800 Edge Rmk 144”/151”/156” - Polaris INDY TRAIL RMK Service Manual

GENERAL INFORMATION
800 EDGE RMK 144", 151", 156"
MODEL: . . . . . . . . . .
MODEL NUMBER: . S02NM8CS
ENGINE MODEL: . . S2188- -8070PL8C
CARBURETION
Type . . . . . . . . . . . . . . . . TM 40 w/ TPS
Main Jet . . . . . . . . . . . . 390
Pilot Jet . . . . . . . . . . . . . 45
Jet Needle . . . . . . . . . . . 9DGJ3--57/2
Needle Jet . . . . . . . . . . . P-8 (825)
Cutaway . . . . . . . . . . . . 2.0
Fuel Screw . . . . . . . . . . 2.0 Turn
Air Screw 1.0 Turn
Valve Seat . . . . . . . . . . . 1.8
Fuel Octane (R+M/2) . Key Switch Adj.
91 Premium
89 Regular
Throttle Gap
Under Cutaway . . . . . . 0.102² (2.6mm)
Starter Jet . . . . . . . . . . . 145
Pilot Air Jet . . . . . . . . . . N/A
Exhaust Valve Spring . Pink
Low Elevation Exhaust
Valve Spring . . . . . . . . . Purple/White
CLUTCH
Type . . . . . . . . . . . . . . . . P-85
Belt . . . . . . . . . . . . . . . . . 3211080
Belt Width (Projected) 1.438² .
Side Angle (Overall) . . 28°
Outside Circumference 46.625²
Center Distance . . . . . . 11.50²
Shift Weights . . . . . . . . 10-60 Bushed
Primary Spring . . . . . . . Black/Green
Secondary Spring . . . . Silver / Blue
Driven Helix . . . . . . . . . R-11 #3
ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . .
Displacement . . . . . . . . . . . . . . .
Bore . . . . . . . . . . . . . . . . . . . . . . .
Stroke . . . . . . . . . . . . . . . . . . . . .
Piston / Cylinder Clearance
Service Limit . . . . . . . . . . . . . . . .
Piston Marking . . . . . . . . . . . . . .
Piston Ring Marking . . . . . . . . .
Piston Ring End Gap . . . . . . . .
Head ccs (Uninstalled)
Head ccs (Installed) . . . . . . . . .
Operating RPM±200 . . . . . . . . .
Idle RPM±200 . . . . . . . . . . . . . .
Engagement RPM±300
Cylinder Head Torque . . . . . . . .
Cylinder Base Nut Torque
Crankcase Torque (8mm)
Crankcase Torque (10mm)
Flywheel Torque . . . . . . . . . . . . .
1.26
Altitude Altitude
Meters Meters
( (Feet) )
Altitude Altitude
Meters Meters
( (Feet)
Liquid Cooled Case Reed w/TPS
794cc
3.3464² (85mm)
2.7559² (70mm)
. . . 0.006² - 0.0074² (0.15 - 0.188mm)
N/A
3021184
N/A
0.016² - 0.022² (0.41 - 0.56mm)
. . . . . . . 46 - 47cc
33 - 33cc
8000RPM
1500 RPM
. . . . . . 4000 RPM
18-22 ft.lbs. (25-30 Nm)
. . . . 30-34 ft.lbs. (41-47 Nm)
. . . . . 29-24 ft.lbs. (28-33 Nm)
. . . 26-30 ft.lbs. (36-41 Nm)
90 ft.lbs. (124 nm)
JETTING CHART
Below -30°F -30_ to - -10_F
Below 34 C Below -34°C
-34_to -23_C -34 to -23 C
0- -600 560N 540N
(0- -2000)
#4 #4
520N
600- -1200 500
(2000- -4000)
#4 #4
1200 1800 1200- -1800 490 490 470 470
(4000- -6000) ( 000 6000)
#4 #4
1800- -2400 450 50 430 30
(6000- -8000) (6000 8000)
#4 # #3 #3
410 390
2400- -3000 0 390
(8000 10000) (8000- -10000)
#3 #3 #3 #3
3000- -3700 360 360 3 0 340
(10000 12000)
(10000- -12000)
#3 #3 #2 #2
XXX
#X
- # refers to the clip position from top of jet needle.
CLUTCH CHART
DRIVE
Shift Shift Clutch Clutch
Weight Spring
Black Black
0-900 0-900
10 64 10-64
)
Green
(0-3000)
Black Black
900-1500 900-1500
10 64 10-64
(3000-5000) Green
Black Black
1500-2100 1500-2100
10 62 10-62
(5000-7000) Green
Black Black
2100-2700 2100-2700
10-60 10 60
(7000-9000) Green
2700-3300 10-58 Black
(9000-11000)
Green
3300-3900 10-56 Black
(11000-13000)
Green
Fuel Pump Manuf.
Fuel Pump Mark
Oil Pump Manuf.
Oil Pump Mark
Cylinder Head Mark
AMBIENT TEMPERATURE
- -10_to +10_F +10_to +30_F +30_to +50_F
- 23 to - -12 C -23_ to - -12_C -12 to - -1 C -12_to - -1_C -1_to +10_C - 1 to +10 C
520N 500 480
#4 #4 #3
480 460 440
#4 #3 #2
450 450 430 430 410 410
#3 #3 #2
410 0 390 390 370 3 0
#3 #3 #2 #2 #2 #2
370 350 330
3 0 350 330
#2 #2 #2 #2 #2 #2
330 330 320 3 0 300 300
#2 #2 #2 #2 #2 #2
DRIVEN
Chaincase
Clutch Clutch Driven Driven
Gearing Gearing
Spring Helix
(144, 151)
Silver / Silver / R-11 R-11 21- -41 74P 21- -41 74P
Blue #2
HYVO
Silver / Silver / R- -11 R- -11 21- -41 74P 21- -41 74P
Blue #3
HYVO
Silver / Silver / R-11 R-11 21- -41 74P 21- -41 74P
Blue #3
HYVO
Silver / Silver / R-11 R-11 21- -41 74P 21- -41 74P
Blue #3
HYVO
Silver / R-11 21- -41 74P
Blue #3 HYVO
Silver / R-11 21- -41 74P
Blue #3 HYVO
. . . . . Walbro
. . . . . . . N/A
. . . . . . . Mikuni
. . . . . . . . 2540053
. . . . 3021294
Above +50_F
Above +10 C Above +10_C
460
#3
420
#2
390 390
#2
350 350
#2 #2
310
3 0
#2 #2
290 90
#1 #1
DRIVEN
Chaincase
Gearing Gearing
(156)
19 39 72P 19-39 72P
HYVO
19-39 72P 19 39 72P
HYVO
19-39 72P 19 39 72P
HYVO
19-39 72P 19 39 72P
HYVO
19-39 72P
HYVO
19-39 72P
HYVO