Polaris INDY TRAIL RMK, INDY 500 RMK, INDY 700 SKS, INDY 700 EURO SKS, 700 EDGE RMK Service Manual

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PN 9917366

Printed in U.S.A.

2002 DEEP SNOW

SERVICE MANUAL

2002 DEEP SNOW SERVICE MANUAL

INDY TRAIL RMK

INDY 500 RMK

INDY 500 SKS EURO

600 EDGE RMK

INDY 700 SKS / (EURO SKS)

700 EDGE RMK

800 EDGE RMK

PART NUMBER 9917366

Cover 12/23/02 11:54 AM Page 1

DEEP SNOW

SERVICE MANUAL

Foreword

This manual is designed primarily for useby Polaris snowmobile service technicians in a properly equipped shop. Persons using this manual should have a sound knowledge of mechanical theory, tool use, and shop proceduresinordertoperformtheworksafely andcorrectly. Thetechnicianshouldreadthetext and be familiarwith service procedures before starting the work. Certain procedures requirethe use of specialtools. Use onlythe proper tools,as specified. Cleanlinessof parts andtoolsaswell as the workareais of primaryimportance.

Allreferences toleft andright side of thevehicle are from the operator’s perspective when seatedin a normal riding position.

This manual includes procedures for maintenanceoperations, component identification and unit repair,along with service specifications for the Polaris Indy (500 Euro) / 700SKS , TrailRMK, 500 RMK, 600 EDGERMK, 700 EDGE RMK, 800 EDGE RMK snowmobiles. A table of contents is placed at the beginning of each chapter,andan alphabetic index is provided at the endofthemanualforlocationof specificpagenumbersand service information. Keep this manual available for reference in the shop area.

At the time of publication all information contained in this manual was technically correct. However, all materials and specifications are subject to change without notice.

Comments or suggestions about this manual may be directed to: Polaris Sales Inc., Service Publications Department, 2100 Hwy 55 Medina, Minnesota 55340.

Deep Snow Snowmobile Service Manual (PN 9917366)

UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS

Throughout these instructions, important information is brought to your attention by the following symbols:

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

DANGER

Failure to follow DANGER instructionswill result in severeinjuryordeathtothe operator,bystander or person inspecting or servicing the snowmobile.

WARNING

Failure to follow WARNING instructions could result in severe injury or death to the operator, bystander or person inspecting or servicing the snowmobile.

CAUTION:

ACAUTION indicatesspecial precautions thatmust be takento avoid personal injury,orsnowmobile orproperty damage.

NOTE:

A NOTE provides key information to clarify instructions.

Trademarks

Polaris acknowledges the following products mentioned in this manual:

FLEXLOC, Registered Trademark of SPS Technologies Loctite, Registered Trademark of the Loctite Corporation STA-BIL, Registered Trademark of Gold Eagle FOX, Registered Trademark of Fox Shox Nyogel, Trademark of Wm. F. Nye Co. Fluke, Registered Trademark of John Fluke Mfg. Co. Mity Vac, Registered Trademark of Neward Enterprises, Inc. Ammco, Registered Trademark of Ammco Tools, Inc. Torx, Registered Trademark of Textron Hilliard, Trademark of the Hilliard Corporation

GENERAL

MAINTENANCE

ENGINE

CARBURETION

DRIVE/DRIVEN CLUTCHES

SUSPENSIONS

BODY AND STEERING

BRAKES AND FINAL DRIVE

ELECTRICAL

WIRING DIAGRAMS

CHAPTER 1 GENERAL INFORMATION

Publication Part Numbers / Service Manuals 1.1.............

Model Number Identification 1.2...........................

Vehicle Identification Number (VIN) 1.3.....................

Standard Bolt Torque Specifications 1.4....................

Decimal Equivalents 1.5..................................

Tap Drill Size Charts 1.6..................................

Units of Measure Chart 1.7...............................

Recommended Shop Supplies 1.8.........................

Glossary of Terms 1.9 - 1.11....................................

General Precautions 1.12..................................

Notes Page 1.13..........................................

Indy 500 SKS Euro Specifications 1.14 - 1.15......................

Indy 500 RMK Specifications 1.16 - 1.17..........................

Indy Trail RMK Specifications 1.18 - 1.19..........................

600 EDGE RMK Specifications 1.20 -- 1.21.........................

Indy 700 SKS (Euro) Specifications 1.22 -- 1.23.....................

700 EDGE RMK Specifications 1.24 -- 1.25.........................

800 EDGE RMK Specifications 1.26 -- 1.27.........................

GENERAL INFORMATION

1.1

2002 Publication Numbers

Model Model No. Owner’s Manual

Supplement

Parts

Manual

Parts

Microfiche Indy Trail RMK S02SR5BS 9916935 9916936 9916937 Indy 500 RMK S02SR5AS 9916932 9916933 9916934 Indy 500 SKS Euro S02SS5AE 9916941 9916942 9916943 Indy 600 EDGE RMK S02NJ6ES 9916944 9916945 9916946 Indy 700 SKS (Euro) S02SS7CS

(S02SS5AE)

9916938 9916939 9916940

700 EDGE RMK - 136² S02NJ7CSA 9917055 9917056 9917057 700 EDGE RMK - 144² S02NK7CS 9916953 9916954 9916955 700 EDGE RMK -- 151” S02NL7CS 9917061 9917062 9917063 800 EDGE RMK - 144² S02NK8CS 9917058 9917059 9917060 800 EDGE RMK - 151² S02NL8CS 9916950 9916952 9916953 800 EDGE RMK - 156² S02NM8CS 9917064 9917065 9917066

2000 Snowmobile Owner’s Manual (All) - PN 9916649 Snowmobile Assembly Manual - PN 9916508

2002 Service Manuals

120 XC SP 9917361 Trail Sport

Super Sport, Indy 500, 340 Delux

9917362

Two-Up / Touring

Wide Trak LX, 340 Touring, Sport Touring, Trail Touring, 500 Classic Touring, 600 Classic Touring

9917364

Trail Luxury

500Classic, 550 Classic, 600 Classic, 700 Classic

9917363

Deep Snow

TrailRMK, 500 RMK, 500 SKS Euro, 700 SKS, Trail RMK, 600/700/800 EDGE RMK

9917366

Performance

500 XC, 500/600/700/800 XC SP, 800 XCR

9917367

High Performance

440 XCF SP, 440 XC SP, 500/600/700/800 XC SP ,600/700/800 RMK, 800 XCR

9917365

Wallcharts 9917369

GENERAL INFORMATION

1.2

MODEL NUMBER IDENTIFICATION

YEAR DESIGNATION ENGINE DESIGNATION

MODEL / CHASSIS DESIGNATION

2002 MODEL DESIGNATION

S02 SD 5 BS

S=Snow

U= European Model

S= North AmericanModel

MODEL LINE (4TH DIGIT) MODEL TYPE (5TH

DIGIT) S=Gen II A= Feature Option L= Lite B= Basic N= EDGE C= Feature Option W=Mini Indy D= Deluxe

E= Feature Option M--10 F= Feature Option J= 136 RMK (Edge) K= 144 RMK (Edge) L= 151 RMK (Edge) M= 156 RMK (Edge) P= Performance R= RMK (Gen II) S= SKS T= Touring U= Utility

X= Racer 2002 ENGINE DESIGNATION NUMBERS 1A - 121 F/C OHV 4 cycle Fuji 3A - 340 F/C Piston Port Fuji 4A - 440 F/C Cylinder Reed Fuji 4B - 488 L/C Piston Port Fuji 4C - 440VES L/C Case Reed (domestic) 4D -- 440 F/C Piston Port 4E - 488 F/C Piston Port Fuji 5A - 497 L/C Case Reed 2 Cyl (domestic) 5B - 544 F/C Cylinder Reed 5C - 500 VES L/C Case Reed 2 Cylinder (domestic) 6D - 600/700 L/C Case Reed 2 Cylinder(domestic) 6E - 600/440 VES L/C Case Reed 2 Cylinder (domestic) 7A - 700 L/C Case Reed 2 Cylinder (domestic) 7C -- 700 VES L/C Case Reed 2 Cyl (domestic) 8A - 800 VES L/C Case Reed 3 Cylinder Fuji 8B - 800 L/C Case Reed 2 Cylinder (domestic) 8C -- 800 VES L/C Case Reed 2 Cyl (domestic)

MODEL NO. V.I.N. NO.

MFD. DATE:

THIS VEHICLE CONFORMSTO ALL APPLICABLE U.S. FEDERAL AND STATEREQUIREMENTS AND CANADA MOTORVEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE.

MADE IN U.S.A.

7072133

Mfd. by Polaris Industries Inc.. in Roseau, M N under one or more of the following patents:

U.S. Patents

3,605,511 3,613,810 5,050,559 3,580,647 3,867,991 5,048,503 3,483,766 4,793,950 5,056,482 3,533,662 5,038,881 5,099,813 3,545,821 5,172,675 5,074,271 3,605,510 5,090,386 5,191,531 3,525,412 5,050,564 3,613,811

PATENT NOTICE

Patented Canada

882,491/71 883,694/71 864,394/71

Canadian Rd.

34,573/71 34,572/71

1,227,823/87

TUNNEL DECAL

These numbers should be referred to in any correspondenceregardingwarranty, service or replacement parts. The machinemodelandserialnumber identification decalislocatedon the right frontside ofthetunnel. The serial number is permanentlystamped into the tunnel. The model number is embossed on the decal.

Whenever corresponding about an engine it is important that the engine model and serial numbers be called out. Laser engraved model and serial numbers are located on the crankcase (intake side).

GENERAL INFORMATION

1.3

Vehicle Identification Number

Current snowmobiles havea 17 digit VehicleIdentification Number(VIN). TheVIN is organizedas follows: Digits 1-3: WorldManufacturerIdentifier. For Polaris, this is4XA. Digits 4-9: VehicleDescriptor Section. Digits 10-17: Vehicle Indicator Section. Digits 4-8 of the VIN identify the body style, type, engine type, and series. The VIN and the model number must be used with any correspondence regarding service or repair.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4XA SB

5BS022000000

Vehicle Descriptor

Vehicle Identifier

Type

Engine Size

Engine Modifier

Model Year

Manufacturing. Location Code

Individual Serial No.

Body Style

Series

World Mfg. ID

Example of

Current

VIN Number

Check Digit

Vehicle Identification Number / Model Number Key

Body Style Type Engine Size Engine Modifier Series

L=Lite B=Base Model 1=100-199 cc A=Fan S=Domestic

N=Edge D=Deluxe 2=200-299 cc B=Liquid Twin U=Europe

S=Gen II P=Performance 3=300-399 cc C=Case Reed Twin

W=Mini R=RMK 4=400-499 cc D=Liquid Triple

S=SKS 5=500-599 cc E=Case Reed Triple

T=Touring 6=600-699 cc

U=Utility 7=700-799 cc

X=Racer 8=800-899 cc

Year / Letter Identification

The tenth digit of a 17 digit VIN is the model year of the vehicle. Example: W = 1998; X =1999 etc. Refer to the listing below.

1 = 2001 2 = 2002 3 = 2003

GENERAL INFORMATION

1.4

Standard Torque Specifications

Thefollowingtorquespecificationsaretobeusedasageneralguidelinewhentorquevalueisnotspecified. There are exceptions in the steering, suspension, and engine areas. Always consult the torque chart and

the specific

manual section for torque values of fasteners.

Bolt Size Threads/In Grade 2 Grade 5 Grade 8

(MM/Thread)

Torque in. lbs. (Nm)

#10 - 24 27 (3.1) 43 (5) 60 (6.9).............. ................ ...............

#10 - 32 31 (3.6) 49 (5.6) 68 (7.8).............. ................ ..............

To rque ft. lbs. (Nm)*

1/4 - 20 5 (7) 8 (11) 12 (16).............. .................. ................

1/4 - 28 6 (8) 10 (14) 14 (19).............. .................. ..............

5/16 - 18 11 (15) 17(23) 25 (35).............. ................ ..............

5/16 - 24 12 (16) 19 (26) 29 (40).............. ................ ..............

3/8 - 16 20 (27) 30 (40) 45 (62).............. ................ ..............

3/8 - 24 23 (32) 35 (48) 50 (69).............. ................ ..............

7/16 - 14 30 (40) 50 (69) 70 (97).............. ................ ..............

7/16 - 20 35 (48) 55 (76) 80 (110).............. ................ ..............

1/2 - 13 50 (69) 75 (104) 110 (152).............. ................ .............

1/2 - 20 55 (76) 90 (124) 120 (166).............. ................ .............

*To convert ft. lbs. to Nm multiply foot pounds by 1.356. *To convert Nm to ft. lbs. multply Nm by .7376.

GENERAL INFORMATION

1.5

1/64 .0156.........................

1/32 .0312 1 mm = .0394²................... ................

3/64 .0469.........................

1/16 .0625..............

5/64 .0781 2 mm = .0787²......................... ................

3/32 .0938...................

7/64 .1094 3 mm = .1181²....................... ................

1/8 . .1250. .......

9/64 .1406.........................

5/32 .1563 4 mm = .1575²................... ................

11/64 .1719........................

3/16 .1875 5 mm = .1969².............. ................

13/64 .2031........................

7/32 .2188...................

15/64 .2344 6 mm = .2362²........................ ................

1/4 .25..........

17/64 .2656 7 mm = .2756²........................ ................

9/32 .2813...................

19/64 .2969........................

5/16 .3125 8 mm = .3150².............. ................

21/64 .3281........................

11/32 .3438 9 mm = .3543².................. ................

23/64 .3594........................

3/8 .375..........

25/64 .3906 10 mm = .3937²........................ ................

13/32 .4063..................

27/64 .4219 11 mm = .4331²........................ ................

7/16 .4375..............

29/64 .4531........................

15/32 .4688 12 mm = .4724².................. ................

31/64 .4844........................

1/2 .5 13 mm = .5118.......... ...................

33/64 .5156........................

17/32 .5313..................

35/64 .5469 14 mm = .5512²........................ ................

9/16 .5625..............

37/64 .5781 15 mm = .5906²........................ ................

19/32 .5938..................

39/64 .6094........................

5/8 .625 16mm = .6299².......... .................

41/64 .6406........................

21/32 .6563 17 mm = .6693².................. ................

43/64 .6719.......................

11/16 .6875.............

45/64 .7031 18 mm = .7087²........................ ................

23/32 .7188..................

47/64 .7344 19 mm = .7480²........................ ................

3/4 .75..........

49/64 .7656........................

25/32 .7813 20 mm = .7874².................. ................

51/64 .7969........................

13/16 .8125 21 mm = .8268²............. ................

53/64 .8281........................

27/32 .8438..................

55/64 .8594 22 mm = .8661²........................ ................

7/8 .875..........

57/64 .8906 23 mm = .9055²........................ ................

29/32 .9063..................

59/64 .9219.......................

15/16 .9375 24 mm = .9449²............. ................

61/64 .9531........................

31/32 .9688 25 mm = .9843.................. ................

63/64 .9844........................

GENERAL INFORMATION

1.6

SAE Tap Drill Sizes

Thread Size Drill Size Thread Size Drill Size

#0-80 3/64 #1-64 53 #1-72 53 #2-56 51 #2-64 50 #3-48 5/64 #3-56 45 #4-40 43 #4-48 42 #5-40 38 #5-44 37 #6-32 36 #6-40 33 #8-32 29 #8-36 29 #10-24 24 #10-32 21 #12-24 17 #12-28 4.6mm 1/4-20 7 1/4-28 3 5/16-18 F 5/16-24 I 3/8-16 O 3/8-24 Q 7/16-14 U 7/16-20 25/64

1/2-13 27/64 1/2-20 29/64 9/16-12 31/64 9/16-18 33/64 5/8-11 17/32 5/8-18 37/64 3/4-10 21/32 3/4-16 11/16 7/8-9 49/64 7/8-14 13/16 1-8 7/8 1-12 59/64 1 1/8-7 63/64 1 1/8-12 1 3/64 11/4-7 17/64 1 1/4-12 1 11/64 11/2-6 111/32 1 1/2-12 1 27/64 13/4-5 19/16 1 3/4-12 1 43/64 2-4 1/2 1 25/32 2-12 1 59/64 2 1/4-4 1/2 2 1/32 21/2-4 21/4 23/4-4 21/2 3-4 2 3/4

Metric Tap Drill Sizes

Tap Size Drill Size Decimal Equivalent Nearest Fraction

3x.50 3x.60 4x.70 4x.75 5x.80 5x.90 6 x 1.00 7 x 1.00 8 x 1.00 8 x 1.25 9 x 1.00 9 x 1.25 10 x 1.25 10 x 1.50 11 x 1.50 12 x 1.50 12 x 1.75

#39

3/32

#30

1/8

#19

#20

16/64

17/64

5/16

11/32

3/8

13/32

0.0995

0.0937

0.1285

0.125

0.166

0.161

0.196

0.234

0.277

0.265

0.3125

0.3437

0.339

0.375

0.406

3/32 3/32 1/8 1/8 11/64 5/32 13/64 15/64 9/32 17/64 5/16 5/16 11/32 11/32 3/8 13/32 13/32

GENERAL INFORMATION

1.7

Unit of Measure Multiplied by Converts to

ft. lbs. x12 =in.lbs. in. lbs. x .0833 = ft. lbs. ft. lbs. x 1.356 =Nm in. lbs. x.0115 =kg-m Nm x .7376 = ft. lbs. kg-m x 7.233 = ft. lbs. kg-m x86.796 =in.lbs. kg-m x10 =Nm in. x25.4 =mm mm x .03937 =in. in. x2.54 =cm mile (mi.) x1.6 =km km x .6214 = mile (mi.) Ounces (oz) x28.35 = Grams (g) Grams (g) x 0.035 = Ounces (oz) cc x .03381 = Fluid Ounces (oz) lb. x.454 =kg kg x 2.2046 =lb. Cubic inches (cu in) x16.387 = Cubic centimeters (cc) Cubic centimeters (cc) x 0.061 = Cubic inches (cu in) Imperial pints (Imp pt) x 0.568 = Liters (l) Liters (l) x1.76 = Imperial pints (Imp pt) Imperial quarts (Imp qt) x 1.137 = Liters (l) Liters (l) x0.88 = Imperial quarts (Imp qt) Imperial quarts (Imp qt) x 1.201 =USquarts(USqt) US quarts (US qt) x 0.833 = Imperial quarts (Imp qt) US quarts (US qt) x 0.946 = Liters (l) Liters (l) x 1.057 =USquarts(USqt) US gallons (US gal) x 3.785 =Liters (l) Liters (l) x 0.264 = US gallons (US gal) Pounds - force per square inch (psi) x 6.895 = Kilopascals (kPa) Kilopascals (kPa) x 0.145 = Pounds - force per square inch (psi) Kilopascals (kPa) x0.01 = Kilograms - force per square cm Kilograms - force per square cm x98.1 = Kilopascals (kPa)

°Cto°F: 9 (°C + 40) ¸ 5--40=°F °Fto°C: 5 (°F+40)¸ 9--40=°C

GENERAL INFORMATION

1.8

Description Part Number

Chaincase Lubricant - Quart 2871280.......................

Chaincase Lubricant - Gallon 2870464......................

Chaincase Lubricant - 2.5 Gallon 2872281...................

Fuel System Deicer (Isopropyl) 2870505.....................

Loctite Primer T - 6 Oz. Aerosol 2870585....................

Loctite RC 680 - 10cc Retaining Compound 2870584..........

Loctite/Chisel -- Gasket Remover - 18 Oz. 2870601...........

Metal Polish - 8 Oz. 2870632...............................

DOT 3 Brake Fluid 2870990...............................

Fogging Oil 2870791......................................

Nyogelt Grease 2871329.................................

Fox Shock Oil 2870995....................................

Premium All Season Grease (14 oz) 2871423................

Premium All Season Grease (3 oz) 2871322.................

Premium 60/40 Anti-Freeze/Coolant 2871323................

Premium Carbon Clean Fuel System Additive 2871326........

Polaris Battery Tender 2871076............................

Carbon Clean Fuel System Additive 2871326.................

T-9 Metal Protectant 2871064..............................

Crankcase Sealant 3 Bond 1215 2871557...................

GENERAL INFORMATION

1.9

ACS: Alternator control switch. ACV: Alternating current voltage. Air Gap Spark Test: Agoodcheckfor ignition voltage and general ignition system condition. Spark shouldarc 3/8” (1

cm) minimum from end of high tension lead to ground. Several testers are available commercially.

Alternator: Electrical generator producing alternating current voltage. Bore: Diameter of cylinder. BTDC: Before Top Dead Center. Bump Steer: When skis toe in and toe out through suspension travel. CDI: Capacitor Discharge Ignition. Ignition system which stores voltage generated by the stator plate exciter coil in a

capacitor or condenser (in CDI box). At thepropermomentavoltagegeneratedbythestatorplatepulsercoilclosesan electronicswitch (thyristor) intheCDI boxandallows the voltage in the capacitor to discharge into the primary windings of the ignition coil.

Center Cylinder: On three cylinder engines, the cylinder between Mag and PTO ends. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8” or 1 cm). Polaris measures chain length in number of

pitches. Clutch Buttons: Plastic bushings which transmit rotation of the clutch to the movable sheave in thedrive anddriven

clutch. ClutchOffset: Driveanddrivenclutches are offsetsothat drive beltwillstay nearlystraightasit movesalongthe clutch

face as the engine torques back. Clutch Weights: Threelevers in the drive clutchwhich relative to their weight,profileandengineRPMcausethedrive

clutch to close. Coil: Awindingofwirearoundanironcorewhichhas the ability to generate an electricalcurrent whenamagneticfield

passes through it.

Combustion Chamber: Space between cylinder head and piston dome at TDC. Compression: Reduction in volume or squeezing of a gas. Condenser/Capacitor: A storage reservoir for electricity, used in both E.T. and CDI systems. Crankshaft Run-Out: Run-out or “bend” of crankshaft measured with a dial indicator while crankshaft is supported

between centers on V blocks or resting in lower half of crankcase. Measure at various points especially at PTO. Maximum allowable run-out is .006” (.02 cm).

DCV: Direct current voltage. Detonation: The spontaneous ignition of the unburned fuel/air mixture after normal spark ignition. Piston looks

“hammered”through,rough appearance around hole. Possible causes: 1)leanfuel/air mixture; 2) low octane fuel; 3) over-advanced ignition timing; 4)compression ratio too high for the fuel octane.

Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and out-of-round in the cylinder bore.

Displacement: The volume of the cylinder displaced by the piston as it travelsfromBDC to TDC. The formula is:

Effective Compression Ratio: Compression ratio measured from after the piston closes the exhaust port. Electrical Open: Open circuit. An electrical circuit whichisn’t complete. (i.e.poor connections or brokenwire at hi-lo

beam switch resulting in loss of headlights. Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended

component. (i.e. a bare wire touching the snowmobile chassis under the seat resulting in loss of taillights and brake lights).

End Seals: Rubber seals at each end of the crankshaft. Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt.

Flat Head Bolt: To be used where finished surfaces require a flush fastening unit. Countersunk. Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction. g: Gram. Unit of weight in the metric system. Head V o lume: Cylinder head capacity in cc, head removed from engine with spark plug installed.

Bore x Stroke x 3.1416

= Displacement in CCs

GENERAL INFORMATION

1.10

Heat Exchanger: A device used to transfer heat. They dissipate engine heat to the atmosphere.

HexHead Bolt: Standardtypeofwrench-appliedhexagonhead,characterized by clean, sharp corners trimmed

to close tolerances. Recommended for general commercial applications. Hi-Fax: Trademark of Himont Advanced Materials. The special slide material which fits onto the bottom of the

suspension rails.

High Side: Sled pushes or tips up toward outside of turn. High TensionWire: Theheavy insulated wire which carries the high secondaryvoltagefromthecoil tothesparkplug. Hole Shot: A term used when machine starts a race from a dead stop. Holed Piston: Piston in which a hole has formed on the dome. Possible causes: 1) detonation; 2) pre-ignition. IgnitionCoil: A typeoftransformerwhichincreasesvoltage in the primary windings (approx. 200V) to a higher voltage

in the secondary windings (approx. 14KV -32KV) through inductions. Secondary voltage is high enough toarc the air gap at the spark plug.

IgnitionGenerating Coil: Excitercoilorprimary charge coil. Statorplatecoilwhichgeneratesprimary ignitionvoltage. CDI system uses one ignition generating coil.

Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb. Kg/cm2: Kilograms per square centimeter. Metric equivalent of PSI. Keystone Ring: A piston ring with bevel on upper surface. Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction.

Metric equivalent of ft. lbs.

LRing: A wide face piston ring with an ”L” shaped cross section. Leg of ”L” goes up when installing on piston. Labyrinth Seal: A pressure typecenter seal identified by series of grooves and lands. Polarisengines us this type of

seal to separate the cylinders in the crankcase halves.

Left Side: Always referred to based on normal operating position of the driver. Lighting Coil: Generates voltage for lights, battery charging, etc by electromagnetic induction. Loose: When the rear of the vehicle slides outward in a turn. The track does not grab sufficiently. mm: Millimeter. Unit of length in the metric system. 1mm = .040”. Mag End: Flywheel side of engine. Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the

windings. This is how mechanical energy in our engines is converted to electrical energy in the lighting coil, ignition generating coils and trigger coil.

Ohm: The measurement of electrical resistance opposing current flow.

Oval Head Screw: Fully specified as ”oval countersunk”, this head is identical to the standard flat head, but

possesses a rounded upper surface for attractiveness of design.

PTO End: Power Take Off drive (clutch side).

Pan Head Screw: Provides a low, large diameter head, but with characteristically high outer edges along the

outeredgeof the headwheredrivingaction is mosteffective. Slightly differentheadcontourwhensupplied with Phillips Recess. See dotted line.

Piston Clearance: Total distance between piston and cylinder wall. PistonErosion: Pistondomemelts. Usuallyoccursat theexhaustportarea. Possible causes: 1) leanfuel/airmixture;

2) improper spark plug heat range; 3) Poor fuel.

Pre-Ignition: A problem in combustion where the fuel/air mixture is ignited beforenormal spark ignition. Piston looks melted at area of damage. Possible causes: 1)incorrect spark plug heatrange; 2) spark plug notproperly torqued; 3) “glowing” piece of head gasket, metal burr or carbon in the combustion chamber; 4) lean fuel/air mixture; 5) Incorrect ignition timing.

Primary Circuit: Thiscircuitisresponsibleforthe voltagebuildupinthe primarywindingsofthe coil. Inthe CDIsystem thepartsinclude the exciter coil,the trigger coil, the wiresfromstatorplatetoCDIboxandtothelowresistanceprimary windings in the ignition coil.

Primary Clutch: Drive clutch on engine. Primary Compression: Pressure built up in the crankcase of a two stroke engine.

GENERAL INFORMATION

1.1 1

psi.: Pounds per square inch. Pushing: Whenthe front of the vehicle does not steeras much as the driverdesires. The skis donot grab sufficiently. R&R: Remove and replace. RFI: RadioFrequencyInterference. Caused by high voltage from the ignition system. Therearespecialplugcapsand

spark plugs to help eliminate this problem. Mandated in Canada.

RPM: Revolutions Per Minute. Resistance: Inthe mechanicalsense,frictionor load. Intheelectricalsense,ohms. Bothresultinenergy conversionto

heat.

Right Side: Always referred to based on normal operating position of the driver.

Round Head Screw:The familiar head most universally used for general application. Good slot depth, ample

underhead bearing surface and finished appearance are characteristic of this head.

Running Time: Ignition timing at specified RPM. Secondary Circuit: Thiscircuitconsists ofthelargesecondarycoilwindings,hightensionwire andgroundthroughthe

spark plug air gap.

Secondary Clutch: Driven clutch on chaincase or jackshaft. SeizedPiston: Gallingof the sidesofapiston. Usually there is atransferofaluminumfromthe piston onto the cylinder

wall. Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4)stuck piston rings.

Self Steer: Pulling the machine to the inside of the track. Spark Plug Reach: Length of threaded portion of spark plug. Polaris uses 3/4” (2 cm) reach plugs. Static Timing: Ignition timing when engine is at zero RPM. Stator Plate: The plate mounted under the flywheel supporting the primary ignition components and lighting coils. Stroke: Themaximum movement of the piston from bottom deadcentertotop deadcenter. Itischaracterizedby180°

of crankshaft rotation.

Surge Tank: The fill tank in the liquid cooling system. TDC: Top Dead Center. Piston’s most outward travel from crankshaft. Transfer: The movement of fuel/air from the crankcase to the combustion chamber in a two stroke engine. Trigger Coil: Pulser coil. Generates the voltage for triggering (closing) the thyristor and timing the spark in CDI

systems. Small coil mounted at the top of the stator plate next to the ignition generating coil, or on the outside of the flywheel.

V Regulator: Voltage regulator. Maintains maximum lighting coil output at approx. 14.5 ACV as engine RPM increases.

Venturi: Anareaofairconstriction. Aventuriisusedincarburetors tospeedupair flowwhichlowerspressureinventuri tobelowatmosphericpressure,causingfuelto be pushedthroughjets,etc.,andintotheventuri to be mixed with air and form a combustible air/fuel mixture.

Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit.

Watt: Unit of electrical power. Watts = amperes x volts.

GENERAL INFORMATION

1.12

In order to perform service work efficiently and toprevent costly errors, the technician should read the text in this manual, thoroughly familiarizing him/herself with procedures before beginning. Photographs and illustrations havebeenincluded with the text as an aid. Notes,cautions and warningshave also been included forclarification of text and safety concerns. However, a knowledge of mechanical theory, tool use and shop procedures is necessary to perform the service work safely and satisfactorily. Use only genuine Polaris service parts.

Cleanlinessofpartsandtoolsaswellastheworkareaisof primaryimportance. Dirtandforeignmatter will act asanabrasiveandcausedamagetoprecisionparts. Cleanthesnowmobile before beginning service. Cleannew parts before installing.

Watch for sharp edges which can cause personal injury, particularly in the area of the tunnel. Protect hands with gloves when working with sharp components.

If difficulty is encountered in removingor installing acomponent, look tosee if acausefor thedifficulty canbe found. If it is necessary to tap the part into place, use a soft face hammer and tap lightly.

Some of the fasteners in the snowmobile were installed with locking agents. Use of impact drivers or wrenches will help avoid damage to fasteners.

Alwaysfollowtorquespecifications as outlined throughout thismanual. Incorrect torquing may leadtoserious machine damage or, as in the case of steering components, can result in injury or death for the rider(s).

If a torquing sequence isindicated for nuts, bolts or screws, start all fasteners in their holes and handtighten. Then, following the method and sequence indicated in this manual, tighten evenly to the specified torque value. When removing nuts, bolts or screws from a part with several fasteners, loosen them all about 1/4 turn before removing them.

If the condition ofany gasket or O-Ring is inquestion, replaceit witha new one. Besure the matingsurfaces around the gasket are clean and smooth in order to avoid leaks.

Some procedures will require removal of retaining rings or clips. Because removal weakens and deforms theseparts, they should always bereplacedwithnewparts. Wheninstallingnewretainingringsandclipsusecare not to expand or compress them beyond what is required for installation.

Because removal damages seals, replace any oil or grease seals removed with new parts.

Polaris recommends the use of Polaris lubricants and greases, which have beenspecially formulated for the top performance and best protection of our machines. In some applications, such as the engine, warranty coverage may become void if other brands are substituted.

Grease should be cleaned from parts and fresh grease applied before reassembly of components. Deteriorating grease loses lubricity and may contain abrasive foreign matter.

Whenever removing or reinstalling batteries, care should be taken to avoid the possibility of explosion resulting in serious burns. Always disconnect the negative (black) cable first and reconnect it last. Battery electrolyte contains sulphuric acid and is poisonous! Serious burns can result from contact with the skin, eyes or clothing. ANTIDOTE: External - Flush with water. Internal - Drink large quantities or water or milk. Follow with milkofmagnesia,beatenegg,orvegetableoil. Call physician immediately. Eyes - Flushwithwaterfor 15minutes and get prompt medical attention.

GENERAL INFORMATION

1.13

Notes

GENERAL INFORMATION

1.14

MODEL: INDY 500 SKS EUROPEAN..........

MODEL NUMBER: E02SS5AE. ENGINE MODEL: S2209--5044PL5A..

JETTING CHART

AMBIENT TEMPERATURE

Altitude

Below -30°F Below -34°C

-30

_ to --10_F

-34_to -23_C

-- 1 0

_to +10_F

-23_ to --12_C

+10

_to +30_F

-12_to --1_C

+30

_to +50_F

-1_to +10_C

Above +50

Above +10_C

Altitud

Below34

34t

o-23C

23t

o--12C

12t

o--1

1to+10CAbove+10

0--600

(0--2000)

390

380

360

350

330

320

600--1200

(2000--4000)

370

360

340

330

310

300

Meters

1200--1800

350

330

320

300

290

280

Meter

(Feet)

1200180

(4000--6000)

350

330

320

300

290

280

(

)

1800--2400

330

310

300

290

370

250

(6000--8000)

330

300

2400--3000

300

290

280

260

250

230

(8000--10000)

300

3000--3700

280

270

250

240

220

210

(10000--12000)

XXX

- # refers to the clip position from top of jet needle.

CLUTCH CHART

DRIVE DRIVEN

Altitude

Shift Clutch Clutch Driven

Chaincase

Altitud

Shift

Weight

Clutc

Spring

Clutc

Spring

Drive

Helix

Chaincase

Gearing

Meters

0-900

rk Bl

18-41-68P

Meter

(Feet)

0-900

(0-3000)

0-5

Bushed

DarkBlue/

White

Silver

R32

8-4

1-68P

HYVO

900-1800

1-L

18-41-68P

900-180

(3000-6000)

0-A

Bushed

Almond/

Round

Silver

R32

8-4

1-68P

HYVO

1800-2700

18-41-68P

180

0-270

(6000-9000)

Bushed

Almond/

Round

Silver

R32

8-4

1-68P

HYVO

2700-3700

10M

Almond

/R3

18-41-68P

270

0-370

(9000-12000)

10M

Bushed

Almond/

Round

Silver

R32

8-4

1-68P

HYVO

- Production Setting

ENGINE

Type Liquid Cooled Case Reed Twin.......................

Displacement 500cc Fuel Pump Manuf. N/A............... .....

Bore 2.776²² (70.5mm) Fuel Pump Mark N/A....................... .......

Stroke 2.520²² (64mm) Oil Pump Manuf. Mikuni..................... .......

Piston / Cylinder Clearance 0.0045² - 0.0063² (0.11 - 0.16mm) Oil Pump Mark 2540051... ........

Service Limit N/A Cylinder Head Mark 3021048................ ....

Piston Marking 3021038..............

Piston Ring Marking N/A.........

Piston Ring End Gap 0.012² -0.018² (.30 - .46mm)........

Head ccs (Uninstalled) 27.5±.50cc.......

Head ccs (Installed) 25cc.........

Operating RPM±200 8000 RPM.........

Idle RPM±200 1500 RPM..............

Engagement RPM±300 4200 RPM......

Cylinder Head Torque 20-24 ft.lbs. (28-33Nm)........

Cylinder Base Nut Torque 30-34 ft.lbs. (41-47 Nm)....

Crankcase Torque (8mm) 20-24ft.lbs. (28-33 Nm).....

Crankcase Torque (10mm) N/A...

Flywheel Torque 90ft.lbs. (124 Nm).............

CARBURETION

Type TM 38 Mikuni................

Main Jet 370............

Pilot Jet 45.............

Jet Needle 9FH4--57/3...........

Needle Jet P-6...........

Cutaway 1.5............

Fuel Mixture Screw 2 Turns...

Valve Seat 1.5...........

Fuel Octane (R+M/2) 87 Non-Oxygenat

89 Oxygenated ThrottleGap

Under Cutaway 0.098² (2.5mm)......

Starter Jet 155...........

Pilot Air Jet 1.0..........

CLUTCH

Type P 85................

Belt 3211074.................

Belt Width (Projected) 1.438². Side Angle (Overall) 28°.. Outside Circumference 47.625²

Center Distance 12.00²......

Shift Weights 10-56 Bushed........

Primary Spring Dark Blue / White.......

Secondary Spring Silver....

Driven Helix R32 #2.........

GENERAL INFORMATION

1.15

MODEL: INDY 500 SKS EUROPEAN..........

MODEL NUMBER: E02SS5AE. ENGINE MODEL: S2209--5044PL5A..

ELECTRICAL CAPACITIES

Flywheel I.D. 4010523 Fuel Tank 11.8 gallons (44.7 liters)...... ..........

CDI Marking 4010584 Oil Tank 3 quarts (2.8 liters)....... ............

Alternator Output 280 Watts Coolant 5 quarts (4.7 liters)... ............

Ignition Timing 12° BTDC@22500 RPM Chaincase Oil 11 fl. oz. (325cc)..... .......

0.0327² BTDC

0.8294mm BTDC Spark Plug / Gap Champion RN2C / 0.028² (0.7mm)... Voltage Regulator LR7..

Electric Start Option.......

LR7= Full wave voltage regulator

Magneto Pulses 6....

SUSPENSION / CHASSIS CHAINCASE

Body Style Gen II Sprockets / Chain 18-41, 68P HYVO........ ...

Front Suspension Indy XC 10 Reverse Option.. ............

Front Shocks Indy Select Brake Pads Type 81, Large...... .........

IFS Spring Rate 100#/in. Chaincase Center Dist.7.05² (17.91cm)....

Front Spring Preload 3/4² Thread Adjust Driveshaft Sprockets 2 Drivers Wide.

Front Vertical Travel 9.6² (24.4cm) Brake Type Polaris HPB.........

Rear Suspension XTRA-10 EURO... Rear Axle Travel 9.5² (24.1cc)... Front Track Shock Nitrogen Cell..

Spring Rate 190#/in. variable........

Rear Track Shock Indy Select..

Rear Springs .405² (sq.) / 77°......

Track Type 15²x136²x1.25² (38.1x345.44x3.175cm)........

Track Tension 3/8² -1/2² (1-1.3 cm) slack with 10# (4.54kg) weight 16² (40.64cm) ahead of rear idler......

shaft.

Overall Snowmobile Length 116² (295cm).................

Overall Snowmobile Height 45² (114cm).................

Maximum Snowmobile Width 43.5² (110.5cm)...............

OPTIONAL REAR TORSION SPRINGS

(STD)

.405²(Sq.) Diameter x 77°

L.H. 7041655--067 R.H 7041655--067

GENERAL INFORMATION

1.16

MODEL: INDY 500 RMK..........

MODEL NUMBER: S02SR5AS. ENGINE MODEL: S2186--5044PL5A..

JETTING CHART

AMBIENT TEMPERATURE

Altitude

Below -30°F Below -34°C

-30

_ to --10_F

-34_to -23_C

-- 1 0

_to +10_F

-23_ to --12_C

+10

_to +30_F

-12_to --1_C

+30

_to +50_F

-1_to +10_C

Above +50

Above +10_C

Altitud

Below34

34t

o-23C

23t

o--12C

12t

o--1

1to+10CAbove+10

0--600

(0--2000)

440

420

410

390

380

370

600--1200

(2000--4000)

390

380

370

350

340

320

Meters

1200--1800

350

330

320

310

300

290

Meter

(Feet)

1200180

(4000--6000)

350

330

320

310

300

290

(

)

1800--2400

300

290

280

270

260

250

(6000--8000)

300

2400--3000

280

270

260

250

240

230

(8000--10000)

3000--3700

260

250

240

230

220

210

(10000--12000)

XXX

- # refers to the clip position from top of jet needle.

CLUTCH CHART

DRIVE DRIVEN

Altitude

Shift Clutch Clutch Driven

Chaincase

Altitud

Shift

Weight

Clutc

Spring

Clutc

Spring

Drive

Helix

Chaincase

Gearing

Meters

0-900

10-

56Almond

ilver/R-32

18-41-68P

Meter

(Feet)

0-900

(0-3000)

0-5

Bushed

Almon

Round

Silver/

Blue

R-3

8-4

1-68P

HYVO

900-1800

10-ALAlmon

ilver/R-32

18-41-68P

900-180

(3000-6000)

0-A

Bushed

Almon

Round

Silver/

Blue

R-3

8-4

1-68P

HYVO

1800-2700

Almond

ilver/R-32

18-41-68P

180

0-270

(6000-9000)

Bushed

Almon

Round

Silver/

Blue

R-3

8-4

1-68P

HYVO

2700-3700

ilv

R-

18-41-68P

270

0-370

(9000-12000)

10M

Bushed

Almon

Round

Silver/

Blue

R-3

8-4

1-68P

HYVO

- Production Setting

ENGINE

Type Liquid Cooled Case Reed Twin.......................

Displacement 500cc Fuel Pump Manuf. Walbro............... .....

Bore 2.776² (70.5mm) Fuel Pump Mark FPA-3....................... .......

Stroke 2.520² (64mm) Oil Pump Manuf. Mikuni..................... .......

Piston / Cylinder Clearance 0.0045² -0.0063² (0.11 - 0.16mm) Oil Pump Mark 2540051... ........

Service Limit 0.0063” (0.16mm) Cylinder Head Mark 3021048................ ....

Piston Marking N/A..............

Piston Ring Marking N/A.........

Piston Ring End Gap 0.012² -0.018² (0.30 - 0.46mm)........

Head ccs (Uninstalled) 27.5±0.5cc.......

Head ccs (Installed) 25.0cc.........

Operating RPM±200 8000 RPM.........

Idle RPM±200 1500 RPM..............

Engagement RPM±300 4500 RPM......

Cylinder Head Torque 20-24 ft.lbs. (28-33Nm)........

Cylinder Base Nut Torque 30-34 ft.lbs. (41-47 Nm)....

Crankcase Torque (8mm) 20-24ft.lbs. (28-33 Nm).....

Crankcase Torque (10mm) N/A...

Flywheel Torque 90ft.lbs. (124 Nm).............

CARBURETION

Type TM38 Mikuni................

Main Jet 270............

Pilot Jet 45.............

Jet Needle 9FH4-57-2...........

Needle Jet P-6...........

Cutaway 1.5 Notched............

Fuel Screw 0.5 Turns..........

Valve Seat 1.5 Viton...........

Fuel Octane (R+M/2) 87 Non-Oxygenated.

89 Oxygenated

ThrottleGap

Under Cutaway 0.130² (3.3mm)......

Starter Jet 155...........

Pilot Air Jet 0.7 Long..........

CLUTCH

Type P-85................

Belt 3211074.................

Belt Width (Projected) 1.438² (36.52mm). Side Angle (Overall) 28°.. Outside Circumference 47.625² (121cm)

Center Distance 12.00²......

Shift Weights 10 Bushed........

Primary Spring Almond Round.......

Secondary Spring Silver / Blue....

Driven Helix R-32 #3.........

GENERAL INFORMATION

1.17

MODEL: INDY 500 RMK..........

MODEL NUMBER: S02SR5AS. ENGINE MODEL: S2186--5044PL5A..

ELECTRICAL CAPACITIES

Flywheel I.D. Kokusan 4060223 Fuel Tank 11.8 gallons (44.7 liters)...... ..........

CDI Marking 4010259 Oil Tank 3 quarts (2.8 liters)....... ............

Alternator Output 280 Watts Coolant 5 quarts (4.7 liters)... ............

Ignition Timing 22° BTDC@3000RPM±1.5° Chaincase Oil 9 fl. oz.(266cc)..... .......

0.1139² BTDC (±0.0175²)

2.8927mm BTDC (±0.48mm) Spark Plug / Gap Champion RN2C / 0.025² (0.64mm)... Voltage Regulator LR7..

Electric Start Option.......

LR7= Full wave voltage regulator

Magneto Pulses 6....

SUSPENSION / CHASSIS CHAINCASE

Body Style Gen II Sprockets / Chain 18-41, 68P HYVO........ ...

Front Suspension Indy X-10 38² CRC Reverse Option.. ............

Front Shocks Nitrogen Cell Brake Pads Type 81, Large...... .........

IFS Spring Rate 100#/in. Chaincase Center Dist.7.05² (17.91cm)....

Front Spring Preload 1/8² Thread Adjust Driveshaft Sprockets 2 Drivers Wide.

Front Vertical Travel 8.05 in.(21cm) Brake Type Polaris HPB.........

Rear Suspension XTRA-Lite 136²... Rear Axle Travel 12² (30.5cm)... Front Track Shock Nitrogen Cell..

Spring Rate 200#/in. variable........

Rear Track Shock Indy Select..

Rear Springs .347² (sq.) / 77°......

Track Type 15²x136²x1.5² (38.1x345.44x3.81cm)........

Track Tension 3/8² -1/2² (1-1.3 cm) slack with 10# (4.54kg) weight 16² (40.64cm) ahead of rear idler......

shaft.

Overall Snowmobile Length 116² (295cm).................

Overall Snowmobile Height 45² (114cm).................

Maximum Snowmobile Width 43.5² (110.4cm)...............

OPTIONAL REAR TORSION SPRINGS

(STD) FIRM

.347²(Sq.) Diameter x 77° .375” (Sq.) Diameter x 77____

L.H. 7041627--067 L.H. 7041631--067 R.H 7041628--067 R.H. 7041632--067

GENERAL INFORMATION

1.18

MODEL: INDY TRAIL RMK..........

MODEL NUMBER: S02SR5BS. ENGINE MODEL: EC55PM024..

JETTING CHART

AMBIENT TEMPERATURE

Altitude

Below -30°F Below -34°C

-30

_ to --10_F

-34_to -23_C

-- 1 0

_to +10_F

-23_ to --12_C

+10

_to +30_F

-12_to --1_C

+30

_to +50_F

-1_to +10_C

Above +50

Above +10_C

Altitud

Below34

34t

o-23C

23t

o--12C

12t

o--1

1to+10CAbove+10

0--600

(0--2000)

300

290

280

270

260

250

600--1200

(2000--4000)

300

290

280

270

260

250

Meters

1200--1800

300

290

280

270

260

250

Meter

(Feet)

1200180

(4000--6000)

300

290

280

270

260

250

(

)

1800--2400

300

290

280

270

260

250

(6000--8000)

300

2400--3000

300

290

280

270

260

250

(8000--10000)

300

3000--3700

300

290

280

270

260

250

(10000--12000)

300

XXX

- # refers to the clip position from top of jet needle.

CLUTCH CHART

DRIVE DRIVEN

Altitude

Shift Clutch Clutch Driven

Chaincase

Altitud

Shift

Weight

Clutc

Spring

Clutc

Spring

Drive

Helix

Chaincase

Gearing

Meters

0-900

10-62 Dark Bl

ue/

ilver/R-32

18-41-68P

Meter

(Feet)

0-900

(0-3000)

0-6

Bushed

DarkBlue/

White

Silver/

Blue

R-3

8-4

1-68P

HYVO

900-1800

10-

8Da

rk Bl

ue/

ilver/R-32

18-41-68P

900-180

(3000-6000)

0-5

Bushed

DarkBlue/

White

Silver/

Blue

R-3

8-4

1-68P

HYVO

1800-2700

10-

6Da

rk Bl

ue/

ilver/R-32

18-41-68P

180

0-270

(6000-9000)

0-5

Bushed

DarkBlue/

White

Silver/

Blue

R-3

8-4

1-68P

HYVO

2700-3700

1-4 D

rk Bl

ilv

R-

18-41-68H

270

0-370

(9000-12000)

0-5

Bushed

DarkBlue/

White

Silver/

Blue

R-3

8-4

1-68H

YVO

- Production Setting

ENGINE

Type Fan Cooled Reed Assist Twin.......................

Displacement 544cc Fuel Pump Manuf. T aiyo............... .....

Bore 2.874² (73mm) FuelPump Mark FJP-3-100....................... .......

Stroke 2.559² (65mm) Oil Pump Manuf. Mikuni..................... .......

Piston / Cylinder Clearance 0.0035² -0.0049² (0.09 - 0.125mm) Oil Pump Mark 55MB... ........

Service Limit 0.0078² (0.20mm) Cylinder Head Mark EC55PM................ ....

Piston Marking 5MB..............

Piston Ring Marking N.........

Piston Ring End Gap 0.016² -0.022² (0.40 - 0.55mm)........

Head ccs (Uninstalled) 33.8±0.4cc.......

Head ccs (Installed) 27.7cc.........

Operating RPM±200 6800 RPM.........

Idle RPM±200 1600 RPM..............

Engagement RPM±300 3800 RPM......

Cylinder Head Torque 18-19.5 ft.lbs. (25-27 Nm)........

Cylinder Base Nut Torque 24-28 ft.lbs. (33-39 Nm)....

Crankcase Torque (8mm) 16.6-18ft.lbs. (23-35 Nm).....

Crankcase Torque (10mm) N/A...

Flywheel T orque 60-65 ft.lbs. (83-90Nm).............

CARBURETION

Type VM34SS Mikuni................

w/ACCS

Main Jet 270............

Pilot Jet 35.............

Jet Needle 6DEH11-3...........

Needle Jet Q-0 (480)...........

Cutaway 3.0............

Air Screw 1.5 Turns...........

Valve Seat 1.5 Viton...........

Fuel Octane (R+M/2) 87 Non-Oxygenated. Throttle Gap 89 Oxygenated

Under Cutaway .218² (5.54mm)......

CLUTCH

Type P-85................

Belt 3211070.................

Belt Width (Projected) 1.375² (34.93). Side Angle (Overall) 28°.. Outside Circumference 47.250² (120cm)

Center Distance 12.00²......

Shift Weights 10-56 Bushed........

Primary Spring Dark Blue / White.......

Secondary Spring Silver / Blue....

Driven Helix R-32 #2.........

GENERAL INFORMATION

1.19

MODEL: INDY TRAIL RMK..........

MODEL NUMBER: S02SR5BS. ENGINE MODEL: EC55PM024..

ELECTRICAL CAPACITIES

Flywheel I.D. Mitsubishi Fuel Tank 11.8 gallons (44.7 liters)...... ..........

CDI Marking 17620111 Oil Tank 3 quarts (2.8 liters)....... ............

Alternator Output 240 Watts Coolant N/A... ............

Ignition Timing 27° BTDC@3500RPM±1.5° Chaincase Oil 9 fl. oz.(266cc)..... .......

0.175² BTDC (±0.157² -0.195²)

4.45mm BTDC (±3.97 - 4.93mm) Spark Plug / Gap NGK BR9ES / 0.028² (0.7mm)... Voltage Regulator LR7..

Electric Start Option.......

LR7= Full wave voltage regulator

Magneto Pulses 6....

SUSPENSION / CHASSIS CHAINCASE

Body Style Gen II Sprockets / Chain 18-41, 68P HYVO........ ...

Front Suspension Indy XTRA 38² Reverse Option.. ............

Front Shocks Nitrogen Cell Brake Pads Type 81, Small...... .........

IFS Spring Rate 80#/in. Chaincase Center Dist.7.05² (17.9cm)....

Front Spring Preload 5/16² Thread Adjust Driveshaft Sprockets 2 Drivers.

Front Vertical Travel 8.25² (21cm) Brake Type Polaris HPB.........

Rear Suspension XTRA-Lite 136²... Rear Axle Travel 12² (30.5cm)... Front Track Shock Nitrogen Cell..

Spring Rate 181#/in.........

Rear Track Shock Indy Select..

Rear Springs .347² (sq.) / 77°......

Track Type 15²x136²x.1.25² (38.1x345.44x3.175cm)........

Track Tension 3/8² -1/2² (1-1.3 cm) slack with 10# (4.54kg) weight 16² (40.64cm) ahead of rear idler......

shaft.

Overall Snowmobile Length 116² (295cm).................

Overall Snowmobile Height 45² (114cm).................

Maximum Snowmobile Width 43.5² (110.5cm)...............

OPTIONAL REAR TORSION SPRINGS

SOFT MEDIUM(STD) FIRM

.347²(Sq.) Diameter x 77° .375”(Sq.) Diameter x 77°

L.H . L.H. 7041627--067 L.H. 7041631--067 R.H. R.H. 7041628--067 R.H. 7041632--067

GENERAL INFORMATION

1.20

MODEL: 600 EDGE RMK..........

MODEL NUMBER: S02NJ6ES. ENGINE MODEL: S2187--6044PL6E..

JETTING CHART

AMBIENT TEMPERATURE

Altitude

Below -30°F Below -34°C

-30

_ to --10_F

-34_to -23_C

-- 1 0

_to +10_F

-23_ to --12_C

+10

_to +30_F

-12_to --1_C

+30

_to +50_F

-1_to +10_C

Above +50

Above +10_C

Altitud

Below34

34t

o-23C

23t

o--12C

12t

o--1

1to+10CAbove+10

0--600

(0--2000)

450

430

420

400

380

370

600--1200

(2000--4000)

410

390

380

360

340

330

Meters

1200--1800

380

360

350

330

320

300

Meter

(Feet)

1200180

(4000--6000)

380

360

350

330

320

300

(

)

1800--2400

360

430

320

310

290

280

(6000--8000)

360

430

320

310

290

280

2400--3000

340

320

300

290

270

260

(8000--10000)

300

3000--3700

330

310

290

280

260

240

(10000--12000)

330

XXX

- # refers to the clip position from top of jet needle.

CLUTCH CHART

DRIVE DRIVEN

Altitude

Shift Clutch Clutch Driven

Chaincase

Altitud

Shift

Weight

Clutc

Spring

Clutc

Spring

Drive

Helix

Chaincase

Gearing

Meters

0-900

10-

0Bla

ck/

ilver/R-32

19-39 72P

Meter

(Feet)

0-900

(0-3000)

0-6

Bushed

Black

Green

Silver/

Blue

R-3

9-3972P

HYVO

900-1500

10-

8Bla

ck/

ilver/R-32

19-39 72P

900-150

(3000-6000)

0-5

Bushed

Black

Green

Silver/

Blue

R-3

9-3972P

HYVO

1500-2100

ilv

R-

19-39 72P

150

0-210

(6000-9000)

0-5

Bushed

Black

Green

Silver/

Blue

R-3

9-3972P

HYVO

2100-2700

(7000-9000)

10 54

Bushed

Black/ Green

Silver /

Blue

R-32

19-39 72P

HYVO

2700-3350

(9000-11000)

10AL

Bushed

Black/ Green

Silver /

Blue

R-32#319-39 72P

HYVO

3350--4000

(11000-13000)

Bushed

Black/ Green

Silver /

Blue

R-32

19-39 72P

HYVO

- Production Setting

ENGINE

Type Liquid Cooled Case Reed w/TPS.......................

Displacement 593cc Fuel Pump Manuf. Walbro............... .....

Bore 2.9930² 3.041² (77.25mm) Fuel Pump Mark N/A....................... .......

Stroke 2.520 (64mm) Oil Pump Manuf. Mikuni..................... .......

Piston / Cylinder Clearance 0.0044² -0.0058² (0.11 - 0.15mm) Oil Pump Mark 2540097... ........

Service Limit .0059” (0.15mm) Cylinder Head Mark 3022057................ ....

Piston Marking 3021088..............

Piston Ring Marking N/A.........

Piston Ring End Gap 0.012² -0.018² (0.30 - 0.46mm)........

Head ccs (Uninstalled) 36.0cc.......

Head ccs (Installed) 29.0cc.........

Operating RPM±200 8000 RPM.........

Idle RPM±200 1500 RPM..............

Engagement RPM±300 N/A RPM......

Cylinder Head Torque 18-22 ft.lbs. (25-30Nm)........

Cylinder Base Nut Torque 30-34 ft.lbs. (41-47 Nm)....

Crankcase Torque (8mm) 20-24ft.lbs. (28-33 Nm).....

Crankcase Torque (10mm) 26-30ft.lbs. (36-41 Nm)...

CARBURETION

Type TM 38 w/TPS Mikuni................

Main Jet 310............

Pilot Jet 45.............

Jet Needle 9DGI1--60--2...........

Needle Jet P-8 (825)...........

Cutaway 1.5 Notched............

Fuel Screw 2.0 Turns..........

Valve Seat 1.5...........

Fuel Octane (R+M/2) Key Switch Adj..

Premium 91

Regular 87 Non-Oxy.

ThrottleGap

Under Cutaway 0.102² (2.6mm)......

Starter Jet 140...........

Pilot Air Jet N/A..........

Exhaust Spring Green/White Low Elevation Exhaust

Valve Spring Pink.........

CLUTCH

Type P-85................

Belt 3211080.................

Belt Width (Projected) 1.438² (36.53mm). Side Angle (Overall) 28°.. Outside Circumference 48.375² (122.87cm)

Center Distance 11.5²......

Shift Weights 10-56 Bushed........

Primary Spring Black/Green.......

Secondary Spring Silver / Blue....

Driven Helix R-32#3.........

GENERAL INFORMATION

1.21

MODEL: 600 EDGE RMK..........

MODEL NUMBER: S02NJ6ES. ENGINE MODEL: S2187--6044PL6E..

ELECTRICAL CAPACITIES

Flywheel I.D. 4010629 Fuel Tank 11.8 gallons (44.7 liters)...... ..........

CDI Marking 4010554 Oil Tank 3.25 quarts (3.07 liters)....... ............

Alternator Output 280 Watts Coolant 4.3 quarts (4.07 liters)... ............

Ignition Timing 24_@3500RPM±500° Chaincase Oil 11 fl. oz.(325cc)..... .......

With TPS Unplugged.

.1350² BTDC

3.43mm BTDC Spark Plug / Gap Champion RN57YCC / 0.025² (0.64mm)... Voltage Regulator T1..

Electric Start Option.......

Magneto Pulses 6....

SUSPENSION / CHASSIS CHAINCASE

Body Style EDGE RMK Sprockets / Chain 19-39 72P HYVO........ ...

Front Suspension EDGE RMK Reverse Option.. ............

Front Shocks Nitrex Brake Pads Type 81, Large...... .........

IFS Spring Rate 100#/in. Chaincase Center Dist.7.92² (20.12cm)....

Front Spring Preload 3/4² Thread Adjust Driveshaft Sprockets 2 Drivers Wide, XHS.

Front Vertical Travel 7.2² -7.6² (18.3 - 19.3cm) Brake Type Polaris HPB Liquid Cooled.........

Rear Suspension EDGE RMK... Rear Axle Travel 13.8² (35cm)... Front Track Shock Nitrex..

Spring Rate 170#/in.........

Rear Track Shock Indy Select..

Rear Springs .375² (sq.) / 77°......

Track Type 15²x136²x1.75² (38.1x345.44x4.45cm)........

Track Tension 3/8² -1/2² (1-1.3 cm) slack with 10# (4.54kg) weight 16² (40.64cm) ahead of rear idler......

shaft.

Overall Snowmobile Length 102.5² (306cm).................

Overall Snowmobile Height 47.5² (120.7cm).................

Maximum Snowmobile Width 47.25² (120cm)...............

OPTIONAL REAR TORSION SPRINGS

SOFT (STD) FIRM

-- .347²²²²(Sq.) Diameter x 77°°°° .359²²²²(Sq.) Diameter x 77°

°°

N/A L.H.(136” ) 7041627--067 L.H.(136”) 7041629--067 N/A R.H.(136”) 7041628--067 R.H.(136”) 7041630--067

.347²²²²(Sq.) Diameter x 47°°°° .359²²²²(Sq.) Diameter x 47°°°° .375²²²²(Sq.) Diameter x 47°

°°

L.H.(144”/151”)

7042081--067

L.H.(144”/151”)

7042068--067

L.H.(144”/151”)

7042079--067

R.H.(144”/151”)

7042082--067

R.H.(144”/151”)

7042069--067

R.H.(144”/151”)

7042080--067

GENERAL INFORMATION

1.22

MODEL: INDY 700 SKS / (EUROPEAN MODEL)..........

MODEL NUMBER: S02SS7CS / (E02SS7CE

ENGINE MODEL: S2189--7070PL7C..

JETTING CHART

AMBIENT TEMPERATURE

Altitude

Below -30°F Below -34°C

-30

_ to --10_F

-34_to -23_C

-- 1 0

_to +10_F

-23_ to --12_C

+10

_to +30_F

-12_to --1_C

+30

_to +50_F

-1_to +10_C

Above +50

Above +10_C

Altitud

Below34

34t

o-23C

23t

o--12C-12t

o--1

1to+10CAbove+10

0--600

(0--2000)

450

440

420

400

390

370

600--1200

(2000--4000)

430

410

390

380

360

340

Meters

1200--1800

400

390

370

350

340

320

Meter

(Feet)

1200180

(4000--6000)

400

390

370

350

340

320

(

)

1800--2400

380

360

340

330

310

290

(6000--8000)

380

360

330

2400--3000

350

340

320

300

290

270

(8000--10000)

350

300

3000--3700

330

310

290

280

260

240

(10000--12000)

330

XXX

- # refers to the clip position from top of jet needle.

CLUTCH CHART

DRIVE DRIVEN

Altitude

Shift Clutch Clutch Driven

Chaincase

Altitud

Shift

Weight

Clutc

Spring

Clutc

Spring

Drive

Helix

Chaincase

Gearing

European

Meters

0-900

ilv

23-40-70P

Meter

(Feet)

0-900

(0-3000)

0-5

Bushed

Black

Green

Silver/

Blue

3-4

0-70P

HYVO

234070P

HYVO

900-1800

ilv

23-40-70P

900-180

(3000-6000)

0-5

Bushed

Black

Green

Silver/

Blue

3-4

0-70P

HYVO

234070P

HYVO

1800-2700

10-54 Bl

ck/

ilver/R

21-41-70P

180

0-270

(6000-9000)

0-5

Bushed

Black

Green

Silver/

Blue

1-4

1-70P

HYVO

214170P

HYVO

2700-3700

10-AL Bl

ck/

ilver/R

21-41-70P

270

0-370

(9000-12000)

0-A

Bushed

Black

Green

Silver/

Blue

1-4

1-70P

HYVO

214170P

HYVO

- Production Setting

ENGINE

Type Liquid Cooled Case Reed Twin.......................

Displacement 701cc Fuel Pump Manuf. Walbro............... .....

Bore 3.1889² (81mm) Fuel Pump Mark FPA-4....................... .......

Stroke 2.6772² (68mm) Oil Pump Manuf. Mikuni..................... .......

Piston / Cylinder Clearance 0.0044² -0.0058² (0.11 - 0.15mm) Oil Pump Mark 03A... ........

Service Limit 0.0060” Cylinder Head Mark 3021022................ ....

Piston Marking 3021041..............

Piston Ring Marking N/A.........

Piston Ring End Gap 0.014² -0.020² (.36 - .51mm)........

Head ccs (Uninstalled) 37.5±.50cc.......

Head ccs (Installed) 33.5cc.........

Operating RPM±200 8250 RPM.........

Idle RPM±200 1500 RPM..............

Engagement RPM±300 4000 RPM......

Cylinder Head Torque 18-22 ft.lbs. (25-30Nm)........

Cylinder Base Nut Torque 30-34 ft.lbs. (41-47 Nm)....

Crankcase Torque (8mm) 20-24ft.lbs. (28-33 Nm).....

Crankcase Torque (10mm) 26-30ft.lbs. (36-42 Nm)...

Flywheel Torque 90ft.lbs. (124 Nm).............

CARBURETION

Type TM40 Mikuni................

Main Jet 420............

Pilot Jet 38.............

Jet Needle 9DFH10--57 / 3...........

Needle Jet P--8...........

Cutaway 1.5............

Air Screw N/A...........

Valve Seat 1.8...........

Fuel Octane (R+M/2) 87 Non-Oxygenated.

89 Oxygenated

ThrottleGap

Under Cutaway (2.0mm)......

Starter Jet 145...........

Pilot Air Jet 1.1Long..........

Exhaust Valve Spring Green/Yellow.

CLUTCH

Type P-85................

Belt 3211065.................

Belt Width (Projected) 1.438² (3.63cm). Side Angle (Overall) 28°.. Outside Circumference 48.375² (122.87cm)

Center Distance 12.50²......

Shift Weights 10-58 Bushed........

Primary Spring Black/Green.......

Secondary Spring Silver / Blue....

Driven Helix R8 #2.........

GENERAL INFORMATION

1.23

MODEL: INDY 700 SKS / (EUROPEAN MODEL)..........

MODEL NUMBER: S02SS7CS / (E02SS7CE

ENGINE MODEL: S2189--7070PL7C..

ELECTRICAL CAPACITIES

Flywheel I.D. 4010523 Fuel Tank 11.8 gallons (44.7 liters)...... ..........

CDI Marking 4010587 Oil Tank 3 quarts (2.8 liters)....... ............

Alternator Output 280 Watts Coolant 5.5/ 6

quarts (5.2 / 5.7 liters)... ............

Ignition Timing 18° @3000RPM±500 Chaincase Oil 9 / 11

fl. oz.(266 / 325cc)..... .......

0.0815² BTDC

2.075mm BTDC Spark Plug / Gap Champion RN57YCC / 0.025² (0.64mm)... Voltage Regulator LR7..

Electric Start Option.......

LR7= Full wave voltage regulator

Magneto Pulses 6....

SUSPENSION / CHASSIS CHAINCASE

Body Style Gen II Sprockets / Chain 23-40-70P HYVO........ ...

Front Suspension Indy XC 10 Reverse Option.. ............

Front Shocks Indy Select Brake Pads Type 81, Large...... .........

IFS Spring Rate 100#/in. Chaincase Center Dist.7.05² (17.91cm)....

Front Spring Preload 3/4² Thread Adjust Driveshaft Sprockets 2 Drivers Wide.

Front Vertical Travel 9.6² (24.4cm) Brake Type Polaris HPB, Liquid Cooled.........

Rear Suspension XTRA-10 136², (XTRA 10 European)... Rear Axle Travel 9.5 in.(24.1cm)... Front Track Shock Nitrogen Cell..

Spring Rate 200#/in. variable........

Rear Track Shock Indy Select..

Rear Springs .359² (sq.) / 77°......

Track Type 15²x136²x1.25² (38.1x345.44x3.175cm)........

Track Tension 3/8² -1/2² (1-1.3 cm) slack with 10# (4.54kg) weight 16² (40.64cm) ahead of rear idler......

shaft.

Overall Snowmobile Length 116² (295cm).................

Overall Snowmobile Height 45² (114cm).................

Maximum Snowmobile Width 48² (122cm)...............

OPTIONAL REAR TORSION SPRINGS (700 SKS)

SOFT MEDIUM(STD) FIRM

.347”(Sq.) Diameter x 77____ .359²(Sq.) Diameter x 77_ .405”(Sq.) Diameter x 77_

L.H. 7041627--067 L.H. 7041629--067 L.H. 7041655--067 R.H. 7041628--067 R.H. 7041630--067 R.H. 7041656--067

GENERAL INFORMATION

1.24

MODEL: 700 EDGE RMK 136”, 144”, 151”..........

MODEL NUMBER: S02NJ7CS, S02NK7CSA, S02NK7CS, S02NL7CS. ENGINE MODEL: S2190--7070PL7C..

JETTING CHART

AMBIENT TEMPERATURE

Altitude

Below -30°F Below -34°C

-30_ to - -10_F

-34_to -23_C

-- 1 0 _to +10_F

-23_ to - -12_C

+10_to +30_F

-12_to - -1_C

+30_to +50_F

-1_to +10_C

Above +50_F Above +10_C

Altitud

Below34

34t

o-23C

23t

o--12C

12t

o--1

1to+10CAbove+10

0--600

(0--2000)

490

480

460

440

420

400

600--1200

(2000--4000)

470

450

430

410

390

380

Meters

1200--1800

440

420

400

380

370

350

Meter

(Feet)

1200180

(4000--6000)

440

420#3400#3380

370#2350

(

)

1800--2400

410

390

370

350

340

320

(6000--8000)

0#3390

350

2400--3000

380

360

340

320

310

290

(8000--10000)

380#3360

0#23

3000--3700

350

330

320

300

280

260

(10000--12000)

350

330#23

0#2300

0#26

XXX

- # refers to the clip position from top of jet needle.

CLUTCH CHART

DRIVE DRIVEN

Altitude

Shift Clutch Clutch Driven

Chaincase

Altitud

Shift

Weight

Clutc

Spring

Clutc

Spring

Drive

Helix

Gearing

(136”)

Gearing

(144”,151”)

0-900

10--62 Bl

ck/

ilver/R-

21--41 74P

19-39 72P

0-900

(0-3000)

0--6

Bushed

Black

Green

Silver/

Blue

R-8#32

1--4174P

HYVO

193972P

HYVO

900-1500

ilv

R-

21--41 74P

19-39 72P

900-150

(3000-5000)

0--6

Bushed

Black

Green

Silver/

Blue

R-8#32

1--4174P

HYVO

193972P

HYVO

1500-2100

10-

8Bla

ck/

ilver/R-

21--41 74P

19-39 72P

Meters

150

0-210

(5000-7000)

0-5

Bushed

Black

Green

Silver/

Blue

R-8

1--4174P

HYVO

193972P

HYVO

Meter

(Feet)

2100-2700

ilv

R-

21--41 74P

19-39 72P

(

)

210

0-270

(7000-9000)

0-5

Bushed

Black

Green

Silver/

Blue

R-8#32

1--4174P

HYVO

193972P

HYVO

2700--3350

(9000--11000)

10--54

Bushed

Black /

Green

Silver /

Blue

R-8#321--41 74P

HYVO

19-39 72P

HYVO

3350--4000

(11000--13000)

10--AL

Bushed

Black /

Green

Silver /

Blue

R-8#321--41 74P

HYVO

19-39 72P

HYVO

- Production Setting

ENGINE

Type Liquid Cooled Case Reed w/TPS.......................

Displacement 701cc Fuel Pump Manuf. Walbro............... .....

Bore 3.1889² (81mm) Fuel Pump Mark FPA-4....................... .......

Stroke 2.6772² (68mm) Oil Pump Manuf. Mikuni..................... .......

Piston / Cylinder Clearance 0.0043² - 0.0057² (0.11 -- 0.14mm) Oil Pump Mark 03A... ........

Service Limit .0058” Cylinder Head Mark 3021022................ ....

Piston Marking 3021041..............

Piston Ring Marking N/A.........

Piston Ring End Gap 0.014² -0.020² (0.36 - 0.51mm)........

Head ccs (Uninstalled) 37.2±.50cc.......

Head ccs (Installed) 33.5 -- 34.5cc.........

Operating RPM±200 8100 RPM.........

Idle RPM±200 1500 RPM..............

Engagement RPM±300 3900 RPM......

Cylinder Head Torque 18-22 ft.lbs. (25-30Nm)........

Cylinder Base Nut Torque 30-34 ft.lbs. (41-47 Nm)....

Crankcase Torque (8mm) 20-24 ft.lbs. (28-33 Nm) Flywheel Torque90ft.lbs. (124 Nm).....

CARBURETION

Type TM 40 w/TPS Mikuni................

Main Jet 350............

Pilot Jet 45.............

Jet Needle 9DGJ2--57--2...........

Needle Jet P-8 (825)...........

Cutaway 2.0............

Air Screw 1.0 Turns...........

Valve Seat 1.8...........

Fuel Octane (R+M/2) Key Switch Adjustable. ThrottleGap

Under Cutaway 0.984² (2.5mm)......

Starter Jet 145...........

Pilot Air Jet 0.9 Long..........

Fuel Screw 2.0 Turns out..........

Exhaust Valve Spring Orange Low Elevation Exhaust

Valve Spring Green/Yellow.........

CLUTCH

Type P-85................

Belt 3211080.................

Belt Width (Projected) 1.438² (36.53mm). Side Angle (Overall) 28°.. Outside Circumference 46.625²

Center Distance 11.5²......

Shift Weights 10-56 Bushed........

Primary Spring Black/Green.......

Secondary Spring Silver / Blue....

Driven Helix R-8 #3.........

GENERAL INFORMATION

1.25

MODEL: 700 EDGE RMK 136”, 144”, 151”..........

MODEL NUMBER: S02NJ7CS, S02NK7CSA, S02NK7CS, S02NL7CS. ENGINE MODEL: S2190--7070PL7C..

ELECTRICAL CAPACITIES

Flywheel I.D. Kokusan 4010629 Fuel Tank 11.8 gallons (44.7 liters)...... ..........

CDI Marking 4010553 Oil Tank 3.25 quarts (3.1 liters)....... ............

Alternator Output 280 Watts Coolant 4.3 quarts (4.1 liters)... ............

Ignition Timing 18° BTDC@2500RPM±500 Chaincase Oil 11 fl. oz.(325cc)..... .......

With TPS Unplugged.

0.0815² BTDC

2.0705mm BTDC Spark Plug / Gap Champion RN57YCC / 0.025² (0.64mm)... Voltage Regulator LR7..

Electric Start Option.......

LR7= Full wave voltage regulator

Magneto Pulses 6....

SUSPENSION / CHASSIS CHAINCASE

Body Style EDGE Sprockets / Chain 21--41 74P HYVO(136)........ ...

Front Suspension EDGE 19--39 72P HYVO (144, 151)..

Front Shocks Nitrogen Cell Reverse Option...... ............

IFS Spring Rate 100#/in. Brake Pads Type 81, Large.... .........

Front Spring Preload 3/4² Thread Adjust Chaincase Center Dist.7.05² (17.91cm) Front Vertical Travel 7.2² -7.6² (18.3 - 19.3cm) Driveshaft Sprockets 2 Drivers Wide, XHS.

Rear Suspension EDGE RMK 136”, 144² or 151” Brake Type Polaris HPB Liquid Cooled... .........

Rear Axle Travel 13.8² (35cm)--(136), 17”(43cm)--(144, 151)... Front Track Shock Nitrex (136, 144), Ryde FX IFP (151)..

Spring Rate 170#/in.........

Rear Track Shock Indy Select (136, 144) Ryde FX IFP (151)..

Rear Springs .347”sq./47° (136), .359² (sq.) / 77°(144, 151)......

Track Type 15²x136²x1.75² (38.1x345.44x4.44cm) or 15²x144²x2.0² (38.1x365.76x5.08cm)........

Track Tension 3/8² -1/2² (1-1.3 cm) slack with 10# (4.54kg) weight 16² (40.64cm) ahead of rear idler......

shaft.

Overall Snowmobile Length 136² Track= 116² (295cm) 144² Track= 119.75² (304.2cm).................

Overall Snowmobile Height 45² (114cm).................

Maximum Snowmobile Width 44.25² (122cm)...............

OPTIONAL REAR TORSION SPRINGS

SOFT (STD) FIRM

-- .347²²²²(Sq.) Diameter x 77°°°° .359²²²²(Sq.) Diameter x 77°

°°

N/A L.H.(136” ) 7041627--067 L.H.(136”) 7041629--067 N/A R.H.(136”) 7041628--067 R.H.(136”) 7041630--067

.347²²²²(Sq.) Diameter x 47°°°° .359²²²²(Sq.) Diameter x 47°°°° .375²²²²(Sq.) Diameter x 47°

°°

L.H.(144”/151”)

7042081--067

L.H.(144”/151”)

7042068--067

L.H.(144”/151”)

7042079--067

R.H.(144”/151”)

7042082--067

R.H.(144”/151”)

7042069--067

R.H.(144”/151”)

7042080--067

GENERAL INFORMATION

1.26

MODEL: 800 EDGE RMK 144”, 151”, 156”..........

MODEL NUMBER: S02NM8CS. ENGINE MODEL: S2188--8070PL8C..

JETTING CHART

AMBIENT TEMPERATURE

Altitude

Below -30°F

Below -34°C

-30

_ to --10_F

-34_to -23_C

-- 1 0

_to +10_F

-23_ to --12_C

+10

_to +30_F

-12_to --1_C

+30

_to +50_F

-1_to +10_C

Above +50

Above +10_C

Altitud

Below34

34t

o-23C

23t

o--12C

12t

o--1

1to+10CAbove+10

0--600

(0--2000)

560N

540N

520N

500

480

460

600--1200

(2000--4000)

520N

500

480

460

440

420

Meters

1200--1800

490

470

450

430

410

390

Meter

(Feet)

1200180

(4000--6000)

490

470

450

430

410

390

(

)

1800--2400

450

430

410

390

370

350

(6000--8000)

390

350

2400--3000

410

390

370

350

330

310

(8000--10000)

390

350

330

3000--3700

360

340

330

320

300

290

(10000--12000)

360

330

300

XXX

- # refers to the clip position from top of jet needle.

CLUTCH CHART

DRIVE DRIVEN DRIVEN

ltitude

Shift Clutch Clutch Driven

Chaincase

Altitud

Shift

Weight

Clutc

Spring

Clutc

Spring

Drive

Helix

Gearing

(144, 151)

Gearing

(156)

Meters

0-900

Black Silver/R-11 21--41 74P

19-39 72P

Meter

(Feet)

0-900

(0-3000)

10-64

Black

Green

Silver/

Blue

R-1

1#22

1--4174P

HYVO

193972P

HYVO

(

)

900-1500

Black Silver/R--11 21--41 74P

19-39 72P

900-150

(3000-5000)

10-64

Black

Green

Silver/

Blue

R--1

1#32

1--4174P

HYVO

193972P

HYVO

1500-2100

Black Silver/R-11 21--41 74P

19-39 72P

150

0-210

(5000-7000)

10-62

Black

Green

Silver/

Blue

R-1

1#32

1--4174P

HYVO

193972P

HYVO

2100-2700

Black Silver/R-11 21--41 74P

19-39 72P

210

0-270

(7000-9000)

10-60

Black

Green

Silver/

Blue

R-1

1#32

1--4174P

HYVO

193972P

HYVO

2700-3300

(9000-11000)

10-58 Black

Green

Silver /

Blue

R-11#321--41 74P

HYVO

19-39 72P

HYVO

3300-3900

(11000-13000)

10-56 Black

Green

Silver /

Blue

R-11#321--41 74P

HYVO

19-39 72P

HYVO

ENGINE

Type Liquid Cooled Case Reed w/TPS Fuel Pump Manuf. Walbro....................... .....

Displacement 794cc Fuel Pump Mark N/A............... .......

Bore 3.3464² (85mm) Oil Pump Manuf. Mikuni....................... .......

Stroke 2.7559² (70mm) Oil Pump Mark 2540053..................... ........

Piston / Cylinder Clearance 0.006² -0.0074² (0.15 - 0.188mm) Cylinder Head Mark 3021294... ....

Service Limit N/A................

Piston Marking 3021184..............

Piston Ring Marking N/A.........

Piston Ring End Gap 0.016² -0.022² (0.41 - 0.56mm)........

Head ccs (Uninstalled) 46 - 47cc.......

Head ccs (Installed) 33 - 33cc.........

Operating RPM±200 8000RPM.........

Idle RPM±200 1500 RPM..............

Engagement RPM±300 4000 RPM......

Cylinder Head Torque 18-22 ft.lbs. (25-30Nm)........

Cylinder Base Nut Torque 30-34 ft.lbs. (41-47 Nm)....

Crankcase Torque (8mm) 29-24ft.lbs. (28-33 Nm).....

Crankcase Torque (10mm) 26-30ft.lbs. (36-41 Nm)...

Flywheel Torque 90ft.lbs. (124 nm).............

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

ThrottleGap

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.........

GENERAL INFORMATION

1.27

MODEL: 800 EDGE RMK 144”, 151”, 156”..........

MODEL NUMBER: S02NM8CS. ENGINE MODEL: S2188--8070PL8C..

ELECTRICAL CAPACITIES

Flywheel I.D. Kokusan 4010629 Fuel Tank 11.8 gallons (44.7 liters)...... ..........

CDI Marking 4010522 Oil Tank 3.5 quarts (3.3 liters)....... ............

Alternator Output 280 Watts Coolant 4.3 quarts (4.1 liters)... ............

Ignition Timing 29° BTDC@4000RPM±500 Chaincase Oil 11 fl. oz.(325cc)..... .......

0.2146² BTDC

5.4510mm BTDC Spark Plug / Gap Champion RN57YCC / 0.025² (0.64mm)... Voltage Regulator LR7..

Electric Start Option.......

LR7= Full wave voltage regulator

Magneto Pulses 6....

SUSPENSION / CHASSIS CHAINCASE

Body Style EDGE Sprockets / Chain 144”/151”--21:41 74P........ ...

Front Suspension EDGE CRC 156”--19:39 72P..

Front Shocks Nitrex or Ryde FX IFP Reverse Option...... ............

IFS Spring Rate 100#/in. Brake Pads Type 81, Large.... .........

Front Spring Preload Nitrex 3/4² Thread Adjust Chaincase Center Dist.7.05² (17.91cm)

Ryde FX IFP 3 13/16” Thread Adj. Driveshaft Sprockets 2 Drivers Wide.

Front Vertical Travel 7.2² -7.6² (18.3 - 19.3cm) Brake Type Polaris HPB Liquid Cooled.........

Rear Suspension EDGE RMK... Rear Axle Travel 144” -- 17”(43cm) 151” -- 17.5”(44.5cm) 156” -- 18”(46cm)... Front Track Shock Nitrex or Ryde FX IFP.. Rear Track Shock Select or Ryde FX IFP..

Spring Rate 170#/in. All Models.........

Rear Springs .359² (sq.) / 47° All Models.......

Track Type 15²x144²x2.0² (38.1x365.76x5.08cm) or 15²x151²x2.0² (38.1x383.40x5.08cm) or........

15”x156”x2.0” (38.1x396.24x5.08cm)

Track Tension 3/8² -1/2² (1-1.3 cm) slack with 10# (4.54kg) weight 16² (40.64cm) ahead of rear idler......

shaft.

Overall Snowmobile Length 144² Track 119.75² (304.2cm) / 151² Track= 123.5² (314cm).................

156” Track N/A

Overall Snowmobile Height 48.5² (123cm).................

Maximum Snowmobile Width 47.25² (120cm)...............

OPTIONAL REAR TORSION SPRINGS

SOFT MEDIUM(STD) FIRM

.347²²²²(Sq.) Diameter x 47°°°° .359²(Sq.) Diameter x 47° .375²²²²(Sq.) Diameter x 47°

°°

L.H. 7042081--067 L.H.7042068--067 L.H.7042079--067 R.H. 7042082--067 R.H. 7042069--067 R.H. 7042080--067

CHAPTER 2 MAINTENANCE AND TUNE UP

General Maintenance Inspection Sheet 2.1.................

Recommended Maintenance Products 2.2..................

Air Filter Maintenance 2.3................................

Sediment Trap, Oil / Fuel Filter Maintenance 2.4.............

ACCS Maintenance 2.5..................................

General Lubrication 2.6..................................

Water Pump Belt Tension 2.7.............................

Chaincase Oil / Drive Chain Maintenance 2.8...............

Suspension Lubrication 2.9 -- 2.10...............................

Cooling System Inspection and Maintenance 2.11............

General Track Inspection and Maintenance 2.12 - 2.13..............

Spark Plug Inspection 2.14................................

PVT Drive Belt Inspection and Maintenance 2.15.............

Headlight Inspection and Replacement 2.16.................

Handlebar Adjustment 2.17................................

Brake Systems Inspection and Adjustment 2.18..............

Throttle Lever Freeplay Adjustment 2.19.....................

General Cleaning and Lubrication Recommendations 2.20 -- 2.22.....

__1. Check cylinder head and base area for signs of exhaust or

coolant leaks. __2. Re-torque cylinder heads & cylinder base nuts (cold). __3. Check compression and record readings. __4. Check ignition timing.

______ observed BTDC

______ corrected BTDC __5. Inspect recoil starter rope.. __6. Check drive to driven clutch offset (belt removed). __7. Remove clutches, disassemble & inspect all wear

surfaces. Clean sheaves, repair clutch as necessary,

reassemble clutches and torque to specifications. __8. Check belt condition. __9. Check and adjust belt deflection. __10. Inspect rubber engine mounts. __11. Torque engine mounting plate to chassis fasteners. __12. Adjust engine torque stop (if equipped) (0.10”-0.30”). __13 Carburetor Inspections.

A. Adjust choke plungers.

B. Adjust pilot air screw.

C. Synchronize carburetor slide valves at idle.

and off idle. D. Adjust engine idle RPM. E. Adjust throttle lever free play. F . Synchronize oil pump lever. G. Inspect Choke/Throttle Cables. H. Inspect vent lines for wear or kinking.

__14. Remove chaincase cover, flush chaincase, inspect.

and adjust chain, refill with new chaincase oil.

__15. Change primary fuel filter and oil filter. __16. Check fuel and oil line condition and routing. __17 Inspect fuel and oil tank vent lines/routing. __18. Inspect airbox fit/air filter. Clean or replace. __19. Change shock oil (Fox) annually before storage. __20. V.E.S (Variable Exhaust System) - if applicable.

A. Disassemble and clean components.

__21. ACCS

A. Inspect vent lines.

Polaris Service T echnician: __________________________ Authorized Dealer: _________________________________ Base Inspection Price: ______________________________ Date: __________ Parts: __________ Labor: ___________

__21a. Brakes-Hydraulic

A. Check brake fluid level. B. Check for proper hose routing; tighness of banjo bolts and line

fasteners. C. Check forsystemflu id leaks. D. Visually inspect pads for wear damage or looseness. E. Check security and surface condition of brake disc. F . Flush brake fluid and change every two years.

__21b. Brake-Mechanical

A. Check cable conditions / routing. B. Check brake pad and brake disc condition and mounting. C. Adjust brake to proper specifications.

__22. Check auxiliary shut-off switch & perform throttle safety

switch tests.

__23. Inspect brake light, tail light, oil light and all electrical accessories. __24. Inspect Hi/Lo beam operation and aim headlight; check fasteners. __25. Liquid cooled models:

A. Check coolant level and specific gravity. B. Check water pump drive belt condition & deflection

(where applicable). C. Check coolant hose, routing and clamps. D. Inspect heat exchangers condition and fasteners. E. Check coolingsystemfor proper coolant circulation. F . Replace recovery line filter: NOTE: Must use correct filter. G. Check coolant recovery line one way check valve (must hold

pressure) where applicable. H. Pressure test coolingsystem.

__26. Fan Cooled: Inspect cooling fins and shrouds. __27. Remove chaincase cover, flush chaincase, inspect chain & sprock-

ets and adjust chain. Inspect chaincase seals.

__28. Check condition of drive shaft and jackshaft bearings. Lubricate

greaseable bearings with Premium All Season grease.

__29. Inspect and adjust reverse cable (if applicable). __30. Remove ski pivot bushings and lubricate. __31. Inspect ski wear bars. __32. Check camber alignment and lubricate spindles. __33. Remove radius rod end bushings, lubricate and reinstall, inspect all

radius rod ends.

__34. Reinstall skis and inspect/adjust toe alignment. __35. Check handlebar centering and lubricate all steering pivots. __36. Torque tie rod end bolts and jam nuts. __37. Inspect steering arms and torque bolts. Inspect handlebar bolt

torque.

__38. Lubricate rear suspension pivot shafts. __39. Torque suspension mounting bolts and check all rear suspension

fasteners and components.

__40. Inspect rear suspension wheels, bearings and hi-fax. __41. Inspect track for damage. Adjust tension and alignment.

For optimum performance and reliability , repeat the above maintenance and inspections annually (preferably before off-season storage) or every 1000 miles, except where noted.

RECOMMENDATION: ________________________________________

___________________________________________________________

MAINTENANCE / TUNE UP

2.1

1500 Mile (2400 km) Maintenance Inspection

MAINTENANCE / TUNE UP

2.2

Recommended Maintenance Products

ENGINE OIL RETAINING/SEALINGPRODUCTS

Part # Description Packaging

(size / quantity)

Part # Description Packaging

(size/quantity) 2871721 Synthetic 2-Cycle Premium Gold Quarts/ 6 2870652 Fuel Stabilizer 16 oz / 12 2871722 Synthetic 2-Cycle Premium Gold Gallon / 4 2872280 Fuel Stabilizer 2.5Gallon/2 2871723 Synthetic 2-Cycle Premium Gold 16 Gallon Drum 2871329 Nyogelt Grease 2oz 2871884 Synthetic 2 Cycle Premium Gold 55 Gallon Drum 2871064 T -9Metal Protectant each 2871098 Premium 2-Cycle Oil (TC-W3) QuartCans/12 2870632 MetalPolish 10oz / each 2871097 Premium 2-Cycle Oil (TC-W3) Gallon / 6 2871076 Battery Tendert each 2871240 Premium 2-Cycle Oil (TC-W3) 2.5Gallon/2 2870585 Primer N, Aerosol 25 gr / 1 2871566 Premium 2-Cycle Oil (TC-W3) 16 Gallon Drum 2870584 680 Retaining Compound 10cc / each 2871385 Premium 2-Cycle Oil (TC-W3) 30 Gallon Drum 2871949 Threadlock 242 50cc / 10 2871096 Premium 2-Cycle Oil (TC-W3) 55 Gallon Drum 2871950 Threadlock 242 6cc / 12 2872927 VES2 CycleSynthetic Oil Quart 2871951 Threadlock 262 50cc / 10 2872925 VES2 CycleSynthetic Oil Gallon 2871952 Threadlock 262 6cc / 12 2872924 VES2 CycleSynthetic Oil 55 Gallon Drum 2871953 Threadlock 271 6cc / 12 2872607 Nature Oil (TC-W3) Gallon 2871954 Threadlock 271 36cc / 6 2872926 Nature Oil (TC-W3) 55 Gallon Drum 2871955 Instant Adhesive: Prism401 3cc / 30

MAINTENANCE PRODUCTS 2871956 Pipe Sealant 565 50cc / 6 2872435 Cross Shaft Break-in Lube 8oz/12 2871957 Silicone, Black RTV 3oztube/12 2872436 Cross Shaft Break-in Lube 2.5 Gal / 2 2871958 Silicone, Black RTV 11 oz Cartridge/12 2871326 CarbonClean Plus 12 oz / 12 2871959 UltraBlueRTV 3.35 oz / 12 2871280 Premium Chaincase Lubricant Quart/12 2871960 UltraBlueRTV 13 oz Cartridge/12 2870464 Premium Chaincase Lubricant Gallon / 4 2871961 518 Flange Sealant 50cc / 10 2872281 Premium Chaincase Lubricant 2.5Gallon/2 CRANKCASE SEALANTS 2872951 Synthetic Chaincase Lubricant 12 oz. 2871557 3 Bond 1215 5oz 2873105 Synthetic Chaincase Lubricant Quart VALUE PACKS 2873106 Synthetic Chaincase Lubricant Gallon 2871967 Synthetic Lube Value Pack 4/Valuepack 2872952 Synthetic Chaincase Lubricant 2.5 Gallon 2871593 TC-W3 Lube Value Pack 4/Valuepack 2871323 Premium Antifreeze 60/40 Premix Gallon / 6 W AXAND POLISH 2871534 Premium Antifreeze 60/40 Premix Quart/12 2871589 Revival/Detailing Kit 6 / Kit 2870995 Premium Gas Shock Oil Quart/6 2871966 Restore polish/scuff remover 12 / 12 oz. 2872279 Premium Gas Shock Oil 2.5Gallon/2 2871965 Reflect Wax Final Finish 12 / 12 oz. 2870990 Premium Brake Fluid DOT-3 12oz / 12 2871964 Renew vinyl rubber protector 12 / 12 oz. 2870791 Premium Fogging Oil (spray) 12/12 oz RACING FUELS 2871517 Premium Fogging Oil (liquid with spout) Quart/12 2873019 100 Octane 5 Gallon 2871518 Premium Fogging Oil (liquid) Gallon / 6 2872980 100 Octane 16 Gallon Drum 2871312 Grease Gun Kit (All Season) 3oz/4 2872981 100 Octane 55 Gallon Drum 2871322 Premium All Season Grease 24oz / 10 2873019 110 Octane 5 Gallon 2871423 Premium All Season Grease 143oz/ 2872982 110 Octane 16 Gallon Drum 2871460 Premium Starter Grease 2oz/12 2872983 110Octane 55 Gallon Drum 2871592 Barrel Pump (for 16/30/55 gal. drums) Each 2871285 Flex Spout (fits gal. and 2.5 gal. jugs) 25 2870505 Isopropyl 10 oz / 24

MAINTENANCE / TUNE UP

2.3

Air Filter Maintenance

The intake foam filter limits snow ingestioninto the intake system. When operating in loose powder snow,check top of foam filter periodically to remove any accumulation of snow.

CAUTION:

Do not operate machine with the intake filters removed. This can cause carburetor icing resulting in poor fuel economy or carburetor malfunction.

Key Components

A Intake Foam Filter B Air Intake Box C Air Plenum D Dash Cowl

MAINTENANCE / TUNE UP

2.4

Water / Sediment Trap Maintenance

Most Polaris snowmobile incorporate patented carburetor bowl water / sediment traps which are located at the bottom of each carburetor. The trap consists of a hose with a plug which should beinspected for contamination at least every 2000 miles (3200 km).

Cleaning Procedure - Plug

1. Turn the fuel tank supply valve off.

2. Position acontainerorshoptowelsto catch the contaminatedgasoline.

3. Slide the clamp (1) away from the drain plug (2) and remove the drain plug from the sediment tube.

4. Wipe off residue from plug and reinstall with clamps. Continue until all the traps have been emptied.

Oil Filter / Fuel Filter Maintenance

Mostmodels use an oilfilter (2) which is of aspecialdesignandmustnot besubstituted. This filter should be changed annually or every 1200 miles (1920 km). Inspect oil line condition at 2000 miles (3200 km).

NOTE: The direction of the arrows indicates the direction of the flow through the filters.

Edgemodelsutilize aspecial oilfilter (3)that isbuilt into the oil sending unit located in the bottom of the oil tank. It should be replaced every other season.

NOTE: After changing the oil filter, the oil injection system must be bled of all trapped air.See your dealer for instructions or have your dealer perform the filter change and bleeding operation for you.

When draining the traps, fuel spillage will occur. Be sure to work in a well ventilated area away from anything which may cause the fuel to ignite such as open flames, sparks, heaters, trouble lights, cigarettes, etc.

Fuel Filter

Oil Filters

The in tank fuel filter (1) and fuel lines should be inspected regularly. Special attention should be given tothe system’s fuelline condition after periods of storage. Normal deterioration from weather and fuel compounds can occur.

Do not use pliers or a similar tool to remove fuel lines. Damage could occur.

Do not kinkthe fuel line. Damage could occur. If a fuelhas been damaged or kinked, replace it.

MAINTENANCE / TUNE UP

2.5

ACCS (Altitude Compensating Carburetor System) Maintenance

Some models are equipped with Polaris ACCS. The ACCS is designed to compensate automaticallyfor changes inaltitude without having to change carburetor jets.

ACCS does not require peroidic maintenance. See your dealer for ACCS service or adjusment.

NOTE: Tampering or adjustments totheACCSmaycause severe engine damage.

A. Airbox B. Vent Line Attachment C. ACCS Valve

MAINTENANCE / TUNE UP

2.6

Lubricate the following fittings with Polaris Premium All Season grease annually or approximately every 1000 miles (1600 km). Remove weight from the component being greased to permit better penetration and flushing of the joint.

S Spindles, left and right. S Rear suspension pivot shafts. S Lubricate both front ski pivots at fitting as shown using

Polaris All Season grease.

S Grease jackshaft and driveshaft (clutch side) bearings. S Use an aerosol lubricant on the steering post support

bracket.

S Grease steering post lower pivot. S Greasecenter steering arm (bell crank), pitmanarm,and

idler arm (where applicable).

NOTE: A grease gunkit complete with grease and adaptors is available to lubricate all fittings on Polaris snowmobiles.

Jackshaft Bearing Greasing

Loosen driven clutch retaining bolt and pull clutch outward to expose bearing. Usea point type grease gun fitting to injectgrease through hole in flangette into bearing until grease purges out inside or outside bearing seal. Push clutch back ontoshaft andreplace clutch retaining bolt.

Driveshaft Bearing Greasing

Inject grease into fitting on speedometer drive adaptor until grease purges out inside or outside bearing seal.

Aerosol

Polaris Premium All Season Grease 14 oz. PN 2871423

Grease Gun Kit PN 2871312

Grease Gun Adapter: 2871174 Point Type

Jackshaft

Driveshaft

Replace if width is less than .25² (6.35mm). Nominal new widthis .345² (8.75mm).

MAINTENANCE / TUNE UP

2.7

Water Pump Belt Tension -

700 and 800 Domestic big block Twins.

The water pump belt on 600 RMK, 700 RMK and 800 RMK domestic big block twin snowmobile engines should be inspected every 1500 miles. Belts should be inspected by measuring the width at several locations around the belt. Belt width at any location should notbe thinner than .250² (6.35mm). Replacethebeltifyounotice any loose cords, broken cracked or missing cogs, andvariations inwidth. If thewater pump belt fails, serious engine damage could result. Nominal thickness of a new belt should be approximately .345² (8.75mm).

Check belt tension by rotating crankshaft 1/8 turn at a time. The tension should be equal at all points of rotation.

1. Aweightisneededtotest belt deflection. Construct a weightout of wireandweights suchas thick washers. Usethe illustrationto assist you. The finishedweight should weigh 2 lbs.

2. Measure the belt deflection using the following procedure:

a. Hang weight midway between pulleys. Weight

must hang free and not rest on any part of machine.

b. Layastraightedgeorstraightpieceofstiffmateri-

al (steel is suggested) across the top ofboth pulleys. Thestraight edge should measureapproximately 1/8² x8² x1².

c. Measure the gap between the belt and the

straight edge at the point where the weight is hanging.

d. Measured distance must be between .1² and

.25². If the measured distance is more than the specification, try another waterpump belt.

NOTE: Do not use tools to assemble belt on pulleys. Damage can occur which could shorten belt life. Before installing new belt, check pulley teeth, remove all foreign material, dirt, and oil. Never install a used belt ona different engine. Install belt so writing on the belt can be read from the right side of the machine.

Oil Pump Adjustment

Refer to Chapter 3 for oil pump adjustment procedures.

Wide Enough to Span Belt

.062² to .090² Wire Suggested

Weight should equal 2 lbs.

Weight Construction

Hang Weight Here

MAINTENANCE / TUNE UP

2.8

Chaincase Oil Level

The drive chain is continuously immersed in oil. Proper oil level is determined by checking the level on the dipstick with machine placedon a level surface. The oil level should be between the “safe” marks on thedipstick. Addoilthrough dipstickopening to maintain proper level. Use Polaris chaincase oil. Do not overfill.

CAUTION:

Do not mix or useother types of lubricant. Excessivewear tochain, sprockets and bearings may result.

Drive Chain Tension - Chaincase cover installed

To obtain correct chain tension:

1. Elevate rear of machine so track is off floor.

2. Rotate driven clutch counterclockwise to move all chain slack to the tensioner side. Lock the brake lever.

3. Loosen adjuster bolt jam nut.

4. Finger tighten adjuster bolt until it can no longer be adjusted by hand.

5. Back off adjuster bolt 1/4 turn.

6. Tighten jam nut while holding adjuster bolt.

7. The chain is now tensioned. Release brake lever lock.

Drive Chain Tension - Chaincase cover removed

To obtain correct chain tension:

1. Remove drain plug (F) and drain oil into a suitable container. Dispose of properly.

2. Remove the chaincase cover.

3. While putting a slight reverse tension on the chain by turning brake disc as indicated by the arrow (A), there should be approximately 1/4-3/8² (.6-1 cm) deflection on the chain at point (B). Refer to illlustration 1.

4. The chain is adjusted by loosening the adjusting bolt locknut (C) and turning adjusting bolt (D) until correct chain deflection is obtained.

5. Lock the adjusting bolt locknut (C) whileholding awrench onthe adjusting bolt (D) to prevent it from turning.

6. Reinstall the chaincase cover and drain plug. Add Polaris synthetic chaincase lubricant (PN 2871478) through the dipstick opening to the level described above.

NOTE: Clean the magnetic plug (E) every 500 miles (800 km) and whenever checking or changing lubricant.

Dipstick

Magnetic Plug

Ill. 1

Polaris Chaincase Lubricant

Quart PN 2871280 Gallon PN 2870464

2.5 Gallon PN 2872281

MAINTENANCE / TUNE UP

2.9

Suspension Lubrication

To maintain rider comfort and to retard wear of the pivot shafts, the suspension pivot shafts should be lubricated with Polaris Premium All Season Grease, PN 2871423, at 500 miles (800 km) initially; 1000 miles (1600 km) and before summer storage each year. The riding characteristics of thesnowmobile will be affectedbylack of lubricationoftheseshafts. NOTE: Agreasegunkit complete with grease and adaptors is available tolubricateallfittings on Polaris snowmobiles. Order PN 2871312.

Suspension Lubrication

XTRA Lite Style

XTRA 10 Style

Polaris Premium Grease PN 2871423 Grease Gun Kit PN 2871312

L LUBRICATION POINTS -- XTRA-Lite

Grease all fittings

Forward

(Both Sides)

L LUBRICATION POINTS

Grease at fittings

Forward

MAINTENANCE / TUNE UP

2.10

EDGE RMK Style

Forward

LLLL

Filter - Filter is located before the check valve

Check Valve

Flow

Check Valves - tapered side points in flow direction

Filter

Flow

Check Valve

MAINTENANCE / TUNE UP

2.1 1

WARNING

Never remove the pressure cap when the engine is warmor hot. Ifthe pressurecap is toberemoved, theengine must be cool. Severe personal injury could result from steam or hot liquid.

Useofanon-standard pressure cap will not allow the recoverysystemtofunctionproperly. If thecap shouldneed replacement, install the correct Polaris cap withthe same pressure rating. Refer tothe appropriateparts manual.

Coolant Level

Coolant level in the reservoir or surge tank must be maintained between the minimum and maximum levels to prevent overheating and serious engine damage.

Recommended Coolant

Usea50/50 or 60/40 mixtureof antifreezeanddistilled water dependingonthefreeze protectionrequiredforyour area. Do not use tap water in the system or reduced cooling or filter contamination may result. Replace coolant every 2 years or if contaminated. Inspect coolant filter annually for contamination and replace if necessary.

Bleeding the Cooling System - Pressure Caps

If the cooling systemshouldbecomelowinthetankand/or fillerneck,thesystemshouldbebledofanytrappedairusing the following procedure:

1. Allow the system to cool completely.Fill the reservoir with coolant to the maximum indicated mark.

2. With pressurecap removed, addcoolant and fill to the top of the filler neck.

3. Install the pressure cap with the lever lock up in its release position and run the engine at low idle RPM (600±100)to allow all air topurgeand prevent trapped air which can lead to overheating. Reset idle to specified RPM after bleeding.

Bleeding the Cooling System - Surge Tanks

If the cooling system shouldbecomelowinthesurgetank, the system must be bled of any trapped air using the following procedure:

1. Allowthesystemtocoolcompletely.Fillthesurgetank with coolant to the maximum indicated mark.

2. Start the engine and loosen the bleed screw on thetop of the water pump until trapped air has been purged. Tighten the bleed screw.

3. Loosenthebleedscrewattheendandtopofthewater outlet manifold until trapped air has been purged. Tighten the bleed screw.

4. Recheck the surge tank coolant level and add coolant again if necessary.

Lift Lock Lever To Bleed

Remote Filler Neck Shown

Caution:

Increase RPM slowly when lever lock is up to avoid loss of coolant.

Remote Filler

Neck

Bleed at 600 RPM

Fill Surge Tank

Manifold Bleed Screw

MAINTENANCE / TUNE UP

2.12

WARNING

When performing the following checks and adjustments, stay clear of all moving parts to avoid serious personal injury.

Track Maintenance

WARNING

Nevermake this maintenance check with the engine running as serious personal injury can result.

Using a hoist, safely lift and support the rear of the snowmobile off theground. Rotatethetrack by hand to check foranypossibledamage.

To inspect track rods, carefully examine the track along the entire length of each rod, bending the track and inspecting for breakage. The three most common places where breakageoccurs areshown in the illustration.

If any rod damage is found, the track should be replaced.

WARNING

Broken track rods are a serious hazard, since they can cause a rotating track to come off the machine. Never operate orrotate atorn or damaged track under power. Serious personal injury or death may occur.

Track Alignment

Track alignment affects track tension. Misalignment will cause excessive wear to the track, hifax, and slide rail.

A periodic check should be made to see that the track is centered and running evenly on the slide rails. NOTE: If excessive hi-fax wear occurs due to poor snow conditions, additional wheel kits are available.

1. Safely support the rear of the machine with the track off the ground.

2. Start the engine and apply a small amount of throttle until the track turns slowly at least five complete revolutions. Stop the engine.

3. Inspect track alignment by looking through the track window to makesure the railsareevenly spaced on eachside. If thetrack runs to the left, loosenleft locknut and tighten the left adjusting bolt. If the track runs to the right, loosen right locknut and tighten the right adjusting bolt.

4. After adjustmentsarecomplete, be sure totightenlocknuts and idler shaft bolts. Torque to specification.

21312

Track window

Lug

Looking through track window, make sure the rails are evenly spaced on each side.

Rail

Hi-fax

Idler Shaft Bolt

Lock Nut

Idler Shaft Bolt Torque 35 - 40 ft. lbs. (48 - 55 Nm)

MAINTENANCE / TUNE UP

2.13

Track Tension Data

Suspension Weight Measurement Location Measurement

XTRA 10 121², 133², 136² 10 lbs. (4.54 kg) 16² ahead of rearidler shaft 3/8- 1/2² (1 - 1.3 cm)

XTRA Lite 136² 10 lbs (4.54 kg) 16² ahead of rear idler shaft 3/8 - 1/2² (1 - 1.3 cm)

EDGE RMK 136” 10 lbs (4.54kg) 16² ahead of rear idlershaft 3/8 - 1/2² (1 - 1.3 cm)

EDGE RMK 144”/151”/156” 10 lbs (4.54 kg) 16² ahead of rear idler shaft 3/8 - 1/2² (1 - 1.3 cm)

WARNING

When performing the following checks and adjustments, stay clear of all moving parts to avoid serious personal injury.

Track Tension - XTRA Lite / Xtra 10 / EDGE RMK

1. Turn the machine off.

2. Lift the rear of the machine and safely support it off the ground.

3. Place a 10 lb. (4.5 kg) weight on the track at a point approximately 16² (40.6 cm) ahead of the center of the rear idler wheel.

4. Checkforproperslack betweenthe trackclipwearsurface andthe hi-fax(C). NOTE: Measureat the point wherethe weight is hanging.

If the track needs adjustment:

5. Loosen rear idler shaft bolts (D) on both sides of the machine.

6. Loosen track adjusting bolt locknuts (A).

7. Tighten or loosen the track adjusting bolts (B) evenly as necessary to obtain proper track tension.

8. Tighten idler shaft bolts and adjuster bolt locknuts.

NOTE: Trackalignment affects track tension. Misalignment willcause excessive wear tothe track and sliderail. Excessive Hi Fax wear will appear on units with track tension set too tight.

10 lb. Weight (4.5 kg)

Track

Hi-fax

MAINTENANCE / TUNE UP

2.14

Spark Plug Selection

Original equipment parts or their equivalent should always be used. However, the heat range of spark plugs is of utmost importance. A spark plug with a heat range which is too high will cause engine damage. A spark plug with a heat range which is too low will cause excessive fouling.

In selecting a spark plug heat range for production, a manufacturer is forced to assume that the engine is going to be operated under extreme heavy duty conditions. This protects the enginefrom internal damage in the event that thepurchaser actually does operatethe engine in thismanner. This selection however, could causethe customer who normally operates the engine under medium or light duty to experience spark plug failure.

CAUTION:

A plug with a heat range which istoo high may cause enginedamage if the engine is operated in conditionsmore severe than that for which the spark plug was intended.

Anewenginecan cause temporary sparkplug fouling even thoughthe heat rangeis correct, due tothe preservative which has been added during assembly of the engine to combat rust and corrosion. Avoid prolonged idle speeds, as plug fouling and carbonization will result. Always use resistor type spark plugs.

NOTE: Incorrect fuel mixture can often cause a spark plug to appear to be too dark or too light in color. Before changing spark plug heat ranges, be sure the correct jetting is installed in the carburetors and proper carburetor function is verified.

The spark plug and its condition is indicative of engine operation. The spark plug firing end condition should be read after the engine iswarmed up andthe vehicle is driven at higher speeds. Immediately check the spark plug for correct color.

Normal

The insulator tip is gray, tan, or light brown. There will be a few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service.

NOTE: The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetion adjustments.

Wet Fouled

The insulator tip is black. A damp oily film covers the firing end. There may be a carbon layer over the entire nose. Generally,theelectrodes are notworn. General causesare excessiveoil, use ofnon-recommended injection oil, excessive idling, idle too low or too rich, or weak ignition output.

1. Inspect electrodesforwearandcarbonbuildup. Lookforasharpouteredgewithnoroundingorerosionofthe electrodes.

2. Clean with electrical contact cleaner or a glass bead spark plug cleaner only.

CAUTION:

A wire brush or coated abrasive should not be used.

3. Measure gap with a wire gauge and adjust to specifications by bending ground electrode carefully.

4. Coat spark plug threads with a small amount of anti-seize compound.

5. Install spark plug and torque to specification.

Spark Plug Torque: 12-14 Ft. Lbs (16.6-19.3 Nm)

MAINTENANCE / TUNE UP

2.15

Drive Belt

WARNING

Inspect the condition of the drive belt. Inspect clutch sheaves for damage, wear,orbeltresidue. Cleanwithnon-oil base cleaner such as isopropyl alcohol.

To ensure belt life, installbeltssotheyoperateinthesamedirectionofrotation. Positiontheidentificationnumbers so that you can read them standing on left side of machine. This will keep the belt rotating in the same direction. If belt has been operated with numbers readable from right side of machine, re-install belt in this direction.

Belt Removal

1. Be sure key switch is off and engine has come to a complete stop. Remove the retaining knob or pin and open the clutch guard.

2. Apply brake (or lock parking brake if so equipped).

3. Grasp beltfirmly midway between clutches and pull upward and rearward to open the driven clutch sheaves. Remove the belt fromthedrivenclutchandthenfromthedriveclutch.

Belt Installation

1. Drop the drive belt over the drive clutch and pull back the slack.

2. Turn the driven clutch moveable sheave clockwise while at the sametimepushinginwardandforcingthebeltdown betweenthe sheaves.

3. Hold the belt down between the sheaves and roll the bottom portion over the outer clutch sheave. Once installed, be sure to work the belt to the outeredge of thesheave. Be sureto release parking brake if applied.

4. Close the clutch guard and reinstall the retaining knob or pin.

Belt Inspection

5. Refer to PVT Section for belt inspection and width measurement.

6. Measurebeltlengthwith atape measure around theouter circumference of thebelt. Beltswhichmeasure shorteror longer than a nominal length may requiredriven clutch or engine adjustment to obtain proper belt deflection.

7. Replace belt if worn past the service limit. Belts with thin spots, burn marks, etc., should be replaced to eliminate noise, vibration, or erratic operation. See Troubleshooting Chart at the back of this chapter for possible causes. NOTE: If a new belt is installed, check belt deflection. Install so part numbers are easily read from left side of machine.

Refer to the specification charts for belt specifications and measurement procedures.

Removal

Installation

Center Distance

MAINTENANCE / TUNE UP

2.16

Headlight Adjustment

The headlight canbe adjusted for vertical aim using the following procedure:

1. Place the snowmobile on a level surface with the headlight approximately 25’ (7.6 m) from a wall.

2. Measure the distance from the floor to the center of the headlight and make a mark on the wall.

3. Start the engine and turn the headlight switch to high beam.

4. Observe theheadlight aim. The mostintensepart of the headlight beam should be aimed 2² (5.1 cm) below the mark placed on the wallinStep 2. NOTE: Rider weight must be includedon the seat.

5. If necessary, the headlight aim can be adjusted by turning the adjustment knoblocated insidethe hood just below theheadlamp opening. Turn knob in or out as needed for proper aim.

Removing Halogen Bulbs - Low Beam

NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin

leaves a residue, causing a hot spot which will shortend the life of the lamp.

1. PInch ends of spring together and lift until it releases from spring retainer.

2. Lift spring carefully around wire harness and flip to outside of housing.

3. With wire harness attached to bulb, withdraw bulb from housing.

4. Grasp bulb by metal base and carefully separate bulb from harness.

Installing Low Beam Bulb

1. Hold bulb by metal base only and install into wire harness.

2. Insert bulb into housing.

3. Carefully flip spring back into housing placing it around wire harness.

4. Squeezespringtogether until it isoverspringretainer andrelease.

5. Verify headlight aim.

Removing and Installing Halogen Bulbs - High Beam

1. Remove wire harness.

2. Grasp bulb firmly and twist it 1/2 turn counterclockwise.

3. Remove bulb from housing and replace with new bulb.

4. Place bulb andhousing back insideholeand turn housing1/2 turn clockwise to lock into place.

5. Reinstall wire harness to housing.

25’ (7.6 m)

Lamp Center Height

2² (5.1 cm)

Headlight Adjustment Knob

Wire Harness

Spring

Bulb

MAINTENANCE / TUNE UP

2.17

Taillight Bulb Replacement

1. Remove (5) Phillips screws from taillight lens.

2. Working from front to back, carefully pry lens away from housind and remove.

3. Pull bulb straight out from socket and insert new bulb.

4. Reinstall lens.

Handlebar Adjustment

1. Remove handlebar cover.

2. Using a 7/16² (11 mm) wrench, loosen four nuts on bottom of adjuster block. NOTE: Turn handlebar to left orright foraccess to back nuts.

3. Adjust handlebar tothe desired height. Be sure thathandlebars, brakelever and throttle lever operatesmoothly and do not hit the gas tank, windshield or any other part of the machine when turned fully to the left or right.

4. Torque the handlebar adjuster block bolts to specification. Maintain an equal gap at front and rear of block.

5. Replace handlebar cover.

WARNING

Improper adjustment of the handlebars, or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in loss of control.

Bulbs

Lens

Socket Screws

Handlebar Adjuster Block Bolt Torque 11-13ft.lbs.(15-18Nm)

MAINTENANCE / TUNE UP

2.18

Replenishing Brake Fluid

Remove brake fluid master cylinder reservoir cover. Add Polaris brake fluid as required to bring the level up to the top of the fluid levelmark on the insideofthereservoir (B). Theproperfluidlevel is 1/4-5/16² (.6-.8 cm) below the lip of the reservoir opening.

NOTE: On some models, the brake fluid level can be seen through the plastic reservoir. The fluid should be maintained between the minimum and maximum marks on the reservoir for those models.

Inspect the reservoir to be sure it contains the correct amount of fluid. Use only Polaris DOT 3 high temperature brake fluid. Change fluid every 2 years or whenever the fluid is dark or contamination is suspected.

WARNING

Donotoverfillthemastercylinder. Fluid expansion could cause brakes tolock, resulting in serious injury ordeath. Once a bottle of brake fluid is opened, use what is necessary and discard the rest. Do not store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. This causes the boiling temperature of the brake fluid to drop, leading to early brake fade and the possibility of serious injury.

Bleeding the Hydraulic Brake System

Air in the hydraulic brake system will cause a springy or spongy brake lever action. Bleeding is necessary to remove air from the system.

1. Remove brake fluid master cylinder reservoir cover and gasket.

CAUTION:Brakefluidis a hazardous material. Contactwith decals, paint, andmany plasticswill cause damage.

Use proper precautions when handling brake fluid.

2. Fill the master cylinderreservoir andreplace gasket and cover. Keep the fluid level 1/4-5/16² (.6-.8 cm)below lip of reservoir opening.

3. Slip a rubber tube over the ball of the bleeder valve and direct the flow of fluid into a container.

WARNING

Neverre-usebrakefluid. Brakefluidishygroscopic, meaningitrapidlyabsorbs moisture fromtheair. Thiscauses the boiling temperature of the brake fluid to drop, leading to early brake fade and the possibility of serious injury.

4. Squeeze brake lever a full stroke. Then unscrew bleeder valve (A) 3/4 of a turn to release air.

5. Close bleeder valve first and then release brake lever.

Repeat steps 4 and 5 until fluid flows from bleeder valve in a solid stream free of air bubbles. Do not allow reservoir to run dry or air will be drawn into system.

6. Re-fill reservoir to proper level after bleeding operation. Do not

overfill the master cylinder.

7. Replace gasket and cover.

Duringthe bleeding procedure makesure to keep thereservoir as level as possible to minimize the possibility of air entering the system.

Master Cylinder Fluid Level 1/4 - 5/16² (.6 - .8 cm) below lip of

reservoir opening

1/4-5/16² (.6-.8 cm)

Polaris DOT 3 High Temp Brake Fluid PN 2870990

Bleeder Tube

MAINTENANCE / TUNE UP

2.19

Throttle Lever Free Play

Throttle lever free play must always provide a specified clearance between throttle lever and throttle block. This clearance is controlled by the throttle cable sleeve(s) and the idle speed screw(s).

If the idle speed screw(s) is adjusted inward and the cable sleeve(s) is not adjusted to take up the throttle lever to throttle block clearance, the engine may misfire or kill upon initial throttle opening.

CAUTION:

After anyidle speed adjustments are made, thethrottle lever to throttle blockclearance and oil pumpadjustment must be checked and adjusted.

NOTE: When adjustments are made on models which have more than one carburetor, refer to Section 6, Carburetion, for proper carburetor synchronization adjustments.

Reverse Adjustment

Due to break-in or replacement of components, the reverse shift mechanism may require adjustment.

1. Loosen jam nuts on linkage rod (A).

2. Turn the threaded linkage rod (B) to lengthen or shorten the throw until reverse engages fully.

3. Tighten jam nuts and re-check adjustment.

.010-.030² (.25-.8mm)

Throttle Lever Freeplay .010 - .030² (.25 - .8 mm)

Shift Lever

Shift Lever Actuator

Cotter Pin

Clevis Pin

Chaincase Cover Assembly

MAINTENANCE / TUNE UP

2.20

Cleaning And Preservation Of Hood, Chassis And Trim

Properstoragestarts by cleaning, washing and waxing the hood, chassis,upholstery and plastic parts. Cleanand touch up with paint any rusted or bare metal surfaces. Ensure that all corrosive salt and acids are removed from surfaces before beginning preservation with waxes and rust inhibitors (grease, oil, or paint).

Ifthemachineisequippedwithabattery,disconnectthebattery cables andcleanthecablesandbatteryposts. Fill battery to proper level with distilled water and charge to full capacity. Remove and store the battery in a cool dry place.

The machine should be stored in a dry garage or shed out of the sunlight and covered with a fabric snowmobile cover. Do not use plastic to cover the machine; moisture will be trapped inside causing rust and corrosion problems.

Controls And Linkage

All bushings, spindle shafts and tie rod ends should becoated with a light coat of oil or grease. Throttle controls and cables should be lubricated. Force a small amount of lubricant down cables.

Electrical Connections

Separate electrical connector blocks and clean corrosive build-up from connectors. Lubricate or pack connector blocks with Nyogelt grease and reconnect. Replace worn or frayed electrical wire and connectors.

Clutch And Drive System

Removedrive belt and store in a cool dry location. Lubricate sheave facesandramps of drive and drivenclutches with light oil or rust inhibitor. All lubrication applied as a rust preventative measure must be cleaned off before installing belt for service and operating machine.

Chaincase Lubricant

Change chaincase lubricant as outlined in this section. Remove the outer cover and clean the chaincase thoroughly.

Nyogelt Grease PN 2871329

MAINTENANCE / TUNE UP

2.21

Lubrication

Refer to page 2.5-2.10 for complete lubrication information. To prevent corrosion, always grease jackshaft and drive

shaft (clutch side) bearings with premium all season grease. Loosen driven clutch retaining bolt and pull clutch outward to expose bearing. Use a point type grease gun fitting to inject grease through hole in flangette into bearing until grease purges out inside or outside bearing seal. Push clutch back on shaft and replace clutch retaining bolt. Inject grease into fitting on speedometer drive adaptor until grease purges out inside or outside bearing seal. Lubricate both front ski pivots at bushings and spindles. See Ill.1 and 2.

Use T-9 Metal Protectant (or equivalent) on shock absorber shafts to help prevent corrosion.

Under normal conditions moderate track tension should be maintained during summer storage. Rubber track tension should be maintained at the prescribed normal operating tension specified in this manual. The rear of the machine should be supported off the ground to allow free hanging of track.

Ski Spindle and Bushings

Ill. 1

Polaris Premium All Season Grease PN 2871423 14 oz.

Grease Gun Adapter: 2871174 Point Type

Jackshaft Bearing

Driveshaft Bearing

Grease

Ill. 2

T-9 Metal Protectant PN 2871064

MAINTENANCE / TUNE UP

2.22

Engine and Carburetor

Fog engine with Polaris Fogging Oil (aerosol type) accordingtodirections oncan. Onmodelswithcarburetor vacuum fittingsthe fogging oilcanbe sprayed throughthe fitting.

Treat the fuel system with Polaris Carbon Clean. If PolarisCarbon Clean is notused, fueltank, fuellines, and carburetor shouldbe completely drainedof gasoline.

Battery

Disconnect and remove battery. Fill with distilled water. Clean terminals and cables. Apply dielectric grease. Charge until specific gravity is at least 1.270 (each cell). If machine is to be stored for one mont h or longer, fil l and charge battery monthly using Polaris Battery Tender, or a 1 amp trickle charger to maintain at 1.270 specific gravity.

Exhaust System

Atapproximately 2000 miles, or inpreparationofoffseasonstorage, it is a good ideato checkthe exhaust system for wear or damage. To inspect, allow the engine and exhaust system to cool completely. Open the hood and inspect the muffler andpipes for cracks ordamage. Check for weak or missing retaining springs or damper/support grommets.

WARNING

Exhaust system temperatures can exceed 900° F(500° C). Serious burns may occur if this inspection is per- formed without allowing adequate time for the exhaust system to cool. Never perform this procedure with the engine running.

Polaris Fogging Oil PN 2870791 Carbon Clean PN 2871326

Polaris Battery Tender PN 2871076

MAINTENANCE / TUNE UP

2.23

Notes

CHAPTER 3 ENGINES

Engine Torque Specifications 3.1...........................

Engine Torque Sequences 3.2 -- 3.4.............................

Engine Removal 3.5 -- 3.8......................................

Engine Installation 3.9 -- 3.12.....................................

550 Engine Disassembly and Inspection 3.13 -- 3.19.................

550 Engine Assembly 3.20 -- 3.25..................................

500/600 Engine Disassembly and Inspection 3.26 -- 3.30.............

500/600 Engine Assembly 3.31 -- 3.35..............................

700/800 Big Block Disassembly and Inspection 3.36 -- 3.42...........

700/800 Big Block Assembly 3.43 -- 3.46............................

EV Maintenance 3.47 -- 3.49......................................

Optional EV springs 3.50...................................

Cylinder Honing 3.51 -- 3.52.......................................

Piston Inspection 3.53......................................

Crankcase Inspection 3.54..................................

Connecting Rod Inspection 3.55.............................

Crankshaft Truing 3.56 -- 3.57.....................................

Crankshaft Indexing 3.58 -- 3.59...................................

Cylinder Head Inspection 3.60...............................

Piston Inspection 3.61......................................

Oil Pump Operation / Adjustment 3.62 -- 3.65........................

Cooling System 3.66 -- 3.70.......................................

Recoil Disassembly and Assembly 3.71......................

Troubleshooting 3.72 -- 3.73.......................................

ENGINES

3.1

Engine Torque Specifications

When tightening bolts, nuts, or screws, a torque pattern should be followed to ensure uniform equal tension is appliedtoallfasteners. Propertorqueapplicationprevents fastenersfromlooseningor breaking incriticalservice. It also minimizes wear and eliminates premature or needless repair costs. Following uniform torque application sequence patterns ensures optimum performance from precision machined, close tolerance assemblies.

The most common units of torque in the English system are ft. lb. and in. lb. In the Metric system, torque is commonly expressed in units of kg-m or Nm (Newton Meters). Multiply foot pounds by .1383 to obtain kg-m. Move decimal point one place to the right to obtain Nm from kg-m.

Engine

Cylinder Head Cylinder

Base Nuts

Crankcase

8mm

Crankcase

10 mm

Flywheel

550 Fan Cooled Twin Cylinder EC55

18-19.5 ft.lbs. (25-27 Nm)

24-28 ft.lbs. (33-39 Nm)

16.6-18 ft.lbs. (22-25 Nm)

N/A 60-65 ft.lbs.

(83-90 Nm)

SN50** 20-24 ft.lbs.

(29 - 33 Nm)

30-34ft.lbs (41-47 Nm)

20-24 ft.lbs. (28 - 33 Nm)

N/A

90 ft. lbs. (124 Nm)

SN60-70** SN70** SN80**

18-22 ft. lbs. (25 - 30 Nm)

30-34ft.lbs (42-47 Nm)

20-24 ft.lbs. (28 - 33 Nm)

26-30 Ft lbs (36-41 Nm)

90 ft. lbs. (124 Nm)

** Torque head bolts prior to torquing cylinder base nuts.. Apply Loctitet 242.

All 6mm Crankcase Bolts 108 in. lbs. (12.4 Nm).....

All 7/16-14 Engine Mount Strap Bolts 44-48 ft. lbs. (60-66.3 Nm).....

CYLINDER HEAD

CRANKCASE - TWIN CYLINDER - Fuji

CYLINDER BASE

MAG SIDE

PTO SIDE

ENGINES

3.2

Torque Sequences - EC55 Engines

ENGINES

3.3

Torque Sequence / Domestic 500

CYLINDER HEAD

Domestic 500

CYLINDER BASE

Domestic 500

CRANKCASE

Domestic 500

ENGINES

3.4

Torque Sequence / Domestic 600 / 700 / 800

CYLINDER BASE

Domestic Twins 600 / 700 / 800

CRANKCASE

Domestic Twins 600 / 700 / 800

CYLINDER HEAD

Domestic Twins 600 / 700 / 800

ENGINES

3.5

Engine Removal, Typical

1. On some models, it may be necessary to removethe hood for easier access to engine components or to prevent damage.

2. Disconnect battery ground (--) from battery (if applicable). Shut off fuel.

3. Remove fuel pump or CDI from airbox if applicable.

4. Remove airbox.

Ground Cable

ENGINES

3.6

Engine Removal, Typical-Cont.

5. Free recoil rope from chassis.

NOTE:Be sure to tie a knot in recoil rope upon removal so rope doesn’t wind up into recoil housing.

6. Loosen clamps at carburetor mounting flange. Pull carbs from adaptors andsecure out ofthe way. Note routing of all cables and hoses for reassembly.

7. Disconnect oil pump control cable.

8. Disconnect and plug oil supply line.

TIP: A bolt or spare water trap plug can be used to plug the oil line from the oil reservoir.

ENGINES

3.7

Engine Removal, Typical-Cont.

9. Remove drive belt.

NOTE:If drive clutch removal is necessary, it may be done at this time. Refer to Chapter 5, clutches.

10. Remove exhaust system.

11. Disconnect coolant supplyhosesasnecessary at the most convenient location on liquid cooled models. Drain coolant into suitable container.

ENGINES

3.8

Engine Removal, Typical-Cont.

12. Disconnect electrical connections from stator and starter motor (where applicable).

13. Remove two front and two rear engine mount bolts (nuts) that secure engine mount plate (straps) to chassis.

14. Remove engine from chassis.

ENGINES

3.9

Engine Installation, Typical

1. Prepare chassis for engine installation by moving hoses and wiring out of the way.

2. If model is equipped with a torque stop, loosen locking screw and turn torque stop in to gain clearance when installing engine.

NOTE:Torquestop must be adjusted properly afterclutch alignment (see chapter 5, clutches)

3. Check condition of bonded rubber engine mounts. Be sure mounts are tight before installing engine. With engine mounting plate ormount straps installed on engine, set engine on rubber mounts and loosely install mounting bolts and nuts.

4. Install drive belt (and clutch if removed) and check clutch offset/alignment. Adjust torque stop (where applicable). Refer to chapter 5, clutches, for torque stop adjustment procedure.

5. Tighten engine mounting bolts to specification.

Engine Mounting Bolt TorqueFront - 28 Ft lbs (67 Nm)

Rear - 28 Ft lbs (67 Nm)

ENGINES

3.10

Engine Installation, Typical-Cont.

6. Apply a light film of Polaris dielectric grease to all connections. Connect all stator connections and temperature switch.

7. Connect oil supply line to oil pump. Bleed oil pump by opening bleed screw until oil flows steadily. Tighten bleed screw securely. Install throttle cable to oil pump and check adjustment. Refer to General Inspection Procedures in this chapter for oil pump adjustment procedure.

8. Install carburetors and tighten clamps. Make sure hoses and cables are routed correctly.

9. Connect oil lines to carburetors

Nyogelt greasePN 2871329 - 1/4 oz.

ENGINES

3.1 1

Engine Installation, Typical-Cont.

10. Install coolant hoses where applicable. Make sure hoses are routed properly and hose clamps are positioned and tightened securely.

11. Route and install recoil rope to chassis.

12. Install starter and starter cables (electric start models).

13. Install exhaust system in reverse order of disassembly.

ENGINES

3.12

Engine Installation, Typical-Cont.

14. Install hood if previously removed.

15. Install airbox.

16. Secure fuel pump and CDI box.

17. Fill cooling system (liquid models) with Polaris Premium Antifreeze 60/40 premix.

18. Add a full tank of premix fuel (50:1) to fuel tank.

19. Start engine and check operation. Bleed cooling system on liquid models. See Cooling System Bleeding Procedures in this chapter.

Polaris Premium Antifreeze 60/40 premix

Quart PN 2871534 Gallon PN 2871323

ENGINES

3.13

Engine Disassembly / Assembly - Fuji 550 Fan Cooled Engines

NOTE: Inspect all parts for wear or damage during disassembly. Replace all seals, O-rings, and gaskets with Genuine Polaris parts during assembly. Refer to pages 3.47-3.56 for general inspection procedures.

Disassembly

1. Remove coil pack from fan shroud, and disconnect it from the wiring harness.

2. Loosen carburetor clamps and remove each carburetor.

3. Using a pliers, detach the oil lines from the carburetors.

ENGINES

3.14

Disassembly - Continued

4. Remove the carburetor mounting boots using a allen wrench.

5. Remove both the cylinder head and exhaust side fan shroud s from the engine assembly.

6. After removing the fan shrouds, take note of the vibration dampener located between the two intake ports.

ENGINES

3.15

Disassembly - Continued

7. Remove the CDI module from the flywheel cover.

8. Remove the flywheel cover.

9. Prior to removing the flywheel, insert a piece of nylon rope or cord into a spark plug hole. Rotate the crankshaft counter-clockwise until it will no longer turn over.

ENGINES

3.16

Disassembly - Continued

10. Remove the recoil cam.

11. Loosen and remove the flywheel nut.

12. Using a flywheel puller, remove the flywheel from the engine. Do not install puller bolts more than 5/16² (7mm) into flywheel threads or stator damage may result.

Flywheel Puller

PN 2871043

ENGINES

3.17

Disassembly - Continued

13. Remove the flywheel.

14. The stator plate can be removed without taking off the stator.

15. Remove the oil pump taking note of the o-ring and shim(s).

ENGINES

3.18

Disassembly - Continued

16. Remove the cylinder head.

17. Remove the head gasket. During removal, note that the head gasket is stamped with “EX” and “UP”.

18. Loosen and remove each cylinder.

ENGINES

3.19

Disassembly - Continued

19. Remove the reed valves from the crankcase.

20. Using an awl andpiston pin puller, removethe pistons.

CAUTION:

Wear eye protection during piston c-clip removal to prevent eye injury.

21. Turn crankcase over and remove the crankcase bolts. Turn over and separate the case halves.

22. Refer to General Inspection section for crankshaft inspection and measurement procedures.

Piston Pin Puller PN 2870386

ENGINES

3.20

Engine Assembly

1. Prior to assembly,makesure that youhave all of the oil pump shims when the oil pump was removed, and that the shims are installed in the correct order.

2. Insert oil pump drive gear.

3. Insert oil pump driveshaft spacer.

ENGINES

3.21

Engine Assembly - Continued

4. Lay crankshaft into the lowercase half. Make sure that the crankshaft rotates smoothly and doesnot bind. Rotatethe bearings sothat the anti-rotation pins rest in their appropriate galleries.

5. Apply 3-Bondä sealer to top half of crankcase. Lubricate oil pump drive gear.

6. Install the upper case half.

7. Turn the crankcase over and torque the case bolts in sequence illustrated in beginning of chapter.

3-Bond ä 1215 PN 2871557 120 Gram Tube

Crankcase Bolt Torque

16.6 - 18 ft.lbs. (22 - 25 Nm)

ENGINES

3.22

Engine Assembly - Continued

8. Install pistons with arrow (") on piston facing flywheel, with locating pins to intake side. Install C-clips securely in piston groove.

9. Lubricate rings andpistonswith two stroke oil. Install rings with letter, mark, or beveled side facing upward.

10. Install the reed valves in the crankcase. After installing the reed valves, insert the base gaskets.

11. Install each cylinder. Torque cylinder base nuts in sequence illustrated in beginning of chapter.

Cylinder Base Nut Torque 24 - 28 ft.lbs. (33 - 39 Nm)

ENGINES

3.23

Engine Assembly - Continued

12. Install the cylinder head gasket with the “EX” on the exhaust side, and “UP” on the intake side of the engine.

13. Insert the dowels into the flywheel housing.

NOTE: Refer to picture for proper installation of alignment dowels.

14. Tighten flywheel housing to crankcase.

ENGINES

3.24

Engine Assembly - Continued

15. Install the flywheel andinsert thelock washer.

16. T orque the flywheel nut. During the procedure, use a flywheel holding wrench to prevent the flywheel from rotating.

17. Reinstall the flywheel cover and CDI module.

Flywheel Holding WrenchPN 8700229

Flywheel Nut Torque 60 - 65 ft.lbs. (83 - 90 Nm)

ENGINES

3.25

Engine Assembly - Continued

18. Insert the vibration dampener into the cooling fins between the intake ports. Reinstall the two fan shrouds making sure that they interlock before fastening tightly.

19. Using a new o-ring, reinstall the oil pump.

20. Install each carburetor and torque the carburetor mountingclamps Reinstall oil lines on the oil pump.

Oil Pump Mounting Screw Torque: 48 - 72 in.lbs. (5.5 - 8.3 Nm)

ENGINES

3.26

Engine Disassembly / Assembly -- Domestic 500 / 600 Engine NOTE: Inspect all parts for wear or damage during disassembly. Replace all seals, O-rings,

and gaskets with Genuine Polaris parts during assembly. Refer to pages 3.47-3.56 for general inspection procedures.

Disassembly

1. Remove carburetor mount adaptors, reed cages, stuffers, and oil pump. Note position of stator wire guide. Measure air gap between fiber reed and reed block as shown. The air gap should not exceed .015² (.4 mm). If clearance is excessive DO NOT attempt to reverse the reeds to reduce the air gap. Always replacethem if damaged. Checkeachfiber reedfor white stress marks or missing material. Replace if necessary.

2. Remove cylinder head cover and inspect O-rings and sealing surfaces for damage or debris. Use new O-rings upon assembly.

Reed Pedal Clearance .015² (.38 mm) max.

Exaggerated for illustration

ENGINES

3.27

Disassembly, Cont.

3. Remove cylinder base nuts. Note location of acorn nuts on exhaust side (where applicable).

4. Carefully removecylinders while supportingpistons and connecting rods to prevent piston damage. Refer to General Inspection Procedures in this chapter.

5. Remove outer piston pin C-clips using a scribe through access slot in piston.

6. Placesupport block underpistonand remove piston pins using pin puller.

7. Remove water pump cover from front of engine.

Piston Pin Puller PN 2870386 Support Block PN 2870390

ENGINES

3.28

Disassembly, Cont.

8. Remove recoil housing and drive hub.

9. Remove flywheel using heavy-duty flywheel puller. Use drive clutch puller T-handleor a wrench to hold puller.

10. Before removing stator plate, note where ignition timing marks arelocated, or scribeadditional marks for reference upon reassembly.

11. Mark or note location of engine mount straps and remove.

Flywheel Puller PN 2871043 T-Handle PN 5020326

ENGINES

3.29

Disassembly, Cont.

12. Remove bolts and separate case halves. Keep bolts in order for assembly.

13. T o prevent damage to snap-ring grooves, lift crankshaft straight upward and out of lower case.

14. If pump shaft removal is necessary, remove retaining pin from crankcaseusing a diagonalcutter or similar tool.

15. T ap out the drive shaft using a center punch and hammer. Locate the center punch in the centering hole on theoil pump endof the shaft. Be careful not to damage the bearing. This will remove the oil seal and the mechanical seal from the crankcase.

ENGINES

3.30

Assembly

1. Insert bushing intocaseonoilpumpsideofcase. Press in until firmly seated in case.

2. Install the bearing washer to the oil pump end of the shaft.

S Lubricate shaft, insert shaft through the case on

water pump side into the bushing on oil pump side.

3. Lubricate and install bearing washer and brass bushing onto the shaft on waterpump side.

NOTE:If front bushing is replaced it may be necessary to drill a retaining pin hole in the new bushing. If there is no hole in the bushing:

S Measure depth ofthe retainingpin hole in theold

bushing.

S Using the retainingpinholeasaguide,carefully

drillaholein the new bushing tothesamedepth and diameter as the hole in the old bushing. Be careful not to enlarge the retaining pin hole, or drill too deep.

S Install new retaining pin.

4. Lubricate and install oil seal with seal lip out (towards you) until it is against the bushing.

Align hole in bushing with weep hole and retaining pin hole

Oil Pump Side

Water Pump Side

O--ring

Rear bushing

Bearing Washers

Mechanical Seal

Front Brass Bushing

Seal (Spring faces mechanical seal)

Oil Pump side

Water Pump side

Flat washers

Impeller

Nut

ENGINES

3.31

Assembly, Cont.

5. Lubricate and install new mechanical seal using the Mechanical Seal Guide Tool PN 2872010.

6. Press a new mechanical seal into case until fully seated.

7. Lubricate all crankshaft bearings with Premium 2-Cycle or Premium Gold Engine Lubricant.

8. Apply 1/3 oz. (10 cc) cross shaft break-in lube to oil pump gears.

9. Install seals on crankshaft withspring facing inward (toward crankshaft).

10. Clean and de-grease lower crankcase and install crankshaft assembly, aligning seals and snap ring with grooves in case.

11. Apply a thin coatingof3-Bond 1215sealant to lower crankcase mating surface.

12. Install upper crankcase on lower crankcase.

13. Apply Loctite 242 to threads of bolts and install. Torque bolts in three steps to specification outlined in beginning of this chapter following the sequence shown at right

14. Install oil pump,beingcareful to engage pump shaft in drive shaft location, after case is assembled.

Mechanical Seal Guide Tool 500 / 600 V.E.S domestic engines 8.4mm: PN 2872010

Oil Pump Cross Shaft Break-in Lube: PN 2872435 - 8 oz. PN 2872436 - 2.5 Gallon

1 4

PTO EndMAG End

ENGINES

3.32

Assembly, Cont.

15. Assemble engine mount straps to crankcase.

16. Lubricate main bearing oil holes with Polaris Premium 2 Cycle or Premium Gold engine oil and rotate crankshaft to distribute oil evenly.

17. Install a new C-clip in both pistons (inside) with gap facing down. Be sure clip is fully seated in groove.

18. Lubricate and install new connecting rod small end bearing in rod.

19. Install piston with arrow facing exhaust (ring locating pins shouldbe facing intake). Warming the piston may help to ease installation of pin.

20. Install remaining C-clip with gapdown. Besureboth clips are fully seated in the groove.

21. Install new base gasket. Be sure gasket surface is clean and free of nicks, burrs, or scratches.

22. Lubricate andinstallpiston rings onpistonwithmark on end of ring facing upward.

23. Place piston support under skirt and lubricate pistons and cylinders thoroughly.

24. Align ring end gaps withlocating pins and compress rings. Install cylinder carefully with a gentle front to rear rocking motion. Install cylinder base nuts loosely. Do not tighten them at this time. Repeat Steps 22-25 for other cylinder.

CAUTION:

Do not twist or force cylinder during installation.

25. Install new cylinder head O-ringsandinstallcylinder head. Make sure O-rings are properly seated in grooves. Apply a light filmof greaseto hold O-rings in place if necessary.

Engine Mount Strap Torque: 44-48 ft. lbs. (60-66 Nm)

Straight Edge

Piston Ring Cutaway

Keystone Piston Ring

ENGINES

3.33

Assembly, Cont.

26. Install new cylinder head cover O-rings and install cylinder head cover. Make sure O-rings are properly seated in grooves. Apply a light film of grease to hold O-rings in place if necessary.

27. Loctite 242 to threads of head bolts and install.

28. T orque head bolts to specification outlined in beginning of this chapter in proper sequence.

29. T orque cylinder base nuts outlined in beginning of this chapter in proper sequence.

30. Install washers and water pump impeller as shown and torque nut to 10 ft. lbs. (14 Nm).

Cylinder Head

6 7

Cylinder Base

Washer

10.3x14x1mm 10 ft.lbs.

(14 Nm)

Washer .325x.75x.063²

Mechanical Seal

Impeller Nut Torque: 10 Ft lbs (14 Nm)

ENGINES

3.34

Assembly, Cont.

31. Install water pump cover with new gasket.

32. Install new exhaust manifold gaskets and manifold.

33. Install reed valves, stuffers, and carburetor adaptors. Place stator wire guide on Mag side carburetor adaptor bolt.

34. Install stator assembly, aligning timing marks or marks made upon disassembly. Seal stator wires with high temperature silicone sealant. Install and tighten stator screws to specification.

35. Measure trigger (pulse) coil gap and compare to specification.

Water Pump Cover Bolt Torque: 9 Ft lbs (12.5 Nm)

Exhaust Manifold Bolt Torque: 16 Ft lbs (22 Nm)

Seal Stator Wires

Apply Loctitet 262 to Taper

Stator Screw Torque 60 in. lbs. (7 Nm)

Trigger (Pulse) Coil Gap Minimum: .020² (.5mm )

Maximum: .040² (1.0mm )

ENGINES

3.35

Assembly, Cont.

36. Apply Loctitet 262 evenly tothe flywheelmounting taper on crankshaft. Install woodruff key.

37. Install flywheel. Apply Loctitet 242 to crankshaft threads. Install washer and nut.

38. Use flywheel holder to hold flywheel and torque nut to specification found in beginning of this chapter.

39. Install recoilhubandrecoil housing. Torque boltsto specification.

40. Install engine in chassis and align clutches.

41. Refer to General Inspection Procedures in this chapter to fill and bleed cooling system and oil pump.

Flywheel Holder: PN 8700229

Recoil Hub and Housing Bolt Torque:

108 in. lbs. (12.5 Nm)

ENGINES

3.36

Engine Disassembly / Assembly -- Domestic 700 / 800 Engines

Disassembly

1. Remove oil pump.

2. Remove recoil housing.

3. Remove recoil hub. Inspect waterpump drive belt for missing, cracked, orbroken drive cogs. Replace if worn.

Measure the belt at 4 different points as shown. Replaceifwidthislessthan.250²,(6.35mm). Nominalnew width is .345², (8.75mm). Refer to Chapter 2, Maintenance for water pump belt installation.

Replace if width is less than .25² (6.35mm)

ENGINES

3.37

Disassembly, Cont.

4. Remove drive gears and belt.

5. Remove flywheel nut using flywheel holder.

6. Remove flywheel using flywheel puller.

7. Note the ignition timing strip on the flywheel.

8. Before removing stator plate, mark the plate and crankcase for reference upon assembly.

Flywheel Holder PN 8700229

Flywheel Puller PN 2871043

Polaris INDY TRAIL RMK, INDY 500 RMK, INDY 700 SKS, INDY 700 EURO SKS, 700 EDGE RMK Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual