Polaris 2002 Snowmobile Owner'S Manual Download Page 178

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176

INDEX

Accessories

60–65

. . . . . . . . . . . . . . . . . .

Adjustment, Backrest

. . . . . . . . . . . . .

Adjustment, Front Suspension

44–50

. . .

Adjustment, Handlebar

. . . . . . . . . . . .

Adjustment, Headlight

129

. . . . . . . . . . .

Adjustment, Indy Select Front Track

Shock

. . . . . . . . . . . . . . . . . . . . .

Adjustment, Indy Select Rear Shock

. .

Adjustment, Rear Rear Scissor Stop

. .

Adjustment, Rear Torque Arm, SKS Mod-

els

. . . . . . . . . . . . . . . . . . . . . . . .

Adjustment, Rear Torsion

Spring, Xtra 12

. . . . . . . . . . . . . .

Adjustment, Steering

144

. . . . . . . . . . . . .

Adjustment, Rear Suspension

. . . . . . .

Adjustments, Carburetor

118

. . . . . . . . . .

Air Intake System

111-112

. . . . . . . . . . .

Alignment, Ski

145

. . . . . . . . . . . . . . . . .

Anti--Theft System

170

. . . . . . . . . . . . . .

Backrest

. . . . . . . . . . . . . . . . . . . . . . .

Backrest Adjustmen

. . . . . . . . . . . . . .

Battery

153-155

. . . . . . . . . . . . . . . . . . .

Battery Connections

154

. . . . . . . . . . . . .

Battery Fluid

153

. . . . . . . . . . . . . . . . . . .

Battery Installation

155

. . . . . . . . . . . . . .

Battery Removal

154

. . . . . . . . . . . . . . . .

Bearing, Driveshaft

107

Bearing, Jackshaft

107

. . . . . . . . . . . . . . .

Before Starting the Engine

Brakes

66-67

. . . . . . . . . . . . . . . . . . . .

Clear Operating Area

. . . . . . . . . . .

Engine Stop Switch

. . . . . . . . . . . .

Lighting Check

. . . . . . . . . . . . . . . .

Owner’s Manual

. . . . . . . . . . . . . . .

Park Brake

. . . . . . . . . . . . . . . . . . .

Steering Inspection

. . . . . . . . . . . . .

Tether Switch

. . . . . . . . . . . . . . . . .

Throttle

. . . . . . . . . . . . . . . . . . . . . .

Track Inspection

. . . . . . . . . . . . . . .

Belt Deflection, Drive Belt

135

. . . . . . . .

Belt Installation, Drive Belt

133

. . . . . . . .

Belt Installation, Electronic Reverse 133

Belt Removal, Drive Belt

132

. . . . . . . . .

Belt Removal, Electronic Reverse

132

. . .

Belt Troubleshooting

163

. . . . . . . . . . . .

Belt/Wear Burn

163

. . . . . . . . . . . . . . . . .

Bleeding Cooling System

121-123

. . . . .

Brake Bleeding

127

. . . . . . . . . . . . . . . . .

Brake Components

125

. . . . . . . . . . . . . .

Brake Fluid Replenishment

126

. . . . . . . .

Brake Inspection, Hydraulic

124

. . . . . . .

Brake Lever Travel

67-68, 125-128

. . . . .

Brake Lever, Mechanical

128

. . . . . . . . . .

Brakes

67-68

. . . . . . . . . . . . . . . . . . . . . .

Bulb Replacement, Headlight

130

. . . . . .

Bulb Replacement, Side Bulbs

131

. . . . .

Bulb Replacement, Taillight

131

. . . . . . .

Carburetion

. . . . . . . . . . . . . . . . . . . . .

Carburetor Adjustments

118

. . . . . . . . . .

Carburetor Information

118

. . . . . . . . . . .

Carburetor Protection During

Storage

151

. . . . . . . . . . . . . . . . . . .

Cargo Carrier

. . . . . . . . . . . . . . . . . . .

Chaincase Oil Level

109

. . . . . . . . . . . . .

Gearcase Oil Level / WideTrak

110

. . . . .

Choke and Cable Lubrication

108

. . . . . .

Clear Operating Area

. . . . . . . . . . . . .

Clutch Alignment and Offset

135

. . . . . .

Clutch Center Distance

136

. . . . . . . . . . .

Clutch System

134

. . . . . . . . . . . . . . . . . .

Clutches

. . . . . . . . . . . . . . . . . . . . . . .

Coil Spring Options

. . . . . . . . . . . . . .

Cold Weather Driveaway

. . . . . . . . . .

Coolant

120

. . . . . . . . . . . . . . . . . . . . . . .

Coolant Level

120

. . . . . . . . . . . . . . . . . .

Cooling System Maintenance

121

. . . . . .

Cooling System, Bleeding

121-123

. . . .

Cooling, Engine

119

. . . . . . . . . . . . . . . .

Crossing a Slope

. . . . . . . . . . . . . . . . .

Daily Storage

. . . . . . . . . . . . . . . . . . .

Decal, Airbox

. . . . . . . . . . . . . . . . . . .

Decal, Cargo Carrier

. . . . . . . . . . . . . .

Decal, Clutch Cover

. . . . . . . . . . . . . .

Decal, Electronic Reverse

. . . . . . . . . .

Decal, Operator Caution

. . . . . . . . . . .

Decal, Operator Warning,

32-35

. . . . . . .

Decal, Passenger

. . . . . . . . . . . . . . . . .

Decal, Pressure Cap

. . . . . . . . . . . . . .

Decal, Standard Reverse

. . . . . . . . . . .

Decal, Track Warning

. . . . . . . . . . . . .

Deicers

. . . . . . . . . . . . . . . . . . . . . . . .

Drive Belt Deflection

135

. . . . . . . . . . . .

Drive Belt Installation

133

. . . . . . . . . . . .

Drive Belt Removal

132

. . . . . . . . . . . . .

Drive Chain Tension

123

. . . . . . . . . . . . .

Electronic Reverse Belt

Installation

133

. . . . . . . . . . . . . . . .

Electronic Reverse Belt

Removal

132

. . . . . . . . . . . . . . . . . .

Emergency Starting

. . . . . . . . . . . . . . .

Emergency Stopping Procedure

88-89

. .

Summary of Contents for 2002 Snowmobile

Page 1: ......

Page 2: ...haust from this product contains chemicals known to cause cancer birth defects or other reproductive harm PROPOSITION 65 WARNING Snowmobile engines discharge fuel and exhaust which contain chemicals k...

Page 3: ...now Our new web site It s designed just for YOU S Technical tips S New product introductions S Event schedules S Parts and Service Manual information S Exciting details about The Way Out Check it out...

Page 4: ...2 NOTES...

Page 5: ...safe and enjoyable operation of your vehicle Your Owner s Manual contains instructions for minor maintenance but major repairs are covered in the Polaris Service Manual and should be performed by a F...

Page 6: ...eatures Section 4 The Perfect Fit 43 63 This section explains how to tailor the suspension and other features for an optimum riding experience Section 5 Getting Ready to Ride 65 71 This section explai...

Page 7: ...cle Identification Numbers 9 Section 1 contains helpful information for owners and drivers and illustrates the location of important identification numbers that should be recorded in your Owner s Manu...

Page 8: ...he illustrations and photos used in this manual are general representations Your model may differ n Follow the maintenance program outlined in this manual Preventive maintenance ensures that critical...

Page 9: ...t not be altered or removed The sound of your snowmobile may not be welcome to non snowmobilers so you have a responsibility to operate your snowmobile with concern for others We do our part by manufa...

Page 10: ...lt to adopt rigorous safety training programs that encourage protection of our environment including wildlife and vegetation Snowmobile clubs and other organizations are working together to protect ou...

Page 11: ...se Remove the spare key and store it in a safe place Your key can be duplicated only by obtaining a key blank from Polaris and mating it with your existing key The VIN and engine serial numbers are ne...

Page 12: ...10 NOTES...

Page 13: ...11 SECTION 2 SAFETY Operator Safety 12 27 Safety Decals and Locations 28 34 Section 2 describes safe vehicle operation and identifies warning decals and their locations...

Page 14: ...mobile or in this manual alerts you to the potential for personal injury Indicates a potential hazard that could result in serious injury or death Indicates a potential hazard that may result in minor...

Page 15: ...ngly recommend that the operator check major and vital safety components before every ride All Polaris snowmobiles are designed and tested to provide safe operation when used as directed Failure of cr...

Page 16: ...of the track Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation Serious injuries may result if hands feet or clothing become entangled in the track...

Page 17: ...proper throttle brake and steering control Use of a backrest may hinder your weight shifting ability This could affect your ability to control this rider active vehicle in certain extreme driving sit...

Page 18: ...vided on page 26 for your reference To better enjoy your ride be prepared warm and comfortable Control becomes more difficult with two people on board More space is required to make turns and longer d...

Page 19: ...ning snowmobile operation They ve been established for your protection Always be alert and pay attention to the trail ahead of you Multiplying speed MPH by 1 5 will equal the approximate number of fee...

Page 20: ...kments may also hide your view Always leave yourself a way out Variances in snow depth and or water currents may result in uneven ice thickness Always check with local residents or authorities for gen...

Page 21: ...rd packed snow or ice may lead to loss of vehicle control and result in serious injury or death Slow down to maintain control under these conditions It s dangerous to drive on ice or other slippery su...

Page 22: ...er side of the hill If you re unable to continue up a hill turn the machine downhill before it loses momentum If this isn t possible spin the track just enough to dig in to prevent it from rolling bac...

Page 23: ...emote don t defeat the purpose of the guard by removing it It s provided for your safety Do Not Operate Engine With Drive Belt Removed Any servicing that requires operation without a belt must be perf...

Page 24: ...Away Whenever your snowmobile has been parked for a length of time especially overnight always make sure the skis and track are loosened from ice and snow before attempting to drive Apply the throttl...

Page 25: ...track and or engine If the machine becomes stuck in snow clear the running board area of snow then step down the snow in front of the machine so that when the throttle is opened the snowmobile will b...

Page 26: ...these models indicates single rider operation See page 30 for decal location Driving 2 Up Some Polaris snowmobiles are designed for two riders A decal on the hood of these models indicates that the v...

Page 27: ...y course and have an operator s certificate For their protection as well as yours make sure they take a snowmobile safety course Everyone can benefit from the course n Don t jump your snowmobile Jumpi...

Page 28: ...0 60 5 48 37 27 16 6 5 15 26 36 47 57 68 10 40 28 16 4 9 21 33 46 58 70 83 95 15 36 22 9 5 18 36 45 58 72 85 99 11 2 20 32 18 4 10 25 39 53 67 82 96 11 0 12 4 25 30 16 0 15 29 44 59 74 88 10 4 11 8 13...

Page 29: ...27 33 38 45 50 20 4 9 17 23 29 36 42 48 54 61 30 7 13 21 28 35 42 48 55 63 69 40 9 16 24 32 39 47 53 61 69 76 50 11 18 26 34 41 49 57 64 73 80 60 12 19 27 35 43 51 59 66 75 82 70 13 20 28 36 44 52 60...

Page 30: ...djustment with engine running Do not operate engine with this guard open Never run engine with drive belt removed Never service clutches yourself see your dealer Airbox Warning Decal 2 This warning de...

Page 31: ...with the track or a fall from seat back may result in severe injury or death Cargo Carrier Warning Decal 5 Machines with a cargo carrier will have this warning decal on the rear rack or on the tailli...

Page 32: ...on either the console or the hood of your machine indicates whether it s designed for the operator only 1 Up or the operator and a passenger 2 Up For more information on operating capacities see page...

Page 33: ...s be in the gear indicated by the shift lever Always apply throttle slowly On machines with reverse it is especially important to maintain track tension as specified in the Owner s Manual If specified...

Page 34: ...or death To avoid loss of control always S Look behind before and while backing S Avoid sharp turns S Shift to or from reverse only when stopped S Apply throttle slowly S For more information see your...

Page 35: ...added weight and change in weight distribution Reduce vehicle speeds and al low added space for maneuvering since steering control may be reduced S Always wear an approved helmet eye protection and ad...

Page 36: ...VER LOCK May relax when used for long periods Do not leave brake engaged for more than five minutes ALWAYS Be seated and in position to control vehicle Stop engine before attempting adjustments Know t...

Page 37: ...35 SECTION 3 FEATURES AND CONTROLS Location of Controls 36 38 Features 39 41 Section 3 illustrates the locations of your snowmobile s controls and features...

Page 38: ...l machines 1 Fuel Filler Cap some models have a fuel gauge in the cap 2 Ignition Switch 3 Brake Lever 4 Speedometer may include indicator warning lights 5 Tachometer may include indicator warning ligh...

Page 39: ...Not all models come with these features Refer to your Owner s Manual Supplement for a list of features on your machine Accessories are available from your Polaris dealer 1 Headlight Dimmer Switch 2 Po...

Page 40: ...ese features are illustrated on this page Not all models come with these features Refer to your Owner s Manual Supplement for a list of features on your machine Accessories are available from your Pol...

Page 41: ...14 Trailing Arm 4 Handlebar 15 Skis 5 Seat 16 Front Bumper 6 Storage Rear 17 Console 7 Taillights 18 Rear Bumper 8 Backrest 19 Passenger Hand Hold 9 Tunnel Extension 20 Lifting Hand Hold 10 Passenger...

Page 42: ...Arm 4 Handlebar 15 Skis 5 Seat 16 Front Bumper 6 Storage Rear 17 Console 7 Taillights 18 Rear Bumper 8 Backrest 19 Passenger Hand Hold 9 Tunnel Extension 20 Lifting Hand Hold 10 Passenger Hand Hold S...

Page 43: ...shield 14 Trailing Arm 4 Handlebar 15 Skis 5 Seat 16 Front Bumper 6 Storage Rear 17 Console 7 Taillights 18 Rear Bumper 8 Backrest 19 Passenger Hand Hold 9 Tunnel Extension 20 Lifting Hand Hold 10 Pas...

Page 44: ...42 NOTES...

Page 45: ...tments 49 58 Handlebar Adjustment 59 Backrest Adjustment 59 Accessories 60 63 Polaris offers a wide range of adjustments so that every machine may be set up to suit individual needs This section expla...

Page 46: ...ould be made to one area at a time in order to properly evaluate the change All snowmobile suspensions have a front and a rear suspension each of which has adjustment options Independent Front Suspens...

Page 47: ...bumper down as far as it will go on the shock rod and test ride the machine The bumper will move up on the rod in direct relation to the amount of travel If the shock travel is full the bumper will b...

Page 48: ...ight Turn it to the left to decrease preload In the illustrations at right B indicates high preload and C indicates low preload Increasing the spring preload too much may adversely affect the handling...

Page 49: ...Shock Valving If you find that spring preload adjustment alone is not sufficient changing the valving of your Foxt or RYDE FXt shocks may give you the ride adjustment you want The purpose of shock va...

Page 50: ...n of the shock increases stiffening the ride By turning counterclockwise the compression decreases softening the ride The factory setting is in the softest position screw all the way out counterclockw...

Page 51: ...s point Make adjustments to one area at a time so you can evaluate the change For further assistance see your dealer Suspension Performance Tips DRider weight usually determines the position at which...

Page 52: ...distance between the ground and the rear bumper at the exact location used for measurement X This is measurement Y To determine sag commonly referred to as ride in subtract measurement Y from X Sag X...

Page 53: ...vided only as a guideline to be used for initial suspension set up Your set up may vary based on your desired riding style 1 Turn screw clockwise to stiffen compression 2a Limiter strap in high positi...

Page 54: ...measure the distance between the ground and the rear bumper at the exact location used for measurement X This is measurement Y To determine sag commonly referred to as ride in subtract measurement Y...

Page 55: ...ailable if greater tension is desired Contact your dealer for more information Rear Torque Arm Adjustment SKS Models On SKS models only the rear torque arm may be lowered from the stock mounting posit...

Page 56: ...nts to the compression valving by turning the screw located near the base of the shock Adjustment Locate the adjustment screw A near the base of the shock In half turn increments turn the screw clockw...

Page 57: ...nt screw A near the base of the shock In half turn increments turn the screw clockwise to increase compression valving and stiffen the ride or counterclockwise to reduce compression and soften the rid...

Page 58: ...vent of suspension coupling these torque arms could move independently of each other Rear suspension coupling links the movement of the front and rear torque arms to each other There are two types of...

Page 59: ...arm Adjusting the RRSS either allows more weight to transfer to the rear for more traction or allows less weight to transfer to the rear resulting in improved cornering performance An adjustment dot i...

Page 60: ...tool 1 located in your tool kit To increase weight transfer or ski lift during acceleration move the RRSS to the rearward hole on high position The RRSS may also be rotated to a lower position for eve...

Page 61: ...andlebar adjuster block bolts to 11 13 ft lbs 1 5 1 8 kg m 5 Replace handlebar cover Backrest Adjustment The passenger backrest on some models is adjustable To move the backrest forward or backward li...

Page 62: ...all models Order PN 2870668 Use only Polaris parts and accessories on your Polaris snowmobile Use of unapproved parts and accessories may result in DNon compliance with government industry requirement...

Page 63: ...per or excessive stud installation or the use of non Polaris traction products If traction products are added to the track wear strips must be installed in the tunnel to avoid excessive wear Never add...

Page 64: ...y to add track studs to maintain proper vehicle control Proper balance must be maintained between the number of studs and the length of carbide on skags The more studs used the longer the carbide on t...

Page 65: ...termine if your model has wear strips Wear strips are designed for a specific stud length See your dealer s studding chart for recommended traction accessories Components as viewed from the rear of th...

Page 66: ...64 NOTES...

Page 67: ...rottle Freeplay DBrake DFluid Levels DSteering DMirrors DGear Start the Engine and Check 71 DLights DStop Switch DSkis and Track cold warm DPre ride warm up Certain items must be checked before each r...

Page 68: ...es evenly and smoothly The lever should immediately return to the idle position without binding or hesitation If the throttle does not function smoothly DO NOT start the engine Have the throttle servi...

Page 69: ...ulic system multiplies the force of your hand squeezing the brake lever Proper operation depends on an adequate supply of air and moisture free hydraulic brake fluid in the system If the brake lever f...

Page 70: ...vel Firmly depress the brake lever Measure the distance A between the lever and brake block The distance should be no more than 3 4 1 9 cm If the distance is greater than this recommendation the brake...

Page 71: ...break To release the lock squeeze the brake handle until the lever returns to the unlock position The park brake light on the console will light up when the park brake lever lock is set and the engin...

Page 72: ...k track edges and cause other track damage Examples of marginal lubrication would include frozen bodies of water without snow cover icy trails and no snow conditions NOTE Track damage or failure cause...

Page 73: ...headlight high and low beam taillight and brake light for normal operation n Mirror Adjustment Adjust your mirrors so they can be used to their full advantage n Check Surroundings to Verify Clear Ope...

Page 74: ...72 NOTES...

Page 75: ...78 79 Fuel 80 82 Oil 83 84 Carburetion 85 Engine Stop Switch 86 Throttle Safety Switch 86 Throttle Lever 87 Emergency Stopping and Starting 88 89 Reverse Operation 90 92 Daily Storage 92 Towing 93 Sec...

Page 76: ...or wants to stop use intermittent choking to the HALF ON position Before starting the engine always refer to all safety warnings pertaining to snowmobile operation Never start your snowmobile without...

Page 77: ...utral and the brake engaged This will allow the engine to warm without engaging the drive system NOTE Don t leave the machine in this position for more than five minutes Engine RPM should be at idle b...

Page 78: ...old flow characteristics Do not operate at prolonged full throttle for the first three hours of operation Vary the throttle openings and machine speeds to reduce friction on all close fitting machined...

Page 79: ...olaris products We are continuously testing lubricants and provide the highest performance products available for your engine Please refer to the table below to determine the preferred and acceptable...

Page 80: ...e several revolutions 3 Release the throttle apply the brakes shut off the engine and lower the machine to the ground 4 Grasp the skis by their front loops and move them from side to side This will lo...

Page 81: ...may be driven following normal safety practices Always inspect for track damage before operating the snowmobile Use of traction products such as studs ice growsers etc will increase the possibility of...

Page 82: ...ll the tank neck If you get gasoline in your eyes or if you swallow gasoline see your doctor immediately If you spill gasoline on your skin or clothing immediately wash it off with soap and water and...

Page 83: ...Fuel Switch Some Polaris snowmobiles are equipped with a key function to adjust the timing on the machine as you change fuels It s very important to the life of your engine that you use this feature W...

Page 84: ...e are approximately two gallons of fuel left in the tank when the fuel gauge reads RES Fuel System Deicers If you use non oxygenated fuel Polaris recommends the regular use of isopropyl based fuel sys...

Page 85: ...visible in the oil tank If oil is not visible continued operation may cause serious engine damage Never mix brands of two cycle oil Serious chemical reactions may occur causing injection system blocka...

Page 86: ...he illustration indicates a low oil level When the oil reaches the low level mark add one U S quart of oil to the tank Always use a Polaris oil cap never substitute Your Polaris oil cap may be vented...

Page 87: ...ed by snow build up on the pre filter in the air intake system Either condition may be caused by improper carburetor adjustment All carburetors have been preset at the factory for adequate fuel supply...

Page 88: ...tionary by exerting pressure on the pivot pin in the direction shown in the illustration B Apply a slight amount of throttle A properly functioning switch must shut down the engine The throttle safety...

Page 89: ...the throttle cable may cause the safety switch to activate preventing the engine from starting If this occurs return the machine to an authorized Polaris dealer for service If an emergency exists and...

Page 90: ...oke Floods engine Half throttle or less Engine Stop Switch Interrupts ignition circuit All Throttle Safety Switch Interrupts ignition circuit All Tether Switch Option Interrupts ignition circuit All E...

Page 91: ...en the clutch guard 2 Push on the inner sheave of the clutch and rotate clockwise slightly to relieve belt tension 3 Starting at one of the tower struts wind the strap counterclockwise around the clut...

Page 92: ...always be in the gear indicated by the shift lever Apply the throttle slowly until you re sure which gear is engaged Sometimes the drive belt will drag in the drive clutch causing slight tension in th...

Page 93: ...3 Slowly apply the throttle until movement starts and until you are certain you are in reverse NOTE The maximum engine RPM will be 6000 when in reverse NOTE If the engine has stopped running the snow...

Page 94: ...the success of this reverse system To set for higher altitude start the engine and hold the button down until the light on the instrument panel flashes rapidly then release the button This is the set...

Page 95: ...ith a rope No braking power can be applied to an object being towed with a rope Only a stiff metal pole connecting the towed object and tow hitch on the snowmobile should be used If passengers are to...

Page 96: ...94 NOTES...

Page 97: ...11 139 Track Maintenance 140 143 Steering System 144 147 Suspension Maintenance 148 149 Extended Storage 150 152 Battery 153 155 This section defines your role and your dealer s role in your snowmobil...

Page 98: ...continue maintenance checks at 1000 mile 1600 km intervals All necessary replacement parts and labor incurred with the exception of authorized warranty repairs become the responsibility of the registe...

Page 99: ...r operation Daily 66 86 Check operation of headlights taillight brakelight Daily 71 129 Check park brake function Daily 69 Secure hood Daily 70 Check track alignment X 142 Steering arm and tie rod end...

Page 100: ...pivot X X X 101 Grease driveshaft bearing always perform before storage X X 107 Check and drain water trap X X 116 Grease rear suspension pivot shafts X X 107 Grease jackshaft bearing always perform b...

Page 101: ...tenance and services performed on the snowmobile 150 Mile 240 km Initial Maintenance Inspection Authorized Polaris Servicing Dealer Servicing Technician Date Mileage 1000 Mile 1600 km Maintenance Insp...

Page 102: ...Additional Services Performed Authorized Polaris Servicing Dealer Servicing Technician Date Mileage Type of Service Additional Services Performed Authorized Polaris Servicing Dealer Servicing Technici...

Page 103: ...spindles Raise the front end of the machine to permit better grease entry into the spindle area DLubricate both front ski pivots at fitting as shown DGrease jackshaft and driveshaft clutch side beari...

Page 104: ...ation affects your ride and the life of your suspension For detailed information about suspension lubrication and adjustments see your Polaris dealer NOTE The following illustrations are general repre...

Page 105: ...103 MAINTENANCE Lubrication L L L L L L L L L...

Page 106: ...104 MAINTENANCE Lubrication L L L L L L Both sides L L L L...

Page 107: ...105 MAINTENANCE Lubrication L L L L L L L L L L L L...

Page 108: ...106 MAINTENANCE Lubrication Suspension Lubrication X 10 EDGE L L L L L...

Page 109: ...ing seal may take only two pumps Push the clutch back onto the shaft and replace the clutch retaining bolt Torque to 18 ft lbs 2 48 kg m Driveshaft Bearing Greasing Inject grease into the fitting on t...

Page 110: ...f turn the handlebars to the left and lubricate liberally as shown Choke and Cable Lubrication Lubricate the choke slide 2 and cables with Polaris Cable Lubricant PN 2870510 Before turning the engine...

Page 111: ...oil level place the machine on a level surface The oil level should be between the safe marks on the dipstick A Add Polaris chaincase oil PN 2871280 through the dipstick opening Do not overfill Flush...

Page 112: ...surface The oil level should be between the safe marks on the dipstick A See your Polaris dealer for the recommended oil for your machine Do not overfill NOTE Clean the magnetic plug B every 500 mile...

Page 113: ...top of the foam filter periodically to remove any accumulation of snow NOTE These illustrations are general representations Your model may differ 1 Intake Foam Filter 2 Air Intake box 3 Dash Cowl Ope...

Page 114: ...ill cause excessive fouling and engine malfunctioning In selecting a spark plug heat range for production a manufacturer assumes that the engine will be operated under extreme heavy duty conditions an...

Page 115: ...often cause a spark plug to appear too dark or too light in color Before changing spark plug heat ranges be sure the correct main jet is installed in the carburetor s Refer to the Owner s Manual Supp...

Page 116: ...g rotating clockwise 4 Torque to 18 22 ft lbs 2 5 3 kg m 5 Check spark plug gap refer to your Owner s Manual Supplement 6 Install spark plug cap If spark plug color indicates overheating the cause of...

Page 117: ...nance follow the oil recommendation chart on page 77 The use of other lubricants may cause improper function of the valve mech anism and increase the frequency of required cleaning due to excessive bu...

Page 118: ...off 2 Position a container or shop towels to catch the contaminated gasoline 3 Slide the clamp 1 away from the drain plug 2 and remove the drain plug from the sediment tube 4 Wipe residue from the pl...

Page 119: ...of all trapped air See your dealer for instructions or have your dealer perform the filter change and bleeding operation for you NOTE The direction of the arrows indicates the direction of flow throug...

Page 120: ...the carburetors are synchronized or balanced is important Properly adjusted carburetors can greatly improve engine performance fuel economy engine life and reliability If you notice any of the follow...

Page 121: ...age Check for weak or missing retaining springs or damper support grommets Engine Cooling Liquid Cooled Models The cooling system on liquid cooled models consists of the following major components DRe...

Page 122: ...mperature indicator light is controlled by a switch in the engine cooling system If the engine coolant reaches a certain temperature the switch completes a circuit that turns the light on If you must...

Page 123: ...roperly Recovery System Models If the coolant level becomes low in the recovery tank bleed the system of any trapped air Visually inspect the coolant filter B and replace it if it s dirty 1 Fill the r...

Page 124: ...icated mark 5 Start the engine and run at a fast idle for two to three minutes Occasionally loosen the bleed screw to purge any trapped air in the system 6 Shut offtheengine and check therecovery tank...

Page 125: ...coolant extrusions will be warm 5 If needed fill coolant to maximum recommended mark 6 Replace the pressure cap and carefully lower the front end of the machine Drive Chain Tension To obtain correct c...

Page 126: ...ss than 1 2 1 3 cm Brake pads must be replaced when the brake pad material becomes thinner than the backing plate approximately 1 16 A kit is available for replacing brake pads See your dealer A Prope...

Page 127: ...Plate 5 Brake Pad Material Replace when thickness is less than 1 16 Excessive Lever Travel Hydraulic brakes are self adjusting but if excessive brake pad clearance develops as described on page 124 th...

Page 128: ...the sight glass is any color other than black add brake fluid Use only Polaris DOT 3 high temperature brake fluid PN 2870990 Polaris brake fluid is sold in 12 oz bottles After opening a bottle of bra...

Page 129: ...e Then unscrewbleeder valve3 4 ofa turn to release air 5 Close bleeder valve and release brake lever 6 Repeat steps 4 and 5 until fluid flows from the bleeder valve in a solid stream free of air bubbl...

Page 130: ...and measure the clearance between the lever and the brake block This distance brake lever reserve A should be no more than 3 4 1 9 cm If brake lever reserve exceeds this amount see your dealer for ser...

Page 131: ...he 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 the headlight aim The most intense part of the headlight beam should be a...

Page 132: ...y metal base and carefully separate bulb from harness Installing the Bulb 1 Hold bulb by metal base and install into wire harness 2 Insert bulb into housing 3 Carefully flip spring back into housing p...

Page 133: ...hdraw from housing Installing the Side Bulbs 1 Hold bulb assembly by plastic base and plug into wire terminal 2 Insert bulb assembly into housing 3 Turn bulb assembly 1 4 turn to left to secure in hou...

Page 134: ...equipped 3 Grasp the belt firmly midway between the clutches and pull upward and rearward Remove the belt Electronic Reverse Belt Removal 1 Remove ONE of the three belt tension adjuster bolts A and s...

Page 135: ...portion over the outer clutch sheave B Work the belt to the outer edge of the sheave Release parking brake if it s locked 4 Close the clutch guard and reinstall the retaining knob or pin Electronic Re...

Page 136: ...such as adding or removing weights will void the warranty If you become aware of higher than normal clutch engagement an unusual vibration or an unusual shift pattern contact your dealer immediately...

Page 137: ...or this reason Polaris recommends that only O E M belts be used Other belts may match the dimensions but can drastically change the shift pattern resulting in poor performance See your dealer for serv...

Page 138: ...learance should be a minimum of 010 to a maximum of 030 from the engine case 2 Adjust if necessary and lock the jam nut Reverse Kit Maintenance If your snowmobile is equipped with reverse or if you ha...

Page 139: ...r snowmobile some maintenance will be required Follow these recommendations Chain Tension Maintain the proper chain tension as outlined on page 123 Oil Level Maintain the oil level between the safe ma...

Page 140: ...le E Wrench F Shielded screwdriver only models with Indy Select or AFX shocks Always keep the tool kit with the snowmobile If necessary a replacement tool kit may be purchased from your Polaris dealer...

Page 141: ...inter Survival Kit S Trail Map S Owner s Manual S First Aid Kit Fall Tune Up For maximum performance arrange for a fall service tune up with your Polaris dealer His experienced and trained service tec...

Page 142: ...3 cm WideTrak Type 10 lbs 4 54 kg 16 ahead of rear idler shaft 3 4 1 1 9 2 5 cm XTRA Lite 121 133 136 10 lbs 4 54 kg 16 ahead of rear idler shaft 3 8 1 2 1 1 3 cm Edge RMK 136 10 lbs 4 54 kg 16 ahead...

Page 143: ...rear idler wheel NOTE Measure at the point where the weight is hanging 4 Check for specified slack between the wear surface of the track clip and the plastic Hi fax C If the track needs adjustment 5...

Page 144: ...Misalignment will cause excessive wear to the track and slide rail 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...

Page 145: ...esulting in excessive wear NOTE If excessive Hi fax wear occurs due to poor snow conditions additional wheel kits are available See your dealer for more information IMPORTANT Track damage or failure c...

Page 146: ...djustment Each week or before a long ride check fasteners and tighten if necessary Specific fasteners that should be checked are marked with a in the following illustrations CRC Suspension With Rack S...

Page 147: ...n the skis at point X should be 1 8 to 1 4 greater than at point Y NOTE If the skis are misaligned we recommend that your dealer correct the alignment since camber adjustment may also be affected Impr...

Page 148: ...146 MAINTENANCE Steering System X Y 10 10 All other steering systems Edge IFS Steering System X Y 10 10...

Page 149: ...ineso the skis are approximately 6 15 2 cm from the ground 2 Remove the attaching nuts and pry the skag downward 3 Remove the forward portion of the skag Reverse this procedure for new skag installati...

Page 150: ...aler for Hi fax replacement NOTE Hi fax wear pat terns are somewhat different on XTRA 12 suspensions The rear portion will wear rapidly at first After this initial break in period the rapid wear will...

Page 151: ...nowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components Cleaning and Preservation of Hood Chassis and Trim Proper storage starts with clea...

Page 152: ...is PN 2870791 Follow the engine fogging instructions provided on the can Always add a fuel conditioner stabilizer or Premium Carbon Clean PN 2871326 to the fuel tank Follow the instructions on the can...

Page 153: ...at bottom dead center BDC the lowest position in the cylinder On twin cylinder models the opposite piston will be up 5 Pour approximately two ounces of Polaris injector oil into the spark plug hole 6...

Page 154: ...le Whenever the snowmobile is transported 1 Turn the fuel valve clockwise to OFF to shut off the fuel supply 1 Turn the valve counter clockwise to ON to turn the fuel supply on 2 NOTE The fuel valve i...

Page 155: ...or clothing If contact occurs seek immediate medical attention KEEP OUT OF REACH OF CHILDREN EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia be...

Page 156: ...sconnect red positive battery cable second 5 Carefully lift the battery out of the snowmobile Do not tip it sideways or spill electrolyte Tap water contains minerals that will damage a battery and sho...

Page 157: ...l the battery vent line It must be free from obstructions and securely installed Routethevent lineproperlyto preventkinks andto allow for proper drainage 3 Connect and tighten the red positive cable f...

Page 158: ...156 NOTES...

Page 159: ...157 SECTION 8 TROUBLESHOOTING Suspension Troubleshooting 158 162 Belt Troubleshooting 163 Engine Troubleshooting 164 166 Section 8 is a quick reference guide to solving problems...

Page 160: ...unter clockwise Adjust front track shock spring to less preload Machine darts from side to side Make sure skis are aligned properly Make sure spindles and all steering components are free turning Make...

Page 161: ...ping by turning screw counter clockwise Machine darts from side to side Make sure skis are aligned properly Make sure spindles and all steering components are free turning Ensure use of E Z Steer skag...

Page 162: ...oper track tension Machine darts from side to side Make sure skis are aligned properly Make sure spindles and all steering components are free turning Make sure skags are straight on skis Check Hi fax...

Page 163: ...miter strap on front torque arm to high position See your dealer for optional mounting Too little weight transfer when climbing Verify sag measurement refer to set up decal or page 50 Adjust torsion s...

Page 164: ...les and all steering components are free turning Make sure skags are straight on skis Install E Z Steer skags Front end pushes Check for worn skags Check for binding suspension shafts and grease all p...

Page 165: ...educe RPM Avoid riding in high ambient temperatures Ice and snow build up between track and tunnel Warm the engine at least five minutes Take the drive belt off the machine in extremely cold weather a...

Page 166: ...if necessary SEE YOUR DEALER Harsh drive clutch engagement Drive belt worn or too narrow Excessive belt sheave clearance Replace drive belt SEE YOUR DEALER Drive belt turns over Wrong belt for applic...

Page 167: ...Worn drive belt Excessive belt sheave clearance Loose torque stop Sticky clutch Inspect and replace if necessary SEE YOUR DEALER Inspect and adjust SEE YOUR DEALER Engine doesn t start electric start...

Page 168: ...perate satisfactori ly when dried Running too lean a mixture too small a main jet will cause seizure resulting in loss of power SEE YOUR DEALER This indi cates a major engine problem that must be repa...

Page 169: ...167 NOTES...

Page 170: ...168 NOTES...

Page 171: ...169 SECTION 9 WARRANTY Service And Warranty Information 170 Warranty 171 173 Polaris Extended Service Contract 174 175 Section 9 contains specific warranty information...

Page 172: ...anty will aid in notification of recovered units to their proper owner Obtaining Service and Warranty Assistance Read carefully and understand the service data and the Polaris warranty contained in th...

Page 173: ...TRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registrat...

Page 174: ...cts in parts components or snowmobile due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not c...

Page 175: ...ervice you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original s...

Page 176: ...ris Star Card Conditions DThe Polaris Extended Service Contract must be purchased within 90 days from the date of the unit s registration DEach repair visit it subject to a 50 00 deductible DThe Exten...

Page 177: ...s stator plate and sensors Wiring and other electrical components are ex cluded from coverage DOil injection system coverage is limited to the control module sen sors solenoids pump and throttle cable...

Page 178: ...ooling System 121 123 Brake Bleeding 127 Brake Components 125 Brake Fluid Replenishment 126 Brake Inspection Hydraulic 124 Brake Lever Travel 67 68 125 128 Brake Lever Mechanical 128 Brakes 67 68 Bulb...

Page 179: ...r 54 Indy Select Rear 55 Inspection Hydraulic Brakes 124 Inspection Steering 144 Inspection Track 143 Inspection Water Pump Belt 115 Installing the Side Bulbs 131 Lighting Check 71 Liquid Cooled Model...

Page 180: ...rive System 150 Controls and Linkage 149 Electrical Connections 151 Track and Suspension 152 Supplies 139 Surge Tank 122 123 Suspension Adjustment Features 44 Suspension Adjustment EDGE RMK 50 Suspens...

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Polaris 2002 Snowmobile, Owner'S Manual

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