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Polaris INDY TRAIL RMK Service Manual

2002 deep snow
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Table of Contents

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Cover 12/23/02 11:54 AM Page 1
INDY 500 RMK
INDY 500 SKS EURO
600 EDGE RMK
Indy 700 Sks / (EURO SKS)
700 EDGE RMK
800 EDGE RMK
2002 DEEP SNOW
SERVICE MANUAL
PART NUMBER 9917366
PN 9917366
Printed in U.S.A.

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Summary of Contents for Polaris INDY TRAIL RMK

  • Page 1 Cover 12/23/02 11:54 AM Page 1 INDY TRAIL RMK INDY 500 RMK INDY 500 SKS EURO 600 EDGE RMK INDY 700 SKS / (EURO SKS) 700 EDGE RMK 800 EDGE RMK 2002 DEEP SNOW SERVICE MANUAL PART NUMBER 9917366 PN 9917366...
  • Page 2 This manual includes procedures for maintenance operations, component identification 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 provided at the end of the manual for location of specific page numbers and service information.
  • Page 3 NOTE: A NOTE provides key information to clarify instructions. Trademarks Polaris acknowledges the following products mentioned in this manual: FLEXLOC, Registered Trademark of SPS Technologies Loctite, Registered Trademark of the Loctite Corporation STA-BIL, Registered Trademark of Gold Eagle FOX, Registered Trademark of Fox Shox Nyogel, Trademark of Wm.
  • Page 4 GENERAL MAINTENANCE ENGINE CARBURETION DRIVE/DRIVEN CLUTCHES BODY AND STEERING SUSPENSIONS BRAKES AND FINAL DRIVE ELECTRICAL WIRING DIAGRAMS...
  • Page 6 ......1.16 - 1.17 Indy Trail RMK Specifications ......

  • Page 8: General Information

    GENERAL INFORMATION 2002 Publication Numbers Model Model No. Owner’s Manual Parts Parts Supplement Manual Microfiche Indy Trail RMK S02SR5BS 9916935 9916936 9916937 Indy 500 RMK S02SR5AS 9916932 9916933 9916934 Indy 500 SKS Euro S02SS5AE 9916941 9916942 9916943 Indy 600 EDGE RMK...

  • Page 9: Model Number Identification

    8C -- 800 VES L/C Case Reed 2 Cyl (domestic) TUNNEL DECAL PATENT NOTICE MODEL NO. MADE IN U.S.A. Mfd. by Polaris Industries Inc.. in Roseau, MN under one or V.I.N. NO. more of the following patents: Patented Canada U.S. Patents...

  • Page 10: 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.

  • Page 11: Standard Torque Specifications

    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.
  • Page 12 GENERAL INFORMATION 1/64 ......0156 1/32 ....0312 .
  • Page 13 GENERAL INFORMATION SAE Tap Drill Sizes Thread Size Drill Size Thread Size Drill Size #0-80 3/64 1/2-13 27/64 #1-64 1/2-20 29/64 #1-72 9/16-12 31/64 #2-56 9/16-18 33/64 #2-64 5/8-11 17/32 #3-48 5/64 5/8-18 37/64 #3-56 3/4-10 21/32 #4-40 3/4-16 11/16 #4-48 7/8-9 49/64...
  • Page 14 GENERAL INFORMATION Unit of Measure Multiplied by Converts to ft. lbs. x 12 = in. lbs. in. lbs. x .0833 = ft. lbs. ft. lbs. x 1.356 = Nm in. lbs. x .0115 = kg-m x .7376 = ft. lbs. kg-m x 7.233 = ft.
  • Page 15 ..2871326 Polaris Battery Tender ......
  • Page 16 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.
  • Page 17 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.
  • Page 18 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.
  • Page 19 Because removal damages seals, replace any oil or grease seals removed with new parts. 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.
  • Page 20 GENERAL INFORMATION Notes 1.13...
  • Page 21 GENERAL INFORMATION INDY 500 SKS EUROPEAN MODEL: ..MODEL NUMBER: E02SS5AE ENGINE MODEL: S2209- -5044PL5A JETTING CHART AMBIENT TEMPERATURE CARBURETION Below -30°F -30_ to - -10_F - -10_to +10_F +10_to +30_F +30_to +50_F Above +50_F Altitude...
  • Page 22 Front Spring Preload 3/4² Thread Adjust Driveshaft Sprockets 2 Drivers Wide Front Vertical Travel 9.6² (24.4cm) Brake Type ..Polaris HPB Rear Suspension . . . XTRA-10 EURO Rear Axle Travel . . .
  • Page 23 GENERAL INFORMATION INDY 500 RMK MODEL: ..MODEL NUMBER: S02SR5AS ENGINE MODEL: S2186- -5044PL5A JETTING CHART AMBIENT TEMPERATURE CARBURETION Below -30°F -30_ to - -10_F - -10_to +10_F +10_to +30_F +30_to +50_F Above +50_F Altitude Altitude...
  • Page 24 Front Spring Preload 1/8² Thread Adjust Driveshaft Sprockets 2 Drivers Wide Front Vertical Travel 8.05 in.(21cm) Brake Type ..Polaris HPB Rear Suspension . . . XTRA-Lite 136² Rear Axle Travel . . .
  • Page 25 GENERAL INFORMATION INDY TRAIL RMK MODEL: ..MODEL NUMBER: S02SR5BS ENGINE MODEL: EC55PM024 JETTING CHART AMBIENT TEMPERATURE CARBURETION Below -30°F -30_ to - -10_F - -10_to +10_F +10_to +30_F +30_to +50_F...
  • Page 26 GENERAL INFORMATION INDY TRAIL RMK MODEL: ..MODEL NUMBER: S02SR5BS ENGINE MODEL: EC55PM024 ELECTRICAL CAPACITIES Flywheel I.D..Mitsubishi Fuel Tank ..
  • Page 27 GENERAL INFORMATION 600 EDGE RMK MODEL: ..MODEL NUMBER: S02NJ6ES ENGINE MODEL: S2187- -6044PL6E JETTING CHART CARBURETION AMBIENT TEMPERATURE Type ....TM 38 w/TPS Mikuni Below -30°F -30_ to - -10_F...
  • Page 28 Driveshaft Sprockets 2 Drivers Wide, XHS Front Vertical Travel 7.2² - 7.6² (18.3 - 19.3cm) Brake Type ..Polaris HPB Liquid Cooled Rear Suspension . . . EDGE RMK Rear Axle Travel .

  • Page 29: Indy 700 Sks

    GENERAL INFORMATION INDY 700 SKS / (EUROPEAN MODEL) MODEL: ..MODEL NUMBER: S02SS7CS / (E02SS7CE) ENGINE MODEL: S2189- -7070PL7C JETTING CHART AMBIENT TEMPERATURE CARBURETION Below -30°F -30_ to - -10_F - -10_to +10_F +10_to +30_F +30_to +50_F Above +50_F...
  • Page 30 Driveshaft Sprockets 2 Drivers Wide Front Vertical Travel 9.6² (24.4cm) Brake Type ..Polaris HPB, Liquid Cooled Rear Suspension . . . XTRA-10 136², (XTRA 10 European) Rear Axle Travel . . .
  • Page 31 GENERAL INFORMATION 700 EDGE RMK 136”, 144”, 151” MODEL: ..MODEL NUMBER: S02NJ7CS, S02NK7CSA, S02NK7CS, S02NL7CS ENGINE MODEL: S2190- -7070PL7C JETTING CHART CARBURETION AMBIENT TEMPERATURE Type ....TM 40 w/TPS Mikuni Below -30°F -30_ to - -10_F...
  • Page 32 Rear Suspension . . . EDGE RMK 136”, 144² or 151” Brake Type ..Polaris HPB Liquid Cooled Rear Axle Travel . . . 13.8² (35cm)--(136), 17”(43cm)--(144, 151) Front Track Shock Nitrex (136, 144), Ryde FX IFP (151) Spring Rate .

  • Page 33: 800 Edge Rmk 144”/151”/156”

    GENERAL INFORMATION 800 EDGE RMK 144”, 151”, 156” MODEL: ..MODEL NUMBER: S02NM8CS ENGINE MODEL: S2188- -8070PL8C JETTING CHART CARBURETION AMBIENT TEMPERATURE Type ....TM 40 w/ TPS Below -30°F -30_ to - -10_F...
  • Page 34 Ryde FX IFP 3 13/16” Thread Adj. Driveshaft Sprockets 2 Drivers Wide Front Vertical Travel 7.2² - 7.6² (18.3 - 19.3cm) Brake Type ..Polaris HPB Liquid Cooled Rear Suspension . . . EDGE RMK Rear Axle Travel .
  • Page 36 CHAPTER 2 MAINTENANCE AND TUNE UP General Maintenance Inspection Sheet ....Recommended Maintenance Products ....Air Filter Maintenance .
  • Page 38 Inspect vent lines. __34. Reinstall skis and inspect/adjust toe alignment. __35. Check handlebar centering and lubricate all steering pivots. Polaris Service Technician: __________________________ __36. Torque tie rod end bolts and jam nuts. Authorized Dealer: _________________________________ __37. Inspect steering arms and torque bolts. Inspect handlebar bolt Base Inspection Price: ______________________________ torque.
  • Page 39 MAINTENANCE / TUNE UP Recommended Maintenance Products ENGINE OIL RETAINING/SEALING PRODUCTS Part # Description Packaging Part # Description Packaging (size / quantity) (size/quantity) 2871721 Synthetic 2-Cycle Premium Gold Quarts/ 6 2870652 Fuel Stabilizer 16 oz / 12 2871722 Synthetic 2-Cycle Premium Gold Gallon / 4 2872280 Fuel Stabilizer...
  • Page 40 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.
  • Page 41 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).
  • Page 42 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.
  • Page 43 Grease Gun Kit PN 2871312 S Grease center steering arm (bell crank), pitman arm, and idler arm (where applicable). NOTE: A grease gun kit complete with grease and adaptors is available to lubricate all fittings on Polaris snow- mobiles. Aerosol...

  • Page 44: Oil Pump Adjustment

    MAINTENANCE / TUNE UP Water Pump Belt Tension - Replace if width is less than .25² 700 and 800 Domestic big block Twins. (6.35mm). Nominal new width is .345² (8.75mm). The water pump belt on 600 RMK, 700 RMK and 800 RMK domestic big block twin snowmobile engines should be inspected every 1500 miles.

  • Page 45: Chaincase Oil Level

    5. Lock the adjusting bolt locknut (C) while holding a wrench on the adjusting bolt (D) to prevent it from turning. 6. Reinstall the chaincase cover and drain plug. Add Polaris synthetic chaincase lubricant (PN 2871478) through the dipstick opening to the level described above.

  • Page 46: Suspension Lubrication

    To maintain rider comfort and to retard wear of the pivot shafts, the suspension pivot shafts should be lubricated with Polaris 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 of the snowmobile will be affected by lack of lubrica- tion of these shafts.
  • Page 47 MAINTENANCE / TUNE UP EDGE RMK Style L L L L L L L L L L L L L L L L L L L L L L L L Forward 2.10...

  • Page 48: Coolant Level

    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. 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.

  • Page 49: Track Alignment

    MAINTENANCE / TUNE UP WARNING When performing the following checks and adjustments, stay clear of all moving parts to avoid serious personal injury. Track Maintenance WARNING 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.
  • Page 50 MAINTENANCE / TUNE UP Track Tension Data Suspension Weight Measurement Location Measurement XTRA 10 121², 133², 136² 10 lbs. (4.54 kg) 16² ahead of rear idler shaft 3/8 - 1/2² (1 - 1.3 cm) XTRA Lite 136² 10 lbs (4.54 kg) 16²...
  • Page 51 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.
  • Page 52 MAINTENANCE / TUNE UP Drive Belt WARNING Inspect the condition of the drive belt. Inspect clutch sheaves for damage, wear, or belt residue. Clean with non-oil base cleaner such as isopropyl alcohol. To ensure belt life, install belts so they operate in the same direction of rotation. Position the identification numbers so that you can read them standing on left side of machine.
  • Page 53 MAINTENANCE / TUNE UP Headlight Adjustment 25’ (7.6 m) The headlight can be adjusted for vertical aim using the following pro- cedure: 1. Place the snowmobile on a level surface with the headlight Lamp Center approximately 25’ (7.6 m) from a wall. Height 2.

  • Page 54: Taillight Bulb Replacement

    MAINTENANCE / TUNE UP Taillight Bulb Replacement Lens 1. Remove (5) Phillips screws from taillight lens. 2. Working from front to back, carefully pry lens away from housind and remove. 3. Pull bulb straight out from socket and insert new bulb. 4.
  • Page 55 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.
  • Page 56 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 - .030²...
  • Page 57 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).
  • Page 58 Lubricate both front ski pivots at bushings and spindles. See Ill.1 and 2. Ill. 1 Polaris Premium All Season Grease PN 2871423 14 oz. Grease Gun Adapter: 2871174 Grease...

  • Page 59: Exhaust System

    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.
  • Page 60 MAINTENANCE / TUNE UP Notes 2.23...
  • Page 62 CHAPTER 3 ENGINES Engine Torque Specifications ......Engine Torque Sequences ......3.2 -- 3.4 Engine Removal .
  • Page 64 ENGINES Engine Torque Specifications When tightening bolts, nuts, or screws, a torque pattern should be followed to ensure uniform equal tension is applied to all fasteners. 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.
  • Page 65 ENGINES Torque Sequences - EC55 Engines CYLINDER HEAD SIDE SIDE CYLINDER BASE CRANKCASE - TWIN CYLINDER - Fuji...
  • Page 66 ENGINES Torque Sequence / Domestic 500 CYLINDER HEAD Domestic 500 CYLINDER BASE Domestic 500 CRANKCASE Domestic 500...
  • Page 67 ENGINES Torque Sequence / Domestic 600 / 700 / 800 CYLINDER HEAD Domestic Twins 600 / 700 / 800 CRANKCASE Domestic Twins 600 / 700 / 800 CYLINDER BASE Domestic Twins 600 / 700 / 800...
  • Page 68 ENGINES 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 Ground Cable applicable). Shut off fuel. 3.
  • Page 69 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.
  • Page 70 ENGINES Engine Removal, Typical-Cont. 9. Remove drive belt. NOTE:If drive clutch removal is necessary, it may be done at this time. Refer to Chapter 5, clutches. 10. Remove exhaust system. 11. Disconnect coolant supply hoses as necessary at the most convenient location on liquid cooled models. Drain coolant into suitable container.
  • Page 71 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.
  • Page 72 ENGINES 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.
  • Page 73 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. Connect oil supply line to oil pump. Bleed oil pump by opening bleed screw until oil flows steadily.
  • Page 74 ENGINES 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).
  • Page 75 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.
  • Page 76 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.
  • Page 77 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.
  • Page 78 ENGINES 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.
  • Page 79 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 than 5/16² (7mm) into flywheel threads or stator damage may result. Flywheel Puller PN 2871043 3.16...
  • Page 80 ENGINES 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). 3.17...
  • Page 81 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...
  • Page 82 ENGINES 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.
  • Page 83 ENGINES Engine Assembly 1. Prior to assembly, make sure that you 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.
  • Page 84 ENGINES Engine Assembly - Continued 4. Lay crankshaft into the lower case half. Make sure that the crankshaft rotates smoothly and does not bind. Rotate the bearings so that the anti-rotation pins rest in their appropriate galleries. 5. Apply 3-Bondä sealer to top half of crankcase.
  • Page 85 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.
  • Page 86 ENGINES 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.
  • Page 87 ENGINES Engine Assembly - Continued 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.lbs.
  • Page 88 ENGINES 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.lbs.
  • Page 89 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.
  • Page 90 ENGINES 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.
  • Page 91 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.
  • Page 92 ENGINES Disassembly, Cont. 12. Remove bolts and separate case halves. Keep bolts in order for assembly. 13. To prevent damage to snap-ring grooves, lift crankshaft straight upward and out of lower case. 14. If pump shaft removal is necessary, remove retaining pin from crankcase using a diagonal cutter or similar tool.
  • Page 93 ENGINES Assembly Oil Pump Side 1. Insert bushing 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. Lubricate shaft, insert shaft through the case on water pump side into the bushing on oil pump side.
  • Page 94 ENGINES Assembly, Cont. 5. 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 6. Press a new mechanical seal into case until fully seated.
  • Page 95 15. Assemble engine mount straps to crankcase. Engine Mount Strap Torque: 44-48 ft. lbs. (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.
  • Page 96 ENGINES 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.
  • Page 97 ENGINES Assembly, Cont. 31. Install water pump cover with new gasket. Water Pump Cover Bolt Torque: 9 Ft lbs (12.5 Nm) 32. Install new exhaust manifold gaskets and manifold. Exhaust Manifold Bolt Torque: 16 Ft lbs (22 Nm) 33. Install reed valves, stuffers, and carburetor adaptors.
  • Page 98 ENGINES Assembly, Cont. 36. Apply Loctitet 262 evenly to the flywheel mounting taper on crankshaft. Install woodruff key. 37. Install flywheel. Apply Loctitet 242 to crankshaft threads. Install washer and nut. 38. Use flywheel holder to hold flywheel and torque nut to specification found in beginning of this chapter.
  • Page 99 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.
  • Page 100 ENGINES 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.
  • Page 101 ENGINES Disassembly, Cont. 9. Remove bolts holding water pump housing to Hose Clamp crankcase. Loosen hose clamp and remove housing. 10. Inspect water pump weep hole for signs of leakage or blockage. Inspect Weephole 11. Remove crankshaft seal from housing by driving seal to inside of housing.
  • Page 102 ENGINES 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.
  • Page 103 ENGINES Disassembly, Cont. 16. Remove reed cover, reed stuffers, and reeds. Reed Valve Inspection 17. Measure air gap between fiber reed and reed Reed Pedal Exaggerated block as shown. The air gap should not exceed Clearance .015² for illustration .015² (.4 mm). If clearance is excessive DO NOT (.38 mm) max.
  • Page 104 ENGINES 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. Remove Clamps 23.
  • Page 105 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 compressed air. 2. Apply 3-Bondä 1215 sealant to upper crankcase half.
  • Page 106 ENGINES Assembly, Cont. 4. If studs were removed or new crankcase installed, apply Loctiteä 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 (4.76-4.88²) from crankshaft parting line.
  • Page 107 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.
  • Page 108 ENGINES 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. Install Seal Apply 3-Bond 15. Apply 3 Bondä sealant to pump housing crankcase Hose Clamp mating surface and carefully install onto crankcase.
  • Page 109 ENGINES Assembly, Cont. 17. Install flywheel and torque flywheel nut 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.
  • Page 110 Gasket with a Scotch Britet pad or similar soft abra- sive brush. Valve 5. Lubricate exhaust valve with Polaris Premium Gold 2-cycle engine lubricant. Install valve in cylinder and move it through the entire travel Clean with Solvent range to check for free movement without bind- ing.
  • Page 111 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 lbs (8.3 Nm) 4.
  • Page 112 ENGINES Variable Exhaust System (V.E.S.) 5. Install V.E.S. assembly onto cylinder and torque V.E.S. housing bolts to specification. Set spring adjuster screw to desired specification. V.E.S. Housing Bolt Torque: 9 Ft lbs (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.
  • Page 113 ENGINES Polaris Variable Exhaust System Springs Spring PN COLOR Load @ 1.0 In. Load @ .630 In. Free Length Wire Dia. (LBS.) (LBS.) (In.) ± ± ± ± 0.4 ± ± ± ± 0.5 7041786--01 RED/WHITE 1.854 .041 7041786--02 BLUE/WHITE 1.740...

  • Page 114: Cylinder Honing

    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.
  • Page 115 (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!
  • Page 116 ENGINES 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 right angles to the pin as shown. Determine the largest diameter within this area and refer to the chart below for clearance specifications.
  • Page 117 ENGINES Crankcase Inspection / Bearing Fit Any time crankshaft bearing failure occurs and the case is to be reused, Polaris recommends check- ing the bearing fit into the case halves using the fol- lowing procedure. 1. With case halves cleaned,...
  • Page 118 NOTE:Specialized 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.

  • Page 119: Crankshaft Runout Inspection

    When measuring from the PTO side: SMeasure 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...
  • Page 120 ENGINES Crankshaft Truing Cont. NOTE:The 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 HIGH .004 (.1mm) illustration at right, strike the shaft at point A with a HIGH .004 (.1mm) brass hammer.

  • Page 121: Crankshaft Indexing

    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.
  • Page 122 ENGINES Crankshaft Indexing (Continued) 6. Bend the pointer or move the degree wheel until the pointer aligns with the 180 or 120° mark on the degree wheel. 7. With the pointer aligned, make sure the degree wheel and pointer are secured and will not move out of position.
  • Page 123 ENGINES Cylinder Head Inspection 1. Inspect each cylinder head for warping. Replace cylinder head if warp exceeds service limit. Cylinder Head Warp Service Limit: .003² (.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.

  • Page 124: Piston Inspection/Measurement

    ENGINES Piston Inspection/Measurement 1. Check 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 (3/8²) up from the bottom of the skirt at a 90°...
  • Page 125 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 test with 40:1 premix in fuel tank.

  • Page 126: Oil Pump Bleeding

    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. 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.
  • Page 127 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. Measurement “B”...
  • Page 128 ENGINES 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 .010² - .030² (.25 - .8mm). See figure 1. .010-.030²...
  • Page 129 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.
  • Page 130 ENGINES Cooling System 500 RMK / 500 SKS (Euro) 500 SKS Euro only Hose, tee to bottle Hose, tee to Hose, brake cooler to rear extrusion brake cooler Hose, bulkhead to rear extrusion Hose, tee to pump in BRAKE COOLER ENGINE THERMOSTAT BY-- PASS...
  • Page 131 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 Hose, bulkhead to rear extrusion Protective conduit Hose, engine out to bottom close-off Hose, tee to pump in BY-- PASS ENGINE COOLANT...
  • Page 132 ENGINES Hose Gripper/Rear Close--off Cooling System - 600 RMK Gripper, De-Icer Cooling Extrusions Hose, Gripper/Brake Hose, Brake Cool- Cooler er/Bypass Rear Exchanger Hose, Bottle/ Pump Cooler, Center 3 outlet Hose, Cooler Center Hose, Gripper/Cooler Center Hose, Engine Out/Front ENGINE BY-- PASS THERMOSTAT COOLANT BOTTLE...
  • Page 133 ENGINES 151” and Longer only Cooling System - 700, 800 RMK Rear Exchanger = Colant Flow Rear Cooler Plate Gripper/De--Icer Hose, Gripper/Brake Cooler Hose, Tee/Brake Cooler Hose, Engine Out Cooler, Center Hose, Gripper/Rear Hose, Cooler/Bottle Closeoff Hose, Gripper/Center Cooler Hose, Tee to Engine Hose, Center Cooler/Tee ENGINE BY---PASS...

  • Page 134: Recoil Disassembly

    ENGINES Recoil Disassembly CAUTION: 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.
  • Page 135 ENGINES Engine Troubleshooting PROBLEM PROBABLE CAUSE Will not start/ -Check ignition switch for run position, moisture contamination hard starting -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...
  • Page 136 ENGINES Engine Troubleshooting PROBLEM PROBABLE CAUSE Lights don’t -Engine must be running work -Check wiring harness connector -Check for burned 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...
  • Page 138 CHAPTER 4 FUEL SYSTEM / CARBURETION Fuel System Warnings ....... . . Jet Part Numbers .
  • Page 140 FUEL SYSTEM / CARBURETION Whenever servicing the carburetor or fuel system, it is important to heed the following warnings. WARNING Gasoline is extremely flammable and explosive under certain conditions. Always stop the engine and refuel 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.
  • Page 141 FUEL SYSTEM / CARBURETION Jet Needle Part Numbers (Mikuni) JET NEEDLE NO. PART NO. JET NEEDLE NO. PART NO. 5DP7 ... 3130155 6DH4 ....3130402 5DT49 .
  • Page 142 FUEL SYSTEM / CARBURETION Mikuni TM 38 / TM 40 Jet Part Numbers DESCRIPTION PART NUMBER DESCRIPTION PART NUMBER Jet Needles Pilot Air Jets Cont. Jet Needle J8-9FH04-57 3130794 Pilot Air Jet 3131257 Jet Needle J8-9EH01-57 3130795 Pilot Air Jet 3131258 Jet Needle J8-9DH01-54 3130796...
  • Page 143 FUEL SYSTEM / CARBURETION Mikuni TM 38 / TM 40 Jet Needle Overview Leaner This needle (example) is a 9DH01--57. The first number is 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.
  • Page 144 FUEL SYSTEM / CARBURETION Mikuni TM 38 / TM 40 Overview Gasket Check Top Cap Valve Slide Flush With Top of Bore Mixing Body Lever Piston Valve(E) Funnel Fuel Screw(G) Pilot Jet(F) Main Jet Needle(C) Starter Jet(B) Jet(F) Float/ Plunger Needle Pilot Air Jet(A) &...
  • Page 145 FUEL SYSTEM / CARBURETION Mikuni TM 38 / TM 40 Exploded View Top Cap Gasket Adjustment Screw Check Valve Ring Lever Plate Plate O-ring Packing Adjuster Funnel E-Ring Ring Spring Spring Guide Pilot Jet Holder Main Jet Piston Valve Starter Jet Spring Jet Needle Float/Needle &...
  • Page 146 FUEL SYSTEM / CARBURETION Mikuni VM 34SS Exploded View Mixing Chamber Top (Including Gasket) Throttle Spring Plunger Cap Throttle Plate Plunger Spring E-Ring Jet Needle Plunger Throttle Valve Needle Jet Spring Air Screw Plate Spring Float Arm Packing Throttle Stop Screw Pilot Float Pin Ring...
  • Page 147 FUEL SYSTEM / CARBURETION Altitude Compensating Carburetor System (ACCS) ACCS Valve ACCS Valve 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.
  • Page 148 FUEL SYSTEM / CARBURETION 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.
  • Page 149 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.
  • Page 150 (under hood) the pressure difference will change, causing erratic fuel flow. Polaris has airbox venting on some models. The vent lines are connected to 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.
  • Page 151 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.
  • Page 152 FUEL SYSTEM / CARBURETION 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.

  • Page 153: Pilot Jet

    FUEL SYSTEM / CARBURETION The pilot system’s main function is to meter fuel at idle and low speed driving. Though its main function is to supply fuel at low speed, it does feed fuel continuously throughout the entire operating range. Fuel for the pilot jet is drawn from the float bowl, mixed with air regulated by the air screw, and delivered to the engine through the pilot outlet.

  • Page 154: Throttle Valve

    FUEL SYSTEM / CARBURETION Throttle valve cutaway effect is most noticeable at 1/4 throttle opening. The amount of cutaway is pre-determined for a 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.
  • Page 155 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 of the “E” clip on the needle. Moving the clip down raises the Clip Position needle in the jet passage and richens the mixture.

  • Page 156: Jetting Guidelines

    Carburetors on most Polaris models are calibrated for an altitude of 0-3000 ft (0-900 meters) and ambient temper- 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.
  • Page 157 FUEL SYSTEM / CARBURETION The function of a carburetor is to produce a com- bustible air/fuel mixture by breaking fuel into tiny particles in the form of vapor, to mix the fuel with air in a proper ratio, and to deliver the mixture to the engine.
  • Page 158 FUEL SYSTEM / CARBURETION EFFECT THROTTLE OPENING - TYPICAL MIKUNI VM Throttle Valve Cut-Away Jet Needle/Needle Jet Polaris TM-38 / TM 40 Mikuni component effect versus throttle opening chart. needle valve main jet Main jet needle needle jet throttle valve...
  • Page 159 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 Idle Speed Screw disassembling, clean outside of carburetor thoroughly Choke Passages...
  • Page 160 FUEL SYSTEM / CARBURETION Carburetor Disassembly and Inspection 6. Remove water trap assembly from float bowl 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.
  • Page 161 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.
  • Page 162 FUEL SYSTEM / CARBURETION 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.
  • Page 163 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. MIKUNI Throttle Cable Synchronization (Throttle Gap) Center of slide under cutaway 2.
  • Page 164 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 1. Remove carburetor rack from engine. Before disassembling, clean outside of carburetor thoroughly with solvent.
  • Page 165 FUEL SYSTEM / CARBURETION Disassembly Cont. 6. From top of carb, loosen allen head screw holding needle in position. Slide holding plate to side. 7. Reach into top of carb with a long nose pliers and remove needle. 8. Inspect needle for wear. 9.
  • Page 166 FUEL SYSTEM / CARBURETION Carburetor Disassembly Cont. 10. Remove water trap/drain plug (17 mm) and single screw on bottom of carb. 11. Remove float body NOTE:Float body will not come off unless water trap/drain plug, which is threaded and screws into main jet housing, is removed.
  • Page 167 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...
  • Page 168 FUEL SYSTEM / CARBURETION Carburetor Assembly 1. Install pilot jet, main jet, starter jet, and idle screw. 2. Install float/needle & seat assembly. 3. Place carburetor in an inverted position. 4. Connect pressure tester to fuel inlet fitting. Apply 5 psi pressure and observe for one minute.
  • Page 169 FUEL SYSTEM / CARBURETION Throttle Synchronization Procedure- Mikuni TM-38 Flatslide Carburetors Mikuni TM-38 carburetors are synchronized at wide open throttle without the 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.
  • Page 170 FUEL SYSTEM / CARBURETION Throttle Synchronization Procedure- Mikuni TM-38 Flatslide Carburetors 5. On remaining carb(s), loosen phillips head screw inside the offset nut. 6. When screw 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.
  • Page 171 FUEL SYSTEM / CARBURETION Choke Adjustments With the dash mounted choke control toggle flipped to the Choke Toggle Position 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.
  • Page 172 FUEL SYSTEM / CARBURETION 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. In the two cycle engine, the pressure in the crankcase changes with the up and down stroke of the piston.
  • Page 173 FUEL SYSTEM / CARBURETION WARNING 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 area where refueling is performed or where gasoline is stored.
  • Page 174 FUEL SYSTEM / CARBURETION Fuel system diagnosis should follow a specific path, first examining the fuel tank, then the 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.
  • Page 175 FUEL SYSTEM / CARBURETION Troubleshooting Tips, 1/4-3/8 Throttle: Obstruction in main jet or needle jet Jet needle worn or out of adjustment Pilot system malfunction Incorrect throttle valve cutaway Troubleshooting Tips, 3/8-3/4 Throttle: 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...
  • Page 176 CHAPTER 5 DRIVE / DRIVEN CLUTCHES Recommended Tools ....... . . Drive Clutch Weights .
  • Page 178 DRIVE / DRIVEN CLUTCHES WARNING All drive clutch maintenance, disassembly and assembly must be performed only by an authorized Polaris dealer who has attended current model Dealer Service Seminars, has received a certificate of completion, and displays the Polaris Servicing Dealer decal.
  • Page 179 DRIVE / DRIVEN CLUTCHES G - (B Modified) Gram Weight: 34 1 Gram Weight: 37.5 1 Gram Weight: 41.5 1 Gram Weight: 47.5 1 PN 5630107 PN 5630109 PN 5630063 PN 5630080 Gram Weight: 49 1 Gram Weight: 32.5 1 Gram Weight: 51 Gram Weight: 53 1 PN 5630225...
  • Page 180 DRIVE / DRIVEN CLUTCHES Gram Weight: 44 1 Gram Weight: 53.5 1 Gram Weight: 52 1 Gram Weight: 50 1 PN 5630065 PN 5630234 PN 5630244 PN 5630243 10 Bushed 10M-W Bushed Gram Weight: 47.5 1 Gram Weight: 55.5 1 Gram Weight: 51.5 1 Gram Weight: 46 1 PN 5630245...
  • Page 181 DRIVE / DRIVEN CLUTCHES 10-62 Bushed 10-AL Bushed 10-66 Bushed 10-64 Bushed Gram Weight: 62 Gram Weight: 53 1 Gram Weight: 66 Gram Weight: 64 PN 1321586 PN 1321531 PN 1321584 PN 1321585 10-60 Bushed 10-58 Bushed 10A Bushed 10-56 Bushed Gram Weight: 60 Gram Weight: 58 Gram Weight: 55...
  • Page 182 DRIVE / DRIVEN CLUTCHES PART NUMBER COLOR CODE WIRE DIAMETER FREE LENGTH +/- Force lbs. @ .125² 2.50”- -1.19” (+/- - 12lbs.) 7041021 Clear .157² 4.38² 70--130 7041022 Black .140² 4.25² 44--77 7041063 Purple .168² 4.37² 75--135 7041062 Silver .208² 3.12²...
  • Page 183 DRIVE / DRIVEN CLUTCHES Driven Clutch Springs Part Number Description Soft 7041198 7041782 Black-5 Coil 7041501 Gold-6 Coil 7041296 Blue 7041499 Silver 7041646 Silver/Blue Firm 7042022 Blue/Orange Driven Spring Charts Blue and Blue/Orange Blue/Orange Silver/Blue Silver or Silver/Blue Blue Gold or Black Silver Gold and Black...
  • Page 184 DRIVE / DRIVEN CLUTCHES P-85 Drive Clutch Do not lubricate drive clutch components Cover Cover Bushing Retaining Ring Washer Spring Roller Jam Nut Weight w/Bushing Weight Pin Roller Pin Guide Button Shim Sleeve Bushing Moveable Insert Spider Spacer Clutch Assembly (Less weights, spring) Moveable Sheave Fixed Sheave...
  • Page 185 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 Ramp Driven Plate Driven Bushing Retaining Ring Adjustment Cam Spring Washer Washer Button Screw Moveable Sheave...
  • Page 186 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 internal components installed for its specific engine model.
  • Page 187 DRIVE / DRIVEN CLUTCHES 9000 8000 ENGINE OPERATING RANGE ±250 RPM 7000 6000 5000 ENGAGEMENT 4000 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.
  • Page 188 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.
  • Page 189 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.
  • Page 190 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.
  • Page 191 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- lent total thickness) must be reinstalled during assembly. If sheaves are not marked, or if total thickness of existing shim washers under spider is not recorded, clutch will be out of balance when reassembled and must be replaced.

  • Page 192: Roller Installation

    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.

  • Page 193: Spider Button Shimming

    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.
  • Page 194 DRIVE / DRIVEN CLUTCHES Spider Button Shimming, Cont. Measure tower width at bottom 2. Measure the dimension between towers at the lower of travel half of the towers as shown. Use Dial Caliper 3. Install spider buttons using a soft face hammer. Measure each 4.
  • Page 195 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 Marks 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-...
  • Page 196 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 cover to prevent bushing damage. Maintain alignment by tightening cover bolts evenly and carefully. Spider Cover Bolt Torque - 90 in.
  • Page 197 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.

  • Page 198: Spider Indexing

    DRIVE / DRIVEN CLUTCHES Spider Indexing NOTE:Spider 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.
  • Page 199 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.
  • Page 200 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 helix down with a soft faced hammer.
  • Page 201 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. Tabs Aligned 6. Slide moveable sheave off and inspect sheave surfaces for wear or grooving. Note size and number of shim washers between sheaves.
  • Page 202 DRIVE / DRIVEN CLUTCHES Assembly 1. Install appropriate washer(s) on fixed shaft. Optional Thin Adjustment Washer (P-85) .048² - 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 setting.
  • Page 203 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.
  • Page 204 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 1/4 turn removed.
  • Page 205 DRIVE / DRIVEN CLUTCHES Installation 1. Install proper number of spacer washers on jackshaft between clutch and jackshaft bearing. Inspect Jackshaft Bearing Excessive vibration or abnormal drive belt wear can be caused by a worn bearing or jackshaft on the driven clutch side.
  • Page 206 DRIVE / DRIVEN CLUTCHES Drive Belt Part No. Belt Width* Side Center Outer Notes (Projected) Angle Circum- Overall* Center* ference* +.100² - - .000² 3211042 1.375² 32° 12.00² 47.250² Common production belt for P-85 systems (34.93mm) 3211045 1.375² 32° 12.00² 47.125²...
  • Page 207 DRIVE / DRIVEN CLUTCHES Drive Belt Inspection 1. Measure belt width and replace if worn severely. Generally, belt should be replaced if clutches can no longer be adjusted to provide proper belt deflection. Projected Belt The top edges have been trimmed on some Width drive belts.
  • Page 208 DRIVE / DRIVEN CLUTCHES Belt Deflection Too much belt deflection - If the belt is too long or the Belt too high on initial engagement center distance too short, the initial starting ratio will be too high, resulting in performance loss. This is due to the belt rising too high in the drive clutch sheaves upon en- gagement.
  • Page 209 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.
  • Page 210 DRIVE / DRIVEN CLUTCHES Clutch Offset Inspection Offset - Non-Electric Start Models NOTE:Proper offset aligns the fixed sheaves of both clutch assemblies. This allows the clutches to be No gap at aligned throughout the shift range. 5/8² Offset point “A” All models with P85 1.
  • Page 211 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 alignment. 1. After clutch offset has been verified, inspect alignment.
  • Page 212 DRIVE / DRIVEN CLUTCHES Belt to Sheave Clearance Inspection Force belt to one side NOTE:The 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 clutch weight to engine RPM.
  • Page 213 DRIVE / DRIVEN CLUTCHES Kit PN 2871025 Item Qty. Part Description Part No. P-85 Drive Clutch Moveable Bushing 5020627 Removal and Installation Tool P-90 Drive Clutch and Driven Clutch 5020628 Bushing Installation Tool Drive Clutch Cover Bushing Removal and 5020629 Installation Tool (for all drive clutches) P-85 Driven Clutch DU Split Bushing 5020630...
  • Page 214 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.
  • Page 215 DRIVE / DRIVEN CLUTCHES P-85 Drive Clutch Movable Sheave Bushing Removal Piston Pin 1. Inspect bushing and replace if excessively worn. Puller (Item 1) 2. Install handle end of piston pin puller (PN 2870386) securely into bench vise and lightly grease puller threads.
  • Page 216 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 Teflonä...
  • Page 217 DRIVE / DRIVEN CLUTCHES P-85 Driven Clutch Movable Sheave Large Bushing Installation NOTE: The P-85 driven moveable has a split bushing. The bushing is held in place after installation by screws. 11. Insert bushing (PN 3569803) into clutch and tap lightly with a soft face hammer.
  • Page 218 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...
  • Page 219 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 c) Driven clutch spring broken or installed...
  • Page 220 DRIVE / DRIVEN CLUTCHES Belt Wear / Burn Diagnosis Possible Cause Of Wear Or Burning 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 1.25² to achieve optimum starting ratio Cold weather startups Be patient.
  • Page 222 CHAPTER 6 BODY AND STEERING Indy Trail RMK Front Suspension ..... . . Indy 500 SKS Euro Front Suspension ....
  • Page 224 BODY AND STEERING Steering Assembly - Indy Trail RMK Torque Specifications 28-30 ft.lbs (38-41 Nm) 35-40 ft.lbs (47-54 Nm) 40--45 ft.lbs. (45--62 Nm) 45-50 ft.lbs (61-68 Nm) 55--60 ft.lbs. (76--83 Nm) Apply Premium All Season Grease, PN2871322 (3oz.), to all grease zerks located on suspension assemblies.
  • Page 225 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 (3oz.), to all grease zerks located on suspension assemblies.
  • Page 226 BODY AND STEERING Steering Assembly - Indy 700 SKS / 700 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 (3oz.), to all grease zerks located on suspension assemblies.
  • Page 227 BODY AND STEERING Steering Assembly - Indy 500 RMK Torque Specifications 17-19 ft.lbs. (23-26 Nm) 28-30 ft.lbs (38-41 Nm) 35-40 ft.lbs (47-54 Nm) 40--45 ft.lbs (55--62 Nm) 45-50 ft.lbs (61-68 Nm) Apply Premium All Season Grease, PN2871322 (3oz.), to all grease zerks located on suspension assemblies.
  • Page 228 BODY AND STEERING Steering Assembly - EDGE RMK 600 / 700 / 800 Torque Specifications 28-30 ft.lbs (38-41 Nm) 35-40 ft.lbs (47-54 Nm) 54--66 ft.lbs ( 75--91 Nm) 135-165 ft.lbs (187--228 Nm) Apply Premium All Season Grease, PN2871322 (3oz.), to all grease zerks located on suspension assemblies.

  • Page 229: Alignment Bar Specifications

    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.
  • Page 230 BODY AND STEERING Camber Definition - All IFS The following definitions of camber use automotive Positive, Negative, and Neutral (0°) Camber terminology to describe positive and negative posi- tions. Refer to the illustration at right. 0 (Neutral) Camber - Spindle is 90° (perpendicu- lar) to ground + (Positive) Camber - Spindle bottom is canted inward toward chassis...
  • Page 231 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.
  • Page 232 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. WARNING A maximum set up width is listed in the chart 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.
  • Page 233 BODY AND STEERING CAMBER INSPECTION All Models - Elevate Front End - Shocks Installed Typical CRC Shown - Style varies by model Suspension Free Hanging With IFS Shocks Installed Upper radius rod Lower radius rod Radius Rod End Jam Nuts Attaching Bolts Measure Here Refer to specifications for:...
  • Page 234 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. Measure Here 2.
  • Page 235 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 Fig.
  • Page 236 BODY AND STEERING Toe Adjustment, All Models 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. Lift 3-5²...
  • Page 237 BODY AND STEERING Toe Adjustment - XTRA CRC and XC-10 CRC, cont. 3. To adjust toe, 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.
  • Page 238 - weld up or weld down, etc. Some of the bolts 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. Tools Camber-2001 42.5²XC-10 CRC...
  • Page 239 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. 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...
  • Page 240 BODY AND STEERING Camber Adjustment - XTRA CRC and XC-10 CRC, (Cont.) 8. Using a 3/8² drive 11/16² (1.7 cm) crow foot wrench and 20² (51 cm) long 3/8² (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.
  • Page 241 BODY AND STEERING Carbide to Ski Placement A good starting point for placement of carbide is 50/50 (50% forward and 50% behind the ski mounting bolt). This can be varied depending on the aggressiveness of the car- bide and the strength of the driver. Make sure the leading edge of the carbide has a small chamfer.
  • Page 242 BODY AND STEERING 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.
  • Page 243 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.
  • Page 244 BODY AND STEERING Steering Arm Orientation WARNING Steering arm orientation is important to ensure proper steering tie rod end thread engagement and steering perfor- mance. Always mark steering arms and spindles before removal for reference upon reassembly. When 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.

  • Page 245: Ski Skag Installation

    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.

  • Page 246: Ski Installation

    BODY AND STEERING Ski Installation METAL SKI INSTALLATION Ski Spindle Front of - 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 position.

  • Page 247: Torsion Bar Removal

    5. Remove support and torsion bar. 6. Repeat procedure for second torsion bar. Torsion Bar Installation 1. Rivet support in place using Polaris PN 7621449 rivets. NOTE: These high strength “Q” rivets are the only replacement rivets recommended for this application.
  • Page 248 BODY AND STEERING Handlebar Torque and Sequence 1. Remove handlebar cover. 2. Using a 7/16² (11 mm) wrench, loosen four nuts on bottom of adjuster block. NOTE: Turn handlebar to left or right for access to back nuts. 3. 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...
  • Page 249 BODY AND STEERING WARNING 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 or if 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.

  • Page 250: Seat Cover Replacement

    BODY AND STEERING Seat Cover Replacement 1. Remove seat assembly as outlined on page 6.26. 2. Remove seat and seat covering to be replaced. Carefully remove staples by loosening with a small flat blade screwdriver. Pull each staple straight out with a pliers.
  • Page 251 If this happens you must replace the entire seat base assembly. 8. Using a staple gun, tack each side of the vinyl cover in place using two staples. If cover has a Polaris emblem carefully align emblem with bottom edge of seat.
  • Page 252 Hood Repair Currently there is no procedures or materials recommended by Polaris 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.
  • Page 253 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.
  • Page 254 BODY AND STEERING Nosepan Replacement Procedure - Gen II XTRA-10 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.
  • Page 255 BODY AND STEERING Nosepan Replacement Procedure - Gen II XC-10 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.
  • Page 256 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.

  • Page 257: Decal Installation

    BODY AND STEERING Decal Removal 1. Before removing old decal, it is important to note its position by marking it in several locations. 2. Remove old decal completely. NOTE: A small amount of solvent will aid in removing the old decal. 3.
  • Page 258 BODY AND STEERING Problem Possible Cause Solution *Machine darts from side to side -Incorrect ski toe alignment -Adjust to correct toe alignment -Incorrect camber -Adjust to correct camber -Loose or worn steering compo- -Tighten or replace nents or fasteners -Cracked or broken skis, skags, or -Replace if necessary carbides Tie rod hits trailing arm...
  • Page 260 CHAPTER 7 SUSPENSIONS Rear Suspension Theory of Operation ....7.1 - 7.2 Suspension Overview and Setup ..... . . Shock Tuning .
  • Page 262 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.
  • Page 263 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. Coil Spring Free length - the length of a coil spring with no load ap-...
  • Page 264 SUSPENSIONS Suspension Overview Many factors influence the overall handling characteristics of snowmobile suspensions. Rider weight, riding style, course conditions, and the condition of suspension components are some of the 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 wear in.

  • Page 265: Shock Tuning

    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 turning the adjuster screw.
  • Page 266 SUSPENSIONS Overall Suspension Setup for Optimal Performance Set Up Recommendations for Optimum Performance* Deep Powder Snow Powder - Hardpack Hardpack n Front Torque Arm - n Front Torque Arm - n Front Torque Arm - low position for maximum standard position for overall High position for increased lift and floatation.
  • Page 267 SUSPENSIONS Hi-Fax Replacement - All Models Hi-Fax replacement on all Polaris models is similar. Hi Fax Wear Limit When any area of the Hi-Fax is worn to 1/8² (.3 cm), it should be replaced. This will save wear on other vital components.
  • Page 268 SUSPENSIONS Xtra 10/Xtra Lite - - Torque Specifications, Suspension Mounting and Lubrication Points 3/8² top shock mounting bolts ....... . . 28-30 ft.
  • Page 269 SUSPENSIONS Rear Suspension Exploded View / XTRA Lite Front track shock spring preload washers PN 5210953. Rear Torque Arm Front Torque Arm...
  • Page 270 SUSPENSIONS XTRA Lite Rear Suspension Torsion Springs Rear Track Shock Carrier Wheel NO TAG Rail Bumper Front Torque Arm Front Track Shock Torsion Spring Front Track Forward Spring Bogie Wheel Rear Torque Arm Rear Pivot Arm Rail Tip Hi-fax Rail Bumper Bogie Wheel Rear Track...
  • Page 271 SUSPENSIONS XTRA 10 Rear Suspension Rear Limiter Front Track Shock Strap Rear Track Shock Limiter Strap Pivot Arm Pivot Arm Shaft Shaft Rear Torsion Spring Forward Carrier Wheel Rear Track Shock Rear Torsion Spring Front Torque Limiter Strap Idler Wheel Rail Bumper Bogie...
  • Page 272 SUSPENSIONS EDGE RMK Torque Specifications, Suspension Mounting and Lubrication Points 3/8² suspension mounting bolts ....... 35 - 40 ft.
  • Page 273 SUSPENSIONS EDGE RMK Exploded view Rear Torque ARm Front Torque Arm 7.12...

  • Page 274: Suspension Adjustment

    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.
  • Page 275 SUSPENSIONS The XTRAä 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.
  • Page 276 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.
  • Page 277 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- RRSS - low tween the front and rear torque arms. To increase the position shown stiffness of the suspension, the RRSS should be set in the high position.
  • Page 278 SUSPENSIONS 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;...
  • Page 279 SUSPENSIONS WARNING Changing shock valving on models equipped with Ryde FXt or Foxt shocks requires 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.
  • Page 280 SUSPENSIONS Compression Damping Adjustable Shocks Snowmobiles equipped with the Indy Select or Ryde FXt shocks allow the 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.
  • Page 281 SUSPENSIONS How to Adjust Rear Suspension If the 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.
  • Page 282 SUSPENSIONS Following is a list of all available springs for the rear suspension. These springs can be used to better suit individu- al riding preference. Xtra Lite/136” Optional Suspension Set Ups, See Suspension Tuning Decal Under Hood. Torsion Spring Part No. Wire Dia./Degrees 7041629--067 LH .359”...
  • Page 283 SUSPENSIONS IFS Shock Springs Xtra 10 / Xtra Lite / EDGE RMK Part Total # of Active Rate (#/in) Free Wire End Dia End Dia O.D.” Tabbed Application Number Coils # of Length Dia. Coils 7041396-067 13.35 11.35 50.00 11.88” .283”...
  • Page 284 SUSPENSIONS Stock Valving Listed By Shock Part Number IFS Shock Valving Front Track Shock Valving 7042059 7041801 7042084 7041810 Shock PN Shock PN Ryde FX Ryde FX 1.125x.093 Top out .700x.012 1.250x.010 .900x.010 1.300x.008 .700x.012 .800x.012 Compress. Compress. 1.000x.008 1.000x.006 .800x.008 .900x.012 Stack...
  • Page 285 SUSPENSIONS Ryde FXt t t t Shock Chart Front Track Shocks Front Track Shocks Extended Collapsed- Shock Rod Shock PN Stroke(in) IFP Depth (in) Shaft Part # Length(in) Length (in) (in) 7042084 12.51 8.92 3.59 0.49 4.77 1700182 7041980 10.85 7.79 3.06 0.49...
  • Page 286 SUSPENSIONS Foxä Shock Maintenance Changing oil on Foxä Shocks is recommended annually and should be included when performing end of season storage preparation. 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.
  • Page 287 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 (1/4²) - Part Number 5431355 Valve Washer Part Numbers Part No.
  • Page 288 SUSPENSIONS Foxä 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 soft jaws (aluminum or brass) of vise.
  • Page 289 SUSPENSIONS Foxä 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 at least 1 1/2²...
  • Page 290 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.
  • Page 291 SUSPENSIONS Foxä Shock Maintenance Seal Replacement, Cont. 7. Inspect valve piston ring for wear. The outer surface of the ring should be even in color. Set aside damper rod assembly for reinstallation. 8. Position shock in vise with Body Clamp Tool positioned as shown.
  • Page 292 SUSPENSIONS Foxä 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.
  • Page 293 SUSPENSIONS Foxä Shock Maintenance Assembly, Cont. 6. Insert IFP. 7. Install body cap until O-ring is lightly seated. 8. Mount shock in vise by top eyelet as 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.
  • Page 294 SUSPENSIONS Foxä Shock Maintenance Assembly, Cont. 12. Place a shop towel over the end of IFP tool and slowly push IFP to specified depth. 13. With the IFP set and the bleeder screw removed, slowly stroke shock to force air through piston oriface.
  • Page 295 SUSPENSIONS Foxä Shock Maintenance Assembly, Cont. 16. Install pressurizing valve with new O-ring and tighten securely. 17. Set the nitrogen tank pressure regulator to 200 - 205 PSI. 18. Insert the Foxä Safety Needle and charge with nitrogen to 200 PSI. Pull the needle straight outward and remove from the pressurizing valve while holding the pressure hose on the fitting.
  • Page 296 SUSPENSIONS Foxä 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 it will not pivot, possibly resulting in damage to shaft and seals.
  • Page 297 SUSPENSIONS t t t t Valve Washer Part Numbers. Foxt t t t Part Numbers can be found on pg 7.26. Ryde FX Polaris # Thickness Diameter 1700080 ..0.004 ..
  • Page 298 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 it is important that all the gas pressure be discharged from the unit. Refer to the instructions listed below for the proper procedure of discharging the gas pressure from a shock.
  • Page 299 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.
  • Page 300 SUSPENSIONS Place the shock piston rod upper mount in bench vise, Flats 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 straightness, nicks or burrs.
  • Page 301 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...
  • Page 302 SUSPENSIONS 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.
  • Page 303 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. Refer to the instructions listed below for the proper procedure of discharging the gas pressure from a shock.
  • Page 304 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 mount in 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.
  • Page 305 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 air 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.
  • Page 306 SUSPENSIONS Suspension Troubleshooting - XTRA Lite Style Problem Solution 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...
  • Page 307 SUSPENSIONS Suspension Troubleshooting - XTRA 10 Style Problem Solution 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...
  • Page 308 SUSPENSIONS Suspension Troubleshooting - EDGE RMK 7.47...
  • Page 310 CHAPTER 8 BRAKES / FINAL DRIVE Track and Chaincase Specifications ....Jackshaft RPM Charts ....... . 8.2 -- 8.4 HYVO Sprocket Part Numbers .
  • Page 312 Length x Width Height Indy 500 SKS 15² x 136² 1.25² Indy 700 SKS 15² x 136² 1.25² Indy Trail RMK 15² x 136² 1.25² Indy 500 RMK 15² x 136² 1.50² Indy 600 EDGE RMK 15² x 136² 1.75²...
  • Page 313 BRAKES / FINAL DRIVE...
  • Page 314 BRAKES / FINAL DRIVE...
  • Page 315 BRAKES / FINAL DRIVE...
  • Page 316 BRAKES / FINAL DRIVE HYVOtSprocket Part Numbers Top Sprockets For 3/4² HYVOt Drive Systems 3221084 3221085 3221086 3221087 3221088 3221089 3221090 3221091 3221092 HYVOt Drive Chain Chain Length (Pitch) Part Number 3224071 3224070 3224069 Bottom Sprockets For 3/4² HYVOt Drive Systems Standard Bottom Sprockets Reverse Sprockets 2900010...
  • Page 317 BRAKES / FINAL DRIVE Sprocket / Chain Combinations - - 7.05² Center Distance Chain Case ² 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. Upper Sprocket Lower Sprocket Chain Length...
  • Page 318 BRAKES / FINAL DRIVE Sprocket / Chain Combinations - - 7.92² Chain Case Acceptable gearing / chain combinations are listed below for the 7.92² (center distance) chaincase. Do not use this chart for models with 6.625² or 7.05² chaincase. Refer to page 8.1 for chaincase center distance by model. Combinations listed as “not recommended”...

  • Page 319: Compensating Port

    Hydraulic Brake System Overview View 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.
  • Page 320 5. Add brake fluid to within 1/4-5/16² (.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.
  • Page 321 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 1/2² (1.3 cm.) from handlebar. No Closer Than 1/2²...
  • Page 322 BRAKES / FINAL DRIVE 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 10. Brakelight Switch 11. Cartridge Kit 12. LH Control Asm 13.
  • Page 323 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. Pour out the fluid in the reservoir into a container.
  • Page 324 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.
  • Page 325 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.
  • Page 326 Brake Line Torque - 1 ft. lb. (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.
  • Page 327 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 lever.
  • Page 328 BRAKES / FINAL DRIVE 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.
  • Page 329 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 not allow brake fluid to come in contact with finished surfaces. 2. Using a small screwdriver, lift long spring arm out of its notch in the housing.
  • Page 330 BRAKES / FINAL DRIVE 2. Rotate the straight spring arm counterclockwise while tilting the park lever down and inserting the pivot post into the pivot hole. Pivot Hole Rotate 3. Release the straight arm of the spring and push the park lever pivot post down into position.
  • Page 331 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.
  • Page 332 BRAKES / FINAL DRIVE 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. 8.
  • Page 333 BRAKES / FINAL DRIVE Hydraulic Caliper Disassembly 1. Carrier Bracket Attaching Bolts 2. Carrier Bracket 3. Piston 4. Piston Seal 5. Spring Clip 6. Stop Light Switch 7. Brake Pads 8. Brake Line 9. Bleeder Screw 10. Caliper 11. Rope Guide WARNING The rider’s safety depends on cor- rect installation.
  • Page 334 BRAKES / FINAL DRIVE 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.
  • Page 335 BRAKES / FINAL DRIVE Hydraulic Brake Assembly, Cont. 4. Examine pads for wear or damage. If pad thickness is less than 1/32² (.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.
  • Page 336 BRAKES / FINAL DRIVE 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 1. Mark hood hinges for ease of alignment when reassembling.
  • Page 337 BRAKES / FINAL DRIVE Rear Suspension Removal, Cont. 6. Remove three 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.
  • Page 338 BRAKES / FINAL DRIVE 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.
  • Page 339 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 bearings on drive shaft: If bearings are loose internally or rough they should be replaced.

  • Page 340: Jackshaft Installation

    BRAKES / FINAL DRIVE 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. Loctiteä 680 PN 2870584 2. Reinstall snap rings. 3. Press new seals in until outer edge is flush with chaincase shoulder.
  • Page 341 BRAKES / FINAL DRIVE Jackshaft Installation, Cont. 5. If shaft is not 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.
  • Page 342 BRAKES / FINAL DRIVE 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.
  • Page 343 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.
  • Page 344 BRAKES / FINAL DRIVE Final Assembly 1. Check speedometer cable routing. 2. Grease angle drive and bearing with Polaris grease. Polaris Premium All Season Grease PN 2871423 3. Torque bottom chaincase sprocket bolt to specification. Bottom Chaincase Sprocket Bolt Torque - 19 ft.
  • Page 345 Washer Seal Sleeve Brake Hub Cotter Pin 9. Add 9 oz. (11 oz. on models equipped with reverse) of Polaris chaincase oil to the Snap Ring chaincase. Verify proper level with dipstick. Ill. 2 Polaris Synthetic Gearcase Lube PN 2871477 (Gallon) PN 2871478 (12 ounces) 10.
  • Page 346 BRAKES / FINAL DRIVE 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 21/32²: P90 Electric Start Off- set: 1.28²...
  • Page 347 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.
  • Page 348 BRAKES / FINAL DRIVE The following illustration indicates sprocket position with the Polaris Reverse Kit in 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.
  • Page 349 BRAKES / FINAL DRIVE Reverse System Maintenance Chain Retention Bracket Screw Washer Pinion Gear Spur Washer Pinion Shaft O Ring Pinion Gear Drive Compression Spring Drive Coupler Retainer Washer Drive Coupler Reverse Gear Bolt Chain Tension Adjustment 1. Elevate the rear of machine and support so track is off the floor.
  • Page 350 BRAKES / FINAL DRIVE Oil Change 1. Change annually, prior to off season storage. Oil Level 1. Using Polaris chaincase lubricant, maintain proper oil level. Proper level is checked by removing dipstick. 2. Wipe off any metal particles from the dipstick.
  • Page 352 ..... 9.4 - 9.5 Indy Trail RMK Electrical Exploded View ..Indy 500 SKS / 600 EDGE RMK Electrical Exploded View .
  • Page 354 Volts and Ohms quality multitester will work. However, due to ease of opera- Dial tion and durability, Polaris 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.
  • Page 355 ELECTRICAL Multimeter Usage W = 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.
  • Page 356 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.

  • Page 357: Ignition Timing

    ELECTRICAL Ignition Timing Maximum Advance (Depending on Model) 1000 2000 3000 4000 5000 6000 7000 8000 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 at a “flat”...
  • Page 358 ELECTRICAL Degrees to Piston Position - - BTDC Conversion Chart ‘ If the ignition timing specification is listed in degrees only, convert to either inches or mm BTDC and use a dial indicator to verify timing marks. NOTE: Due to differing rod lengths and engine strokes, consult the engine model list for correct engine.
  • Page 359 ELECTRICAL Indy Trail RMK Stator Assembly Wiring Harness Flywheel / Fan Assembly 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.
  • Page 360 ELECTRICAL Indy 500 RMK (SKS Euro) / 600 EDGE RMK Stator Flywheel Water Pump Pulley CDI Controller 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...
  • Page 361 ELECTRICAL I700 / 800 EDGE RMK Stator Plate Flywheel Housing Flywheel Exciter Water / Oil Pump Drive Belt RFI Cap Lighting Coil CDI Control Unit Wiring Harness 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.
  • Page 362 ELECTRICAL Timing Procedure - All Models NOTE: Always check ignition timing with the engine at room temperature only (20_C/68_F). 1. Refer to the timing specification charts at the beginning of this section to determine the proper ignition timing for the engine you are working on. 2.

  • Page 363: Battery Testing

    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 must be taken. NOTE: Do not service the battery unless it will be put into regular service within 30 days.
  • Page 364 ELECTRICAL Load Test NOTE:This 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.
  • Page 365 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- Remove battery, test and/or service.
  • Page 366 ELECTRICAL Starter Motor Static Testing (Disconnect R/W Wire) 1. Remove starter motor and disassemble. (See page 9.14 for exploded view) Mark end covers and housing for proper reassembly. 2. Remove pinion retaining snap ring, spring and pinion gear. 3. Remove brush end bushing dust cover. 4.
  • Page 367 ELECTRICAL Starter Assembly Ring Gear Brush and Spring 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. 4.
  • Page 368 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 ohms. Starter Installation 1. Position starter motor so there is no less than .100² clearance between the ring gear and the starter motor pinion gear.

  • Page 369: Regulated Voltage

    ELECTRICAL Unregulated Voltage - continued 2. Turn the multitester dial to the Volts AC (Vµ) position. 3. Disconnect the alternator to main harness connector at engine. 15-45 4. 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.
  • Page 370 Polaris Snowmobiles: Polaris Domestic twin cylinder engines ........
  • Page 371 ELECTRICAL Headlight Bulb Filament Continuity Test 1. Turn the Multitester dial to the ohms (W) position. 2. Disconnect the wire harness from the headlight bulb. 3. 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.
  • Page 372 ELECTRICAL Ignition Switch Testing (Non-Electric Start) 1. Set the multitester dial to the ohms (W) 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.
  • Page 373 ELECTRICAL Coolant Temperature Indicator Testing Ground the Black/White wire Circuit (with the engine running) to test Power the light. Blk/W Temp 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.

  • Page 374: Speed Control Assurance Adjustment

    ELECTRICAL Insulator Off Idle Switch Auxiliary Kill Switch Contacts Ignition Primary Conductor Plungers Outward Idle Switch 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.

  • Page 375: Speed Control Assurance Replacement

    ELECTRICAL 1. Set the multitester in the ohms (W) 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).
  • Page 376 ELECTRICAL Use the multitester ohmmeter to test the resistance of the fuel sender. Position Ohms Range Empty 95 W 90 - 97.5 W Full 4.5 - 13 W The supply voltage to the gauge should be 13.5 VAC. Fuel Gauge Diode Fuse (0.2A)
  • Page 377 However, upon removal of the TPS, you must mark the TPS position on the carburetor and replace it in the exact same position as removal. Polaris has developed a TPS test kit for aid in setting the Throttle Position Sensor to specification.
  • Page 378 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...

  • Page 379: Tps Adjustment

    Decrease 3. When the TPS is set to 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 Fuji engines (800 XCR). 9.26...
  • Page 380 ELECTRICAL 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.
  • Page 381 ELECTRICAL Condition: No Spark Disconnect the single black (black/white) wire from the CDI Module to Check the ignition switch, wire harness, throttle safety switches the ignition kill circuit. Does it have a spark? and kill switch for proper adjustment or short to ground. Repair Yes! or replace as necessary.
  • Page 382 ELECTRICAL Notes 9.29...
  • Page 384 CHAPTER 10 WIRING DIAGRAMS...
  • Page 386 Cooling System, 3.62 Cooling System Bleeding, 2.11, 3.62 Alignment Bar Specifications, 6.6 Cooling System Diagram, 3.64, 3.65, 3.66 Crankcase Inspection, 3.50 Crankshaft Bearing Inspection, 3.50 Crankshaft Indexing, 3.54, 3.55 Battery Charging, 9.11 Crankshaft Truing, 3.52 Battery Filling, 9.11 Cylinder Cleaning, 3.48 Battery Storage, 9.11 Cylinder Deglazing, 3.47 Battery Testing, 9.10...
  • Page 387 Hi/Lo Beam Switch Testing, 9.18 HiFax Inspection, Replacement, 7.6 Engine Installation, 3.9–3.13 HiFax Removal, 7.6 Engine Removal, 3.5–3.9 Hone Selection, 3.47 Engine Torque Specifications, 3.1 Honing Procedure, 3.48 Honing to Oversize, 3.47 Hood Repair, 6.29 Hydraulic Caliper Disassembly, 8.22 Float Chamber Venting, 4.11 Float Level Adjustment, 4.23 Float System, 4.18 Fox Shock Assembly, 7.31, 7.32, 7.33, 7.34, 7.35...

  • Page 388: Table Of Contents

    Ski Installation, 6.23 Ski Skag Installation, 6.22 Oil Pump Adjustment, 2.7 Ski Spindle Bushing Replacement, 6.19, 6.20 Oil Pump Adjustment Procedure, 3.61 Spark Plugs, 2.14 Oil Pump Bleeding, 3.59 Specific Gravity Test, 9.10 Oil Pump Bushing End Play Adjustment, 3.59, 3.60 Speed Control Assurance Adjustment, 9.21 Oil Pump Operation, 3.58 Speed Control Assurance Replacement, 9.22...
  • Page 389 Track Alignment, Alignment, Track, 2.12 Troubleshooting, Suspension, Xtra 10, 7.43, 7.44 Troubleshooting, Suspension, Xtra Lite, 7.42 Track Maintenance, 2.12 Track Specifications, 8.1 Track Tension, 2.13 Track Tension Data, 2.13 Unregulated Voltage, 9.15, 9.16 Troubleshooting, Drive / Driven Clutches, 5.41, 5.42 Troubleshooting, Oil Pump, 3.58 Troubleshooting, Seat Harness, 9.18 Water Pump Belt Tension, Domestic Engines, 2.7...
  • Page 391 ELECTRICAL INDY 500 RMK 500 SKS EURO 10.2...

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