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Polaris Manuals
Snowmobiles
INDY 700 SKS
Service manual
Polaris INDY 700 SKS Service Manual
2002 deep snow
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Understanding Safety Labels and Instructions
Contents
Table of Contents
General Information
General Information
Chapter 1 General Information
Model Number Identification
Engine Designation Numbers
Tunnel Decal
Vehicle Identification Number / Model Number Key
Year / Letter Identification
Standard Bolt Torque Specifications
SAE Tap Drill Sizes
Metric Tap Drill Sizes
Carburetion
Jetting Chart
Clutch Chart
Indy 500 RMK Specifications
Indy Trail RMK Specifications
EDGE RMK Specifications
EDGE RMK Specifications
Indy 700 Sks
800 Edge Rmk 144”/151”/156”
Maintenance and Tune up
1500 Mile (2400 Km) Maintenance Inspection
Chapter 2 Maintenance and Tune up
Recommended Maintenance Products
Air Filter Maintenance
Key Components
Cleaning Procedure - Plug
Oil Filter / Fuel Filter Maintenance
Water / Sediment Trap Maintenance
ACCS (Altitude Compensating Carburetor System) Maintenance
Driveshaft Bearing Greasing
Jackshaft Bearing Greasing
Oil Pump Adjustment
Water Pump Belt Tension
Weight Construction
Chaincase Oil Level
Drive Chain Tension - Chaincase Cover Installed
Drive Chain Tension - Chaincase Cover Removed
Suspension Lubrication
XTRA 10 Style
XTRA Lite Style
EDGE RMK Style
Bleeding the Cooling System - Pressure Caps
Bleeding the Cooling System - Surge Tanks
Coolant Level
Recommended Coolant
Track Alignment
Track Maintenance
If the Track Needs Adjustment
Track Tension - XTRA Lite / Xtra 10 / EDGE RMK
Track Tension Data
Normal
Spark Plug Selection
Wet Fouled
Belt Inspection
Belt Installation
Belt Removal
Drive Belt
Headlight Adjustment
Installing Low Beam Bulb
Removing and Installing Halogen Bulbs - High Beam
Removing Halogen Bulbs - Low Beam
Handlebar Adjustment
Taillight Bulb Replacement
Bleeding the Hydraulic Brake System
Master Cylinder Fluid Level
Replenishing Brake Fluid
Reverse Adjustment
Throttle Lever Free Play
Cleaning and Preservation of Hood, Chassis and Trim
Clutch and Drive System
Controls and Linkage
Electrical Connections
Lubrication
Battery
Engine and Carburetor
Exhaust System
Engines
Engine Torque Specifications
Torque Sequences - EC55 Engines
Torque Sequence / Domestic 500
Torque Sequence / Domestic 600 / 700 / 800
Engine Removal, Typical
Engine Installation, Typical
Engine Disassembly / Assembly - Fuji 550 Fan Cooled Engines
Engine Assembly
Engine Disassembly / Assembly
Assembly
Disassembly, Cleaning, Inspection - VES
Variable Exhaust System (V.E.S.)
V.E.S. Adjustment
Exhaust Valve Springs for Low Elevation
Polaris Variable Exhaust System Springs
Cylinder Hone Selection
Cylinder Honing
De-Glazing
Honing to Oversize
Cleaning the Cylinder after Honing
Honing Procedure
Port Chamfering
Piston Measurement
Crankcase Bearing Interference Fit
Crankcase Inspection / Bearing Fit
Crankshaft Main Bearing Inspection
Connecting Rod (Big End) Bearing Inspection
Connecting Rod Small End Inspection
Piston Pin / Needle Bearing Inspection
Crankshaft Runout Inspection
Crankshaft Truing
Crankshaft Indexing
Cylinder Head Inspection
Cylinder Measurement
Cylinder out of Round
Cylinder Taper
Piston Inspection/Measurement
Piston Ring Installed Gap
Oil Pump Operation and Troubleshooting
Oil Pump Bleeding
Oil Pump Bushing End Play Adjustment
Mikuni Flatslide Carburetors
Oil Pump Adjustment Procedure
Roundslide Carburetors
Cooling System
Domestic Twins Bleeding Procedure
Filling and Bleeding Procedure
Cooling System 500 RMK / 500 SKS (Euro)
Cooling System - 700 SKS (Euro)
Cooling System - 600 RMK
Cooling System - 700, 800 RMK
Recoil Disassembly
Engine Troubleshooting
Fuel System / Carburetion
Chapter 4 Fuel System / Carburetion
Jet Part Numbers
Jet Needle Part Numbers (Mikuni)
Needle Jet Part Numbers (Mikuni)
Mikuni TM 38 / TM 40 Jet Part Numbers
Mikuni TM 38 / TM 40 Jet Needle Overview
Mikuni TM 38 / TM 40 Overview
Mikuni TM 38 / TM 40 Exploded View
Mikuni VM 34SS Exploded View
Altitude Compensating Carburetor System (ACCS)
High Atmospheric Pressure
Low Atmospheric Pressure
Explanation of Gasoline Volatility
Float Chamber Venting
Fuel Delivery System - Typical
Mikuni VM Carburetor
Pilot Air Screw
Pilot Jet
Throttle Valve
Jet Needle / Needle Jet
Throttle Opening Vs. Fuel Flow
Jetting Guidelines
Main Jet
Float System
Carburetor Removal, Disassembly, and Inspection (Typical VM Mikuni)
Carburetor Disassembly and Inspection
Float Level Adjustment
Leak Testing Needle and Seat
Throttle Cable Synchronization (Throttle Gap)
Throttle Synchronization Procedure
Carburetor Removal, Disassembly, and Inspection
Carburetor Disassembly
Carburetor Assembly
Mikuni TM-38 Flatslide Carburetors
Adjustment Procedure
Choke Adjustments
Maintenance
Troubleshooting
Troubleshooting Tips, 1/4-3/8 Throttle
Troubleshooting Tips, 3/8-3/4 Throttle
Troubleshooting Tips, Full Throttle
Drive / Driven Clutches
Essential Drive Clutch Tools
Driven Clutch Spring Data
Driven Clutch Springs
Driven Spring Charts
P-85 Drive Clutch
P-85 Driven Clutch
Driven Clutch Adjustments
Identification
Disassembly and Inspection
Roller Installation
Spider Roller Removal
Spider Button Shimming
Drive Clutch Assembly
Spider Indexing
Driven Clutch Removal
Disassembly
Helix Angles and Effects
Helix Ramps
Installation
Drive Belt Inspection
Belt Wear / Burn Diagnosis
Belt Deflection
Measuring Belt Deflection
Adjusting Belt Deflection (P-85)
Clutch Offset Inspection
Clutch Offset Adjustment
Clutch Alignment Inspection
Clutch Alignment Adjustment
Torque Stop Adjustment
Crankcase Torque Stop
Belt to Sheave Clearance Inspection
Belt to Sheave Clearance Adjustment
P-85 Drive Clutch Cover Bushing Removal
P-85 Drive Clutch Cover Bushing Installation
P-85 Drive Clutch Movable Sheave Bushing Removal
P-85 Drive Clutch Movable Sheave Bushing Installation
P-85 Driven Clutch Movable Sheave Large Bushing Removal
P-85 Driven Clutch Movable Sheave Large Bushing Installation
Drive / Driven Clutches Troubleshooting
Body and Steering
Steering Assembly - Indy Trail RMK
Steering Assembly - Indy 500 SKS European
Steering Assembly - Indy 700 SKS / 700 SKS European
Steering Assembly - Indy 500 RMK
Steering Assembly - EDGE RMK 600 / 700 / 800
Inspection
Alignment Bar Specifications
Camber Definition - All IFS
Radius Rod and Tie Rod End Torque Procedure
Rod End Engagement Guidelines - All IFS
2002 IFS Steering Alignment Specifications
Spindle Centering / Set up Width
Camber Inspection
Camber - Acceptable Range
Camber Adjustment
Radius Rod End Jam Nut Torque
Radius Rod Attaching Bolt Torque
Chapter 6 Body and Steering
Handlebar Centering
Toe Adjustment, All Models
General Set up Tips
Tools
XTRA CRC and XC-10 CRC Steering Alignment
Camber Adjustment - XTRA CRC and XC-10 CRC
CRC Steering Adjustment
Spindle to Chassis Centering
Handlebar Centering-CRC
Carbide to Ski Placement
Indy Select / Ryde AFX IFS Shock
Ski Spindle Bushing Removal / Replacement
Ski Spindle Bushing Installation
Steering Arm Orientation
Ski Skag Installation
Ski Skag Installation - EZ Steer
Ski Skag Removal
Ski Skag Removal - EZ Steer
Metal Ski Installation
Plastic Ski Installation
Ski Installation
Torsion Bar Installation
Torsion Bar Removal
Handlebar Torque and Sequence
One Piece Fuel Tank/Seat Removal
Two Piece Fuel Tank/Seat Removal
Seat Cover Replacement
Hood Repair
Models with Grommets in Tool Flap
Taillight Assembly Replacement
Nosepan Replacement Procedure - Gen II XTRA-10
Nosepan Replacement Procedure - Gen II XC-10
Nosepan Replacement Procedure - EDGE RMK
Decal Installation
Decal Removal / Installation
Suspensions
Troubleshooting
Rear Suspension Operation
Weight Transfer
Springs
Optional Torsion Springs
Setting Initial Torsion Spring Preload
Suspension Overview
Shock Tuning
Overall Suspension Setup for Optimal Performance
Set up Recommendations for Optimum Performance
Hi-Fax Removal
Hi-Fax Replacement - All Models
Suggested Hi Fax Wear Limit
Front Torque Arm
Rear Suspension Exploded View / XTRA Lite
Rear Torque Arm
XTRA Lite Rear Suspension
XTRA 10 Rear Suspension
EDGE RMK Exploded View
Suspension Adjustment
Adjustable Features and Adjustment Options
Independent Front Suspension (IFS)
Rear Suspension
Adjustment Procedures
Rear Spring Tension
Front Suspension Setup and Adjustments
Front Torque Arm Limiter Strap Adjustment - XTRA-10
Compression Damping Adjustable Shocks
How to Adjust IFS
How to Adjust Rear Suspension
IFS Shock Springs Xtra 10 / Xtra Lite / EDGE RMK
Stock Valving Listed by Shock Part Number
IFS Shock Valving
Front Track Shock Valving
Rear Track Shock Valving
Front Track Shocks
Rear Track Shocks
IFS Shocks
Foxä Shock Maintenance
Gas Shock Recharging Kit
2002 Fox Optional Valving Listed by Shock Part Number
Valve Washer Part Numbers
Seal Replacement
Ryde Fxä Shock Maintenance
Depressurizing Shock
Ryde FX 7041968 GENERAL REBUILD PROCEDURES
Suspension Troubleshooting - XTRA Lite Style
Suspension Troubleshooting - XTRA 10 Style
Suspension Troubleshooting - EDGE RMK
Brakes / Final Drive
2002 Tracks
2002 Chaincases
Hyvotsprocket Part Numbers
Top Sprockets for 3/4² Hyvot Drive Systems
Hyvot Drive Chain
Bottom Sprockets for 3/4² Hyvot Drive Systems
Hydraulic Brake System Overview
Compensating Port
Brake Bleeding - Fluid Change
Hayest Master Cylinder
Park Brake Lever Lock
Hayest Master Cylinder Removal
Replacing Cartridge Subassembly
Brake Line Torque
Polaris DOT 3 Brake Fluid
Cover Screw Torque
Lever And/Or Pivot Pin Removal
Lever And/Or Pivot Pin Installation
Park Brake Lever And/Or Spring Removal
Park Brake Lever And/Or Spring Installation
Friction Pad Replacement
Brake Pad Thickness
Caliper Bolt Torque
Reservoir Cover Torque
Hydraulic Caliper Disassembly
Hydraulic Brake Cleaning and Inspection
Hydraulic Brake Assembly
Drive System Disassembly
Rear Suspension Removal
Chaincase Removal
Chaincase Bearing Removal
Jackshaft Removal
Driveshaft Removal
Chaincase Assembly
Jackshaft Installation
Driveshaft Installation
Chaincase Mounting Bolt Torque
Flangette Nut Torque
Track Installation
Final Assembly
Chaincase Cover Bolt Torque
Polaris Synthetic Gearcase Lube
Clutch Alignment Tool
Driven Clutch Retaining Bolt Torque
Reverse Installation Tips
Reverse System Maintenance
Chain Tension Adjustment
Oil Change
Oil Level
Adjustment
Reverse Linkage Rod End Play
Electrical
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Quick Links
1
Indy 700 Sks
2
800 Edge Rmk 144”/151”/156”
3
Drive Chain Tension/Chaincase Cover Installed/Removed
Download this manual
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
Printed in U.S.A.
Table of
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Table of Contents
Troubleshooting
Oil Pump Operation and Troubleshooting
125
Engine Troubleshooting
135
Troubleshooting
174
Troubleshooting Tips, 1/4-3/8 Throttle
175
Drive / Driven Clutches Troubleshooting
218
Suspensions
260
Suspension Troubleshooting - XTRA Lite Style
306
Suspension Troubleshooting - XTRA 10 Style
307
Suspension Troubleshooting - EDGE RMK
308
Headlight Bulb Filament Continuity Test
371
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