZYX Fl Ss G IN S PS 7 24 Go POLARIS SUSPENSIONS Fox Shock Maintenance Changing oil on Fox Shocks is recommended annually and should be included when performing end of season storage preparation
198. i E reram 3130136 flow characteristics as the following 125 aka nla 3130108 340 nand Na 3130137 510N 540 130 aNg paha 3130109 3505 c fixis 3130138 520N 580 135 ie ves 3130110 360 cc 3130139 530N 600 L n 3130111 370 suceda 3130290 540N 620 E LEE 3130112 380 5 ag utes 3130140 550N z 660 150 cu ces 3130113 EINEN 3130480 560N 700 155 eener 3130114 400 3130141 T60 resets nae 3130115 410 o rris 3130599 For Example Do NOT substitute a 165 eo inm 3130116 4205 ias 3130142 530 Main J et in place of a 530N LEE 3130117 KEE 3130143 Main J et A regular 530 will GEES 3130118 MOD 3130144 have a leaner effect than a 530N 180 cesi ens 3130119 A50 amd Nag 3130145 panaman 3130120 d sre 3130146 1901 c oec 3130121 410 iaa 3130147 19573 aes 3130122 490 ic Na maana tes 3130148 200 ve dt 3130123 IEN 3130149 210 REES 3130124 KE RE 3130150 220 sawa na 3130125 KI 3130151 230 RE 3130126 590 voee 3130152 KREE 3130127 GENEE 3130153 Gb POLARIS 4 1 Tel FUEL SYSTEM CARBURETION Jet Needle Part Numbers Mikuni ET NEEDLE NO PART NO ET NEEDLE NO PART NO 5DP ss cessus 3130155 OD Ha nananakawan 3130402 5DT49 ii ous 3130154 OD CH 3130391 SDPO eege 3130333 6DH7 i eene 3130329 KRIER 3130310 ODHE ici esce 3130645 5DT2 x duret 3130473 6DH29 ek eyes 3130462 5DJ8 4 5 ibus 3130667 ODP I ee 3130156 Oda ca 3130528 DEET cix es 3130374 OCEY AA 3130476 6EJ26 t rtis 3130423 DE cee keke 3130725 BEIS iD 3130680 06 GY 3 oos us 313
199. icrofiche 3916836 9916933 9916947 Indy 600 EDGE RMK SO2N GES 3916946 Indy 700 SKS Euro S02557C5 9916938 9916939 9916940 S02S S5AE 3517057 3516957 3517002 SO2NKECS S02NL8CS 9916952 9916953 2000 Snowmobile Owner s Manual All PN 9916649 Snowmobile Assembly Manual PN 9916508 2002 Service Manuals 120 XC SP 9917361 Trail Sport 17362 Super S port Indy 500 340 Delux 991736 Two Up Touring 9917364 Wide Trak LX 340 Touring Sport Touring Trail Touring 500 Classic Touring 600 Classic Touring Trail Luxury 500 Classic 550 Classic 600 Classic 700 Classic 9917363 Deep Snow 9917366 Trail RMK 500 RMK 500 SKS Euro 700 SKS Trail RMK 600 700 800 EDGE RMK Performance 9917367 500 XC 500 600 700 800 XC SP 800 XCR High Performance 17 440 XCF SP 440 XC SP 500 600 700 800 XC SP 600 700 800 RMK 800 XCR pe 9917369 d GENERAL INFORMATION MODEL NUMBER IDENTIFICATION 2002 MODEL DESIGNATION YEAR DESIGNATION ENGINE DESIGNATION S Snow S02 D 5 B S MODEL CHASSIS DESIGNATION MODEL LINE 4TH DIGIT MODEL TYPE 5TH DIGIT S Gen II A Feature Option L Lite B Basic N EDGE C Feature Option W Mini Indy D Deluxe E Feature Option M 10 F Feature Option J 2136 RMK Edge K 144 RMK Edge L 151 RMK Edge M 156 RMK Edge P Performance R RMK Gen II S SKS Tz Touring U Utility X Racer 2002 ENGINE DESIGNATION NUMBERS 1A 121 F C OHV 4 cy
200. ides 2 Rivetholes across from one another in unison 3 Liquid cooled models will have recesses on both sides like reference A Fan cooled models will not have recesses and will look like reference B on both sides o BODY AND STEERING Nosepan Replacement Procedure Gen II XC 10 IMPORTANT When installing a replacement nosepan the open circles representrivets installed from inside the nosepan through the bottom The filled in circles representrivets installed from the under side of nosepan through to the top NOTE The rivet for polyethylene nosepans is PN 7621467 NOTE Rivet holes may require drilling into the bulkhead Tipped In trailing arm style NOTE 1 When transfer drilling holes do not force pan into a position which is not uniform with the other side Use the same method to drill both sides 2 Rivetholes across from one another in unison BODY AND STEERING Nosepan Replacement Procedure EDGE RMK IMPORTANT When installing a replacement nosepan the open circles represent rivets installed from inside the nosepan through the bottom The filled in circles represent rivets installed from the under side of nosepan through to the top NOTE The rivet for polyethylene nosepans is PN 7621467 NOTE Rivet holes may require drilling into the bulkhead _ M ES LA EJ EN Hp NP dim eee A AT SCH c NOTE 1 When transfer drilling holes do not force pan into a position whi
201. ifting chaincase or remov ing drive shaft assembly 8 26 Gp POLARIS BRAKES FINAL DRIVE Es Chaincase Removal Cont 8 Tap on end of driveshaft with a soft face hammer and slide the chaincase off of the driveshaft Remove chaincase Chaincase Bearing Removal 1 Remove bearing retaining snap rings 2 Pry out old seal from back side of chaincase 3 Press outold bearing from side shown Ifbearing appears tight use heat to expand chaincase bore Always press bearing toward snap ring side of chaincase when removing Inspect chaincase for any damage and replace if required Jackshaft Removal 1 Remove O Ring seal sleeve and brake disc by tapping on jackshaft end with a soft face hammer 2 Remove jackshaft 3 Forsetscrew and Skwez loc bearings inspectdrive shaft and jackshaft in bearing contact area If diameter is 001 025 mm less than non contact area shafts should be replaced J ackshaft and Driveshaft Service Limit 001 025 mm NOTE On models with pressed bearing on jackshaft shaft will have to be brought through bulkhead slot in order to re move from unit Es BRAKES FINAL DRIVE Driveshaft Removal 1 Tip machine back on left side 2 Remove driveshaft by pushing through bearing hole on the bulkhead then pulling driveshaft toward you 3 After drive shaft has been removed inspect condition of drive sprockets and replace if required NOTE On models with pressed be
202. iking with a ham mer always be sure to re check previously straightened areas to verify truing Refer to the illustrations below Crankshaft Alignment Fixture PN 2870569 Crankshaft Runout Inspection When checking the crankshaft runout it is important to measure with a dial indicator in the correct position W hen measuring on the flywheel side SM easure runout 1 2 12 7mm from the bearing flat W hen measuring from the PTO side SM easure runout where the taper starts after the bearing flat Refer to the illustrations Acceptable crankshaft runout is 000 004 0 10mm for all Polaris crankshafts Measure where taper starts PTO Side Crankshaft Truing Cont NOTE T he rod pin position in relation to the dial indicator position tells you what action is required to straighten the shaft 5 To correct a situation like the one shown in the illustration at right strike the shaft at point A with a brass hammer NOTE T he rod pin position in relation to the dial indicator position tells you what action is required to straighten the shaft 6 To correct a situation like the one shown in the illustration atright squeeze the crankshaftat pointA Use tool from alignment kit 7 If the crank rod pin location is 180 from the dial indicator opposite that shown above it will be necessary to spread the crankshaft at the A position as shown in the illustration at right When rebuilding and straightening
203. illight Bulb Replacement 2 17 Throttle O pening vs Fuel Flow 4 16 Throttle Synchronization 4 24 Throttle Synchronization M ikuni TM 38 4 30 4 31 Throttle Valve 4 15 Tie Rod EndTorque Procedure 6 7 TM 38 40 J et Needle Overview 4 4 Toe A djustment 6 13 Toe Adjustment CRC 6 14 Torque Sequence 3 2 3 5 Torque Specifications Suspension M ounting 7 7 Torque Stop Adjustment 5 34 Torsion Bar Installation 6 24 Torsion Bar Removal 6 24 TPS Adjustment 9 26 9 27 TPS Testing 9 24 9 25 Track Alignment A lignment Track 2 12 Troubleshooting Suspension Xtra 10 7 43 7 44 Track M aintenance 2 12 Troubleshooting Suspension Xtra L ite 7 42 Track Specifications 8 1 Track Tension 2 13 U Track Tension D ata 2 13 EE Drive Driven Clutches 5 41 U nregulated Voltage 9 15 9 16 Troubleshooting Oil Pump 3 58 W Troubleshooting Seat H arness 9 18 Water Pump Belt Tension Domestic E ngines 2 7 SMe 1c TOL
204. imiter Strap Adjustment XTRA 10 7 18 Fuel D elivery System Typical 4 12 Fuel Pump M aintenance 4 33 G Gasoline Volatility 4 10 Greasing D riveshaft Bearing 2 6 Greasing J ackshaft B earing 2 6 H Handlebar Adjustment 2 17 Handlebar Centering 6 12 Handlebar Centering CRC 6 17 Handlebar Torque 6 25 H eadlight A djustment 2 16 Headlight Bulb Filament Continuity Test 9 18 H eadlight Bulbs 2 16 Helix R amps 5 26 Hi Lo Beam Switch Testing 9 18 HiFax Inspection Replacement 7 6 HiFax Removal 7 6 Hone Selection 3 47 Honing Procedure 3 48 H oning to Oversize 3 47 Hood Repair 6 29 Hydraulic Caliper Disassembly 8 22 IFS Shock Springs 7 22 Ignition Switch Testing 9 19 Indy Select R yde AF X Shock 6 18 J Jet Needle Part Numbers 4 2 Jet Part Numbers 4 1 L Load Test 9 11 M M ain J et 4 17 M aintenance Products 2 2 Master Cylinder Cartridge Subassembly R eplace ment 8 12 Master Cylinder Inspection 8 12 M aster Cylinder Removal 8 11 M aster Cylinder H ayes 8 11 M easuring Belt Deflection 5 32 Mikuni TM 38 J et Part Numbers 4 3 Needle Bearing Inspection 3 51 Needle J et Part Numbers 4 2 Nosepan Replacement 6 31 6 32 6 33 O Oil Pump Adjustment 2 7 Oil Pump Adjustment Procedure 3 61 Oil Pump Bleeding 3 59 Oil Pump Bushing End Play Adjustment 3 59 3 60 Oil Pump O peration 3 58 Open Circuit Voltage Test 9 10 P Park Brake L ever Spr
205. ine how many shims are to be used NOTE A shim kit is available which contains an assort ment of shims including 002 005 and 010 5 16 Shim Kit PN 2200387 Gp POLARIS DRIVE DRIVEN CLUTCHES Spider Button Shimming Cont j Measure tower width at bottom of travel 2 Measure the dimension between towers at the lower half of the towers as shown Use Dial Caliper 3 Install spider buttons using a soft face hammer 4 Record width of spider buttons on each leg 5 Add shims beneath trailing side spider button to obtain specified button to tower clearance when assembled Button to Tower Clearance P 85 P 90 002 05 mm DRIVE DRIVEN CLUTCHES Drive Clutch Assembly 1 Place the correct number of spacer washers beneath the spider 2 Assemble clutch making sure X marks on movable sheave and spider or reference marks made before disassembly are aligned to achieve proper balance NOTE If belt to sheave clearance is being changed by adding or removing washers from under the spider and the sheaves were marked before disassembly follow in dexing procedure on page 5 21 3 Torque spider to specification Spider Torque P85 and P90 200 ft Ibs 276 Nm Spider Removal Tool PN 2870341 SITE 4 Torque jam nut to specification P 85 Clutches Install weights with weight pin nut on trailing side Use new nuts to ensure proper retention Torque nut to 30 in Ibs
206. ing Photographs and illustrations have been included with the textas an aid Notes cautions and warnings have also been included for clarification of text and safety concerns However a knowledge of mechanical theory tool use and shop procedures is necessary to perform the service work safely and satisfactorily Use only genuine Polaris service parts A Cleanliness of parts and tools as well as the work area is of primary importance Dirtand foreign matter will act as an abrasive and cause damage to precision parts Clean the snowmobile before beginning service Clean new parts before installing A Watch for sharp edges which can cause personal injury particularly in the area of the tunnel Protect hands with gloves when working with sharp components A If difficulty is encountered in removing or installing a component look to see if a cause for the difficulty can be found If itis necessary to tap the part into place use a soft face hammer and tap lightly A Some of the fasteners in the snowmobile were installed with locking agents Use of impact drivers or wrenches will help avoid damage to fasteners A Always follow torque specifications as outlined throughout this manual Incorrect torquing may lead to serious machine damage or as in the case of steering components can result in injury or death for the rider s A If a torquing sequence is indicated for nuts bolts or screws start all fasteners in their holes and hand tighten Then f
207. ing R eplacement 8 18 Pilot Air Screw 4 14 Pilot J et 4 14 Piston Inspection M easurement 3 57 Piston M easurement 3 49 Piston Pin Inspection 3 51 Piston Ring Installed G ap 3 49 3 57 Piston to Cylinder Clearance 3 49 Port Chamfering 3 48 R Radius Rod End Torque Procedure 6 7 Rear Suspension Setup 7 5 Rear Suspension Springs 7 2 Recoil A ssembly 3 67 Recoil Disassembly 3 67 Recommended Coolant 2 11 Regulated Voltage 9 16 Reverse M echanism A djustment A djustment R e verse M echanism 8 39 Rod End Engagement IFS 6 7 S Seat Cover Replacement 6 27 Set U p Width 6 9 Set U p Width CRC 6 16 Shock Tuning 7 4 Short Circuit Current Test 9 16 Ski Installation 6 23 Ski Skag Installation 6 22 Ski Spindle Bushing R eplacement 6 19 6 20 Spark Plugs 2 14 Specific G ravity Test 9 10 Speed Control Assurance A djustment 9 21 Speed Control Assurance Replacement 9 22 Spider Button Shimming 5 16 5 17 Spider Indexing 5 21 Spider Roller Removal 5 15 Spindle Centering 6 9 Spindle to Chassis Centering CRC 6 16 Spring Tension Rear Xtra 10 Style 7 16 Sprocket C hain Combinations 8 6 8 7 Starter Installation 9 15 Starter Solenoid Bench Test 9 15 Steering A djustment CRC M odels 6 16 Steering Alignment High Performance XTRA 10 CRC XC10 CRC 6 15 Suspension Adjustment 7 13 Suspension L ubrication 2 9 T Taillight A ssembly R eplacement Indy Style 6 30 Ta
208. ing to increase its compression rate This may result in complete stacking of the coils and subsequent clutch cover failure Maximum efficiency of the variable speed drive system is dependent upon many factors Included in these are converter offset and alignment belttension beltto sheave clearance and internal condition of the drive and driv en clutch components One of the most critical and easily serviced parts is the drive clutch spring Due to the severe stress the spring is subject to during operation it should always be inspected and checked for tolerance limits during any clutch operation diagnosis or repair With the spring resting on a flat surface measure free length from outer coil surfaces as shown Refer to the chart above for specific free length measurements and tolerances In addition to proper free length the spring coils should be parallel to one another when placed on a flat sur face Distortion of the spring indicates stress fatigue Replacement is required Torque inch Ibs DRIVE DRIVEN CLUTCHES Driven Clutch Springs Soft 7041198 Red EE 7041499 Silver 7041646 Silver Blue 7042022 Blue O range Firm Driven Spring Charts Gel Blue O range 140 Blue O range 120 Silver or Silver Blue Silver Blue 70 Bit 1 Gold or Black 00 old or Blac 60 Silver 80 Red 4 Gold S 29 and Black 60 amp 40 Red E 40 E 30 0 10 67 Degrees of Rotation 150 04 2 5
209. ing warranty service or replacement parts The machine model and serial number identification decal is located on the rightfrontside ofthe tunnel The serial number is permanently stamped into the tunnel The model number is embossed on the decal Whenever corresponding about an engine it is important that the engine model and serial numbers be called out Laser engraved model and serial numbers are located on the crankcase intake side 1 2 Gp POLARIS GENERAL INFORMATION d Vehicle Identification Number Current snowmobiles have a 17 digit Vehicle Identification Number VIN The VIN is organized as follows Digits 1 3 World Manufacturer Identifier For Polaris this is 4XA Digits 4 9 Vehicle Descriptor Section Digits 10 17 Vehicle Indicator Section Digits 4 8 of the VIN identify the body style type engine type and series The VIN and the model number must be used with any correspondence regarding service or repair World Mfg ID Vehicle Descriptor Vehicle Identifier Example of Current VIN N umber Body Style Engine Series Model J Si Engine ea Individual Serial No ze gie Check Manufacturing Modifier Digi Type Digit Location Code Vehicle Identification Number Model Number Key Sem PaPerormance anne Chase Restan OOO Wewm ReRMK IN OEI uid Tee 7 ses 9999 Fea Reed pe aang se EL CT ua ae E emer E Year Letter Identification The tenth digit of a 17 digit V
210. inspections annually preferably before off season stor age or every 1000 miles except where noted RECOMMENDATION Gp POLARIS 2 1 MAINTENANCE TUNE UP Recommended Maintenance Products Description Packaging Part Description Packaging size quantity size quantity 2871721 Synthetic 2 Cycle Premium Gold Quarts 6 2870652 Fuel Stabilizer 16 oz 12 2871722 2871723 2871884 2871098 2871097 2871240 2871566 2871385 2871096 Synthetic 2 Cycle Premium Gold Synthetic 2 Cycle Premium Gold Synthetic 2 Cycle Premium Gold e Oi e Oi Premium 2 Cyc Premium 2 Cyc Premium 2 Cyc Premium 2 Cyc Premium 2 Cyc Premium 2 Cyc eO eO e Oi e Oi TC W3 TC W3 TC W3 TC W3 TC W3 TC W3 ff JS pp 2872927 VES 2 Cycle Synthetic Oil VES 2 Cycle Synthetic Oil 2872925 2872924 Gallon 4 16 Gallon Drum 55 Gallon Drum Quart Cans 12 Gallon 6 2 5 Gallon 2 16 Gallon Drum 30 Gallon Drum 55 Gallon Drum Quart Gallon 55 Gallon Drum 2872280 Fuel Stabilizer 2 5 Gallon 2 2871329 2871064 2870632 2871076 2870585 2870584 2871949 2871950 2871951 2871952 2871953 202 each 10 oz each each 25gr 1 10cc each 50cc 10 6cc 12 50cc 10 6cc 12 VES 2 Cycle Synthetic Oil Nature Oil TC W3 Nature Oil TC W3 MAINTENANCE PRODUCTS Cross Shaft Break in Lube Cross Shaft Break in Lube 6cc 12 36cc 6 3cc 30 50cc 6 2871957 3 oz tube 12 28
211. installing new parts or after steering arm installation refer to the illustrations and text below Always verify proper steering operation after completing adjustments or repairs 1 Reinstall torsion bar linkage where applicable Torque attaching bolts to specification 2002 EDGE RMK g BODY AND STEERING When performing normal maintenance or tune up check the ski skags for wear To prevent damage to the skis and for greater steering control replace all skags which are half worn or greater Ski Skag Removal 1 Remove retaining nuts as shown 2 Push bolt down through ski 3 Pullrearofskag from skias shown This frees the skag for removal from the ski Ski Skag Installation 1 Push skag forward then up into position 2 Reinstall nuts and torque to specification Ski Skag Retaining Nut Torque Steel Ski Steel 15 ft Ibs 21 Nm Plastic Ski 20 25 ft Ibs 27 6 34 5 Nm Ski Skag Removal EZ Steer 1 Remove the three nuts from the skag 2 Pull down and rearward to remove the skag Ski Skag Installation EZ Steer l Install flat bar as shown 2 Install IFS carbide skag 3 Reinstall nuts and torque to specification Ski Skag Retaining Nut Torque 15 ft Ibs 21 Nm Ski Installation METAL SKI INSTALLATION Install ski over spindle slightly in front of ski saddle with ski pointing outside Slide ski forward until spindle is just behind ski saddle and turn to the forward
212. ip out iefaining pin hole towards you until it is against the bushing Rear bushing Bearing Washers Mechanical Seal Front Brass Bushing 2 Seal Spring faces mechanical seal Impeller Nut Oil Pump side Flat washers Water Pump side ENGINES O Assembly Cont 5 10 11 12 13 14 Lubricate and install new mechanical seal using the Mechanical Seal Guide Tool PN 2872010 Mechanical Seal Guide Tool 500 600 V E S domestic en gines 8 4mm PN 2872010 Press a new mechanical seal into case until fully seated Lubricate all crankshaft bearings with Premium 2 Cycle or Premium Gold Engine Lubricant Apply 1 3 oz 10 cc cross shaft break in lube to oil pump gears Oil Pump Cross Shaft Break in Lube PN 2872435 8 oz PN 2872436 2 5 Gallon Install seals on crankshaft with spring facing inward toward crankshaft Clean and de grease lower crankcase and install crankshaft assembly aligning seals and snap ring with grooves in case Apply a thin coating of 3 Bond 1215 sealantto lower crankcase mating surface Install upper crankcase on lower crankcase Apply Loctite 242 to threads of bolts and install MAG End Torque bolts in three steps to specification outlined in beginning of this chapter following the sequence shown at right Install oil pump being carefulto engage pump shaft in drive shaft location after case is assembled A ENGINES Assembly Cont
213. ires The skis do not grab sufficiently R amp R Remove and replace RFI Radio Frequency Interference Caused by high voltage from the ignition system There are special plug caps and spark plugs to help eliminate this problem Mandated in Canada RPM Revolutions P er Minute Resistance In the mechanical sense friction or load In the electrical sense ohms Both resultin energy conversion to heat Right Side Always referred to based on normal operating position of the driver Round Head Screw The familiar head most universally used for general application Good slot depth ample underhead bearing surface and finished appearance are characteristic of this head Running Time Ignition timing at specified RPM Secondary Circuit This circuitconsists ofthe large secondary coil windings high tension wire and ground through the spark plug air gap Secondary Clutch Driven clutch on chaincase or jackshaft Seized Piston Galling ofthe sides ofa piston Usually there is a transfer of aluminum from the piston onto the cylinder wall Possible causes 1 improper lubrication 2 excessive temperatures 3 insufficient piston clearance 4 stuck piston rings Self Steer Pulling the machine to the inside of the track Spark Plug Reach Length of threaded portion of spark plug Polaris uses 3 4 2 cm reach plugs Static Timing Ignition timing when engine is at zero RPM Stator Plate The plate mounted under the flywheel supporting t
214. ires special tools and a sound knowledge of mechanical theory tool use and shop procedures in order to perform the work safely and correctly Shocks contain high pressure nitrogen gas Extreme caution should be observed when handling and working with high pressure service equipment See RydeFXt andFoxt Shock rebuilding information later in this chap ter Always verify ski alignment before making adjustments to the IFS If the skis are misaligned we recommend the camber adjustment be checked as this may also be affected Front Torque Arm Limiter Strap Adjustment XTRA 10 One method of changing ski to snow pressure is to change the length of the front torque arm limiter straps The limiter strap is normally mounted in the fully extended position Turn nut to adjust S Lengthening the straps decreases ski pressure under accelera tion S Shortening the straps increases ski pressure under acceleration To adjust models with quick adjust front limiter straps turn the eyebolt nut to lengthen or shorten the straps To shorten the gt strap turn the nut clockwise To lengthen the strap turn the nut Turning clockwise shortens strap counterclockwise Turning counterclockwise lengthens NOTE Both limiter straps must be adjusted evenly and remain strap equal in length to avoid improper Hi Fax and track wear SUSPENSIONS Compression Damping Adjustable Shocks Snowmobiles equipped with the Indy Select or Ryde FXt shocks allow t
215. is where the ignition timing is specified Refer to chart on page 9 5 Ignition timing must be checked at the specified RPM or inaccurate timing will result Refer to timing specifications at the beginning of this chapter Dial Indicating The Timing Marks Due to differences between engines itis necessary to dial indicate the timing marks on all engines before attempt ing to adjust the ignition timing To indicate the marks L 2 Remove the mag RH cylinder spark plug and install the dial indicator Rotate the crankshaft by hand while observing the dial indicator As the piston touches the indicator plunger the dial will begin to rotate Find the point where the pointer stops rotating and reverses direction This will be TDC Top Dead Center While holding the crankshaft with the piston at TDC zero the indicator by rotating the bezel until the O on the dial and the pointer align Rotate the crankshaft opposite the direction of rotation about 250 BTDC 2 1 2 pointer revolutions Determine the correct ignition timing position from the ignition data charts and rotate the crankshaft in the normal direction of rotation to that position Example If engine timing is 150 BTDC the crankshaft mustbe rotated in the normal direction of rotation so thatthe dial indicator pointer does one complete revolution and stops on 50 This should be 1 1 2 pointer revolutions before top center or 150 BTDC While holding the crankshaft at the correct
216. iscard and replace the piston CAUTION Do not attempt to polish or sand piston 5 Clean piston with denatured alcohol and wipe dry with a clean lintfree cloth Using compressed air blow dry 6 Check inlet and bleeder hole threads for damage Be sure bleeder screw is clear 7 Inspect brake line seat for damage and replace caliper if necessary Hydraulic Brake Assembly 1 Reassemble by reversing disassembly process Be sure all parts are clean and serviceable before reassembling the unit 2 Coatanew piston sealin clean DOT 3 brake fluid and place in groove in the caliper piston bore Seal should be positioned at one point in groove and then gently worked around the groove by hand until properly seated CAUTION Never reuse an old seal 3 Coatpiston thoroughly with brake fluid and work down into bore carefully with a rotating motion until bottomed CAUTION Apply even pressure to avoid cocking the piston in the bore Es BRAKES FINAL DRIVE Hydraulic Brake Assembly Cont 11 Examine pads for wear or damage If pad thickness is less than 1 32 08 cm install new pad holder assemblies If pads are not worn or damaged they may be reused Be sure pads are reinstalled in their original positions If pads are replaced replace in sets and make sure the new pads have the same friction material type code number as the old set Connect hose or line to caliper Place new pads wit
217. it Bushing 5020630 Installation Tool 5 1 P 90 Driven Clutch Bushing Removal Tool 5020631 6 1 P 85 Driven Moveable Sheave Removal Tool 5130862 7 1 P 85 Driven Moveable Sheave 5222768 Removal Bridge 8 1 Main Puller Adapter 5020632 9 1 Adapter Reducer 5010279 10 1 Number Two Puller Adapter 5020633 11 1 Instruction 9912260 You will need to supply Piston pin puller PN 2870386 Bench vise Soft face hammer for P 85 Driven Moveable Small scribe or pick for Cover Bushing Removal Hand held propane torch for P 90 Driven Loctite RC 680 Retaining Compound 2870584 P 85 Drive Clutch Cover Bushing Removal 1 Disassemble clutch as outlined in this section 2 Inspector measure bushing and replace if worn beyond service limit Note Bushing must be installed in cover Refer to the following specifications Cover Bushing Inspection Garmax Style Installed Dimension Nominal Bearing Bore 1 125 28 57mm Service Limit 1 140 28 95mm DRIVE DRIVEN CLUTCHES P 85 Drive Clutch Cover Bushing Removal Cont 3 On models equipped with snap ring remove round wire snap ring from inside of clutch cover using a small scribe or pick and set aside 4 Install main adapter on puller 5 From outside of clutch cover insert removal tool into cover bushing 6 Withinside of covertoward vise slide cover onto puller 7 Install nutonto puller rod and hand tighten Turn puller barrel to increase tension as needed 8
218. ith a long nose pliers and pull the needle out The C clip can then be adjusted forthe desired effect There is a 1mm thick white washer on top ofjet needle that is staked in the throttle slide Needle J et D The needle jet is press fit into carbs and is not replaceable Piston Valve E The piston valve operates in the same manner as Mikuni VM carburetor round slide valves Main J et and Pilot et F The main jets hex and pilot jets air bleed type are identical in style and function as the Mikuni VM carbs There is washer on main jet Do not lose washer upon disassembly Fuel Screw G The fuel screw controls the low speed air fuel mixture at idle Turning the fuel screw out makes the mixture richer and can be adjusted up to five turns out Float Needle amp Seat Assembly H The float needle amp seat are sold as an assembly and cannot be replaced as individual components The floatlevel is pre setin the molding and cannotbe adjusted WARNING DO NOT pressurize the fuel system by forcing compressed air through the fuel tank Forcing airthrough the needle and seatwillcause damage and the float needle amp seat assembly will have to be replaced Carburetor Synchronization R emove the top caps on all carburetors In the body ofthe carburetors there is a phillips head set screw l that connects the slide lever to the throttle lever shaft The carburetor with the fixed set screw is the base carb middle carb on triples PTO carb on twins an
219. ith negative camber the alignment bar cannot be installed through spindles On these models the pitman and idler arm Fig II or bellcrank on non CRC models should be pointed straight forward 6 Lubricate ski pivot bushings with Polaris Premium All Season Grease and install in spindle Torque Ski bolts to specification Install new cotter pin in castle nut 7 Perform Toe Adjustment on page 6 13 Idler Arm Toe Adjustment All Models BODY AND STEERING Toe adjustment on all models must be performed with the vehicle weight on the suspension no rider at Normal Ride Height 1 Make sure the track is properly aligned This will be used as a reference point for toe out measurement 2 To obtain normal ride height of the front suspension lift the front end 3 5 7 6 12 7 cm with the front bumper Lift the machine several times working the suspension and front skis until an average is obtained NOTE To prevent carbide skags from grabbing make sure the surface under the skis will allow full side to side movement Avoid rough concrete asphalt or carpet which may cause carbide skags to grab or catch and restrict movement SERVICE HINT Before final measurement is taken skis should be pushed together lightly at the tips to re move play in the steering components This will help achieve accurate measurement If a strap is used be sure it is not too tight or it will alter measurement this is most important on model
220. k for correct clutch components Slow easy belt engagement easing on the throttle Use fast effective throttle to engage the clutch e CHAPTER 6 BODY AND STEERING Indy Trail RMK Front Suspension 6 3 Indy 500 SKS Euro Front Suspension eevee 6 1 Indy 700 SKS Front Suspension eee 6 2 Indy 500 RMK Front Suspension eee eee ees 6 4 EDGE RMK 600 700 800 Front Suspension 6 5 Front Suspension Inspection cece eee eens 6 6 6 7 2002 IFS Alignment Specifications 6 8 IFS Setup Width B Ern NO LUTANG EON NA ARE 6 9 Camber inspection Adjustment a 6 10 6 11 Handlebar Centering EE eek Rex SR ce d 6 12 Toe Adjustment Lnd a Rex ERE RE edo 6 13 6 14 XTRA CRC XC 10 Steering Alignment 6 15 CRC Steering Adjustment aaa 6 16 CRC Camber Adjustment io i ER ARA AEN 6 17 Carbide Placement re eo Coe eri hard ooo D na 6 18 Ski Spindle Bushing Removal Replacement 6 19 6 20 Steering Arm Orientation aa 6 21 Ski Skag Removal Installation 6 22 Skidnstallatori i a rr ratos rera ede rcd NO S 6 23 Torsion Bar Removal Installation 6 24 Handlebar Torque Sequence sees 6 25 Seat Removal Installation 6 26 6 29 Hood RED ems ants AYA AR ha nG PA PU Ei re dex 6 29 Talllight Assembly 2250 5 saad yeh eri ERE ET 6 30 Nosepan Replacement nnne 6 31 6 33 D
221. ket assembly Track frozen or stuck Track wears un Check tension evenly Check for proper alignment Check for loose bent or broken suspension parts Chaincase Check oil level overheating Check chain tension and Check track tension for over tightness CHAPTER A FUEL SYSTEM CARBURETION Fuel System E ll EE 4 1 JetPar NUMDENS ara a Pathan Penal EE aate a 4 1 4 3 Mikuni TM 38 TM 40 J et Needle Overview 4 4 Mikuni TM 38 TM 40 Overview Exploded View 4 5 4 6 Mikuni VM 34SS Exploded View esee 4 7 ACES OIM Usario a OLEA IAS 4 8 4 9 Gasoline Volatility Lata AN A A ka 4 10 Float Chamber Venting A awe 4 11 Fuel System O KEE 4 12 Mikuni VM TM Carburetor Operation 4 13 4 18 Component Effect Charts uo cards dan 4 19 VM Carburetor Disassembly Inspection Assembly 4 20 4 23 Throttle Synchronization 514 v5 urhe El a 4 24 TM Carburetor Disassembly Inspection Assembly 4 25 4 29 TM Throttle Synchronization s ocio taa 4 30 4 31 Choke Adjustments s cuu alie kam dx reor ast eos SUR 4 32 Fuel e e EE SR MESE MER Re tque ut 4 33 TEE AD andan dee in dieque gate Lo dtu cs 4 34 TOUS OO Uria 4 35 4 36 FUEL SYSTEM CARBURETION Whenever servicing the carburetor or fuel system it is important to heed the following warnings Gasoline is extremely flammable and explosive under certain conditions Always stop the engine and refuel
222. kets 2 Drivers Wide XHS Rear Suspension EDGE RMK 136 144 or 151 Brake Type Polaris HPB Liquid Cooled Rear Axle Travel 13 8 35cm 136 17 43cm 144 151 Front Track Shock Nitrex 136 144 Ryde FX IFP 151 Spring Rate 170 in Rear Track Shock Indy Select 136 144 Ryde FX IFP 151 RearSprings 347 sq 47 136 359 sq 77 144 151 Track Type 15 x136 x1 75 38 1x345 44x4 44cm or 15 x144 x2 0 38 1x365 76x5 08cm Track Tension 3 8 1 2 1 1 3 cm slack with 10 4 54kg weight 16 40 64cm ahead of rear idler shaft Overall Snowmobile Length 136 Track 116 295cm 144 Track 119 75 304 2cm Overall Snowmobile Height 45 114cm Maximum Snowmobile Width 44 25 122cm OPTIONAL REAR TORSION SPRINGS SOFT STD Pi 347 Sq Diameter x 77 359 S q Diameter x 77 N A L H 136 7041627 067 L H 136 7041629 067 R H 136 7041628 067 R H 136 7041630 067 347 Sq Diameter x 47 359 Sq Diameter x 47 375 Sq Diameter x 47 H 144 151 L H 144 151 L H 144 151 7042081 067 7042068 067 7042079 067 H 144 151 R H 144 151 R H 144 151 7042082 067 7042069 067 7042080 067 d GENERAL INFORMATION MODEL 800 EDGE RMK 144 151 156 MODEL NUMBER SO2NM8CS ENGINE MODEL 52188 8070PL8C JETTING CHART
223. l and O ring outof bearing cap Use care to avoid scratching the seal cavity 3 Clean seal cavity and inspect bushing for wear or damage and replace bearing cap if necessary 4 Lubricate new seals and O ring with Polaris shock oil and install Be sure the seals are seated completely in the seal cavity 5 Inspect jounce bumper where applicable and replace if damaged 6 Inspect damper rod for nicks scratches or abrasion Install bearing cap and thick backing washer on damper rod Install compression valve washer stack in same order as disassembly Install valve piston with greater number of slots facing damper rod nut toward IFP Install rebound stack washer and a new nut Torque nut to 12 ft Ibs Valve Nut Torque 12 ft Ibs 17 Nm Gp POLARIS 7 29 SUSPENSIONS Fox Shock Maintenance Seal Replacement Cont 7 Inspectvalve piston ring for wear The outer surface of the ring should be even in color Setaside damper rod assembly for reinstallation 8 Position shock in vise with Body Clamp Tool positioned as shown Clean body clamp tool before installing Shock Body Clamp Tool PN 2871071 9 Using an open end or large adjustable wrench unscrew the body cap from the body 10 Inspect O ring in body cap for damage 11 Note location of Allen screw in internal floating piston IFP for reassembly in body tube Remove IFP through body cap end external threaded end using IFP
224. lace if width is less than 250 6 35mm Nominal new width is 345 8 75mm Refer to Chapter 2 Mainte nance for water pump belt installation ENGINES O Disassembly Cont 4 Remove drive gears and belt 5 Remove flywheel nut using flywheel holder Flywheel Holder PN 8700229 6 Remove flywheel using flywheel puller Flywheel Puller PN 2871043 7 Note the ignition timing strip on the flywheel 8 Before removing stator plate mark the plate and crankcase for reference upon assembly A ENGINES Disassembly Cont 9 Remove bolts holding water pump housing to crankcase Loosen hose clamp and remove housing 10 Inspect water pump weep hole for signs of leakage or blockage 11 Remove crankshaft seal from housing by driving seal to inside of housing Replace seal if removed 12 Remove water pump cover bolts 3 38 Gp POLARIS ENGINES O Disassembly Cont 13 Remove impeller nut 14 Slide shaft out back side 15 Inspect bearings Replace if necessary Replace mechanical seal using the special tools listed below Use the seal press to install a new mechanical seal in cover with spring sleeve toward impeller housing Install seal guide over end of shaft and apply a light film of grease to seal guide Carefully install shaft and bearings in cover Assemble 10x14mm washer impeller washer and nut Torque impeller nut to specification Water Pump Mechanical Seal
225. lb A force of one pound at the end of a lever one foot in length applied in a rotational direction g Gram Unit of weight in the metric system Head Volume Cylinder head capacity in cc head removed from engine with spark plug installed GE POLARIS 1 9 d GENERAL INFORMATION Heat Exchanger A device used to transfer heat They dissipate engine heat to the atmosphere E Hex Head Bolt Standard type of wrench applied hexagon head characterized by clean sharp corners trimmed to close tolerances Recommended for general commercial applications Hi Fax Trademark of Himont Advanced Materials The special slide material which fits onto the bottom of the suspension rails High Side Sled pushes or tips up toward outside of turn High Tension Wire The heavy insulated wire which carries the high secondary voltage from the coil to the spark plug Hole Shot A term used when machine starts a race from a dead stop Holed Piston Piston in which a hole has formed on the dome Possible causes 1 detonation 2 pre ignition Ignition Coil A type oftransformer which increases voltage in the primary windings approx 200V to a higher voltage in the secondary windings approx 14KV 32KV through inductions Secondary voltage is high enough to arc the air gap atthe spark plug Ignition Generating Coil Exciter coil or primary charge coil Stator plate coil which generates primary ignition voltage CDI system uses one ignition generating coil I
226. le if reversed Xtra Lite Type Adjustment Screw EDGE RMK Adjustment Lever SUSPENSIONS Following is a list of all available springs for the rear suspension These springs can be used to better suitindividu al riding preference Xtra Lite 136 Optional Suspension Set Ups See Suspension Tuning Decal Under Hood 7041632 067 RH 375 Sq Diameter x 77 144 151 156 EDGE RMK Optional Suspension Set Ups See Suspension Tuning Decal Un der Hood Torsion Spring Part No Wire Dia Degrees 7042081 067 L H 347 Sq Diameter x 47 7042068 067 L H 359 Sq Diameter x 47_ 7042069 067 R H 359 7042079 067 L H 375 Diameter x 47_ S S Sq Diameter x 47 S 7042080 067 R H 375 Diameter x 47_ q q q q SUSPENSIONS IFS Shock Springs Xtra 10 Xtra Lite EDGE RMK Part otal 0 Active Rate Z In ree Wire nd Dia nd Dia O D bbed Application 4d col dl lll a on is ss ww mu zm ie 15 us w Tuer wsr punswr nav we is 1 zs yes a ms a nav my pia zs Yes usw wr oa sw my pia us ve usw wur ew wow sr xe zm KA p ve een Tus wm mw wm x ie xm ve men Tons ws LU wow xw ise x KA ve een a ww a wow my pra Na een aa as sw nsy y ise zm KA ve eer sr ww KA ia KA ve fw rasa ao x mw mu
227. le speed riding style and trail conditions Werecommend starting with factory settings and then customizing each adjustment individually to suit rider pref erence The machine should be methodically tested under the same conditions after each adjustment trail and snow conditions vehicle speed riding position etc until a satisfactory ride is achieved Adjustments should be made to one area ata time in order to properly evaluate the change The purpose of the front track shock coil spring is to control ride height and front IFS preload If you find that in order to obtain the desired ride effect the spring preload is over four additional washers total of five consider removing the existing spring and installing the next highest rate spring SUSPENSIONS The XTRA 10 suspensions have been designed and set up to deliver a soft ride under average riding conditions Rider weight riding styles trail conditions and vehicle speed each affect suspension action The suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of condi tions It should be noted however that suspension adjustments involve a compromise or trade off A machine set up to perform well in the moguls would not suit the preference of a groomed trail rider Adjustable Features and Adjustment Options Independent F ront Suspension IFS SFront shock spring preload some models require washers S Optional springs SIndy S
228. linder is a small compensating port C which is opened and closed by the master cylinder piston assembly The port is open when the brake lever is released and the piston is outward As the temperature within the hydraulic system changes this port compensates for fluid expansion caused by heat or contraction caused by cooling During system service be sure this portis open Due to the high temperatures created within the system during heavy braking it is very important that the master cylinder reservoir have adequate space to allow for the brake fluid to expand Master cylinder reservoirs should be filled to the top of the fluid level mark on the inside of the reservoir 1 4 5 16 6 8 cm below lip of reservoir opening Never overfill the reservoir This could alter brake function resulting in system component damage or sever personal injury or death This system also incorporates a diaphragm E as part of the cover gasket and a vent port F located between the gasket and the cover The combination diaphragm and vent allow for the air above the fluid to equalize pressure as the fluid expands or contracts Be sure the ventis open and allowed to function If the reservoir is overfilled or the diaphragm vent is plugged the expanding fluid may build pressure in the brake system and lead to brake failure BRAKES FINAL DRIVE Es Brake Bleeding Fluid Change This procedure should be used to change fluid or bleed brakes during regula
229. ll reservoir to proper level after bleeding operation Do not overfill the master cylinder 7 Replace gasket and cover During the bleeding procedure make sure to keep the reservoir as lev el as possible to minimize the possibility of air entering the system MAINTENANCE TUNE UP Throttle Lever Free Play Throttle lever free play must always provide a specified clearance between throttle lever and throttle block This Clearance is controlled by the throttle cable sleeve s and the idle speed screw s Throttle Lever Freeplay 010 030 25 8 mm 010 030 25 8 mm If the idle speed screw s is adjusted inward and the cable Sleeve s is not adjusted to take up the throttle lever to throttle block clearance the engine may misfire or kill upon initial throttle opening CAUTION After any idle speed adjustments are made the throttle lever to throttle block clearance and oil pump adjustment must be checked and adjusted NOTE When adjustments are made on models which have more than one carburetor refer to Section 6 Car buretion for proper carburetor synchronization adjustments Reverse Adjustment Due to break in or replacement of components the re verse shift mechanism may require adjustment Shift Lever Clevis l Loosen jam nuts on linkage rod A Pin 2 Turn the threaded linkage rod B to lengthen or Cotter shorten the throw until reverse engages fully P in 3
230. lter B Air Intake Box C Air Plenum D Dash Cowl MAINTENANCE TUNE UP Water Sediment Trap Maintenance Most Polaris snowmobile incorporate patented carburetor bowl water sediment traps which are located at the bottom of each carburetor The trap consists of a hose with a plug which should be inspected for contamination at least every 2000 miles 3200 km Cleaning Procedure Plug 1 Turn the fuel tank supply valve off 2 Positiona container or shop towels to catch the contaminated gasoline 3 Slide the clamp 1 away from the drain plug 2 and remove the drain 1 plug from the sediment tube 4 Wipe offresidue from plug and reinstall with clamps Continue until all the traps have been emptied A WARNING When draining the traps fuel spillage will occur Be sure to work in a well ventilated area away from anything which may cause the fuel to ignite such as open flames sparks heaters trouble lights ciga rettes etc Oil Filter Fuel Filter Maintenance Most models use an oil filter 2 which is of a special design and must not be substi tuted This filter should be changed annually or every 1200 miles 1920 km In spect oil line condition at 2000 miles 3200 km NOTE The direction of the arrows indicates the direction of the flow through the FuelFilter filters Edge models utilize a special oil filter 3 thatis builtinto the oil sending unitlocated in the bottom of the oil tank It should be repla
231. ltre s 3211074 q DRIVE DRIVEN Belt Width Projected 1 438 36 52mm Altitude zs m muc mend GS Side Angle O verall 28 Weight Spring Spring Helix Gearing Outside Circumference 47 625 121cm Meters oso 1056 dna Siver R32 18 41 68P usne oun ue Center Distance 12 00 Feet 0 3000 Bushed Round Bl 8 HYVO Shift Weights 10 Bushed Primary Spring Almond Round GE 1 1 1800 2700 I Secondary Spring Silver Blue Driven Helix R 32 3 2700 3700 10M Almond KH Production Setting Silver R 32 18 41 68P Blue 3 HYVO Silver R 32 18 41 68P Blue 3 HYVO Silver R 32 18 41 68P Blue 3 HYVO ENGINE Pat Liquid Cooled Case Reed Twin Displacement 500cc Fuel Pump Manuf Walbro BOl Saone g TA Edad 2 776 70 5mm Fuel Pump Mark FPA 3 SITOKG bs tl He see 2 520 64mm Oil Pump Manuf Mikuni Piston Cylinder Clearance 0 0045 0 0063 0 11 0 16mm Oil Pump Mark 2540051 Service Limit 0 0063 0 16mm Cylinder Head Mark 3021048 Piston Marking N A Piston Ring Marking N A Piston Ring End Gap 0 012 0 018 0 30 0 46mm Head ccs Uninstalled 27 5x0 5cc Head ccs Installed 25 0cc Operating RPM 200 8000 RPM Idle RPM 200 1500 RPM Engagement RPM 300 4500 RPM Cylinder Head Torque 20 24 ft lbs 28 3
232. lutches and pull upward and rearward to open the driven clutch sheaves Remove the belt from the driven clutch and then from the drive clutch Belt Installation 1 Drop the drive belt over the drive clutch and pull back the slack 2 Turn the driven clutch moveable sheave clockwise while at the same time pushing inward and forcing the belt down between the sheaves 3 Hold the belt down between the sheaves and roll the bottom portion over the outer clutch sheave Once installed be sure to work the belt to the outer edge of the sheave Be sure to release parking brake if applied 4 Close the clutch guard and reinstall the retaining knob or pin Belt Inspection 5 Refer to the specification charts for belt specifications and measurement procedures Be sure key switch is off and engine has come to a complete stop Remove the retaining knob or pin and open the clutch guard Removal Refer to PVT Section for belt inspection and width measurement Measure belt length with a tape measure around the outer circumference ofthe belt Belts which measure shorteror longer than a nominal length may require driven clutch or engine adjustment to obtain proper belt deflection Replace belt if worn past the service limit Belts with thin spots burn marks etc should be replaced to eliminate noise vibration or erratic operation See Troubleshooting Chart at the back of this chapter for possible causes NOTE If anew
233. ly S Re index marked spider leg to another tower This can be done because spider has little effect on overall clutch balance Re indexing the spider 1 3 turn clockwise or 1 leg will allow the realignment of the moveable and stationary sheaves as previously marked For example S 020 or 032 washer removed re index spider clockwise 1 3 turn S 050 or 064 washer removed re index spider clockwise 1 3 turn S Two 050 or 064 washers removed re index clockwise 2 3 turn NOTE Alignment marks should be within 1 25 mm af ter final assembly and torquing Gp POLARIS DRIVE DRIVEN CLUTCHES Driven Clutch Removal 1 Remove driven clutch retaining bolt 2 Slide driven clutch off jackshaft It may be necessary to use a puller on some driven clutches P 85 clutches externally adjustable can be removed using a 3 point flywheel or steering wheel puller and the 1 4 20 adjustment bolt holes Use a suitable spacer on the end of the jackshaft 3 Inspect jackshaft keyway for wear or damage NOTE Notice the number and thickness of shim washers between driven clutch and jackshaft bearing These must be replaced to maintain proper offset alignment 5 22 Gp POLARIS DRIVE DRIVEN CLUTCHES Disassembly 1 Place clutch on bench CAUTION Wear eye protection during disassembly and assembly of driven clutch 2 Hold fixed sheave and turn movable sheave 1 4 turn Hold movable in place tap
234. mixture Main jets are screwed directly into the needle jet base J etting 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 Carburetors on mostP olaris models are calibrated for an altitude of 0 3000 ft 0 900 meters and ambienttemper atures between 20 to 10 F 29 to 12 C All carburetors must be re calibrated if operated outside the pro duction temperature and or altitude range The main jet installed in production is not correct for all altitudes and or temperatures CAUTION A main jet that is too small will cause a lean operating condition and may cause serious engine damage Jetthecarburetors carefully for elevation and temperature according to the jetting charts in this manual NOTE ltis 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 upward to prevent engine damage When selecting the proper main jetalways use the lowest elevation and tem perature that is likely to be encountered O FUEL SYSTEM CARBURETION The function of a carburetor is to produce a com bustible air fuel mixture by breaking fuel into tiny particle
235. n allen head screw holding needle in position Slide holding plate to side 7 Reachinto top of carb with a long nose pliers and remove needle 8 Inspect needle for wear 9 Remove E rings packing plate spring and rings connecting slide to lever FUEL SYSTEM CARBURETION O Carburetor Disassembly Cont 10 Remove water trap drain plug 17 mm and single screw on bottom of carb 11 Remove float body NOTE F loat body will not come off unless water trap drain plug which is threaded and screws into main jet housing is removed 12 Remove 2 screws holding float needle amp seat assembly in position Remove float needle amp seat assembly 13 Inspect needle for wear NOTE Needles are not available separately If needle is worn or damaged you must replace float needle amp seat as sembly O FUEL SYSTEM CARBURETION Carburetor Disassembly 1 Remove main jet starter jet pilot jet and idle SCrew 2 Clean all passages in carburetor body with carburetor cleaner Dry all passages and jets with compressed air Replace gaskets and any parts which show wear or damage 4 28 Gp POLARIS FUEL SYSTEM CARBURETION O Carburetor Assembly 1 Pressure Tester PN 2870975 5 10 11 12 13 Install pilot jet main jet starter jet and idle screw Install float needle amp seat assembly Place carburetor in an inverted position Connect pressure tester to fuel inlet fitti
236. n bar and bushings linkage where applicable Handlebars and steering post assembly Spindles and bushings Trailing arms and bushings Skis and skags Bell crank Pitman arm Idler arm Steering arms Shock absorbers shock mounts springs All related fasteners check torque Refer to steering exploded views at the beginning of this section Grease all fittings Alignment Bar Specifications Material C 1018 Diameter 1623 625 5 8 15 82 15 87 mm Length 45 114 3 cm PN 8700231 See Service Tool Catalog for ordering information 45 114 3 cm la 2 623 625 5 8 15 83 15 88 mm Camber Definition All IFS The following definitions of camber use automotive terminology to describe positive and negative posi tions Refer to the illustration at right S 0 Neutral Camber Spindle is 90 perpendicu lar to ground S t Positive Camber Spindle bottom is canted inward toward chassis S Negative Camber Spindle bottom is canted outward from chassis BODY AND STEERING Positive Negative and Neutral 0 Camber Front View Radius Rod and Tie Rod End Torque Procedure Radius rod and tie rod ends must be parallel to their respective mounting surface after tightening jam nut as shown atright Hold tie rod or radius rod and tigh ten jam nut If possible support the edge of the rod end as shown to keep it from rotating out of p
237. n is important to provide a surface that will hold oil and allow rings to seat properly If the crosshatch is too steep oil retention will be reduced A cross hatch angle which is too shallow will cause ring vibration poor sealing and overheating ofthe rings due to blow by and reduced contact with the cylinder wall Service life of the pistons and rings will be greatly reduced Cylinder Hone Selection Selecting a hone which will straighten as well as re move material from the cylinder is very important Honing a cylinder with a spring loaded glaze breaker is never advised Polaris recommends using a rigid type hone which also has the capability of oversizing These hones are manufactured by such companies as Sunnen Products Company of St Louis Missouri and Ammco Tools Inc of North Chicago Illinois De glazing If cylinder wear or damage is minimal hone the cylin der lightly with finish stones following the procedure outlined on page 3 52 Honing To Oversize If cylinder wear or damage is excessive it will be nec essary to oversize the cylinder using a new oversize piston and rings This may be accomplished by either boring the cylinder and then finish honing to the final bore size or by rough honing followed by finish honing NOTE P ortable rigid hones are not recommended for oversizing cylinders cylinder boring and finish hon ing The use of an arbor type honing machine is rec ommended For oversize honing always w
238. nch Pound In lb 12 in lbs 1 ft Ib Kg cm2 Kilograms per square centimeter Metric equivalent of PSI Keystone Ring A piston ring with bevel on upper surface Kilogram meter A force of one kilogram at the end of a lever one meter in length applied in a rotational direction Metric equivalent of ft lbs L Ring A wide face piston ring with an L shaped cross section Leg of L goes up when installing on piston Labyrinth Seal A pressure type center seal identified by series of grooves and lands Polaris engines us this type of seal to separate the cylinders in the crankcase halves LeftSide Always referred to based on normal operating position of the driver Lighting Coil Generates voltage for lights battery charging etc by electromagnetic induction Loose When the rear of the vehicle slides outward in a turn The track does not grab sufficiently mm Millimeter Unit of length in the metric system 1mm 040 Mag End Flywheel side of engine Magnetic Induction As a conductor coil is moved through a magnetic field a voltage will be generated in the windings This is how mechanical energy in our engines is converted to electrical energy in the lighting coil ignition generating coils and trigger coil Ohm The measurement of electrical resistance opposing current flow d Oval Head Screw Fully specified as oval countersunk this head is identical to the standard flat head but possesses a rounded upper surface for
239. nd check operation Bleed cooling system on liquid models See Cooling System Bleeding Procedures in this chapter ENGINES O Engine Disassembly Assembly Fuji 550 Fan Cooled Engines NOTE Inspect all parts for wear or damage during disassembly Replace all seals O rings and gaskets with Genuine Polaris parts during assembly Refer to pages 3 47 3 56 for gen eral inspection procedures Disassembly 1 Remove coil pack from fan shroud and disconnect it from the wiring harness 2 Loosen carburetor clamps and remove each carburetor 3 Using a pliers detach the oil lines from the carburetors A ENGINES Disassembly Continued 4 Remove the carburetor mounting boots using a allen wrench 5 Remove both the cylinder head and exhaust side fan shroud s from the engine assembly 6 After removing the fan shrouds take note of the vibration dampener located between the two intake ports Disassembly Continued 7 Remove the CDI module from the flywheel Cover 8 Remove the flywheel cover 9 Prior to removing the flywheel insert a piece of nylon rope or cord into a spark plug hole Rotate the crankshaft counter clockwise until it will no longer turn over Gp POLARIS ENGINES O 3 15 O ENGINES Disassembly Continued 10 Remove the recoil cam 11 Loosen and remove the flywheel nut 12 Using a flywheel puller remove the flywheel from the engine Do not install puller bolts more
240. nd everything looks straight including the tool compartment flap continue with step 11 Bottom View Of Seat Assembly Ing Sewn Seams Tack Cover Here Stapling Channel Tack Cover Here First Location Indicators 11 Staple the remainder of the unattached seat cover to the plastic seatbase as shown in lll 1 HINT Always Staple Here First staple between two existing staples and follow this procedure until the seat cover is completely stapled to the seat base See Ill 2 Staple 12 Turn the seat cushion assembly over and inspect for Here Second wrinkles or imperfections If imperfections are visible remove the staples in the affected area and staple correctly x X Staple Here Third Staple Sequence Models With Grommets In Tool Flap 13 Close tool flap cover making sure it is aligned properly and mark grommet holes 14 Align twist lock with mark from step 13 Verify alignment with grommet in tool flap 15 Using twist lock as a template drill two 160 to 164 holes through vinyl and seat base 16 Rivet twist lock to seat base using rivets provided All Models 17 Trim excess vinyl from the bottom around the back of the seat area only after a satisfactory fit is obtained 18 Reinstall seat by reversing disassembly steps as they apply to your particular model Hood Repair BODY AND STEERING Tool Flap Grommets Currently there is no procedures or materials recommended by
241. nding the ignition system and causing the engine to stop Speed Control Assurance Adjustment Throttle lever free play must always provide a specified clearance between throttle lever and throttle block This Clearance is controlled by the throttle cable sleeve s and the idle speed screw s Throttle Lever Freeplay 010 030 25 8 mm 010 030 25 8 mm If the idle speed screw s is adjusted inward and the cable Sleeve s is not adjusted to take up the throttle lever to throttle block clearance the engine may misfire or kill upon initial throttle opening CAUTION After any idle speed adjustments are made the throttle lever to throttle block clearance and oil pump adjustment must be checked and adjusted NOTE W hen adjustments are made on models which have more than one carburetor referto Section 6 Carbure tion for proper carburetor synchronization adjustments ELECTRICAL 1 Setthe multitester in the ohms Q position 2 Disconnect the switch harness from the main wire harness 3 Connect the two multitester leads to the two switch wires Test 1 Open Circuit Run With the auxiliary shut off switch in the ON position the multitester should read an open circuit OL As the throttle lever is moved from idle to off idle the tester should continue to read an open circuit If the tester fluctuates and the throttle lever to throttle block clearance is adjusted properly the switch ass
242. ndition deflection where applicable Check coolant hose routing and clamps Inspect heat exchangers condition and fasteners Check cooling system for proper coolant circulation Replace recovery line filter NOTE Must use correct filter Check coolant recovery line one way check valve must hold pressure where applicable H Pressure test cooling system Fan Cooled Inspect cooling fins and shrouds Remove chaincase cover flush chaincase inspect chain amp sprock ets and adjust chain Inspect chaincase seals Check condition of drive shaft and jackshaft bearings Lubricate greaseable bearings with Premium All Season grease Inspect and adjust reverse cable if applicable Remove ski pivot bushings and lubricate Inspect ski wear bars Check camber alignment and lubricate spindles Remove radius rod end bushings lubricate and reinstall inspect all radius rod ends Reinstall skis and inspect adjust toe alignment Check handlebar centering and lubricate all steering pivots Torque tie rod end bolts and jam nuts Inspect steering arms and torque bolts Inspect handlebar bolt torque Lubricate rear suspension pivot shafts Torque suspension mounting bolts and check all rear suspension fasteners and components Inspect rear suspension wheels bearings and hi fax Inspect track for damage Adjust tension and alignment ommoo For optimum performance and reliability repeat the above mainte nance and
243. ne Oil Pump Adjustment Refer to Chapter 3 for oil pump adjustment procedures Gp POLARIS MAINTENANCE TUNE UP Replace if width is less than 25 6 35mm Nominal new width is 345 8 75mm Weight Construction 062 to 090 Wire Suggested Wide Enough to Span Belt Weight should equal 2 Ibs Hang Weight Here 2 7 MAINTENANCE TUNE UP Chaincase Oil Level The drive chain is continuously immersed in oil Proper oil level is de termined by checking the level on the dipstick with machine placed on a level surface The oil level should be between the safe marks on the dipstick Add oil through dipstick opening to maintain proper level Use Polaris chaincase oil Do not overfill Polaris Chaincase Lubricant Quart PN 2871280 Gallon PN 2870464 2 5 Gallon PN 2872281 Foo A JU SAFE CAUTION Magnetic P lug Do not mix or use other types of lubricant Excessive wear to chain sprockets and bearings may result Drive Chain Tension Chaincase cover installed To obtain correct chain tension 1 Elevate rear of machine so track is off floor 2 Rotate driven clutch counterclockwise to move all chain slack to the tensioner side Lock the brake lever 3 Loosen adjuster bolt jam nut 4 Finger tighten adjuster bolt until it can no longer be adjusted by hand 5 Back off adjuster bolt 1 4 turn 6
244. ne crankshaft damage Identification This number indicates internal clutch component varia tion for individual engines For easy identification refer to the three numbers behind date code on clutch cover plate These numbers are the last three digits of the clutch part number 5 12 Date Code Last 3 digits of part number Gp POLARIS DRIVE DRIVEN CLUTCHES Disassembly and Inspection 1 Install drive clutch in clutch compression tool 8700220 Mark both moveable and fixed sheave cover and spider with a permanent marker CAUTION Sheaves must be marked to provide a reference point for clutch balance and spider indexing If the sheaves are not marked and spider shim washers are changed or misplaced the clutch will be out of balance and must be replaced See page 5 21 for indexing procedure 2 Carefully and evenly remove cover attaching bolts Do not allow side loading or misalignment of cover or bushing may be damaged Remember there is spring tension on the cover Inspect cover bushing for wear See page 5 36 for inspection and repair procedure Drive Clutch Compression Tool PN 8700220 Drive Clutch Holding Fixture PN 2871358 3 Mountdrive clutch securely in the holding fixture On models equipped with a spider jam nut P 85 Clutches remove jam nut in a counterclockwise direction standard thread using the special tool Spider Spanner J am Nut Tool PN 2870338 4 Install spide
245. ng 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 comes with float and seat Carefully inspect float bowl gasket and replace if necessary Install float bowl on carburetor Install float body Install air adjusting screw Install throttle slide Install jet needle Install funnel Install carburetors on snowmobile Synchronize carbs as outlined on pages 4 29 4 30 Replace top caps Tel FUEL SYSTEM CARBURETION Throttle Synchronization Procedure Mikuni TM 38 Flatslide Carburetors Mikuni TM 38 carburetors are synchronized at wide open throttle withoutthe engine running The middle carburetor on triples and the PTO side carburetor on twins have a non adjustable set screw on the throttle shaft This carbu retor is what the other carb s is synchronized to 1 Remove airbox 2 Remove top caps on all carburetors 3 Hold throttle wide open and view position of carburetor slide on base carburetor Middle carb on triples PTO carb on twins 4 With throttle held wide open turn the slide stop screw with screwdriver until slide is flush with top of base carb opening FUEL SYSTEM CARBURETION O Throttle Synchronization Procedure Mikuni TM 38 Flatslide Carburetors 5 On remaining carb s loosen phillips head screw inside the offset nu
246. ning the adjuster screw On Ryde FX shocks the compression damping can be changed by adjust ing the adjustment cam to the left or right Refer to shock section in this chapter for adjustment NOTE When we refer to high and low speed we are referring to the speed of the shock shaft or valve notvehicle speed Indy Select increase Decrease Increase SUSPENSIONS Overall Suspension Setup for Optimal Performance Set Up Recommendations for Optimum Performance Deep Powder Snow Powder Hardpack Hardpack n Front Torque Arm low position for maximum lift and floatation n Ski Stance Narrow position for maximum maneuverability n FrontTorqueArm standard position for overall handling and speed over Snow Ski Stance Setto rider preference Front TorqueArm High position for increased control and less transfer n Ski Stance Wide position for maximum stability More detailed instructions and options are found on troubleshooting and set up decals under the hood Production Width 41 Optional Width 39 5 High Standard SUSPENSIONS Hi Fax Replacement All Models Hi Fax replacement on all Polaris models is similar When any area of the Hi Fax is worn to 1 8 3 cm it should be replaced This will save wear on other vital components Hi Fax Wear Limit The slide rail is designed to operate in conditions with ad equate snow cover to provide su
247. nspectall frontsuspension and steering components While disassembling make notes of which direction a bolt goes through a part what type of nutis used in the application and which direction do the steering arms go on weld up or weld down etc Some of the bolts used in the IFS are special and cannot be purchased ata hardware store Always use genuine Polaris parts and hardware when replacing front end components Tools Camber 2001 42 5 XC 10 CRC Tools required lt 14 34 S 5 8 alignment bar S b tape measure Camber XTRA CRC amp XC 10 CRC d S Travel location bars 13 70 long PN 5211714 PA S Travel location bars 11 65 long PN 5211822 S Travel location bars 14 34 long PN 5244554 Toe Alignment XTRA CRC S Chassis stand or blocking 0165 gt NOTE The CRC Travel Location Bars are included in kit PN 2871537 along with a 45 alignment bar and as sorted hardware Supplemental kit PN 2872949 includes 14 34 travel location bars that fit 2000 XC 10 CRC models Kit components are also available separately See tool catalog for tool ordering information Refer to the chart below for travel bar application for width camber and toe adjustments on XTRA CRC and XC 10 CRC models See text on following pages for specific procedures XTRA CRC and XC 10 CRC Models When Measuring Set To Inspect Adjust To Inspect Adjust Toe Up Width Camber Travel Location Bar Suspension F ull
248. nt Spring Preload 3 4 Thread Adjust Driveshaft Sprockets 2 Drivers Wide XHS Front Vertical Travel 7 2 7 6 18 3 19 3cm Brake Type Polaris HPB Liquid Cooled Rear Suspension EDGE RMK Rear Axle Travel 13 8 35cm Front Track Shock Nitrex Spring Rate 170 in Rear Track Shock Indy Select RearSprings 375 sq 77 Track Type 15 x136 x1 75 38 1x345 44x4 45cm Track Tension 3 8 1 2 1 1 3 cm slack with 10s 4 54kg weight 16 40 64cm ahead of rear idler shaft Overall Snowmobile Length 102 5 306cm Overall Snowmobile Height 47 5 120 7cm Maximum Snowmobile Width 47 25 120cm OPTIONAL REAR TORSION SPRINGS sor em rim UU 367 89 Diameterx 77 359189 Diameter x 77 L H 136 7041627 067 L H 136 7041629 067 N A R H 136 7041628 067 R H 136 7041630 067 347 Sq Diameter x 47 359 Sq Diameter x 47 375 Sq Diameter x 47 H 144 151 L H 144 151 L H 144 151 7042081 067 7042068 067 7042079 067 H 144 151 R H 144 151 R H 144 151 7042082 067 7042069 067 7042080 067 d GENERAL INFORMATION MODEL INDY 700 SKS EUROPEAN MODEL MODEL NUMBER S02SS7CS E02557CE ENGINE MODEL 52189 7070PL7C JETTING CHART AMBIENT TEMPERATURE CAR
249. nternal components installed for its specific engine model Therefore modifications or variations of components at random are never recommended Proper converter setup and adjustments of existing components must be the primary objective in converter operation diagnosis CAUTION All converter maintenance repairs must be performed only by an authorized P olaris service technician who has attended a Polaris sponsored service training seminar and understands the proper procedures as outlined in this manual Because of the critical nature and precision balance incorporated into the drive clutch it is absolutely essential that no attempt at clutch disassembly and or repair be made without factory authorized special tools and service procedures Any unauthorized modifications to clutches such as adding or removing weights will void the warranty Relationship Between Drive Clutch Weights And Spring In Maintaining Operating RPM The drive clutch is an RPM and torque sensing unit designed to transfer the maximum amount of horsepower from the engine to the ground This is accomplished by weights and a spring inside the unit which react to the centrifugal force from the engine RPM The spring and weights work in combination In a properly set up clutch the maximum desired operating RPM will be reached immediately after clutch engagement under full throttle conditions To gain optimum power this RPM should be maintained As centrifugal force pu
250. o 8 92060 ziko eeezo tozz o 8000 eeoco 9 testo 26000 vero S gooro 9000 92600 r 99600 tzoo o izsoo e asz0 0 60000 zez00 Te egoo o zoo0 o s000 t WA Ss3H0N ww INOULS WN el INOULS WN 09 MES Ou WW OCL QOY WW ZLL 9340 1dS903 1d8s93 140993 140503 TdSro3 WdE teo3 Wid2 vb03 140703 9 5 u D C l D Q ELECTRICAL Indy Trail RMK Wiring Harness CDI Control Unit Ignition Coil 240 Watt Charging System NOTE Always verify timing of engine at room temperature only 68 F 20 C Refer to ignition timing procedure on page 9 9 Acceptable Variance Flywheel Flywheel Lines Rotation Stationary Pointers NOTE Acceptable variance is usually one line on either side of the dial indicated timing mark ELECTRICAL Indy 500 RMK SKS Euro 600 EDGE RMK CDI Controller SI RFI Caps Ignition Coil NOTE Always verify timing of engine at room temperature only 68 F 20 C Refer to ignition timing procedure on page 9 9 Acceptable Variance Flywheel Flywheel Lines Rotation Stationary Pointers NOTE Acceptable variance is usually one line on either side of the dial indicated timing mark Gp POLARIS 9 7 ELECTRICAL 1700 800 EDGE RMK Flywheel Housing Water Oil Pump Drive Belt ag RFI Cap Lighting Coil Wiring Harness
251. oats or inlet needle and seat 2 Remove slide valve Inspect for nicks or burrs which may cause sticking Cap er l l Gasket 3 3 Remove jet needle by compressing return spring s toward top cap and removing throttle plate which rests Spring on top of needle E clip Note the E clip position and inspect needle taper for wear An indication of wear SS _ Retainer Plate would be an hourglass shape or polished spots E Clip J et Needle somewhere along the taper Slide Valve i 4 Remove enricher choke plunger Check condition of seal on tip of plunger Any nicks or cuts will cause leakage and a rich fuel condition usually most evident Spri at idle and low speeds Inspect the plunger seat for pang OO damage or foreign material 5 Check choke cable movement Plungers and springs AT should move back and forth freely without binding Plunger Seat FUEL SYSTEM CARBURETION O Carburetor Disassembly and Inspection 6 Remove watertrap assembly from floatbowl and inspect O ring hose and clamp condition Refer to exploded view corresponding with carburetor being serviced 7 Inspect enricher choke fuel supply passage in bowl for obstruction Choke Passages 8 Usea spring loaded automatic center punch to remove float arm pin Remove inlet needle and seat assembly 9 Inspect needle for wear and replace sealing washers upon reassembly CAUTION Do notbend float arm during disassembl
252. odified Gram recht 57 59 1 Gram Do 46 091 Gram Wise 39g 1 Gram Nee 42g 1 PN 5630229 PN 5630301 PN 5630144 PN 5630089 DRIVE DRIVEN CLUTCHES OCC Gram Weight 44d 1 Gram Weare 53 50 1 Gram Wein 509 1 Gram Mesh 529 1 PN 5630065 PN 5630234 PN 5630243 PN 5630244 10 Bushed 10M W Bushed Gram Weight 47 59 1 Gram eo 55 591 Gram Weight 51 59 1 Gram Weight 469 1 PN 5630245 PN 5630274 PN 1321526 PN 1321527 10M Bushed 10M Blue Bushed 10M Red Bushed Gram Weight 49 591 Gram Weight 47 59 1 Gram Weight 44g 1 PN 1321528 PN 1321529 PN 1321530 DRIVE DRIVEN CLUTCHES 10 AL Bushed 10 66 Bushed 10 64 Bushed 10 62 Bushed Gram Weight 53 1 Gram Weight 66 Gram Weight 64 Gram Weight 62 PN 1321531 PN 1321584 PN 1321585 PN 1321586 10 60 Bushed 10 58 Bushed 10A Bushed 10 56 Bushed Gram Weight 60 Gram Weight 58 Gram Weight 55 Gram Weight 56 1 10 54 Bushed 553B 553R 555R Gram Weight 5421 Gram Weight 49 1 Gram Weight51 1 Gram Weight53 1 PN 1321685 PN 1321730 PN 1321731 PN 1321759 DRIVE DRIVEN CLUTCHES PART NUMBER COLOR CODE WIRE DIAMETER FREE LENGTH Force Ibs 125 2 50 1 19 H 12lbs 7041021 po Clear HARO O 4 4 387 70 130 mr 44 11 L mas 75 135 mm 75 213 7011065 117 200 TONTOS 70 159 mg droe 120 300 TORIOBS 120 285 me NAG 7011061 09 212 me GC mm 100 275 7011150 100 220 7011050 120 300 CAUTION Never shim a drive clutch spr
253. ohms Starter Installation 1 Position starter motor so there is no less than 100 clearance between the ring gear and the starter motor pinion gear 2 Torque through bolt mount bracket nuts to specification 3 Torque 8mm drive end mountbolts to specification 4 Torque 6mm brush end bracket to specification 8mm Drive End Mount Bolt Torque 15 ft Ibs 21 Nm 6mm Drive End Mount Bolt Torque 5 ft Ibs 6 9 Nm Mounting Bracket Nut Torque 30 42 in Ibs 3 4 4 8 Nm Starter P inion Gear Unregulated Voltage l Test resistance of lighting coil and compare to specifications in the model specific wiring diagram Reminder Meter resistance must be subtracted from reading NOTE 0 3to 0 5 ohms may be less than the internal resistance of your meter leads or meter Before measuring the stator resistance shortthe meter leads together and read the display and record this measurement S ubtract this reading from the stator resistance readings EXAMPLE Short meter leads together meter reads 0 7 ohms Measure stator resistance meter reads 1 10 ohms Subtract 0 7 ohms meter lead resistance from 1 10 ohms reading obtained when checking yellow lead to brown lead True reading is 1 10 ohms observed reading when checking stator 0 7 ohms meter lead resistance 0 4 ohms true stator resistance ELECTRICAL Unregulated Voltage continued 2 3 4 Turn the multitester dial to the
254. oint of kinking it If it becomes kinked it must be replaced Always inspect fuel lines when replacing or if carbs carb racks or fuel pumps are removed from chassis FUEL SYSTEM CARBURETION O Mikuni VM Carburetor 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 itis important that the throttle valve is closed when starting the engine Cable Adjuster Lock Nut Plunger Spring Plunger Cap Starter Plunger Inlet Starter Air Throttle Valve FA r Starter Starter J et O FUEL SYSTEM CARBURETION The pilotsystem s main function is to meter fuel atidle 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 regulated by the air screw and delivered
255. ollowing the method and sequence indicated in this manual tighten evenly to the specified torque value When removing nuts bolts or screws from a part with several fasteners loosen them all about 1 4 turn before removing them A If the condition of any gasket or O Ring is in question replace it with a new one Be sure the mating surfaces around the gasket are clean and smooth in order to avoid leaks A Some procedures will require removal of retaining rings or clips Because removal weakens and deforms these parts they should always be replaced with new parts When installing new retaining rings and clips use care not to expand or compress them beyond what is required for installation A Because removal damages seals replace any oil or grease seals removed with new parts A Polaris recommends the use of Polaris lubricants and greases which have been specially formulated for the top performance and best protection of our machines In some applications such as the engine warranty coverage may become void if other brands are substituted A Grease should be cleaned from parts and fresh grease applied before reassembly of components Deteriorating grease loses lubricity and may contain abrasive foreign matter A Whenever removing or reinstalling batteries care should be taken to avoid the possibility of explosion resulting in serious burns Always disconnect the negative black cable first and reconnect it last Battery electrolyte contains s
256. ompletely onto trailer it may need to be pulled or pushed to avoid belt wear burning Check for correct clutch components Use fast effective throttle to engage the clutch Gp POLARIS DRIVE DRIVEN CLUTCHES Belt Deflection Too much belt deflection If the belt is too long or the ET center distance too short the initial starting ratio will be Belt too high on initial engagement too high resulting in performance loss This is due to the belt rising too high in the drive clutch sheaves upon en gagement Notenough belt deflection belt too tight If the drive belt is too short or the center distance too long the ratio will again be incorrect In addition the machine may creep when the engine idles causing damage to the in ternal face of the drive belt DRIVE DRIVEN CLUTCHES Measuring Belt Deflection IMPORTANT NOTE Do not apply excessive pressure to force belt into driven sheaves This will result in an improper measurement If belt deflection cannot be adjusted within specification using methods below inspect center distance and compare to specifications on page 5 32 1 Measure belt deflection with both clutches at rest and in their full neutral position 2 Place a straight edge on the belt and apply downward pressure while measuring at the point shown Belt Deflection 11 4 3 2 cm Adjusting Belt Deflection P 85 Beltdeflection can be adjusted without removing the clutch from the jack
257. or initial cold drive away When possible do not go in deep snow when towing another ma chine Use fast effective throttle to engage the clutch Not all ma chines are intended for pulling heavy loads or other machines Spinning track while vehicle is stuck high RPM low vehicle speed high ambient temp Example 8000 RPM 10mph vehicle speed 60 mph indicated on speedometer Ice and snow piled up between track and tunnel overnight or after stopping for a long period of time enough to re freeze the snow Poor running engine Bog Miss Backfire etc Loading machine on trailer Clutch malfunction Slow easy belt engagement easing on the throttle 5 30 Lower the gear ratio Remove windage plates from driven clutch If possible move to better snow conditions and reduce RPM Avoid riding in very high ambient temperatures Break loose snow and ice under tunnel Allow longer than normal warmup Allow belt to warm sufficiently and increase grip ability on clutch sheaves Use fast effective throttle when engaging clutch Maintain good state of tune including throttle and choke synchro nization Check for fouled spark plug s Check for foreign material in carbs Make sure no water or ice in fuel tank lines or carbure tors Use caution when loading machine Carbide skags may gouge into trailer and prevent drive train from spinning freely Use enough speed to drive completely onto trailer If machine cannot be driven c
258. oses an electronic switch thyristor in the CDI boxand allows the voltage in the capacitorto discharge into the primary windings of the ignition coil Center Cylinder On three cylinder engines the cylinder between Mag and PTO ends Center Distance Distance between center of crankshaft and center of driven clutch shaft Chain Pitch Distance between chain link pins No 35 3 8 or 1 cm Polaris measures chain length in number of pitches Clutch Buttons Plastic bushings which transmit rotation ofthe clutch to the movable sheave in the drive and driven clutch Clutch Offset Drive and driven clutches are offset so that drive belt will stay nearly straightas itmoves along the clutch face as the engine torques back Clutch Weights Three levers in the drive clutch which relative to their weight profile and engine RPM cause the drive clutch to close Coil A winding of wire around an iron core which has the ability to generate an electrical current when a magnetic field passes through it Combustion Chamber Space between cylinder head and piston dome at TDC Compression Reduction in volume or squeezing of a gas Condenser Capacitor A storage reservoir for electricity used in both E T and CDI systems Crankshaft Run Out Run out or bend of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in lower half of crankcase Measure at various points especially at PTO Maximum all
259. osition until jam nut is tight When tie rod ends are properly tightened the tie rod should rotate freely approxi mately 1 8 turn Rod End Engagement Guidelines All IFS Tie Rod Or Radius Rod End Must Engage Rod A Minimum Of 2x Thread Diameter When Adjustment Is Complete EXAMPLE 7 16 Rod End x 2 7 8 Minimum Thread Engagement 7 8 llmm x 2 22mm Minimum Thread Engagement 22mm Gp POLARIS Mounting Surface Incorrect Correct Tie Rod Or Diameter Of Rod Radius Rod End x 2 Minimum Thread Engagemen t Thread Engagement 6 7 g BODY AND STEERING 2002 IFS Steering Alignment Specifications The following information is to be used for 2002 Polaris Snowmobile front suspension setup The data in the following table is based on the 2002 Polaris factory settings Maximum Width and Camber measurements are to be taken with the front end elevated and shocks at full extension Toe alignmentis measured at ride height Maximum Setup Width 1 4 6mm 42 5 EDGE 500 600 700 800 XC SP 500 Indy Supersport 550 500 600 700 Classic Frontier TEMA 36 75 93 35cm 0 5 16 0 80cm iS MK a 36 94 93 83cm 11 32 5 16 86 80cm 39 5 EDGE RMK D 600 700 800 Edge RMK 39 49 100 30cm 1 5 16 2 62 80cm 1 8 3 8 41 EDGE RMK 600 700 800 Edge RMK 40 95 104 01cm 13 16 5 16 2 11 80cm TOE OUT 40 48 102 82cm 5 8 5 16 1 64 80cm ALL MODELS 38X
260. owable run out is 006 02 cm DCV Direct current voltage Detonation The spontaneous ignition of the unburned fuel air mixture after normal spark ignition Piston looks hammered through rough appearance around hole Possible causes 1 lean fuel air mixture 2 low octane fuel 3 over advanced ignition timing 4 compression ratio too high for the fuel octane Dial Bore Gauge A cylinder measuring instrument which uses a dial indicator Good for showing taper and out of round in the cylinder bore Displacement The volume of the cylinder displaced by the piston as ittravels from BDC to TDC The formula is Bore x Stroke x 3 1416 Displacement in 4 CCs Effective Compression Ratio Compression ratio measured from after the piston closes the exhaust port Electrical Open Open circuit An electrical circuit which isn t complete i e poor connections or broken wire athi lo beam switch resulting in loss of headlights Electrical Short Short circuit An electrical circuit which is completed before the current reaches the intended component i e a bare wire touching the snowmobile chassis under the seat resulting in loss of taillights and brake lights End Seals Rubber seals at each end of the crankshaft Engagement RPM Engine RPM at which the drive clutch engages to make contact with the drive belt de Flat Head Bolt To be used where finished surfaces require a flush fastening unit Countersunk Foot Pound Ft
261. owable tolerance is 015 6 mm Noise in drive system Broken drive clutch components Inspect replace Excessive drive clutch button tower Install new buttons or shim clearance out existing buttons Inspect replace Bearing failure chaincase jackshaft or front drive shaft Inspect adjust or replace Drive chain loose or worn sprocket teeth broken Inspect replace Driven clutch bushing worn excessively or Inspect replace spring broken Drive chain adjustment too tight too loose Inspect adjust Drive belt surface flat spots Inspect replace Over rev during initial accel S pider roller position remaining in detent Add spider shim washers eration or during heavy pulling at low ground speeds Add driven washers Reduce gear ratio chaincase Engine bogs after engage Improper driven clutch setup models ment Worn belt Replace Excessive belt deflection Subtract driven clutch wash ers Improper offset alignment Inspect adjust Broken or misadjusted torque stop Inspect adjust replace Broken motor mount Inspect replace J ackshaft bearing seizure Replace DRIVE DRIVEN CLUTCHES Drive Driven Clutches Troubleshooting SYMPTOMS PROBABLE CAUSE REMEDY Engine RPM below specified a Wrong or broken drive clutch spring a Replace with recommended spring operating range although en b Drive clutch shift weight too heavy b Install correct shift weight kit to gine is properly tuned
262. 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 Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause a springy or spongy brake lever action Bleeding is necessary to re move air from the system 1 Remove brake fluid master cylinder reservoir cover and gasket CAUTION Brake fluid is a hazardous material Contact with decals paint and many plastics will cause damage Use proper precautions when handling brake fluid 2 Fillthe mastercylinderreservoir and replace gasketand cover Keepthe fluid level 1 4 5 16 6 8 cm below lip of reservoir opening 3 Slip a rubber tube over the ball of the bleeder valve and direct the flow of fluid into a container Neverre use 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 4 Squeeze brake lever a full stroke Then unscrew bleeder valve A 3 4 of a turn to release air Bleeder Tube 5 Close bleeder valve first and then release brake lever Repeat steps 4 and 5 until fluid flows from bleeder valve in a solid stream free of air bubbles Do not allow reservoir to run dry or air will be drawn into system 6 Re fi
263. pection 3 56 Cylinder H oning 3 47 Cylinder M easurement 3 56 D D ecal Installation 6 34 D ecal Removal 6 34 Drive Belt 5 29 Drive Belt Inspection 5 30 Drive Belt Installation 2 15 Drive Belt Removal 2 15 Drive Chain Tension 2 8 Drive Clutch A ssembly 5 18 5 19 Drive Clutch Bushing Replacement P 85 5 36 5 37 5 38 Drive Clutch Disassembly D rive Clutch Inspec tion 5 13 5 14 5 15 5 16 Drive Clutch Identification 5 12 Drive Clutch Installation 5 19 5 20 Drive Clutch R emoval 5 12 Drive Clutch Service Tools 5 1 Drive Clutch Spring D ata 5 6 Drive System A ssembly 8 29 8 30 8 31 8 32 8 33 8 34 8 35 8 36 Drive System Disassembly 8 25 8 26 8 27 8 28 Driven Clutch A ssembly 5 25 5 26 5 27 Driven Clutch Bushing Replacement P 85 5 39 5 40 Driven Clutch Disassembly 5 23 5 24 Driven Clutch Installation 5 28 Driven Clutch Removal 5 22 Engine Installation 3 9 3 13 E ngine Removal 3 5 3 9 Engine Torque Specifications 3 1 F Float Chamber Venting 4 11 Float L evel Adjustment 4 23 Float System 4 18 Fox Shock A ssembly 7 31 7 32 7 33 7 34 7 35 Fox Shock Disassembly 7 27 7 28 Fox Shock E ye Replacement 7 35 Fox Shock M aintenance 7 25 7 27 7 28 7 29 7 30 7 31 7 32 7 33 7 34 7 35 7 37 Fox Shock Seal Replacement 7 29 7 30 Fox Shock Valve Part Numbers 7 23 7 26 Friction Pad Replacement Type H 4 8 20 8 21 Front Torque Arm L
264. preload to achieve the desired ride affect 1 2 of a turn will affect the ride considerably There are approximately 3 turns of adjustment available Ski Spindle Bushing Removal 1 Using a a scribe center punch or paint mark the spindle and steering arm for reference during reassembly Note direction of steering arm bolt and remove 2 Remove steering arm 3 Slide spindle and ski assembly out bottom of trailing arm Inspect spindle for wear or damage 4 Remove old bushings and washer from bottom of spindle tube with a drift punch Inspectcondition of washer and replace if worn Install new bushings tapered end first Gp POLARIS BODY AND STEERING Bushings i Washer 6 19 5 BODY AND STEERING Ski Spindle Bushing Installation 5 Grease spindle shaft and new bushings with Polaris All Season Grease All Season Grease PN 2871322 3 oz PN 2871423 14 oz 6 Install spindle into trailing arm with grease fitting facing rearward 7 With ski facing straight forward attach steering arm Align with marks made in step 1 8 Install steering arm boltand torque to specification Spindle Bolt Torque 28 30 ft Ibs 38 6 41 4 Nm BODY AND STEERING Steering Arm Orientation Steering arm orientation is importantto ensure proper steering tie rod end thread engagementand steering perfor mance Always mark steering arms and spindles before removal for reference upon reassembly When
265. r maintenance or after complete brake service Brake fluid may damage painted or plastic surfaces Take care not to spill and wipe up any spills immediately Cover parts to avoid damage 1 Clean reservoir cover thoroughly 2 Remove screws cover and diaphragm from reservoir 3 Inspect vent slots A in cover and remove any debris or blockage 4 Ifchanging fluid remove fluid from reservoir with a Mity Vac pump or similar tool NOTE Do notremove brake lever when reservoir fluid level is low Mity Vac PN 2870975 5 Add brake fluid to within 1 4 5 16 6 8 cm of reservoir top Polaris DOT 3 Brake Fluid PN 2870990 6 Install a box end wrench on caliper bleeder screw fitting Attach a clean clear hose to fitting and place the other end in a clean container Be sure the hose fits tightly on fitting NOTE Fluid may be forced from compensation port B when brake lever is pumped Place diaphragm C in reservoir to prevent spills Do not install cover 7 Slowly pump lever D until pressure builds and holds 8 While maintaining lever pressure open bleeder screw Close bleeder screw and release brake lever Do not release lever before bleeder screw is tight or air may be drawn into caliper 9 Repeat procedure until clean fluid appears in bleeder hose and all air has been purged Add fluid as necessary to maintain level in reservoir CAUTION Maintain a
266. r removal tool and remove spider in a counterclockwise direction standard thread Spider Removal Tool PN 2870341 Gp POLARIS 5 13 DRIVE DRIVEN CLUTCHES Disassembly Cont 5 Measure the total thickness of the spacer washers installed beneath spider and record CAUTION NOTE In order to maintain proper belt to sheave clear ance and clutch balance the same washers or equiva lenttotal thickness must be reinstalled during assembly If sheaves are not marked orif total thickness of existing shim washers under spider is not recorded clutch will be out of balance when reassembled and must be replaced Be sure to follow indexing procedure on page 5 21 if belt to sheave clearance is being adjusted 6 Inspect both sheave surfaces for wear or damage Inspect movable sheave bushing See page 5 38 for inspection and repair procedure 7 Using an 1 8 Allen wrench with a 3 8 combination wrench remove drive clutch fly weights Note direction of weight pin with nut on trailing side Inspecteach weight Surface should be smooth with no waves or galling Place boltinside weightto check flyweight bushing and pin surface for wear NOTE The weight bushing is nota service partand both weight and pin must be replaced if worn 8 Inspectall rollers bushings and roller pins by pulling a flat metal rod across the roller Roller can also be inspected by rolling with finger to feel for flat spots roug
267. r to pass through piston assembly NOTE During installation some shock oil will overflow Wrap a shop cloth around shock body to catch pos sible oil overflow Fastinstallation of the piston rod and assembly may displace the floating piston from its original posi tion This must not occur if the damper is expected to perform as designed Using an open face spanner tighten cylinder head securely into the shock cylinder P ressurize the shock reservoir through the pressure valve with nitrogen gas to the specified gas pres sure NOTE Adjust gas pressure to 200psi After being compressed the piston rod should fully extend from the shock once the shock has been pressurized With the gas pressure pushing against the pressure valve end cap firmly tighten the pressure valve assembly and re install the small button head screw Re install any bearing sleeves and or bushings in the lower shock mount SUSPENSIONS Suspension Troubleshooting XTRA Lite Style rte o Rear suspension bottoms too easily Increase torsion spring preload Increase rear shock compression valving by turning screw clockwise if equipped with optional Indy Select shock Rides too stiff in rear Check for binding suspension shafts and grease all pivot points Decrease torsion spring preload adjustments Decrease rear shock compression valving by turning screw counterclockwise if equipped with optional Indy Select shock Machine darts from side to side
268. rburetor mounting air leak lean Crankshaft seal air leak lean Fuel pump diaphragm damaged rich Float level incorrect Air bleed obstructed 0 0000 NM MW MW WN Tel FUEL SYSTEM CARBURETION Troubleshooting Tips 1 4 3 8 Throttle S S S S Obstruction in main jet or needle jet J et needle worn or out of adjustment Pilot system malfunction Incorrect throttle valve cutaway Troubleshooting Tips 3 8 3 4 Throttle S S S S Main jet incorrect size or clogged lean Needle jet damaged or loose Needle jet jet needle worn rich E clip position incorrect for altitude and temperature Troubleshooting Tips Full Throttle 4 36 S Uu NM AM NM MW MW WN Main jet size rich or lean Fuel filter blocked lean Fuel vent lines or check valves plugged Exhaust system plugged Air box restricted Fuel pump weak Exhaust leaking into engine compartment rich Water in float bowl lean Gp POLARIS CHAPTER 5 ZO DRIVE DRIVEN CLUTCHES Recommended Tools uta a 5 1 Drive Clutch Weights EE 5 2 5 4 Drive Clutch Spring Matrix and Part Numbers 5 5 Driven Clutch Spring Data 42519 wed ale Cr d d 5 6 P 85 Drive Clutch Exploded VieW o ooooooomoo 5 7 P 85 Driven Clutch Exploded View 5 8 PVT Operation Theory xx oes SE AN 5 9 5 11 Drive Clutch Remoyal EE 5 12 Drive Clutch Disassembly and Assembly 5 13 5 19 Drive Clutch Installation i335 dg eg E sa ces
269. re Too high a level allows more fuel than necessary to leave the nozzle enriching the mixture Too low a level re sults in a leaner mixture since not enough fuel leaves the nozzle Therefore the predetermined fuel level should not be changed arbitrarily 4 18 Float Guide P in Needle Valve Float Arm Gp POLARIS FUEL SYSTEM CARBURETION O m INCREASI DECREASING a O 0 1 8 1 4 3 8 1 2 5 8 34 1 8 FULL THROTTLE OPENING TYPICAL MIKUNI VM SSS gt Throttle Valve Cut Away jet Needle Needle J et Polaris TM 38 TM 40 Mikuni component effect versus throttle opening chart needle valve main jet Main jet needle needle jet throttle valve bypass 77 Slow pilot outlet airjet choke plunger star starterjet fuel screw 0 start idle 1 4 1 2 3 4 Full Throttle P osition O FUEL SYSTEM CARBURETION CAUTION Wear eye protection when using compressed air or cleaning solvents Review all fuel system warnings found on page 4 1 before proceeding Carburetor Removal Disassembly and Inspection Typical VM Mikuni 1 Remove carburetor from engine Before disassembling clean outside of carburetor thoroughly with solvent ldle Speed Screw Choke Passages Pilot Air CAUTION Screw Do not use compressed air to dry at this time The float chamber could become pressurized resulting in damage to the fl
270. rea where refueling is performed or where oo BBBBB 8 gasoline is stored Do not weld or operate a torch near the fuel system Remove fuel tank before any chassis welding is per formed If you get gasoline in your eyes or if you swallow gasoline see your doctor immediately If you spill gasoline on your skin or clothing immediately wash itoff with soap and waterand change clothing Never startthe engine or let run in an enclosed area Gasoline powered engine exhaust fumes are poison ous and can cause loss of consciousness and death in a short time Turn fuel valve off Remove air silencer Position a shop cloth or container below drain plug and water trap plug Remove drain plug and sealing O Ring or slide clamp upward and remove water trap plug Drain water fuel Clean trap with electrical contact cleaner and dry with compressed air Lightly grease O ring and install water trap assembly into bottom of float bowl or reinstall trap plug in hose and position Tighten securely Turn fuel on start engine and check for possible fuel leaks Reinstall air box The water traps should be periodically inspected and drained Draining frequency will depend upon fuel supply riding conditions and fuel handling precau tions 4 34 Float Water Trap Plug Gp POLARIS FUEL SYSTEM CARBURETION Tel Fuel system diagnosis should follow a specific path first examining the fuel tank then the
271. red Visually inspect piston pin for damage discoloration or wear Run your fingernail along the length of the pin and replace it if any rough spots galling or wear is detected Connecting Rod Small End Inspection 1 Clean small end of connecting rod and inspectinner bore with a magnifying glass Look for any surface irregularities including pitting wear or dents Run your fingernail around the inside of the rod and check for rough spots galling or wear Oil and install needle bearing and pin in connecting rod Rotate pin slowly and check for rough spots or any resistance to movement Slide pin back and forth through bearing while rotating and check for rough spots With pin and bearing centered in rod twist ends back and forth in all directions to check for excessive axial play Pull up and down evenly on both ends of pin to check for radial play Replace pin and bearing if there is any resistance to rotation or excessive axial or radial movement If play or roughness is evident with a new pin and bearing replace the connecting rod Gp POLARIS ENGINES O 3 55 O ENGINES Crankshaft Truing Lubricate the bearings and clamp the crankshaft securely in the holding fixture On three cylinder crankshafts straighten one of the ends Magneto or PTO and then straighten the center section Place the center section in the holding fixture and then straighten the remaining end If truing the crankshaft requires str
272. rews that hold the TPS on the carburetors 2 Turn the TPS clockwise to decrease voltage or counterclockwise to increase voltage 3 Whenthe TPS is setto the desired voltage tighten the holding screws and verify voltage is 4 0 to 4 2 volts at Wide Open Throttle for Polaris domestic engines and 3 77 volts for F uji engines 800 XCR TPS Adjustment Continued 4 When the TPS is set and voltage is verified remove the tester and re install the snowmobile TPS harness 5 When storing the TPS tester remove the red terminal of the tester and insert it in the blank terminal of the harness Gp POLARIS ELECTRICAL 9 27 ELECTRICAL Condition No Spark Disconnect the single black black white wire from the CDI Module to the ignition kill circuit Does it have a spark Yes No Disconnect the stator to CDI module wires Test the resistance values of the stator coils as per the wiring diagrams Are the resistance val ues within specs Isolate which component s resistance is not within specs Remove the flywheel and stator Recheck the resistances look for pinched or bare harness wires or replace the coil Condition Incorrect Advance Retard Follow the engine timing procedure for checking running timing at recommended RPM Is the timing within limits No Yes Remove the ignition kill circuit by disconnecting the single black wire between the CDI module and the machine harness Is the timing now corr
273. rge to a light more water state when discharged The hydrometer can measure state of charge and differences between cells in a multi cell battery Readings of 1 270 or greater should be observed in a fully charged battery Differences of more than 025 between the lowest and highest cell readings indicate a need to replace the battery Lead acid J 0 Charged Less Than Less Than ING gee ee AS 11 80V 11 9V ae E d H E State Of Charge Conventional Yumacron Nu Lead acid Type 10096 100 Charged 1 1265 1 1275 a Charged 210 225 50 Charged 1 160 1 175 25 Charged 1 120 1 135 0 Charged Less Than Less Than 1 100 1 115 at 80 F NOTE Subtract 01 from the specific gravity for electrolyte at 40 F and compare these values to the chart ELECTRICAL Load Test NOTE T his test can only be performed on machines equipped with electric start This test cannot be performed if the engine or starting system is not working properly A battery may indicate a fully charge condition on the OCV test and the specific gravity test but still not have the storage capacity necessary to properly function in the electrical system For this reason a battery capacity or load test should be conducted whenever poor battery performance is encountered To perform the test hook a multitester to the battery in the same manner as in the OCV test The reading should be 12 6 volts or greater Engage the electric starter and vie
274. ring one inch For example if 150 pounds of force are required to compress a spring 1 inch the spring rate would be 150 in Straight rate spring the spring requires the same amount of force to compress the lastone inch of travel as the first one inch of travel For example ifa 150 Z in spring requires 150 pounds of force to compress itone inch 300 pounds of force would compress ittwo inches 450 pounds of force would compress it three inches etc Progressively wound spring the rate of the spring increases as itis compressed For example a 100 200 in rate spring requires 100 pounds of force to compress the first one inch but requires 200 additional pounds to compress the last one inch When a bump is encountered by the suspension the force of the bump compresses the spring If the force were 450 pounds a 100 in spring would compress 4 5 inches A 150 in spring would only compress 3 inches If the suspension had 4 inches of spring travel the 100 in spring would bottom out while the 150 in spring would have one inch of travel remaining Torsion springs are much like coil springs although shaped differently The rate of the torsion spring is con trolled by the free opening angle the installed opening angle the wire diameter of the spring and the number of coils Torsion S pring Load reduces opening angle Iu SUSPENSIONS Suspension Overview Many factors influence the
275. rive System Remove drive belt and store in a cool dry location Lubricate sheave faces and ramps of drive and driven clutches with light oil or rust inhibitor All lubrication applied as a rust preventative measure must be cleaned off before installing belt for service and operating machine Chaincase Lubricant Change chaincase lubricant as outlined in this section Remove the outer cover and clean the chaincase thoroughly MAINTENANCE TUNE UP Lubrication Refer to page 2 5 2 10 for complete lubrication information To prevent corrosion always grease jackshaft and drive shaft clutch side bearings with premium all season grease Loosen driven clutch retaining bolt and pull Ski Spindle clutch outward to expose bearing Use a point type and Bushings grease gun fitting to inject grease through hole in flangette into bearing until grease purges out inside or outside bearing seal Push clutch back on shaft and replace clutch retaining bolt Inject grease into fitting on speedometer drive adaptor until grease purges out inside or outside bearing seal Lubricate both front ski pivots at bushings and spindles See Ill 1 and 2 Hl 1 Polaris Premium All Season Grease PN 2871423 14 oz Grease Gun Adapter 2871174 Point Type Grease Grease J ackshaft Bearing Use T 9 Metal Protectant or equivalent on shock absorber shafts to help prevent corrosion T 9 Metal Protectant PN 2871064 Grease Under normal
276. roperly Enricher plunger are not seating properly Fuel pump diaphragm is ruptured caused by engine backfiring Carburetor slides are not synchronized Main jet too large Needle and seat not seating properly Incorrect float level Check reed valve condition Verify all tune up adjustments carb sync oil pump adjustment pilot screw setting spark plug type and gap venting for carbs proper jetting for altitude and temperature belt tension clutch operation If tune up items are correct check float level jet needle position jet needle wear inlet needle and seat wear Spark quality etc Coolant level low or air in cooling system Incorrect main jet Incorrect timing Incorrect spark plug Water pump belt loose or broken Cooling restriction Inadequate snow for cooling ice and or marginal conditions Check for faulty connections Check alternator output Check diodes rectifier Sulphated battery Battery electrolyte overfilled or low Refer to alternator testing in chapter 9 electrical Gp POLARIS ENGINES O Engine Troubleshooting PROBLEM PROBABLE CAUSE Lights don t Engine must be running work Check wiring harness connector Check for bumed out bulbs Check wiring for shorts or loose connections Disconnect taillight if headlight works short is in taillight wiring or taillight Unit fails to pro Check belt center distance pel itself Check clutch Check chain Check drive sproc
277. rs the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes are excessive oil use of non recommended injec tion oil excessive idling idle too low or too rich or weak ignition output l Inspectelectrodes for wear and carbon buildup Look fora sharp outer edge with no rounding or erosion ofthe electrodes 2 Clean with electrical contact cleaner or a glass bead spark plug cleaner only CAUTION A wire brush or coated abrasive should not be used 3 Measure gap with a wire gauge and adjust to specifications by bending ground electrode carefully 4 Coatspark plug threads with a small amount of anti seize compound 5 Install spark plug and torque to specification Spark Plug Torque 12 14 Ft Lbs 16 6 19 3 Nm MAINTENANCE TUNE UP Drive Belt Inspectthe condition ofthe drive belt Inspect clutch sheaves for damage wear or beltresidue Clean with non oil base cleaner such as isopropyl alcohol To ensure beltlife install belts so they operate in the same direction of rotation P osition the identification numbers so that you can read them standing on left side of machine This will keep the belt rotating in the same direction If belt has been operated with numbers readable from right side of machine re install belt in this direction Belt Removal 1 2 Apply brake or lock parking brake if so equipped 3 Grasp belt firmly midway between c
278. s 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 withoutleaving an excess of fuel or air Whether the proper mixture ratio is maintained or notis the key to efficient engine op eration 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 meetthe requirements for the proper mixture ratio under these varying condi tions a low speed fuel system or pilot system and a main fuel system are provided in Mikuni VM type carburetors TheMikuni carburetor has varying operations de pending upon varying driving conditions It is constructed of a float system pilot system main system and starter system or initial starting de vice 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 ofthe float and the fuel pressure ofthe fuel pump balance the needle valve sticks fastto 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 amountof fuel in the fuel mixtu
279. s required Armature Testing l Using a digital multitester measure resistance between each of the segments of the commutator The reading should indicate 3 ohms or less 2 Measure resistance between commutator and armature shaft Reading should be infinity 3 Place armature in a growler With the growler on position a hacksaw blade lengthwise 1 8 03 cm above armature coil laminates Rotate armature 360 If hacksaw blade is drawn to the armature on any pole the armature is shorted and must be replaced ELECTRICAL Starter Assembly Armature 1 Slide armature into field coil housing 2 Lightly grease drive end bushing and install drive end frame on armature 3 Mount starter vertically in a vice with brush end up While holding negative brushes out against their springs slide brush plate down onto the commutator 5 While holding positive brush springs to the side slide positive brushes into their holders and correctly position the springs on top of the brushes 6 Using a non petroleum grease lubricate brush end bushing and slide it onto end of armature 7 Align threaded holes in brush plate and install dust cover and screws 8 Reinstall through bolts and properly tighten all Screws 9 Lightly grease pinion shaft and install pinion spring stopper and snap ring ELECTRICAL Starter Solenoid Bench Test The only test which can be done on the bench is the pull in coil resistance which should be 3 4
280. s under extreme pressure Use caution when releasing nitrogen gas from shock Protective eyewear should be worn to avoid risk of injury CAUTION Allow all the gas pressure to escape before proceeding with the removal of the pressure valve assembly P ressurized gas could ejectthe valve assembly from the cylinder resulting in bodily injury Once the shock is completely discharged of gas pressure remove the pressure valve assembly from the reservoir cylinder With yourtwo thumbs depress the reservoir end cap 1 2 and remove retaining circlip Use care notto scratch the inside of the reservoir Reinstall pressure valve assembly partway into the end cap Using pliers grasp the end cap by the pressure valve assembly and extract the end cap slowly from the reservoir by pulling straight out Using either an adjustable face spanner or cylinder head socket fully loosen cylinder head and re move rod assembly placing it on a clean shop towel Using the I F P Internal Floating Piston extraction tool thread the tool into the I F P and pull upwards removing the I F P from the reservoir Account for wear band and an O ring Pourthe oil out ofthe shock reservoirand main cylinder body into waste container Discard old oil into an approved storage container and dispose appropriately Never reuse damper oil during shock re build Cleanthe inside ofthe shock body using clean parts cleaning solventand blow dry using compressed air 7 42 Gp POLARIS
281. s with composite skis Toe Alignment All Models Measurement A should be 1 8 1 4 3 17 6 35 mm greater than measure ment B at normal ride height toe out Gp POLARIS Lift 3 5 7 6 12 7 cm and work suspension to find average Toe Adjustment Normal Ride Height A 1 8 1 4 greater than B at normal ride height Skag Centerline Straight Edge ELLE 4 g l 6 13 O BODY AND STEERING Toe Adjustment XTRA CRC and XC 10 CRC cont 3 To adjusttoe hold tie rod flats or support edge of tie rod end with a wrench or flat stock to keep it from rotating Loosen jam nuts on each end of both tie rods Turn tie rod as required to adjust toe 4 Holdtie rod and tighten jam nuts Be sure to position inner and outer tie rod ends parallel to their respective mounting surface as shown When tie rod ends are properly tightened the tie rod should rotate freely approximately 1 8 turn Tie Rod J am Nut Torque 8 14 ft Ibs 11 19 Nm 6 14 Toe Measurement CRC Support Tie Rod End Mounting Surface Incorrect Gp POLARIS BODY AND STEERING XTRA CRC and XC 10 CRC Steering Alignment The following steering alignment procedure can be performed on XTRA CRC or XC 10 CRC front suspensions only and should not be used for 38 RMK CRC or non CRC front suspensions General Set Up Tips Before adjustments are performed on CRC steering i
282. same localbon as used for dimension X This ia dimension Y Ta determine Sag which is commonly referred to as ride in subiract dimension Y fram dimension X Therefore SagsX Y Sag is adjusted by rotating the torsion spring preload cams located on tha rear torque arm see Fig 1 The ideal amount af Sag for the EDGE AMK rear suspension is 4 X Y 4 If the rear suspension rides in less than 3 or more than 5 with the torsion spring preload cams at their maximum range of adjustment optional torsion springs potter or stiffer respectively may be required Remember this la only an initial setup and final spring preload may vary based on rider prelerence and riding conditions OPTIONAL TORSION SPRINGS TRACK SOFT 3 11 0 STANDARD 0oen 1 7041827 067 7041628 067 7041629 067 7041630 067 1 A 347 77 359 77 144 151 7042081 067 7042082 D6r 7042068 057 7042069 067 7042079 067 7042080 067 156 SAT 47 258 47 STR AT Ba A pa BCS Ee Q fy Soft Tension Long End to Front Medium Tension Short End Up Firm Tension Long End Up SUSPENSIONS Shock Tuning The shocks work in two directions Compression damping prevents the shock from bottoming hard while rebound damping keeps the shock from springing back too fast Both compression and rebound damping can be adjusted for high and low speed damping characteristics On Indy Select shocks the compression damping can be changed by tur
283. se semeja 150 3130770 Poa 08 pora gt sumeret 15 3307 ProtAnJer 09 315208 Strerjer 160 33072 The part numbers for main jets and pilot jets are the same as Mikuni VM round slide carburetors SD POLARIS 4 3 O FUEL SYSTEM CARBURETION Mikuni TM 38 TM 40 J et Needle Overview Leaner This needle example is a 9DH01 57 The first number is T the approximate overall length in 10mm increments of the jet needle The 9 indicated the needle is approximately 90mm but less that 100mm in length The letters on the jet needle pee indicate the angle of both tapers The first letter designates 4 the taper angle of the top section closest to the grooves E 5 and the second letter designates the angle of the bottom ta per The taper angles are graduated in 15 15 minute incre Richer ments The jet needle marked 9DH01 57 would have a top taper of 1_0 and a bottom taper of 2 0 The number follow ing the letters on the jet needle is the manufacture s lot num ber and it varies with individual jet needles The last number 57 indicates that the outside diameter is 2 57mm The small er the O D the richer the mixture O D Straight P ortion FUEL SYSTEM CARBURETION Mikuni TM 38 TM 40 Overview Gasket Check 3 T s Een op Bu Pa Valve yi Slide Flush With Top of Bore e LB Lever Y K Mixing Body Iess O cafe a Piston Wl ag H X DTE gt Valve E Funnel S s de
284. shaft 1 Pull belt into driven clutch to slightly open sheaves 2 Loosen three bolts on adjustment cam 3 Turn cam counterclockwise to reduce distance Optional Thin Adjustment Washer P 85 between sheaves Do not rotate past 1 position 048 PN 7555899 4 Torque bolts to specification Production washer is usually 075 thick with other 020 or 030 washers as required May use optional thinner 048 washer PN 7555890 if re quired to obtain proper sheave width Either the 075 or 048 washer must be installed in this location to provide support for the adjustment Clutch Offset Inspection NOTE P roper offset aligns the fixed sheaves of both clutch assemblies This allows the clutches to be aligned throughout the shift range 1 Remove drive belt Belt deflection adjustments affect offset Set belt deflection first 2 Install proper alignment tool depending on type of clutch as shown in Ill 1 3 Rear of driven clutch moveable sheave should just contact tool when clutch is pushed inward on jackshaft Clutch Alignment Tools P85 5 8 Offset PN 2870426 P85 Electric Start 1 Offset straight edge Clutch Offset Adjustment 1 Determine direction driven clutch needs to be adjusted Refer to Clutch Offset Inspection procedure above Remove driven clutch retaining bolt and remove driven clutch Add or take out washers on jackshaft between the driven clutch and jackshaft
285. shaft rotates smoothly and does notbind Rotate the bearings so thatthe anti rotation pins rest in their appropriate galleries 5 Apply 3 Bond sealer to top half of crankcase Lubricate oil pump drive gear 3 Bond 1215 PN 2871557 120 Gram Tube 6 Install the upper case half 7 Turn the crankcase over and torque the case bolts in sequence illustrated in beginning of chapter Crankcase Bolt Torque 16 6 18 ft lbs 22 25 Nm Gp POLARIS 3 21 O ENGINES Engine Assembly Continued 8 Install pistons with arrow on piston facing flywheel with locating pins to intake side Install C clips securely in piston groove 9 Lubricate rings and pistons with two stroke oil Install rings with letter mark or beveled side facing upward 10 Install the reed valves in the crankcase After installing the reed valves insert the base gaskets 11 Install each cylinder Torque cylinder base nuts in sequence illustrated in beginning of chapter Cylinder Base Nut Torque 24 28 ft lbs 33 39 Nm ENGINES O Engine Assembly Continued 12 Install the cylinder head gasket with the EX on the exhaust side and UP on the intake side of the engine 13 Insert the dowels into the flywheel housing NOTE Refer to picture for proper installation of alignment dowels 14 Tighten flywheel housing to crankcase G POLARIS O ENGINES Engine Assembly Continued
286. sheave 1 4 turn counterclockwise 6 Force helix down into place exposing snap ring groove 5 26 The helix spring should always be adjusted within its limits before a helix change is performed The normal rate of change between helix angle steps is 250 RPM under full throttle This is approximately the same result as in going from the No 1 to No 4 spring position P 85 NOTE Increasing spring tension increases engine RPM RPM changes may not be evident if other drive or driven clutch components are substandard NOTE All R Series Mod M T1 and 40 36 helix ramps are cut 0 060 deeper in the snap ring pocket These are made so the driven clutch can open far enough for full shift out with wide 1 7 16 belts If these helix ramps are used with narrow belts 2 two additional for a total of three 030 8 mm washers PN 7556804 should be installed under the snap ring to prevent the belt from touching the inner hub at full shift which can cause belt failure Wide belt models use only the existing washer underthe snap ring Gp POLARIS DRIVE DRIVEN CLUTCHES Assembly Cont 7 Install retainer spacer washer s and snap ring Snap ring should be installed with flat machined side up or toward jackshaft bearing NOTE On models equipped with snap ring retainers as shown below retainer may stay on back of snap ring when clutch is Preload removed Pry lightly to remove retainer and gain 1 4 turn access to
287. shes the weights against the rollers the moveable sheave will force the belt to climb up the drive clutch sheave and increase vehicle speed Pp es D MMC ENGINE OPERATING RANGE 250 REM _ Ss SEEN MIN 6000 a D d ENGAGEMENT ve 4000 3000 If the weights are too light or the spring rate too high the maximum RP M will be too great and the drive belt will not move into high gear at the top of the clutch DRIVE DRIVEN CLUTCHES ENGAGE ME Mira 3000 If the weights are too heavy or spring rate too low the engine RPM will be low and the drive clutch will upshift too fast keeping the engine out of its power band 9000 8000 7000 NG o ENGINE OPERATING RANGE 250 RPM E 000 AE 5000 __ _ ENGAGEMENT 3000 If the weights and spring are matched properly the engine RPM will go to the desired range and remain there on both upshift and backshift DRIVE DRIVEN CLUTCHES The driven clutch operates in conjunction with the drive clutch Its function is to maintain drive belt tension pre venting slippage and sense variations in load requirements necessary to maintain optimum engine torque output and load requirements from the track Output torque is transmitted through the chaincase jackshaft and chain case to the front drive shaft and track When the load on the driven clutch is increased and becomes greater than the torque delivered
288. sion given on the set up decal and adjust bottoms too easily torsion spring blocks accordingly or install optional torsion springs to achieve correct sag dimensions Increase shock compression damping by turning screw clockwise RMK or rotating knob towards right side of machine Vertical Edge Fig 3 4 Rear suspension Check for binding suspension components and grease all pivot paints rides too stiff Check the sag dimension given on the set up decal and adjust torsion spring blocks accordingly or install optional torsion springs to achieve correct sag dimensions Decrease shock compression damping by turning screw counter clockwise RMK or rotating knob towards left side of machine Vertical Edge Fig 3 4 Too much weight Check the sag dimension given on the set up decal and adjust transfer when climbing torsion spring blocks accordingly or install optional torsion springs to achieve correct sag dimensions Move limiter strap on front torque arm to high position Fig 2 Too little weight Check the sag dimension given on the set up decal and adjust transfer when climbing torsion spring blocks accordingly or install optional torsion springs to achieve correct sag dimensions Move limiter strap on front torque arm to low position Fig 2 Front end pushes Check for worn skags Check for binding front suspension and steering components grease all pivot points elevate front of machine Check the sag dimension
289. sion pivot shafts S Lubricate both front ski pivots at fitting as shown using Polaris All Season grease S Grease jackshaft and driveshaft clutch side bearings S Use an aerosol lubricant on the steering post support bracket S Grease steering post lower pivot S Grease center steering arm bell crank pitman arm and Grease Gun Kit PN 2871312 idler arm where applicable Polaris Premium All Season Grease 14 oz PN 2871423 NOTE A grease gun kit complete with grease and adaptors is available to lubricate all fittings on P olaris snow mobiles Jackshaft Bearing Greasing Loosen driven clutch retaining bolt and pull clutch outward to ex pose bearing Use a pointtype grease gun fitting to inject grease through hole in flangette into bearing until grease purges out in side or outside bearing seal Push clutch back onto shaft and re Driveshaft place clutch retaining bolt Grease Gun Adapter 2871174 Point Type Driveshaft Bearing Greasing Inject grease into fitting on speedometer drive adaptor until grease purges out inside or outside bearing seal Water Pump Belt Tension 700 and 800 Domestic big block Twins The water pump belt on 600 RMK 700 RMK and 800 RMK domestic big block twin snowmobile engines should be inspected every 1500 miles Belts should be inspected by measuring the width at several locations around the belt Belt width at any location should notbe thinner than 250 6 35mm
290. snap ring Refer to illustration below Snap ff Ring Retainer NOTE Always install snap ring with chamfer towards helix sharp edge out ward 8 Allow sheaves to close Test clutch by pre loading movable sheave 1 4 turn counterclockwise and releasing Sheave should open and close smoothly with a positive stop Some helix ramps have more than one washer beneath the snap ring DRIVE DRIVEN CLUTCHES Installation 1 Install proper number of spacer washers on jackshaft between clutch and jackshaft bearing Inspect ackshaft Bearing Excessive vibration or abnormal drive belt wear can be caused by a worn bearing or jackshafton the driven clutch side To inspect bearing fit watch the bearing area closely as you try to force the jackshaft up and down If movement is detected disassemble to determine which parts are worn Replace the jackshaft if the new bearing is loose on the shaft The bearing should be greased at 1000 mile 1600 km intervals and before storage NOTE S pacer washers between driven clutch and jack shaft bearing set the offset Refer to adjustment proce dure on page 5 33 to adjust offset between the drive and driven clutch 2 Lightly grease jackshaft keyway or spline With square key in place P 85s slide clutch onto jackshaft 3 Install spacer boltand washer to hold driven clutch in place Driven Clutch Retaining Bolt Torq
291. ssure valve assembly O ring WARNING Nitrogen gas is under extreme pressure Use caution when releasing nitrogen gas from shock Protective eyewear should be worn to avoid risk of in jury CAUTION Allow all the gas pressure to escape be fore proceeding with the removal ofthe pressure valve assembly Pressurized gas and shock oil could eject the valve assembly from the cylinder resulting in bodily injury Using a slotted screwdriver remove the pressure valve assembly from the lower end mount Accountfor an O ring PICTURE 5 Using an adjustable face spanner P N PS45262 fully loosen and remove cylinder head assembly PIC TURES 6 7 Pour the oil out of the shock body Discard old oil into an approved storage container and dispose appropri ately Never reuse damper oil during shock rebuild Using the I F P extraction tool thread the tool into the F P and pull upwards removing the I F P from the shock body Account for wear band and an O ring PICTURE 8 Note Not applicable for emulsion shock P N 7041992 Clean the inside of the shock body using clean parts cleaning solvent and blow dry using compressed air 7 38 Gp POLARIS Place the shock piston rod upper mount in bench vise begin piston and valve removal Arrange parts re moved in the sequence of disassembly The piston should have the flat slots facing the nut end as high lighted in black PICTURE 9 Items to inspect Piston rod for strai
292. steering tie rod ends C to steering arms Itmay be necessary to loosen the tie rod adjustment jam nuts B and adjusttie rod length A as required until rod end studs can be installed in steering arm Torque tie rod end attaching nuts to 28 30 ft lbs 39 41 Nm If tie rod adjustment was necessary do not tighten them until toe adjustment is complete o BODY AND STEERING Carbide to Ski Placement A good starting point for placement of carbide is 50 50 5096 forward and 5096 behind the ski mounting bolt This can be varied depending on the aggressiveness ofthe car bide and the strength of the driver Make sure the leading edge of the carbide has a small chamfer More carbide trailing will cause the machine to track straighter but steering effort will increase 50 50 5 5 60 40 6 4 Indy Select Ryde AFX IFS Shock Snowmobiles equipped with adjust able compression damping IFS shocks will allow the driver to make adjustments to the compression valving of the front shocks by turn ing the screws located near the base of the shocks By turning the screw clockwise the compression of the shock is in creased stiffening the ride By turn ing counter clockwise the com pression is decreased softening the ride The factory setting is inthe softest position Screw all the way out counterclockwise If bottom ing occurs the compression damp ing should be used in conjunction with the spring
293. t 1 After clutch offset has been verified inspect alignment 2 Install proper alignment tool depending on type of clutch as shown in Ill 1 page 5 33 3 There should be a 060 090 1 5 2 25 mm gap between front of driven clutch and tool with the tool justtouching atthe rear Up to 125 3 1 mm gapis acceptable in the front on new machines Clutch Alignment Adjustment 1 Loosen all 4 engine mounting bolts 2 Adjust engine torque stop until clutches are in proper alignment 3 Tighten engine mounts securely Recheck both clutch offset and alignment 5 Verify proper torque stop adjustment Torque Stop Adjustment NOTE T here are two types of torque stops currently used Refer to the illustrations below for adjustment of each type 1 After aligning clutches adjust torque stop by loosening lock nut and rotating stop to proper clearance as shown Hold torque stop and tighten jam nut to 15 17 ft Ibs 20 7 23 5 Nm CRANKCASE TORQUE STOP ENGINE MOUNT TORQUE STOP Adjust gap between stop and engine mount to 010 030 25 75 mm 005 13mm i E CES nn Adjust gap between stop and engine crankcase to 100 2 5 mm 010 25 mm Belt to Sheave Clearance Inspection NOTE T he distance between the belt and the moveable sheave on the drive clutch is very important This dis tance controls the starting ratio lowest starting ratio is most preferable and the position of the clu
294. t 6 Whenscrew is loose hold throttle to wide open Turn offset nut clockwise to raise or counterclockwise to lower until throttle slide is in same position as base carburetor 7 Tighten phillips head screw 8 Replace top caps Gp POLARIS 4 31 O FUEL SYSTEM CARBURETION Choke Adjustments With the dash mounted choke control toggle flipped to the full off position the choke plunger must be seated on the fuel passage way in the carburetor If the plunger is not seated on the passage way the engine will flood or run too rich causing plug fouling and very poor engine perfor mance If cable slack is too greatthere will be excessive toggle free play resulting in hard starting Also the half on position used for intermittent applications will not function If the choke lever assembly becomes damaged a lever kit is available This allows replacementofthe leverassembly rather than the entire cable assembly Installation instruc tions are included with the kit Adjustment Procedure 1 Flip choke toggle to full off position 2 Loosen adjustment locknut A on carburetor s 3 Turn cable sleeve adjusting nut B clockwise on carburetor s until 1 4 6 cm or more choke toggle free play is evident 4 Turn cable sleeve adjusting nut counterclockwise on one carburetor until toggle has zero free play then rotate it clockwise until 1 8 1 4 3 6 cm toggle free play is evident 5 Tighten adjustment lo
295. t Torque Crankcase Torque 8mm Crankcase Torque 10mm Flywheel Torque 1 18 5MB N 0 016 0 022 0 40 0 55mm 33 8x0 4cc 27 cc 6800 RPM 1600 RPM 3800 RPM 18 19 5 ft lbs 25 27 Nm 24 28 ft lbs 33 39 Nm 16 6 18 ft lbs 23 35 Nm N A 60 65 ft lbs 83 90 Nm Gp POLARIS GENERAL INFORMATION d MODEL INDY TRAIL RMK MODEL NUMBER SO2SR5BS ENGINE MODEL EC55PM024 ELECTRICAL CAPACITIES Flywheel I D Mitsubishi FuelTank 11 8 gallons 44 7 liters CDI Marking 17620111 Oil Tank 3 quarts 2 8 liters Alternator Output 240 Watts Coolant N A Ignition Timing 27 BTDC 3500RPM 1 5 Chaincase Oil 9 fl oz 266cc 0 175 BTDC 0 157 0 195 4 45mm BTDC 3 97 4 93mm Spark Plug Gap NGK BR9ES 0 028 0 7mm Voltage Regulator LR7 Electric Start Option LR7 Full wave voltage regulator Magneto Pulses 6 SUSPENSION CHASSIS CHAINCASE Body Style Gen II Sprockets Chain 18 41 68P HYVO Front Suspension Indy XTRA 38 Reverse Option FrontShocks Nitrogen Cell Brake Pads Type 81 Small IFS Spring Rate 80 in Chaincase Center Dist 7 05 17 9cm Front Spring Preload 5 16 Thread Adjust Driveshaft Sprockets 2 Drivers Front Vertical Travel 8 25 21cm Brake Type Polaris HPB Rear Suspension XTRA Lite 136 Rear Axle Tra
296. t least 1 2 1 27 cm of brake fluid in the reservoir to prevent air from entering the master cylinder 10 Tighten bleeder screw securely and remove bleeder hose 11 Add brake fluid to the proper level 12 Install diaphragm cover and screws Tighten screws to specification Reservoir Cover Torque 15 18 in Ibs 1 7 2 1 Nm Es BRAKES FINAL DRIVE Brake Bleeding Fluid Change Cont 13 Field test machine before putting into service Check for proper braking action and lever reserve With lever firmly applied lever reserve should be no less than 1 2 1 3 cm from handlebar No Closer Than 1 2 1 3 cm Brake Lever Reserve Limit Not less than 1 2 1 3 cm from handlebar 14 Check brake system for fluid leaks BRAKES FINAL DRIVE Es Hayest Master Cylinder Cover Screw Kit Cover Asm Kit Incl 1 3 Cover Gasket Parking Lever Spring Master Cylinder Assembly Screw Lever and Pivot Pin Kit Screw Body Reservoir Clamp Kit Brakelight S witch Cartridge Kit LH Control Asm Pivot Pin Kit Parking Lever and Spring Kit DEn oJ SEES PRR BRUNO Park Brake Lever Lock Release park brake lock before driving or brake system failure or fire may result Apply brake lever to release Hayest Master Cylinder Removal 1 Position clean shop cloths to catch spilled fluid CAUTION Brake fluid will damage finished surfaces Do not allow brake fluid to come in contact with
297. tached to the 3 bar slide on the hold down strap will aid in this process NOTE Use the rear two holes for a longer length seat and the forward two holes for the standard length seat Gp POLARIS BODY AND STEERING Seat Cover Seat Bucket Hold Down Strap Seat Foam For Use With Long Seat Storage Box Area Plastic Seat Base 6 27 g BODY AND STEERING 7 Tum the assembly over and begin upholstering by lining up the seat cover vinyl side flaps with the indented square location indicators located on the plastic seat base as shown in Ill 1A CAUTION Apply staples in the stapling channel only See Ill 1 If you apply staples outside the channel you will damage the fuel tank reservoir in the seat base If this happens you must replace the entire seat base assembly 8 Usinga staple gun tack each side ofthe vinyl cover in place using two Staples If cover has a Polaris emblem carefully align emblem with bottom edge of seat This will help ensure that the cover is positioned properly 9 Align the two sewn seams located atthe rear of the seat cover with the two back corners ofthe seatbase See Ill 1 Pull the vinyl tight and tack the seat cover to the plastic seat base in each corner Use two or three staples per corner 10 Now that the seat cover is correctly positioned and tacked to the plastic seat base in four places turn the assembly over and inspectit If the seat cover seems to fit correctly a
298. tch weight to engine RPM The distance between the belt and move able sheave should be as close to 020 5 mm as pos sible withoutcreating a drag on the belt when positioned around the hub at the bottom of the sheaves 1 Force belt to one side of drive clutch NOTE Measure total belt to sheave clearance with a new belt 2 Install feeler gage between other sheave and belt Belt to Sheave Clearance 020 015 5 mmz 4mm Belt to Sheave Clearance Adjustment Belt to sheave clearance can be adjusted in two ways l Try several new belts to achieve proper clearance 2 Can add or remove shims from under the spider to increase or decrease beltto sheave clearance See Spider indexing on page 5 21 NOTE S pider indexing affects clutch balance and belt to sheave clearance Read procedures carefully before proceeding NOTE Belts with various widths will also affect belt deflection since they will fit differently in the driven clutch Deflection should be checked per procedure on page 5 32 Gp POLARIS DRIVE DRIVEN CLUTCHES Force belt to one side 5 35 DRIVE DRIVEN CLUTCHES Kit PN 2871025 Item Qty Part Description Part No 1 1 P 85 Drive Clutch Moveable Bushing 5020627 Removal and Installation Tool 2 1 P 90 Drive Clutch and Driven Clutch 5020628 Bushing Installation Tool 3 1 Drive Clutch Cover Bushing Removal and 5020629 Installation Tool for all drive clutches 4 1 P 85 Driven Clutch DU S pl
299. ted behind driven clutch area 2 Remove fuel cap and grommet 3 Remove fuel lines 4 fmachine is equipped with gauges unplug gauge wires 5 Remove two bolts in tool box Disconnect taillight wiring 7 Remove two console bolts attaching console to tunnel 8 Remove two console bolts located under hood 9 Remove fuel cap and lift console up Replace fuel cap 10 Lift up at rear of seat and slide out Seat Cover Replacement l 2 Remove seat assembly as outlined on page 6 26 Remove seat and seat covering to be replaced Carefully remove staples by loosening with a small flatblade screwdriver P ull each staple straightout with a pliers Onsome models itwill be necessary to drill outthe rivets holding the strap buckles Reach inside the tool box and rotate the D ring buckle which secures the center hold down strap Push the D ring through the slot in the tool box and carefully pull it through the foam cushion Reassembly Note Forease of assembly hook a wire to the center strap This will allow you to pull the center strap back through the foam and into the storage box Place the seatfoam on the seatbase assembly as shown in Ill 1 Drape the seat cover over the seat foam Insert and pull the two seat bucket hold down straps attached to the seat cover through the two holes in the seat foam and the routed out holes located in the storage box area on the plastic seat base HINT A stiff wire at
300. than 5 16 7mm into flywheel threads or stator damage may result Flywheel Puller PN 2871043 Disassembly Continued 13 Remove the flywheel 14 The stator plate can be removed without taking off the stator 15 Remove the oil pump taking note of the o ring and shim s Gp POLARIS ENGINES O 3 17 A ENGINES Disassembly Continued 16 Remove the cylinder head 17 Remove the head gasket During removal note that the head gasket is stamped with EX and UP 18 Loosen and remove each cylinder 3 18 Gp POLARIS ENGINES O Disassembly Continued 19 Remove the reed valves from the crankcase 20 Using an awl and piston pin puller remove the pistons CAUTION Wear eye protection during piston c clip removal to prevent eye injury Piston Pin Puller PN 2870386 21 Turn crankcase over and remove the crankcase bolts Turn over and separate the case halves 22 Refer to General Inspection section for crankshaft inspection and measurement procedures O ENGINES Engine Assembly 1 Priorto assembly make sure thatyou have all of the oil pump shims when the oil pump was removed and that the shims are installed in the correct order 2 Insert oil pump drive gear 3 Insert oil pump driveshaft spacer 3 20 Gp POLARIS ENGINES O Engine Assembly Continued 4 Lay crankshaft into the lower case half Make sure thatthe crank
301. the center of the rear idler wheel 4 Checkforproperslack between the track clip wearsurface andthe hi fax C NOTE Measure atthe point where the weight is hanging Measurement Location Measurement 10 Ib Weight 4 5 kg If the track needs adjustment 5 Loosen rear idler shaft bolts D on both sides of the machine 6 Loosen track adjusting bolt locknuts A 7 Tighten or loosen the track adjusting bolts B evenly as necessary to obtain proper track tension 8 Tighten idler shaft bolts and adjuster bolt locknuts NOTE Track alignment affects track tension Misalignment will cause excessive wearto the track and slide rail Excessive Hi Fax wear will appear on units with track tension set too tight MAINTENANCE TUNE UP Spark Plug Selection Original equipment parts or their equivalent should always be used However the heat range of spark plugs is of utmost importance A spark plug with a heat range which is too high will cause engine damage A spark plug with a heat range which is too low will cause excessive fouling In selecting a spark plug heat range for production a manufacturer is forced to assume that the engine is going to be operated under extreme heavy duty conditions This protects the engine from internal damage in the event that the purchaser actually does operate the engine in this manner This selection however could cause the cus tomer who normally operates the engine under medium or light
302. the full travel of the ski shock with occa sional light bottoming CAUTION If the plastic nut is unscrewed from the threaded body the nut will break Always leave one thread showing above the plastic nut or the spring coils will stack resulting in damage For the best ride the spring preload should be as low as pos sible Set the preload to use the full travel of the ski shock with occasional light bottoming To determine if your machine is us ing full travel push the shock jounce bumper down as far as it will go on the shock rod and test ride the machine The bumper will move up on the rod in direct relation to the amount of travel For example if the shock travel is full the bumper will be seated at the top of the shock SRemove the existing spring and install the next highest rate spring or SReduce the preload on the existing spring and change the shock valving to obtain the desired effect NOTE Shock valving can only be adjusted or changed on models equipped with Ryde FXt Indy Select or Foxt shocks Gp POLARIS SUSPENSIONS Turning clockwise increases preload Low Preload PA High P reload Always leave at least one thread showing above nut Puch Shock rod jounce ae bumper down as far as it will go on shock rod E gt 7 17 SUSPENSIONS Changing shock valving on models equipped with Ryde FXt orFoxt shocks requ
303. throttle cable freeplay to 010 030 25 8mm See figure 1 4 Verify that carburetor slides leave their resting position within 01 to 03 of throttle cable movement not throttle lever movement 5 Verify that oil pump alignment lines are aligned at the point where the carburetor slides begin to rise from their resting positions See figures 3 and 4 Gp POLARIS A ENGINES Cooling System Never remove the pressure cap when the engine is warm or hot If the pressure cap is to be removed the engine must be cool Severe personal injury could result from steam or hot liquid Use of a non standard pressure cap will not allow the recovery system to function properly If the cap should need replacement install the correct Polaris cap with the same pressure rating Refer to the appropriate parts manual NOTE Always use Polaris premium antifreeze 60 40 premix Bleed system at specified RPM or air will remain trapped in system which may result in overheating Filling and Bleeding Procedure Remove Cap To Bleed If the cooling system should become low in the reservoir tank and or filler neck the system should be bled of any trapped air using the following procedure Domestic Twins Bleeding Procedure 1 Fill cooling system Leave pressure cap off Bleed Screw 2 With engine running at specified idle speed loosen bleed screw on thermostat housing 3 Continue adding antifreeze mixture to reservoir until system is pur
304. tighten adjuster and rear shaft bolts to specification 3 8 Suspension Bolt Torque 35 40 ft Ibs 48 3 55 2 Nm 7 16 Suspension Bolt Torque 45 50 ft Ibs 62 1 69 Nm BRAKES FINAL DRIVE Es Final Assembly 1 Check speedometer cable routing 2 Greaseangle drive and bearing with P olaris grease Polaris Premium All Season Grease PN 2871423 3 Torque bottom chaincase sprocket bolt to specification Bottom Chaincase Sprocket Bolt Torque 19 ft Ibs 26 2 Nm 4 Torque jackshaft nut to specification On models with castle nut if cotter pin does not align tighten nut until it does Apply brake to hold jackshaft while torquing J ackshaft Castle Nut Torque 50 ft Ibs 69 Nm 5 To obtain correct chain tension place a slight reverse tension on the chain as indicated in the illustration at right 6 There should be approximately 1 4 3 8 6 95 cm total deflection on the chain at point B Loosen adjuster bolt locknut and turn adjuster bolt C until correct chain deflection is obtained Chain Deflection 1 4 3 8 6 95 cm Es BRAKES FINAL DRIVE Final Assembly Cont 7 Tighten adjuster bolt locknut A securely while holding the adjuster bolt B 8 Install chaincase cover gasket in chaincase with gapatthetop Install chaincase coverand torque cover bolts to specification Chaincase Cover Bolt Torque 8 10 ft Ibs 11 14 Nm Spring
305. timing position mark the flywheel with chalk or a white marker directly in line with the stationary pointer or line on the fan or recoil housing through the timing inspection window 19680 z 2246 09 0 L0SV6 0 26 ereo rozze 28238 10818 Scoto 96821 91620 eoov7 zeeoz 95999 89720 E6929 ezoe 9 oeezo s2865 90220 e9195 ecec e po96 y SIE S908 o overs EPGEO 98658 96998 b6PI 8 SEL 90870 coz oe eree z 09900 zcsz9 e sovoo ziszo vzeco ve 2081 9 25185 60120 0289 1 EScE 999679 86 99 s 88 0 FCO 0970 eo es6z0 0097 66 70 66012 67920 20sz 0 6sezo esol PL6Z O EvSS ba co N 9rce o 2066 S 90970 8sez 0 peges 6izeo voces ekzz o E2070 08020 25610 80267 eso E 80910 86710 zoog 06210 6942 LL 16110 28562 96010 evezz Skizz s0010 rese zslpz 21600 vezez zeve 2 eesoo cori eoz 5700 oe161 69281 42900 s6171 BIER s0900 esce Ers 9e50 0 22700 8ottL zivoo ostoi 88860 sseo 0 z060 0800 95200 vipgo Lizo o 141000 seloo zereo POLO O c 8c S 6292 S BEIER 6120 S 6862 LJ trr 61086 20156 0ez e 80967 2027 Ze cerez v66
306. ting S P 85 driven clutches have 1 spring locat ing hole in the movable sheave and 4 holes in the helix NOTE The driven clutch helix moveable assembly has several different spring locations which affect clutch shift ing and RPMs Tighter spring tension will raise engine RPMs during clutch upshift and allow quicker downshift when pulling or negotiating a hill The lighter tension posi tions will tend to have a slower downshift and a harder up shift 4 Align inner keyway between the helix and movable sheave With the spring in place slide helix onto shaft 5 12mm Gp POLARIS DRIVE DRIVEN CLUTCHES Assembly Cont Helix Angles and Effects The driven clutch helix was selected for overall performance in relation to the other driven system components In fine tuning situations requiring a slight adjustment of engine operating RPM or improved backshift we recommend trying a helix change before changing other components Polaris has several helix angles available for the P 85 and P 90 driven clutch Refer to the chart below for specific angle effects and identification Helix Ramps Description PN Degrees Type 3 x a 5130724 40 LEE P35 R6 RG 5131292 42 34 LEE RI R3 365 5130383 365 p90 103036 5131161 40 38 36 P30 3636 51362 3636 P30 353634 5131163 36 36 34 P30 mr penes fro 5 Hold fixed sheave and turn movable
307. tion ofthe suspension for the bump reducing secon dary kick back TheFRSS is made of a resilient material allowing smooth action and preventing any suspension componentdam age This unique feature is applied to the XTRAt 10 rear suspension Patents are pending Front Torque Arm FTA Rear Scissor FRSS with short low leg to rear Note the front torque arm must collapse further to collapse rear Susa rm Front Torque Arm FTA Rear Scissor FRSS RRSS FRSS with long high leg to rear Note this forces rear scissor to collapse with less front torque arm movement than when in short position This keeps the rails more parallel to the chassis SUSPENSIONS The RRSS controls weight transfer from the rear sus pension to the skis It also influences the stiffness of the ride by controlling the amount of coupling action be tween the front and rear torque arms To increase the stiffness of the suspension the RRSS should be set in the high position NOTE OnXTRA 10and EDGE models only the RRSS can be totally removed for maximum weight transfer However unless the torsion springs and rear shock valv ing are changed the ride will be compromised Always maintain equal adjustment on both sides Be sure rear scissor stop face is square with the face of the scissor arm to ensure complete contact Rear Spring Tension Rear spring tension adjustments are made by rotating the eccentric spring block A as shown with the
308. tle Gap 89 Oxygenated aoo 300 ya Ps em ga 2 Under Cutaway 218 5 54mm X refers to the clip position from top of jet needle CLUTCH Type ick Goat Eats P 85 Beli venei cS 3211070 Belt Width Projected 1 375 34 93 Side Angle Overall 28 Outside Circumference 47 250 120cm Center Distance 12 00 CLUTCH CHART DRIVE DRIVEN Altitude Shift Clutch Clutch Driven Chaincase Weight Spring Spring Helix Gearing Meters 0 900 10 62 Dark Blue Silver R 32 18 41 68P Feet 0 3000 Bushed White Blue 2 HYVO Shift Weights 10 56 Bushed Silver R32 i F 3000 6000 Bushed White Blue 2 HYVO S amaw gt pring T Dark Plae White 1800 2700 10 56 Dark Blue Silver R 32 18 41 68P GE leg SE 6000 9000 Bushed White Blue 2 HYVO riven Helix zl Eb Production Setting ENGINE TP Fan Cooled Reed Assist Twin Displacement 544cc Fuel Pump Manuf Taiyo Bore RA tma hens 2 874 73mm Fuel Pump Mark FJ P 3 100 KEEN 2 559 65mm Oil Pump Manuf Mikuni Piston Cylinder Clearance 0 0035 0 0049 0 09 0 125mm Oil Pump Mark 55MB Service Limit 0 0078 0 20mm Cylinder Head Mark EC55PM Piston Marking Piston Ring Marking Piston Ring End Gap Head ccs Uninstalled Head ccs Installed Operating RPM 200 Idle RPM 200 Engagement RPM 300 Cylinder Head Torque Cylinder Base Nu
309. to idle Engine runs but overloads with fuel Carburetion and plug fouling Engine runs but overheats Battery will not charge battery equipped mod els only 3 72 Check ignition switch for run position moisture contamination Check auxiliary shut off switch operation Check fuel supply Check wiring from engine to coil s or spark plug s Check spark plug s Disconnect engine connector to eliminate any shorts that might be in the system If starter won t work electric models check wires from starter solenoid and battery or check battery and battery cables Open or broken reed valves Crankcase plug is out Head gasket faulty Poor ring sealing piston damage Spark plug fouled Secondary coil faulty or wires disconnected poor ground on secondary coil mount Primary coil shorted or open Ignition switch shorted contaminated with moisture Auxiliary switch shorted or contaminated with moisture Restricted fuel flow air flow Clogged main jet Timing Clutching Engine not running on all cylinders Clogged fuel filter Incorrect track tension Incorrect main jet Throttle slides not fully open Chain too tight Clutching Excessive driveline friction HiF ax overheating Engine not running on all cylinders Incorrect air mixture setting Throttle stop screw incorrectly adjusted Restricted pilot jet Low compression Tight belt Piston damage Enricher plunger not seating p
310. tool Be prepared to catch piston ring and piston as itcomes out Remove Allen screw from center of piston Inspectbleeder screw O ring and IFP sealing O ring for wear or damage Replace O rings upon reassembly 12 Carefully clean all parts thoroughly with electrical contact cleaner or solvent and dry with compressed air Inspect shock body for scratches or wear 7 30 Gp POLARIS SUSPENSIONS Fox Shock Maintenance Assembly 1 Install bleeder screw in IFP until O ring is lightly seated NOTE Bleeder screw must be positioned toward body cap externally threaded end of shock body 2 Compress flexible piston ring around valve piston and install piston into shock body 3 Screw in bearing cap by hand until O ring is fully seated 4 Invert shock and mount bearing cap flats lightly in vise Caution Be sure damper rod is fully extended 5 Fill with shock fluid to approximately 1 2 54cm from end of body SUSPENSIONS Fox Shock Maintenance Assembly Cont 6 Insert IFP 7 Install body cap until O ring is lightly seated 8 Mountshockin vise by top eyeletas shown Support shock and strike body cap end 2 3 times with a soft faced hammer to remove all air trapped inside the valve piston Allow shock to stand for 3 5 minutes CAUTION Do not over tighten vise or bearing cap may be damaged 9 Unscrew body cap and remove 10 Remove IFP bleeder screw Remove ge t
311. tor dial to V setting 4 Connect test leads parallel with test component Observe polarity Usage Test battery voltage Test DC regulator Test voltage drop for bad connections Test supply voltage to electric fuel gauge Nun un Gp POLARIS 9 1 ELECTRICAL Multimeter Usage Q Ohms resistance measuring component resistance values testing coils wiring etc Used to test resistance to the flow of electricity in a circuit or component A reading of OL means an open circuit or infinite resistance Sometimes the leads themselves will have some resistance Touch the leads together and subtract this resis tance from the component reading to achieve the actual reading Test Method 1 Connect black lead to Com meter terminal 2 Connect red lead to VQ meter terminal 3 Turn selector dialto O setting 4 Isolate test component from the rest of the electrical circuit by disconnecting wires from harness 5 Connecttest leads to the circuit to be tested Usage S Testing coil resistance S Testing switch operation S Testing wire continuity A Amps AC used to test lighting coil output Used to test the power of an alternator coil Test Method Connect black lead to Com meter terminal 14 00 AC Connect red lead to 10A meter terminal Disconnect engine harness from system Connect across the specified coil wires Start engine and let it idle Readings should be above 5 Amps atany RPM NOT
312. transferred to the track pulling itforward This energy also tries to pull the suspension forward The front torque arm reacts to this force by pushing down on the frontofthe track in effectap plying more weight to the front of the track and reducing the weighton the skis Itis important to note that energy used to lift the front of the machine is not available to push the vehicle for ward Changing the angle of the front torque arm changes the suspension s reaction to the force Adjusting the length of the limiter strap will change the front torque arm angle Shortening the strap limits the extension of the front of the suspension reducing the angle ofthe torque arm and increasing ski pressure during acceleration Length ening the strap allows the front of the suspension to extend further increasing the angle of the torque arm and decreasing ski pressure during acceleration Limiter strap adjustmenthas a greataffecton weighttransfer LImit er straps only affect acceleration Itis importantto check track tension whenever limiter strap length is changed Front track shock spring preload also affects weight transfer A stiffer spring and or more preload on the spring transfers more weightto the track A softer spring and orless preload keeps more weight on the skis Keep your riding application in mind when choosing springs and setting spring preload Soft springs preload will increase ski pressure but may bottom out Stiff springs preload
313. ue 15 ft Ibs 20 8 Nm 4 P 85 driven clutches should float from side to side 040 080 1 2 mm Without a slight free float jackshaft bearings could be side loaded causing premature bearing failure Driven Clutch Torque Float P 85 040 080 1 2 mm DRIVE DRIVEN CLUTCHES Drive Belt Belt Width Side Projected Angle Overall Center ference 3211042 1 375 1 e 47 250 Common production belt for P 85 systems 34 93mm 3211045 1 375 12 00 47 125 Close tolerance version of 3211042 34 93mm 3211058 1 250 11 00 43 313 Indy Lite belt P 90 31 75mm 3211059 1 250 12 00 45 125 Longer Indy Sport Belt P 90 31 75mm 3211061 1 375 12 00 47 188 CVT version of 3211045 34 93mm 3211065 1 438 12 50 48 375 CVT Double Cog Storm belt 36 53mm 3211066 1 375 12 00 47 250 Double cog CVT thicker than 3211070 Pro 34 93mm duction on higher horsepower snowmobiles 3211067 1 375 12 00 47 250 Double cog Good for short runs on higher 34 93mm horsepower engines Drag Racers Good for lower horsepower trail riding 3211070 1 375 28 12 00 47 250 Common production belt for late model P 85 34 93mm systems 1997 current 3211073 1 438 12 50 48 375 Double cog Good for short runs on higher 36 52mm horsepower engines Drag Racers Good for lower horsepower trail riding 3211074 1 438 12 00 47 625 Double cog Good for short runs on hi
314. ue Front 28 Ft Ibs 67 Nm Rear 28 Ft lbs 67 Nm A ENGINES Engine Installation Typical Cont 6 Apply a light film of Polaris dielectric grease to all connections Connect all stator connections and temperature switch Nyogelt grease PN 2871329 1 4 oz 7 Connectoilsupply line to oil pump Bleed oil pump by opening bleed screw until oil flows steadily Tighten bleed screw securely Install throttle cable to oil pump and check adjustment Refer to General Inspection Procedures in this chapter for oil pump adjustment procedure 8 Install carburetors and tighten clamps Make sure hoses and cables are routed correctly 9 Connectoil lines to carburetors ENGINES O Engine Installation Typical Cont 10 Install coolant hoses where applicable Make sure hoses are routed properly and hose clamps are positioned and tightened securely 11 Route and install recoil rope to chassis 12 Install starter and starter cables electric start models 13 Install exhaust system in reverse order of disassembly O ENGINES Engine Installation Typical Cont 14 Install hood if previously removed 15 Install airbox 16 Secure fuel pump and CDI box 17 Fill cooling system liquid models with Polaris Premium Antifreeze 60 40 premix Polaris Premium Antifreeze 60 40 premix Quart PN 2871534 Gallon PN 2871323 18 Add a full tank of premix fuel 50 1 to fuel tank 19 Start engine a
315. ulphuric acid and is poisonous Serious burns can result from contact with the skin eyes or clothing ANTIDOTE External Flush with water Internal Drink large quantities or water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention GENERAL INFORMATION d Notes 1 13 d GENERAL INFORMATION MODEL INDY 500 SKS EUROPEAN MODEL NUMBER E025S5AE ENGINE MODEL 52209 5044PL5A JETTING CHART AMBIENT TEMPERATURE CANBBRETION Alttude A ete ene ine iot Type aes ug etn TM 38 Mikuni pb E ete WERTEN 370 0 600 3m Pro E SH SEN SES PilotJet 45 0 2000 38 43 43 8 8 8 Jet Needle 9F H4 57 3 ER 370 360 340 330 310 300 Needle Jet P 6 B B B Cutaway ener 1 5 Meters b0o 6000 320 ma a SH P Pa Fuel Mixture Screw 2 Turns 1800 2400 330 310 300 290 370 250 Valve Seat 1 5 eweg ESRB 8 8 e 9 2 Fuel Octane R M 2 87 Non Oxygenated 2400 3000 300 290 280 260 250 230 89 Oxygenated 8000 10000 43 43 2 2 2 1 Wee GE 0 098 2 5mm ie MEE M dl nder Cutaway 5m StarterJet 155 XXX Pilot Air ua 1 0 refers to the clip position from top of jet needle CLUTCH TYPE Saa P 85 CLUTCH CHART Belli 3211074 Belt Width P rojected 1 438 Altitude Shift us Clutch G
316. uring these procedures may deform the shock body cylinder Apply a thin film of oil onto the floating piston wear band and O ring and setaside ready for use Fill the reservoir to its top with shock oil Once filled immediately install floating piston into reservoir and slowly push straight down to specified depth CAUTION Care must be taken to ensure that air is not trapped between floating piston and top of oil level Any air trapped in the oil will cause a lag in the shock absorbers damping ability Apply a lightfilm ofoil onto reservoir end cap O ring and then install reservoirend cap and o ring down into the reservoir approximately 1 2 Install retaining circlip making sure it is firmly in place Tighten down the remaining portion ofthe pressure valve assembly With pliers grasp the end cap by the pressure valve assembly and pull it up into place against the retainer cir clip Fill the main shock body with shock oil to the bottom of the thread within the cylinder With the cylinder head assembly pushed down againstthe piston carefully insert the piston rod and assembly into the cylinder S lightly oscillating the piston rod to allow piston to enter shock body bore A light coating of oil on the piston wear band will ease installation SUSPENSIONS Slowly push the piston rod and assembly into shock body until the cylinder head assembly bottoms on the cylinder counterbore Slight up and down movement may be required to allow all ai
317. ust be less than 1V DC Is it No Yes Connect black tester lead to solenoid end of battery Replace starter solenoid to solenoid cable and red tester lead to solenoid end of solenoid to starter cable C Page 9 13 Turn key to start position The reading must be less than AV DC Is it No Yes Connect black tester lead to solenoid end of solenoid Clean solenoid to starter cable ends or replace to starter cable and red tester lead to starter end of cable same cable D Page 9 13 Turn key to start posi tion The reading must be less than 1V DC Is it No Yes Connect black tester lead to starter frame Connect Clean ends of engine to battery negative cable or red tester lead to battery negative terminal E replace cable Page 9 13 Turn key to start position The reading should be less than 1V DC Is it No Yes If all these tests indicate a good condition yet the starter still fails to turn or turns slowly the starter must be remove for static testing and inspection ELECTRICAL Starter Motor Static Testing iab ON S E by Zi IGNITION SWITCH IGNITION SWITCH SYSTEM BRN GROUND ALTERNATOR 6C T pou 1GNITION WIRE COLORS OUTPUT f l G TERMINAL BROWN GROUND Ka B TERMINAL RED BATTERY m M TERMINAL BLACK IGNITION daran S TERMINAL RED WHITE STARTER Lark IGNITI P z t P N F Disconnect R W Wire iN RAW OFF RUN START RECTI
318. ust t o match engine application and ma chine use Burnt Belts Premature Wear a Wrong or broken drive clutch spring a Replace with recommended spring Also see Belt Wear Burning b Drive clutch shift weight too heavy b Install correct shift weight kit to match Diagnosis Chart on page 5 45 C Driven clutch spring broken or installed engine application in wrong helix location c Replace spring refer to proper d Drive belt too long installation location e Converter sheaves greasy belt slip d Install new belt and or adjust belt page tension f Improper driven clutch setup e Clean clutches install new belt f Install correct parts and or adjust to match engine application and ma chine use 5 42 GO POLARIS DRIVE DRIVEN CLUTCHES Belt Wear Burn Diagnosis Possible Cause Of Wear Or Buming Solution Driving at or about engagement RPM for extended Drive at higher RPM if possible Gear the machine periods in all types of conditions down Make sure belt deflection is at 1 25 to achieve optimum starting ratio Cold weather startups Be patient Warm up engine at least 5 minutes or until it readily responds to throttle input For the quickest most efficient driveaway in extreme cold weather take drive belt off machine and bring it in to a warm environment Break skis and track loose from the snow Engage throttle aggressively for short durations for initial cold driveaway Towing another machine at or about engagement
319. ustration below for procedure Measure from center of one spindle to center of the other spindle with front end elevated and suspension fully extended to determine set up width Measure Set Up Width Here Do not exceed maximum O BODY AND STEERING CAMBER INSPECTION All Models Elevate Front End Shocks Installed Typical CRC Shomn Style varies by model Suspension Free Hanging With IFS Shocks Installed f Upper radius rod dium Radius Rod End Jam Nuts Attaching Bolts Refer to specifications for SFS type S pecified amount of camber To adjust lengthen or shorten appropriate lower radius rod until top of bar is within specified camber distance Measurement should be taken from top of alignment bar to top of ski pivot bushing hole in spindle bushing removed Radius rod must be re attached to trailing arm before measuring CAMBER ACCEPTABLE RANGE EXAMPLE Specified Camber 3 4 19mm Specified Tolerance 5 16 8mm Acceptable Range 7 16 1 1 16 11 27mm Refer to specifications on page 6 8 Specified Camber BODY AND STEERING Camber Adjustment 1 Determine which spindle requires the greatest amount of correction by installing the alignment bar through one side to the opposite spindle Remove the bar and install it through the other side to the opposite spindle 2 Usinga 3 8 1 cm drive 11 16 1 7 cm crow foot wrench and 20 51 cm long
320. ut to specification found in the beginning of this chapter Flywheel Holder PN 8700229 18 Install water pump belt and recoil hub NOTE See domestic twin water pump belt installation in chapter 2 Maintenance for correct belt installation Recoil Hub Bolt Torque 96 108 in Ibs 11 12 5 Nm 19 Install recoil cover and oil pump Make sure oil pump drive slot mates properly with water pump shaft 20 Install reed valve reed stuffer and reed cover ENGINES O Disassembly Cleaning Inspection VES 1 Clean O ring and bellows in warm water and mild detergent Inspect bellows for holes dis Valve cover tortion or damage Replace if necessary In spect O ring for damage Spring Valve cap 2 Clean all other parts with solvent Be sure all Bellows parts are thoroughly clean 3 Inspect the actuator port in cylinder and valve housing Be sure itis clear and not obstructed by debris or carbon 4 Carbon deposits can be removed from valve with a Scotch Britet pad or similar soft abra sive brush 5 Lubricate exhaust valve with Polaris Premium Gold 2 cycle engine lubricant Install valve in cylinder and move it through the entire travel range to check for free movement without bind Clean with Solvent ing If the valve sticks anywhere in the travel range check the valve and valve bore in the cyl inder for carbon deposits and clean if neces sary Clean with Scotch Britet or similar soft
321. vel 12 30 5cm Front Track Shock Nitrogen Cell Spring Rate 181 in Rear Track Shock Indy Select Rear Springs 347 sq 77 Track Type 15 x136 x 1 25 38 1x345 44x3 175cm Track Tension 3 8 1 2 1 1 3 cm slack with 10 4 54kg weight 16 40 64cm ahead of rear idler shaft Overall Snowmobile Length 116 295cm Overall Snowmobile Height 45 114cm Maximum Snowmobile Width 43 5 110 5cm OPTIONAL REAR TORSION SPRINGS 347 Sq Diameter x 77 375 Sq Diameter x 77 L H 7041627 067 L H 7041631 067 R H 7041628 067 R H 7041632 067 d GENERAL INFORMATION MODEL icin vires 600 EDGE RMK MODEL NUMBER SO2NJ 6ES ENGINE MODEL S2187 6044PL6E JETTING CHART CARBURETION r 2 AMBIENT TEMPERATURE Type EE TM 38 w TPS M ikuni Altitud Below 30 F 30 to 10 F 10 to 10 F 410 to 430F 430 to 50_F Above 50 F M a in J et WE eege 3 10 jtude Below 34 C 34 to 23 C 23 to 12 C 12 to 1C 1 to HO C Above 410 C PilotJet 45 Jet Needle 9DG611 60 2 nn ue E ta SN e SN Needle J et P 8 825 TEE ni Sem ai Se um 356 Cutaway 1 5 Notched 2000 4000 a 8 8 8 B FuelScrew 2 0 Turns Meters 1200 1800 380 360 350 330 320 300 Valve Seat 1 5 Feet 6000 6000 ag us
322. ver 3 Squeeze the two spring tabs on the end of the pivot pin at the same time pushing the pivot pin up through the hole 4 Remove the pivot pin and the lever 8 16 Gp POLARIS Lever and or Pivot Pin Installation 1 Install the new lever by actuating the parking brake lever enough distance for the head of the pivot pin to clear the park brake lever 2 Align the lever pivot hole with the housing pivot hole 3 Squeeze the two spring tabs on the end of the pivot pin at the same time pushing the pivot pin down through the hole until the pivot pin snaps into place 4 Reinstall master cylinder assembly Gp POLARIS BRAKES FINAL DRIVE Es 8 17 Es BRAKES FINAL DRIVE Park Brake Lever and or Spring Removal 1 Remove master cylinder cover screws and cover CAUTION Brake fluid will damage finished surfaces Do notallow brake fluid to come in contact with finished surfaces 2 Usinga small screwdriver liftlong spring arm outof its notch in the housing 3 While pulling in an upward direction with the brake lever slightly activated gently wiggle the park brake lever and spring from its pivot hole Park Brake Lever and or Spring Installation 1 Place the spring on the upper pivot post of the park lever with the formed spring arm fit into its position on the outer part of the park lever The straight spring arm will be pointing towards the back 8 18 Gp POLARIS BRAKES FIN
323. w the registered battery voltage while cranking the engine Continue the testfor 15 seconds During this cranking period the observed voltage should notdrop below 9 5 volts If the beginning voltage is 12 6 or higher and the cranking voltage drops below 9 5 volts during the test replace the battery Refilling a Low Battery The normal charge discharge cycle of a battery causes the cells to give off gases These gases hydrogen and oxygen are the components of water Because ofthe loss ofthese gases and the lowering ofthe electrolyte level it will be necessary to add pure clean distilled water to bring the fluid to the proper level After filling charge the battery to raise the specific gravity to1 270 or greater Off Season Storage To prevent battery damage during extended periods of non use the following basic maintenance items must be performed 1 Remove battery from machine and wash the case and battery tray with a mild solution of baking soda and water Rinse with lots offresh water after cleaning CAUTION Do notallow any ofthe baking soda solution to enter the battery or the acid will be neutralized 2 Using a wire brush or knife remove any corrosion from the cables and terminals Make sure the electrolyte is at the proper level Add distilled water if necessary 4 Charge ata rate no greater than 1 10 of the battery s amp hr capacity until the electrolyte s specific gravity reaches 1 270 or greater 5 The battery may be stor
324. will provide more track pressure reduced ski pressure but may result in a less comfortable ride During acceleration the rear ofthe suspension will compress and the IFS will extend pivoting the machine about the front torque arm Because of this pivoting effect rear spring and spring preload also have some effect on weight transfer Softer rear springs or less preload allow more weight transfer to the track and reduce ski pres sure Stiffer rear springs or increased preload allow less weight transfer to the track and increase ski pressure The main function of the rear torque arm is to support the weight of the vehicle and rider as well as to provide enough travel to absorb bumps and jumps Shock valving also has an effect on weight transfer Refer to shock tuning information in this chapter Scissor stops also affect weight transfer See scissor stop information in this chapter SUSPENSIONS Springs Two types of springs are employed in Polaris suspen sions coil springs and torsion springs Following is some of the terminology used when referring to coil springs S Coil Spring Freelength the length ofa coil spring with no load ap Length plied to the spring Installed Length Installed length the length of the shock absorber be tween the spring retainers Ifthe installed length ofthe spring is less than the free length it will be pre loaded S pring rate the amount of force required to compress a coil sp
325. y Do not use exces sive force to remove float arm pin The float pin tower cast ings are very easily damaged and are not repairable Gp POLARIS 4 21 O FUEL SYSTEM CARBURETION 10 Remove main jet and washer or spacer ring and push needle jet into the slide valve chamber to remove Clean air bleed hole in needle jet 11 Remove pilot jet CAUTION Wear eye protection when using compressed air or cleaning solvents Review all fuel system warnings found on page 4 1 before proceeding 12 Remove pilot air screw and clean all passages in the carburetor body with carburetor cleaner Dry all passages and jets with compressed air Replace gaskets and any parts which show wear or damage 13 Reassemble carburetor adjusting float level before installing float bowl Refer to page 4 23 for float level adjustment and leak testing procedures FUEL SYSTEM CARBURETION Tel Float Level Adjustment 1 Remove float bowl 2 With carburetor in an inverted position float arms A should be parallel with body B See illustration at right Arms must be parallel to each other 3 To adjust float arm bend tang contacting inlet needle CAUTION Never bend the float arm itself Leak Testing Needle and Seat 1 2 3 Be sure float level is adjusted properly Invert carburetor Install float chamber and connect pressure tester PN 2870975 to fuel inlet fitting Pressure Tester PN 2
326. y Install 13 70 Bars Install 11 65 Bars Length Extended Shocks XTRA CRC ONLY Installed Install 14 34 Bars for Set Toe w Shocks 42 5 wide XC 10 CRC Installed on XC 10 models models Maximum set up width is the maximum allowable distance between ski spindle centers with front end of vehicle off the ground and suspension fully extended The Maximum Set Up Width specifications listed on page 7 3 are maximum width measurements and are critical to ensure adequate torsion bar engagement with the trailing arm If the suspension is set too wide the torsion bar can come loose and interfere with steering Do not attempt to set the suspension wider than the specified Maximum Set Up Width 9 BODY AND STEERING CRC Steering Adjustment To ensure accurate adjustment of the CRC steering mechanism all steps listed below must be performed in se quential order S Spindle to Chassis Centering must also be checked after adjustment Set Up Width adjustment must also be checked after adjustment Camber Adjustment Handlebar Centering Toe Adjustment Verify Spindle to Chassis Centering and S et up width are within limits 1 Securely support the front of the machine high enough to remove the skis Make sure machine is level 2 Remove skis Spindle to Chassis Centering 3 Follow procedure on page 6 9 Set Up Width Measurement 4 Follow procedure on page 6 9 This is the maximum allowable distance between ski spindle centers with front end of vehicle o

2002 DEEP SNOW SERVICE MANUAL

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