Polaris INDY 500 RMK Manuals

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Polaris INDY 500 RMK Service Manual

Polaris INDY 500 RMK Service Manual (393 pages)

2002 DEEP SNOW

Brand: Polaris | Category: Snowmobiles | Size: 6 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
- 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
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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