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800 EDGE RMK
Polaris 800 EDGE RMK Manuals
Manuals and User Guides for Polaris 800 EDGE RMK. We have
1
Polaris 800 EDGE RMK manual available for free PDF download: Service Manual
Polaris 800 EDGE RMK Service Manual (393 pages)
2002 DEEP SNOW
Brand:
Polaris
| Category:
Snowmobiles
| Size: 6.1 MB
Table of Contents
Understanding Safety Labels and Instructions
3
Contents
4
Table of Contents
6
General Information
6
General Information
8
Chapter 1 General Information
9
Model Number Identification
9
Engine Designation Numbers
9
Tunnel Decal
9
Vehicle Identification Number / Model Number Key
10
Year / Letter Identification
10
Standard Bolt Torque Specifications
11
SAE Tap Drill Sizes
13
Metric Tap Drill Sizes
13
Carburetion
21
Jetting Chart
21
Clutch Chart
21
Indy 500 RMK Specifications
23
Indy Trail RMK Specifications
25
EDGE RMK Specifications
27
EDGE RMK Specifications
28
Indy 700 Sks
29
800 Edge Rmk 144”/151”/156”
33
Maintenance and Tune up
36
1500 Mile (2400 Km) Maintenance Inspection
38
Chapter 2 Maintenance and Tune up
39
Recommended Maintenance Products
39
Air Filter Maintenance
40
Key Components
40
Cleaning Procedure - Plug
41
Oil Filter / Fuel Filter Maintenance
41
Water / Sediment Trap Maintenance
41
ACCS (Altitude Compensating Carburetor System) Maintenance
42
Driveshaft Bearing Greasing
43
Jackshaft Bearing Greasing
43
Oil Pump Adjustment
44
Water Pump Belt Tension
44
Weight Construction
44
Chaincase Oil Level
45
Drive Chain Tension - Chaincase Cover Installed
45
Drive Chain Tension - Chaincase Cover Removed
45
Suspension Lubrication
46
XTRA 10 Style
46
XTRA Lite Style
46
EDGE RMK Style
47
Bleeding the Cooling System - Pressure Caps
48
Bleeding the Cooling System - Surge Tanks
48
Coolant Level
48
Recommended Coolant
48
Track Alignment
49
Track Maintenance
49
If the Track Needs Adjustment
50
Track Tension - XTRA Lite / Xtra 10 / EDGE RMK
50
Track Tension Data
50
Normal
51
Spark Plug Selection
51
Wet Fouled
51
Belt Inspection
52
Belt Installation
52
Belt Removal
52
Drive Belt
52
Headlight Adjustment
53
Installing Low Beam Bulb
53
Removing and Installing Halogen Bulbs - High Beam
53
Removing Halogen Bulbs - Low Beam
53
Handlebar Adjustment
54
Taillight Bulb Replacement
54
Bleeding the Hydraulic Brake System
55
Master Cylinder Fluid Level
55
Replenishing Brake Fluid
55
Reverse Adjustment
56
Throttle Lever Free Play
56
Cleaning and Preservation of Hood, Chassis and Trim
57
Clutch and Drive System
57
Controls and Linkage
57
Electrical Connections
57
Lubrication
58
Battery
59
Engine and Carburetor
59
Exhaust System
59
Engines
62
Engine Torque Specifications
64
Torque Sequences - EC55 Engines
65
Torque Sequence / Domestic 500
66
Torque Sequence / Domestic 600 / 700 / 800
67
Engine Removal, Typical
68
Engine Installation, Typical
72
Engine Disassembly / Assembly - Fuji 550 Fan Cooled Engines
76
Engine Assembly
83
Engine Disassembly / Assembly
89
Assembly
93
Disassembly, Cleaning, Inspection - VES
110
Variable Exhaust System (V.E.S.)
111
V.E.S. Adjustment
112
Exhaust Valve Springs for Low Elevation
113
Polaris Variable Exhaust System Springs
113
Cylinder Hone Selection
114
Cylinder Honing
114
De-Glazing
114
Honing to Oversize
114
Cleaning the Cylinder after Honing
115
Honing Procedure
115
Port Chamfering
115
Piston Measurement
116
Crankcase Bearing Interference Fit
117
Crankcase Inspection / Bearing Fit
117
Crankshaft Main Bearing Inspection
117
Connecting Rod (Big End) Bearing Inspection
118
Connecting Rod Small End Inspection
118
Piston Pin / Needle Bearing Inspection
118
Crankshaft Runout Inspection
119
Crankshaft Truing
119
Crankshaft Indexing
121
Cylinder Head Inspection
123
Cylinder Measurement
123
Cylinder out of Round
123
Cylinder Taper
123
Piston Inspection/Measurement
124
Piston Ring Installed Gap
124
Oil Pump Operation and Troubleshooting
125
Oil Pump Bleeding
126
Oil Pump Bushing End Play Adjustment
126
Mikuni Flatslide Carburetors
128
Oil Pump Adjustment Procedure
128
Roundslide Carburetors
128
Cooling System
129
Domestic Twins Bleeding Procedure
129
Filling and Bleeding Procedure
129
Cooling System 500 RMK / 500 SKS (Euro)
130
Cooling System - 700 SKS (Euro)
131
Cooling System - 600 RMK
132
Cooling System - 700, 800 RMK
133
Recoil Disassembly
134
Engine Troubleshooting
135
Fuel System / Carburetion
138
Chapter 4 Fuel System / Carburetion
140
Jet Part Numbers
140
Jet Needle Part Numbers (Mikuni)
141
Needle Jet Part Numbers (Mikuni)
141
Mikuni TM 38 / TM 40 Jet Part Numbers
142
Mikuni TM 38 / TM 40 Jet Needle Overview
143
Mikuni TM 38 / TM 40 Overview
144
Mikuni TM 38 / TM 40 Exploded View
145
Mikuni VM 34SS Exploded View
146
Altitude Compensating Carburetor System (ACCS)
147
High Atmospheric Pressure
148
Low Atmospheric Pressure
148
Explanation of Gasoline Volatility
149
Float Chamber Venting
150
Fuel Delivery System - Typical
151
Mikuni VM Carburetor
152
Pilot Air Screw
153
Pilot Jet
153
Throttle Valve
154
Jet Needle / Needle Jet
155
Throttle Opening Vs. Fuel Flow
155
Jetting Guidelines
156
Main Jet
156
Float System
157
Carburetor Removal, Disassembly, and Inspection (Typical VM Mikuni)
159
Carburetor Disassembly and Inspection
160
Float Level Adjustment
162
Leak Testing Needle and Seat
162
Throttle Cable Synchronization (Throttle Gap)
163
Throttle Synchronization Procedure
163
Carburetor Removal, Disassembly, and Inspection
164
Carburetor Disassembly
167
Carburetor Assembly
168
Mikuni TM-38 Flatslide Carburetors
169
Adjustment Procedure
171
Choke Adjustments
171
Maintenance
172
Troubleshooting
174
Troubleshooting Tips, 1/4-3/8 Throttle
175
Troubleshooting Tips, 3/8-3/4 Throttle
175
Troubleshooting Tips, Full Throttle
175
Drive / Driven Clutches
176
Essential Drive Clutch Tools
178
Driven Clutch Spring Data
183
Driven Clutch Springs
183
Driven Spring Charts
183
P-85 Drive Clutch
184
P-85 Driven Clutch
185
Driven Clutch Adjustments
188
Identification
189
Disassembly and Inspection
190
Roller Installation
192
Spider Roller Removal
192
Spider Button Shimming
193
Drive Clutch Assembly
195
Spider Indexing
198
Driven Clutch Removal
199
Disassembly
200
Helix Angles and Effects
203
Helix Ramps
203
Installation
205
Drive Belt Inspection
207
Belt Wear / Burn Diagnosis
207
Belt Deflection
208
Measuring Belt Deflection
209
Adjusting Belt Deflection (P-85)
209
Clutch Offset Inspection
210
Clutch Offset Adjustment
210
Clutch Alignment Inspection
211
Clutch Alignment Adjustment
211
Torque Stop Adjustment
211
Crankcase Torque Stop
211
Belt to Sheave Clearance Inspection
212
Belt to Sheave Clearance Adjustment
212
P-85 Drive Clutch Cover Bushing Removal
213
P-85 Drive Clutch Cover Bushing Installation
214
P-85 Drive Clutch Movable Sheave Bushing Removal
215
P-85 Drive Clutch Movable Sheave Bushing Installation
215
P-85 Driven Clutch Movable Sheave Large Bushing Removal
216
P-85 Driven Clutch Movable Sheave Large Bushing Installation
217
Drive / Driven Clutches Troubleshooting
218
Body and Steering
222
Steering Assembly - Indy Trail RMK
224
Steering Assembly - Indy 500 SKS European
225
Steering Assembly - Indy 700 SKS / 700 SKS European
226
Steering Assembly - Indy 500 RMK
227
Steering Assembly - EDGE RMK 600 / 700 / 800
228
Inspection
229
Alignment Bar Specifications
229
Camber Definition - All IFS
230
Radius Rod and Tie Rod End Torque Procedure
230
Rod End Engagement Guidelines - All IFS
230
2002 IFS Steering Alignment Specifications
231
Spindle Centering / Set up Width
232
Camber Inspection
233
Camber - Acceptable Range
233
Camber Adjustment
234
Radius Rod End Jam Nut Torque
234
Radius Rod Attaching Bolt Torque
234
Chapter 6 Body and Steering
235
Handlebar Centering
235
Toe Adjustment, All Models
236
General Set up Tips
238
Tools
238
XTRA CRC and XC-10 CRC Steering Alignment
238
Camber Adjustment - XTRA CRC and XC-10 CRC
239
CRC Steering Adjustment
239
Spindle to Chassis Centering
239
Handlebar Centering-CRC
240
Carbide to Ski Placement
241
Indy Select / Ryde AFX IFS Shock
241
Ski Spindle Bushing Removal / Replacement
242
Ski Spindle Bushing Installation
243
Steering Arm Orientation
244
Ski Skag Installation
245
Ski Skag Installation - EZ Steer
245
Ski Skag Removal
245
Ski Skag Removal - EZ Steer
245
Metal Ski Installation
246
Plastic Ski Installation
246
Ski Installation
246
Torsion Bar Installation
247
Torsion Bar Removal
247
Handlebar Torque and Sequence
248
One Piece Fuel Tank/Seat Removal
249
Two Piece Fuel Tank/Seat Removal
249
Seat Cover Replacement
250
Hood Repair
252
Models with Grommets in Tool Flap
252
Taillight Assembly Replacement
253
Nosepan Replacement Procedure - Gen II XTRA-10
254
Nosepan Replacement Procedure - Gen II XC-10
255
Nosepan Replacement Procedure - EDGE RMK
256
Decal Installation
257
Decal Removal / Installation
257
Suspensions
260
Troubleshooting
260
Rear Suspension Operation
262
Weight Transfer
262
Springs
263
Optional Torsion Springs
264
Setting Initial Torsion Spring Preload
264
Suspension Overview
264
Shock Tuning
265
Overall Suspension Setup for Optimal Performance
266
Set up Recommendations for Optimum Performance
266
Hi-Fax Removal
267
Hi-Fax Replacement - All Models
267
Suggested Hi Fax Wear Limit
267
Front Torque Arm
269
Rear Suspension Exploded View / XTRA Lite
269
Rear Torque Arm
269
XTRA Lite Rear Suspension
270
XTRA 10 Rear Suspension
271
EDGE RMK Exploded View
273
Suspension Adjustment
274
Adjustable Features and Adjustment Options
274
Independent Front Suspension (IFS)
275
Rear Suspension
275
Adjustment Procedures
276
Rear Spring Tension
277
Front Suspension Setup and Adjustments
278
Front Torque Arm Limiter Strap Adjustment - XTRA-10
279
Compression Damping Adjustable Shocks
280
How to Adjust IFS
280
How to Adjust Rear Suspension
281
IFS Shock Springs Xtra 10 / Xtra Lite / EDGE RMK
283
Stock Valving Listed by Shock Part Number
284
IFS Shock Valving
284
Front Track Shock Valving
284
Rear Track Shock Valving
284
Front Track Shocks
285
Rear Track Shocks
285
IFS Shocks
285
Foxä Shock Maintenance
286
Gas Shock Recharging Kit
286
2002 Fox Optional Valving Listed by Shock Part Number
287
Valve Washer Part Numbers
287
Seal Replacement
290
Ryde Fxä Shock Maintenance
298
Depressurizing Shock
298
Ryde FX 7041968 GENERAL REBUILD PROCEDURES
303
Suspension Troubleshooting - XTRA Lite Style
306
Suspension Troubleshooting - XTRA 10 Style
307
Suspension Troubleshooting - EDGE RMK
308
Brakes / Final Drive
310
2002 Tracks
312
2002 Chaincases
312
Hyvotsprocket Part Numbers
316
Top Sprockets for 3/4² Hyvot Drive Systems
316
Hyvot Drive Chain
316
Bottom Sprockets for 3/4² Hyvot Drive Systems
316
Hydraulic Brake System Overview
319
Compensating Port
319
Brake Bleeding - Fluid Change
320
Hayest Master Cylinder
322
Park Brake Lever Lock
322
Hayest Master Cylinder Removal
322
Replacing Cartridge Subassembly
323
Brake Line Torque
326
Polaris DOT 3 Brake Fluid
326
Cover Screw Torque
326
Lever And/Or Pivot Pin Removal
327
Lever And/Or Pivot Pin Installation
328
Park Brake Lever And/Or Spring Removal
329
Park Brake Lever And/Or Spring Installation
329
Friction Pad Replacement
331
Brake Pad Thickness
331
Caliper Bolt Torque
332
Reservoir Cover Torque
332
Hydraulic Caliper Disassembly
333
Hydraulic Brake Cleaning and Inspection
334
Hydraulic Brake Assembly
334
Drive System Disassembly
336
Rear Suspension Removal
336
Chaincase Removal
337
Chaincase Bearing Removal
338
Jackshaft Removal
338
Driveshaft Removal
339
Chaincase Assembly
340
Jackshaft Installation
340
Driveshaft Installation
341
Chaincase Mounting Bolt Torque
341
Flangette Nut Torque
341
Track Installation
343
Final Assembly
344
Chaincase Cover Bolt Torque
345
Polaris Synthetic Gearcase Lube
345
Clutch Alignment Tool
346
Driven Clutch Retaining Bolt Torque
346
Reverse Installation Tips
348
Reverse System Maintenance
349
Chain Tension Adjustment
349
Oil Change
350
Oil Level
350
Adjustment
350
Reverse Linkage Rod End Play
350
Electrical
352
Chapter 9 Electrical
354
Multimeter Usage
354
Test Method
354
Dial Indicating the Timing Marks
357
Ignition Timing
357
Degrees to Piston Position - BTDC Conversion Chart
358
Indy Trail RMK
359
Indy 500 RMK (SKS Euro) / 600 EDGE RMK
360
280 Watt Charging System
361
I700 / 800 Edge Rmk
361
Timing Procedure - All Models
362
Battery Testing
363
Open Circuit Voltage Test (OCV)
363
Preparing a New Battery for Service
363
Specific Gravity Test
363
Charging Procedure
364
Load Test
364
Off Season Storage
364
Refilling a Low Battery
364
Dynamic Testing of the Electric Starting System
365
Armature Testing
366
Starter Housing and Field Coil Inspection
366
Starter Motor Static Testing
366
Starter Assembly
367
Starter Installation
368
Starter Solenoid Bench Test
368
Unregulated Voltage
368
Regulated Voltage
369
Short Circuit Current (AC Amp Test)
369
2-Pulse and 6 Pulse Alternators
370
2002 Flywheels
370
Polaris Snowmobiles
370
Tachometers
370
Headlight Bulb Filament Continuity Test
371
Hi/Lo Beam Switch Testing
371
Seat Harness Troubleshooting
371
Ignition Switch Testing (Electric Start Models)
372
Ignition Switch Testing (Non-Electric Start)
372
Coolant Temperature Indicator Testing
373
Coolant Temperature Sensor
373
Lamp Circuit Test
373
Temp Light Temperature Sensor Test
373
Speed Control Assurance Adjustment
374
Throttle Lever Freeplay
374
Auxiliary Shut-Off
375
Closed Circuit - Kill
375
Open Circuit - Run
375
Speed Control Assurance Replacement
375
TPS (Throttle Position Sensor)
377
TPS Testing
377
TPS Adjustment
379
Condition: no Spark
381
Condition: Incorrect Advance/Retard
381
Wiring Diagrams
384
Index
386
Wiring Diagram
390
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