Table Of Contents - Polaris INDY TRAIL RMK Service Manual

Table of Contents

Understanding Safety Labels And Instructions3
Contents4
General Information6
Table Of Contents6
Model Number Identification9
Engine Designation Numbers9
Tunnel Decal9
Vehicle Identification Number / Model Number Key10
Year / Letter Identification10
Standard Bolt Torque Specifications11
Sae Tap Drill Sizes13
Metric Tap Drill Sizes13
Carburetion21
Jetting Chart21
Clutch Chart21
Indy 500 Rmk Specifications23
Indy Trail Rmk Specifications25
Edge Rmk Specifications27
Indy 700 Sks29
800 Edge Rmk 144"/151"/156"33
Maintenance And Tune Up36
1500 Mile (2400 Km) Maintenance Inspection38
Recommended Maintenance Products39
Air Filter Maintenance40
Key Components40
Water / Sediment Trap Maintenance41
Cleaning Procedure - Plug41
Oil Filter / Fuel Filter Maintenance41
Accs (Altitude Compensating Carburetor System) Maintenance42
Jackshaft Bearing Greasing43
Driveshaft Bearing Greasing43
Water Pump Belt Tension44
Oil Pump Adjustment44
Weight Construction44
Chaincase Oil Level45
Drive Chain Tension - Chaincase Cover Installed45
Drive Chain Tension - Chaincase Cover Removed45
Suspension Lubrication46
Xtra Lite Style46
Xtra 10 Style46
Edge Rmk Style47
Coolant Level48
Recommended Coolant48
Bleeding The Cooling System - Pressure Caps48
Bleeding The Cooling System - Surge Tanks48
Track Maintenance49
Track Alignment49
Track Tension Data50
Track Tension - Xtra Lite / Xtra 10 / Edge Rmk50
If The Track Needs Adjustment50
Spark Plug Selection51
Normal51
Wet Fouled51
Drive Belt52
Belt Removal52
Belt Installation52
Belt Inspection52
Headlight Adjustment53
Removing Halogen Bulbs - Low Beam53
Installing Low Beam Bulb53
Removing And Installing Halogen Bulbs - High Beam53
Taillight Bulb Replacement54
Handlebar Adjustment54
Replenishing Brake Fluid55
Master Cylinder Fluid Level55
Bleeding The Hydraulic Brake System55
Throttle Lever Free Play56
Reverse Adjustment56
Cleaning And Preservation Of Hood, Chassis And Trim57
Controls And Linkage57
Electrical Connections57
Clutch And Drive System57
Lubrication58
Engine And Carburetor59
Battery59
Exhaust System59
Engines62
Engine Torque Specifications64
Torque Sequences - Ec55 Engines65
Torque Sequence / Domestic 50066
Torque Sequence / Domestic 600 / 700 / 80067
Engine Removal, Typical68
Engine Installation, Typical72
Engine Disassembly / Assembly - Fuji 550 Fan Cooled Engines76
Engine Assembly83
Engine Disassembly / Assembly89
Assembly93
Disassembly, Cleaning, Inspection - Ves110
Variable Exhaust System (V.e.s.)111
V.e.s. Adjustment112
Polaris Variable Exhaust System Springs113
Exhaust Valve Springs For Low Elevation113
Cylinder Honing114
Cylinder Hone Selection114
De-Glazing114
Honing To Oversize114
Honing Procedure115
Port Chamfering115
Cleaning The Cylinder After Honing115
Piston Measurement116
Crankcase Inspection / Bearing Fit117
Crankshaft Main Bearing Inspection117
Crankcase Bearing Interference Fit117
Connecting Rod (Big End) Bearing Inspection118
Piston Pin / Needle Bearing Inspection118
Connecting Rod Small End Inspection118
Crankshaft Truing119
Crankshaft Runout Inspection119
Crankshaft Indexing121
Cylinder Head Inspection123
Cylinder Measurement123
Cylinder Taper123
Cylinder Out Of Round123
Piston Inspection/Measurement124
Piston Ring Installed Gap124
Oil Pump Operation And Troubleshooting125
Oil Pump Bleeding126
Oil Pump Bushing End Play Adjustment126
Oil Pump Adjustment Procedure128
Roundslide Carburetors128
Mikuni Flatslide Carburetors128
Cooling System129
Filling And Bleeding Procedure129
Domestic Twins Bleeding Procedure129
Cooling System 500 Rmk / 500 Sks (Euro)130
Cooling System - 700 Sks (Euro)131
Cooling System - 600 Rmk132
Cooling System - 700, 800 Rmk133
Recoil Disassembly134
Engine Troubleshooting135
Fuel System / Carburetion138
Jet Part Numbers140
Jet Needle Part Numbers (Mikuni)141
Needle Jet Part Numbers (Mikuni)141
Mikuni Tm 38 / Tm 40 Jet Part Numbers142
Mikuni Tm 38 / Tm 40 Jet Needle Overview143
Mikuni Tm 38 / Tm 40 Overview144
Mikuni Tm 38 / Tm 40 Exploded View145
Mikuni Vm 34Ss Exploded View146
Altitude Compensating Carburetor System (Accs)147
High Atmospheric Pressure148
Low Atmospheric Pressure148
Explanation Of Gasoline Volatility149
Float Chamber Venting150
Fuel Delivery System - Typical151
Mikuni Vm Carburetor152
Pilot Jet153
Pilot Air Screw153
Throttle Valve154
Jet Needle / Needle Jet155
Throttle Opening Vs. Fuel Flow155
Main Jet156
Jetting Guidelines156
Float System157
Carburetor Removal, Disassembly, And Inspection (Typical Vm Mikuni)159
Carburetor Disassembly And Inspection160
Float Level Adjustment162
Leak Testing Needle And Seat162
Throttle Synchronization Procedure163
Throttle Cable Synchronization (Throttle Gap)163
Carburetor Removal, Disassembly, And Inspection164
Carburetor Disassembly167
Carburetor Assembly168
Mikuni Tm-38 Flatslide Carburetors169
Choke Adjustments171
Adjustment Procedure171
Maintenance172
Troubleshooting174
Troubleshooting Tips, 1/4-3/8 Throttle175
Troubleshooting Tips, 3/8-3/4 Throttle175
Troubleshooting Tips, Full Throttle175
Drive / Driven Clutches176
Essential Drive Clutch Tools178
Driven Spring Charts183
Driven Clutch Springs183
Driven Clutch Spring Data183
P-85 Drive Clutch184
P-85 Driven Clutch185
Driven Clutch Adjustments188
Identification189
Disassembly And Inspection190
Spider Roller Removal192
Roller Installation192
Spider Button Shimming193
Drive Clutch Assembly195
Spider Indexing198
Driven Clutch Removal199
Disassembly200
Helix Angles And Effects203
Helix Ramps203
Installation205
Drive Belt Inspection207
Belt Wear / Burn Diagnosis207
Belt Deflection208
Measuring Belt Deflection209
Adjusting Belt Deflection (P-85)209
Clutch Offset Inspection210
Clutch Offset Adjustment210
Clutch Alignment Inspection211
Clutch Alignment Adjustment211
Torque Stop Adjustment211
Crankcase Torque Stop211
Belt To Sheave Clearance Inspection212
Belt To Sheave Clearance Adjustment212
P-85 Drive Clutch Cover Bushing Removal213
P-85 Drive Clutch Cover Bushing Installation214
P-85 Drive Clutch Movable Sheave Bushing Removal215
P-85 Drive Clutch Movable Sheave Bushing Installation215
P-85 Driven Clutch Movable Sheave Large Bushing Removal216
P-85 Driven Clutch Movable Sheave Large Bushing Installation217
Drive / Driven Clutches Troubleshooting218
Body And Steering222
Steering Assembly - Indy Trail Rmk224
Steering Assembly - Indy 500 Sks European225
Steering Assembly - Indy 700 Sks / 700 Sks European226
Steering Assembly - Indy 500 Rmk227
Steering Assembly - Edge Rmk 600 / 700 / 800228
Inspection229
Alignment Bar Specifications229
Camber Definition - All Ifs230
Radius Rod And Tie Rod End Torque Procedure230
Rod End Engagement Guidelines - All Ifs230
2002 Ifs Steering Alignment Specifications231
Spindle Centering / Set Up Width232
Camber Inspection233
Camber - Acceptable Range233
Camber Adjustment234
Radius Rod End Jam Nut Torque234
Radius Rod Attaching Bolt Torque234
Handlebar Centering235
Toe Adjustment, All Models236
Xtra Crc And Xc-10 Crc Steering Alignment238
General Set Up Tips238
Tools238
Crc Steering Adjustment239
Spindle To Chassis Centering239
Camber Adjustment - Xtra Crc And Xc-10 Crc239
Handlebar Centering-Crc240
Carbide To Ski Placement241
Indy Select / Ryde Afx Ifs Shock241
Ski Spindle Bushing Removal / Replacement242
Ski Spindle Bushing Installation243
Steering Arm Orientation244
Ski Skag Removal245
Ski Skag Installation245
Ski Skag Removal - Ez Steer245
Ski Skag Installation - Ez Steer245
Ski Installation246
Metal Ski Installation246
Plastic Ski Installation246
Torsion Bar Removal247
Torsion Bar Installation247
Handlebar Torque And Sequence248
Two Piece Fuel Tank/Seat Removal249
One Piece Fuel Tank/Seat Removal249
Seat Cover Replacement250
Models With Grommets In Tool Flap252
Hood Repair252
Taillight Assembly Replacement253
Nosepan Replacement Procedure - Gen Ii Xtra-10254
Nosepan Replacement Procedure - Gen Ii Xc-10255
Nosepan Replacement Procedure - Edge Rmk256
Decal Installation257
Decal Removal / Installation257
Suspensions260
Rear Suspension Operation262
Weight Transfer262
Springs263
Suspension Overview264
Setting Initial Torsion Spring Preload264
Optional Torsion Springs264
Shock Tuning265
Overall Suspension Setup For Optimal Performance266
Set Up Recommendations For Optimum Performance266
Hi-Fax Replacement - All Models267
Hi-Fax Removal267
Suggested Hi Fax Wear Limit267
Rear Suspension Exploded View / Xtra Lite269
Front Torque Arm269
Rear Torque Arm269
Xtra Lite Rear Suspension270
Xtra 10 Rear Suspension271
Edge Rmk Exploded View273
Suspension Adjustment274
Adjustable Features And Adjustment Options274
Independent Front Suspension (Ifs)275
Rear Suspension275
Adjustment Procedures276
Rear Spring Tension277
Front Suspension Setup And Adjustments278
Front Torque Arm Limiter Strap Adjustment - Xtra-10279
Compression Damping Adjustable Shocks280
How To Adjust Ifs280
How To Adjust Rear Suspension281
Ifs Shock Springs Xtra 10 / Xtra Lite / Edge Rmk283
Stock Valving Listed By Shock Part Number284
Ifs Shock Valving284
Front Track Shock Valving284
Rear Track Shock Valving284
Front Track Shocks285
Rear Track Shocks285
Ifs Shocks285
Foxä Shock Maintenance286
Gas Shock Recharging Kit286
2002 Fox Optional Valving Listed By Shock Part Number287
Valve Washer Part Numbers287
Seal Replacement290
Ryde Fxä Shock Maintenance298
Depressurizing Shock298
Ryde Fx 7041968 General Rebuild Procedures303
Suspension Troubleshooting - Xtra Lite Style306
Suspension Troubleshooting - Xtra 10 Style307
Suspension Troubleshooting - Edge Rmk308
Brakes / Final Drive310
2002 Tracks312
2002 Chaincases312
Hyvotsprocket Part Numbers316
Top Sprockets For 3/4² Hyvot Drive Systems316
Hyvot Drive Chain316
Bottom Sprockets For 3/4² Hyvot Drive Systems316
Hydraulic Brake System Overview319
Compensating Port319
Brake Bleeding - Fluid Change320
Hayest Master Cylinder322
Park Brake Lever Lock322
Hayest Master Cylinder Removal322
Replacing Cartridge Subassembly323
Brake Line Torque326
Polaris Dot 3 Brake Fluid326
Cover Screw Torque326
Lever And/Or Pivot Pin Removal327
Lever And/Or Pivot Pin Installation328
Park Brake Lever And/Or Spring Removal329
Park Brake Lever And/Or Spring Installation329
Friction Pad Replacement331
Brake Pad Thickness331
Caliper Bolt Torque332
Reservoir Cover Torque332
Hydraulic Caliper Disassembly333
Hydraulic Brake Cleaning And Inspection334
Hydraulic Brake Assembly334
Drive System Disassembly336
Rear Suspension Removal336
Chaincase Removal337
Chaincase Bearing Removal338
Jackshaft Removal338
Driveshaft Removal339
Chaincase Assembly340
Jackshaft Installation340
Driveshaft Installation341
Chaincase Mounting Bolt Torque341
Flangette Nut Torque341
Track Installation343
Final Assembly344
Chaincase Cover Bolt Torque345
Polaris Synthetic Gearcase Lube345
Clutch Alignment Tool346
Driven Clutch Retaining Bolt Torque346
Reverse Installation Tips348
Reverse System Maintenance349
Chain Tension Adjustment349
Oil Change350
Oil Level350
Adjustment350
Reverse Linkage Rod End Play350
Electrical352
Multimeter Usage354
Test Method354
Ignition Timing357
Dial Indicating The Timing Marks357
Degrees To Piston Position - Btdc Conversion Chart358
Indy Trail Rmk359
Indy 500 Rmk (Sks Euro) / 600 Edge Rmk360
I700 / 800 Edge Rmk361
280 Watt Charging System361
Timing Procedure - All Models362
Preparing A New Battery For Service363
Battery Testing363
Specific Gravity Test363
Open Circuit Voltage Test (Ocv)363
Load Test364
Refilling A Low Battery364
Off Season Storage364
Charging Procedure364
Dynamic Testing Of The Electric Starting System365
Starter Motor Static Testing366
Starter Housing And Field Coil Inspection366
Armature Testing366
Starter Assembly367
Starter Solenoid Bench Test368
Starter Installation368
Unregulated Voltage368
Short Circuit Current (Ac Amp Test)369
Regulated Voltage369
2-Pulse And 6 Pulse Alternators370
Polaris Snowmobiles370
Tachometers370
2002 Flywheels370
Headlight Bulb Filament Continuity Test371
Hi/Lo Beam Switch Testing371
Seat Harness Troubleshooting371
Ignition Switch Testing (Non-Electric Start)372
Ignition Switch Testing (Electric Start Models)372
Coolant Temperature Indicator Testing373
Lamp Circuit Test373
Temp Light Temperature Sensor Test373
Coolant Temperature Sensor373
Speed Control Assurance Adjustment374
Throttle Lever Freeplay374
Speed Control Assurance Replacement375
Open Circuit - Run375
Closed Circuit - Kill375
Auxiliary Shut-Off375
Tps (Throttle Position Sensor)377
Tps Testing377
Tps Adjustment379
Condition: No Spark381
Condition: Incorrect Advance/Retard381
Wiring Diagrams384
Index386
Wiring Diagram390