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Polaris 600 EDGE RMK, Service Manual

The Polaris 600 EDGE RMK Service Manual is a comprehensive guide for maintaining and repairing your sled. With this manual, you can easily troubleshoot issues and perform routine maintenance tasks. It's free to download from our website, ensuring you have the essential resource to keep your machine running smoothly.

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DRIVE / DRIVEN CLUTCHES

5.1

WARNING

All drive clutch maintenance, disassembly and assembly must be performed only by an authorized Polaris dealer

who has attended current model Dealer Service Seminars, has received a certificate of completion, and displays

the Polaris Servicing Dealer decal.

Because of the critical nature and precision balance incorporated into the drive clutch, it is absolutely essential that

no attempt at clutch disassembly and/or repair be made without factory authorized tools and service procedures.

Essential Drive Clutch Tools

Refer to the Service Tool Catalog (PN 9914681) for photos and descriptions of all tools. A tool catalog update

is available through the Polaris parts department. The part number is 9915235.
Description

Part Number

Offset Alignment Tool - 21/32” (1.7 cm) P-90 Clutches

2870914

. . . . . . . . .

Offset Alignment Tool - 5/8” (1.6 cm) P-85 Clutches

2870426

. . . . . . . . . . .

T-Handle Drive Clutch Puller (Large Shaft ID)

2870506

. . . . . . . . . . . . . . . .

Drive Clutch Puller - 550 Fuji Engines

2872084

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

Strap Wrench

2870336

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

Replacement Strap for 2870336

2870389

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

Spider Spanner Nut Driver (Jam Nut)

2870338

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

Spider Removal / Installation Tool

2870341

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

Holding Fixture

2871358

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

Holding Fixture Tab

5130518

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

Tapered Reamer

2870576

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

Spider Button Tool

2870985

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

Clutch Bushing Rebuild Tool Kit (P-85/P90)

2871025

. . . . . . . . . . . . . . . . . .

P-85 Drive Clutch Compression Tool

2870984

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

Driven Clutch Puller (P-90)

2871056

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

Torque Wrench, 250 ft. lb.

Commercially Available

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

Torque Wrench, 0-200 in. lb.

Commercially Available

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

Clutch Compression Tool

8700220

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

Clutch Holding Wrench

9314177

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

SLP Button Tool

8716010

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

SLP Clutch Sheave Clamp Tool

8716020

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

Summary of Contents for 600 EDGE RMK

Page 1: ...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 ...

Page 2: ...sition This manual includes procedures for maintenance operations component identification and unit repair along with service specifications for the Polaris Indy 500 Euro 700 SKS Trail RMK 500 RMK 600 EDGE RMK 700 EDGE RMK 800 EDGE RMK snowmobiles A table of contents is placed at the beginning of each chapter and an alphabetic index is provided at the end of the manualfor locationof specificpage n...

Page 3: ... the snowmobile CAUTION A CAUTION indicates special precautions that must be taken to avoid personal injury or snowmobile or prop erty 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 Regi...

Page 4: ...GENERAL MAINTENANCE ENGINE CARBURETION DRIVE DRIVEN CLUTCHES SUSPENSIONS BODY AND STEERING BRAKES AND FINAL DRIVE ELECTRICAL WIRING DIAGRAMS ...

Page 5: ......

Page 6: ... 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 Speci...

Page 7: ......

Page 8: ...02NK8CS 9917058 9917059 9917060 800 EDGE RMK 151 S02NL8CS 9916950 9916952 9916953 800 EDGE RMK 156 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 Cl...

Page 9: ...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 CONFORMS TO ALL APPLICABLE U S FEDERAL AND STATE REQUIREMENTS AND CANADA MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE MADE IN U S A 7072133 Mfd by Polaris Industries Inc in Roseau MN under one or more of the following patents U S Patents 3 60...

Page 10: ...ptor 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...

Page 11: ...es 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 Torque 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...

Page 12: ...m 3937 13 32 4063 27 64 4219 11 mm 4331 7 16 4375 29 64 4531 15 32 4688 12 mm 4724 31 64 4844 1 2 5 13 mm 5118 33 64 5156 17 32 5313 35 64 5469 14 mm 5512 9 16 5625 37 64 5781 15 mm 5906 19 32 5938 39 64 6094 5 8 625 16 mm 6299 41 64 6406 21 32 6563 17 mm 6693 43 64 6719 11 16 6875 45 64 7031 18 mm 7087 23 32 7188 47 64 7344 19 mm 7480 3 4 75 49 64 7656 25 32 7813 20 mm 7874 51 64 7969 13 16 8125 ...

Page 13: ...64 1 1 8 12 1 3 64 1 1 4 7 1 7 64 1 1 4 12 1 11 64 1 1 2 6 1 11 32 1 1 2 12 1 27 64 1 3 4 5 1 9 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 2 1 2 4 2 1 4 2 3 4 4 2 1 2 3 4 2 3 4 Metric Tap Drill Sizes Tap Size Drill Size Decimal Equivalent Nearest Fraction 3 x 50 3 x 60 4 x 70 4 x 75 5 x 80 5 x 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 ...

Page 14: ...061 Cubic inches cu in Imperial pints Imp pt x 0 568 Liters l Liters l x 1 76 Imperial pints Imp pt Imperial quarts Imp qt x 1 137 Liters l Liters l x 0 88 Imperial quarts Imp qt Imperial quarts Imp qt x 1 201 US quarts US qt 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 US quarts US qt US gallons US gal x 3 785 Liters l Liters l x 0 264 US gallon...

Page 15: ...584 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...

Page 16: ...on 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 curren...

Page 17: ...ing 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 ...

Page 18: ... 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 The maximum movement of the piston from bottom dead center to top dead center It is ...

Page 19: ... in their holes and hand tighten 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 of any gasket or O Ring is in question replace it with a new one Be sure the mating surfaces around the gasket are clea...

Page 20: ...GENERAL INFORMATION 1 13 Notes ...

Page 21: ...ushed Almond Round Silver R32 2 18 41 68P HYVO 1800 2700 10 Almond Silver R32 18 41 68P 1800 2700 6000 9000 10 Bushed Almond Round Silver R32 2 18 41 68P HYVO 2700 3700 10M5 Almond Silver R32 18 41 68P 2700 3700 9000 12000 10M5 Bushed Almond Round Silver R32 2 18 41 68P HYVO Production Setting ENGINE Type Liquid Cooled Case Reed Twin Displacement 500cc Fuel Pump Manuf N A Bore 2 776 70 5mm Fuel Pu...

Page 22: ... 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 05 17 91cm Front Spring Preload 3 4 Thread Adjust Driveshaft Sprockets 2 Drivers Wide Front Vertical Travel 9 6 24 4cm Brake Type Polaris HPB Rear Suspension XTRA 10 EURO Rear Axle Travel 9 5 24 1cc Front Track Shock Nitrogen Cell Spring Rate 190 in variable ...

Page 23: ...18 41 68P HYVO 1800 2700 10 Almond Silver R 32 18 41 68P 1800 2700 6000 9000 10 Bushed Almond Round Silver Blue R 32 3 18 41 68P HYVO 2700 3700 10M Almond Silver R 32 18 41 68P 2700 3700 9000 12000 10M Bushed Almond Round Silver Blue R 32 3 18 41 68P HYVO Production Setting ENGINE Type Liquid Cooled Case Reed Twin Displacement 500cc Fuel Pump Manuf Walbro Bore 2 776 70 5mm Fuel Pump Mark FPA 3 Str...

Page 24: ...8 CRC Reverse Option Front Shocks Nitrogen Cell Brake Pads Type 81 Large IFS Spring Rate 100 in Chaincase Center Dist 7 05 17 91cm Front Spring Preload 1 8 Thread Adjust Driveshaft Sprockets 2 Drivers Wide Front Vertical Travel 8 05 in 21cm Brake Type Polaris HPB Rear Suspension XTRA Lite 136 Rear Axle Travel 12 30 5cm Front Track Shock Nitrogen Cell Spring Rate 200 in variable Rear Track Shock In...

Page 25: ...lue R 32 2 18 41 68P HYVO 1800 2700 10 56 Dark Blue Silver R 32 18 41 68P 1800 2700 6000 9000 10 56 Bushed Dark Blue White Silver Blue R 32 2 18 41 68P HYVO 2700 3700 10 54 Dark Blue Silver R 32 18 41 68H 2700 3700 9000 12000 10 54 Bushed Dark Blue White Silver Blue R 32 2 18 41 68H YVO Production Setting ENGINE Type Fan Cooled Reed Assist Twin Displacement 544cc Fuel Pump Manuf Taiyo Bore 2 874 7...

Page 26: ...e Option Front Shocks Nitrogen Cell Brake Pads Type 81 Small IFS Spring Rate 80 in Chaincase Center Dist 7 05 17 9cm Front Spring Preload 5 16 Thread Adjust Driveshaft Sprockets 2 Drivers Front Vertical Travel 8 25 21cm Brake Type Polaris HPB Rear Suspension XTRA Lite 136 Rear Axle Travel 12 30 5cm Front Track Shock Nitrogen Cell Spring Rate 181 in Rear Track Shock Indy Select Rear Springs 347 sq ...

Page 27: ... Black Green Silver Blue R 32 3 19 39 72P HYVO 2100 2700 7000 9000 10 54 Bushed Black Green Silver Blue R 32 3 19 39 72P HYVO 2700 3350 9000 11000 10AL Bushed Black Green Silver Blue R 32 3 19 39 72P HYVO 3350 4000 11000 13000 10 Bushed Black Green Silver Blue R 32 3 19 39 72P HYVO Production Setting ENGINE Type Liquid Cooled Case Reed w TPS Displacement 593cc Fuel Pump Manuf Walbro Bore 2 9930 3 ...

Page 28: ... Preload 3 4 Thread Adjust Driveshaft Sprockets 2 Drivers Wide XHS Front Vertical Travel 7 2 7 6 18 3 19 3cm Brake Type Polaris HPB Liquid Cooled Rear Suspension EDGE RMK Rear Axle Travel 13 8 35cm Front Track Shock Nitrex Spring Rate 170 in Rear Track Shock Indy Select Rear Springs 375 sq 77 Track Type 15 x136 x1 75 38 1x345 44x4 45cm Track Tension 3 8 1 2 1 1 3 cm slack with 10 4 54kg weight 16 ...

Page 29: ...lue R8 2 23 40 70P HYVO 23 40 70P HYVO 1800 2700 10 54 Black Silver R8 21 41 70P 21 41 70P 1800 2700 6000 9000 10 54 Bushed Black Green Silver Blue R8 2 21 41 70P HYVO 21 41 70P HYVO 2700 3700 10 AL Black Silver R8 21 41 70P 21 41 70P 2700 3700 9000 12000 10 AL Bushed Black Green Silver Blue R8 2 21 41 70P HYVO 21 41 70P HYVO Production Setting ENGINE Type Liquid Cooled Case Reed Twin Displacement...

Page 30: ...rake Pads Type 81 Large IFS Spring Rate 100 in Chaincase Center Dist 7 05 17 91cm Front Spring Preload 3 4 Thread Adjust Driveshaft Sprockets 2 Drivers Wide Front Vertical Travel 9 6 24 4cm Brake Type Polaris HPB Liquid Cooled Rear Suspension XTRA 10 136 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 Spr...

Page 31: ...0 58 Bushed Black Green Silver Blue R 8 3 21 41 74P HYVO 19 39 72P HYVO Meters Feet 2100 2700 10 56 Black Silver R 8 21 41 74P 19 39 72P 2100 2700 7000 9000 10 56 Bushed Black Green Silver Blue R 8 3 21 41 74P HYVO 19 39 72P HYVO 2700 3350 9000 11000 10 54 Bushed Black Green Silver Blue R 8 3 21 41 74P HYVO 19 39 72P HYVO 3350 4000 11000 13000 10 AL Bushed Black Green Silver Blue R 8 3 21 41 74P H...

Page 32: ...ront Vertical Travel 7 2 7 6 18 3 19 3cm Driveshaft Sprockets 2 Drivers Wide XHS Rear Suspension EDGE RMK 136 144 or 151 Brake Type Polaris HPB Liquid Cooled Rear Axle Travel 13 8 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 47 136 359 sq 77 144 151 Track Type 15 x136 x1 75 38 1...

Page 33: ...00 10 62 Black Green Silver Blue R 11 3 21 41 74P HYVO 19 39 72P HYVO 2100 2700 10 60 Black Silver R 11 21 41 74P 19 39 72P 2100 2700 7000 9000 10 60 Black Green Silver Blue R 11 3 21 41 74P HYVO 19 39 72P HYVO 2700 3300 9000 11000 10 58 Black Green Silver Blue R 11 3 21 41 74P HYVO 19 39 72P HYVO 3300 3900 11000 13000 10 56 Black Green Silver Blue R 11 3 21 41 74P HYVO 19 39 72P HYVO ENGINE Type ...

Page 34: ...just Chaincase Center Dist 7 05 17 91cm Ryde FX IFP 3 13 16 Thread Adj Driveshaft Sprockets 2 Drivers Wide Front Vertical Travel 7 2 7 6 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 359 sq 47 ...

Page 35: ......

Page 36: ... 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 ...

Page 37: ......

Page 38: ...heck 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 spe...

Page 39: ...ak in Lube 2 5 Gal 2 2871958 Silicone Black RTV 11 oz Cartridge 12 2871326 Carbon Clean Plus 12 oz 12 2871959 Ultra Blue RTV 3 35 oz 12 2871280 Premium Chaincase Lubricant Quart 12 2871960 Ultra Blue RTV 13 oz Cartridge 12 2870464 Premium Chaincase Lubricant Gallon 4 2871961 518 Flange Sealant 50cc 10 2872281 Premium Chaincase Lubricant 2 5 Gallon 2 CRANKCASE SEALANTS 2872951 Synthetic Chaincase L...

Page 40: ...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 A B C D A A A A A A B B B ...

Page 41: ...direction of the arrows indicates the direction of the flow through the filters Edge models utilize a special oil filter 3 that is built 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 f...

Page 42: ...e ACCS is de signed to compensate automati cally for changes in altitude without having to change carburetor jets ACCS does not require peroidic maintenance See your dealer for ACCS service or adjusment NOTE Tampering or adjustments to the ACCS may cause severe en gine damage A Airbox B Vent Line Attachment C ACCS Valve A B C ...

Page 43: ...nk pitman arm and idler arm where applicable NOTE A grease gun kit complete with grease and adaptors is available to lubricate all fittings on Polaris snow mobiles Jackshaft Bearing Greasing Loosen driven clutch retaining bolt and pull clutch outward to ex pose bearing Use a point type grease gun fitting to inject grease through hole in flangette into bearing until grease purges out in side or out...

Page 44: ...tration to assist you The finished weight 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 ma chine b Lay a straight edge or straight pieceof stiff materi al steel is suggested across the top of both pul leys The straight edge should measure approxi mately 1 8 x 8 x 1 c Measure the ...

Page 45: ...r 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 8 6 1 cm def...

Page 46: ...ear The riding characteristics of the snowmobile will be affected by lack of lubrica tion of these shafts NOTE A grease gun kit complete with grease and adaptors is available to lubricate all fittings 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 fitt...

Page 47: ...MAINTENANCE TUNE UP 2 10 EDGE RMK Style Forward L L L L L L L L L L L L L L L L L L L L L L L L ...

Page 48: ... system should become low in the tank and or filler neck the system should be bled of any trapped air us ing the following procedure 1 Allow the system to cool completely Fill the reservoir with coolant to the maximum indicated mark 2 With pressure cap removed add coolant 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 en...

Page 49: ...Track alignment affects track tension Misalignment will cause ex cessive 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 ...

Page 50: ...he machine and safely support it off the ground 3 Place a 10 lb 4 5 kg weight on the track at a point approximately 16 40 6 cm ahead of the center of the rear idler wheel 4 Check for proper slack between the track clip wear surface and the hi fax C NOTE Measure at the point where the weight is hanging If the track needs adjustment 5 Loosen rear idler shaft bolts D on both sides of the machine 6 Lo...

Page 51: ...ng 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 is warmed up and the vehicle is driven at higher speeds Immediately check the spark plug for correct color Normal The insulator tip is g...

Page 52: ... Turn the driven clutch moveable sheave clockwise while at the same time pushing inward and forcing the belt down between the 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 outer edge of the sheave Be sure to release parking brake if applied 4 Close the clutch guard and reinstall the retaining...

Page 53: ... 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 bul...

Page 54: ...t handlebar to the desired height Be sure that handlebars brake lever and throttle lever operate smoothly 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 o...

Page 55: ...r action Bleeding is necessary to re move air from the system 1 Remove brake fluid master cylinder reservoir cover and gasket CAUTION Brake fluid is a hazardous material Contact with decals paint and many plastics will cause damage Use proper precautions when handling brake fluid 2 Fill the master cylinder reservoir and replace gasket and cover Keep the fluid level 1 4 5 16 6 8 cm below lip of res...

Page 56: ...e made the throttle lever to throttle block clearance and oil pump adjustment must be checked and adjusted NOTE When adjustments are made on models which have more than one carburetor refer to Section 6 Car buretion for proper carburetor synchronization adjustments Reverse Adjustment Due to break in or replacement of components the re verse shift mechanism may require adjustment 1 Loosen jam nuts ...

Page 57: ...chine moisture will be trapped inside causing rust and corrosion problems Controls And Linkage All bushings spindle shafts and tie rod ends should be coated 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 Lubrica...

Page 58: ... 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 ...

Page 59: ...er fill and charge battery monthly using Polaris Battery Tender or a 1 amp trickle charger to maintain at 1 270 specific gravity Exhaust System At approximately 2000 miles or in preparation of off season storage it is a good idea to check the exhaust system for wear or damage To inspect allow the engine and exhaust system to cool completely Open the hood and inspect the muffler and pipes for crack...

Page 60: ...MAINTENANCE TUNE UP 2 23 Notes ...

Page 61: ......

Page 62: ...1 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...

Page 63: ......

Page 64: ... 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 8 mm 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 ...

Page 65: ...3 1 6 4 2 5 CYLINDER HEAD 9 5 1 3 7 11 10 6 2 4 8 12 CRANKCASE TWIN CYLINDER Fuji 3 2 4 1 CYLINDER BASE MAG SIDE PTO SIDE ENGINES 3 2 Torque Sequences EC55 Engines ...

Page 66: ...ENGINES 3 3 Torque Sequence Domestic 500 1 2 3 4 5 6 7 8 9 10 11 12 CYLINDER HEAD Domestic 500 3 2 4 1 5 6 7 8 CYLINDER BASE Domestic 500 9 5 1 4 8 12 10 6 2 3 7 11 15 14 13 CRANKCASE Domestic 500 ...

Page 67: ...4 Torque Sequence Domestic 600 700 800 3 2 4 1 5 6 7 8 1 2 3 4 5 6 CYLINDER BASE Domestic Twins 600 700 800 CRANKCASE Domestic Twins 600 700 800 1 2 3 4 5 6 7 8 9 10 11 12 CYLINDER HEAD Domestic Twins 600 700 800 ...

Page 68: ...ls it may be necessary to remove the 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 ...

Page 69: ... wind up into recoil housing 6 Loosen clamps at carburetor mounting flange Pull carbs from adaptors and secure out of the 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 ...

Page 70: ...OTE 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 supply hoses as necessary at the most convenient location on liquid cooled models Drain coolant into suitable container ...

Page 71: ...pical 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 ...

Page 72: ...tches 3 Check condition of bonded rubber engine mounts Be sure mounts are tight before installing engine With engine mounting plate or mount 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 adj...

Page 73: ...il 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 grease PN 2871329 1 4 o...

Page 74: ...s 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 ...

Page 75: ...7 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 ...

Page 76: ...ce all seals O rings and gaskets with Genuine Polaris parts during assembly Refer to pages 3 47 3 56 for gen eral 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 ...

Page 77: ... 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 ...

Page 78: ...emove 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 ...

Page 79: ...ove 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 16 7mm into flywheel threads or stator damage may result Flywheel Puller PN 2871043 ...

Page 80: ...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 ...

Page 81: ...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 ...

Page 82: ...ler remove the 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 ...

Page 83: ...embly 1 Prior to assembly make sure that you have 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 ...

Page 84: ...ngs so that 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 ...

Page 85: ...groove 9 Lubricate rings and pistons with 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 ...

Page 86: ... 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 ...

Page 87: ...nd insert the lock washer 16 Torque 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 Wrench PN 8700229 Flywheel Nut Torque 60 65 ft lbs 83 90 Nm ...

Page 88: ...e 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 mounting clamps Reinstall oil lines on the oil pump Oil Pump Mounting Screw Torque 48 72 in lbs 5 5 8 3 Nm ...

Page 89: ...s 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 015 4 mm If clearance is excessive DO NOT attempt to reverse the reeds to reduce the air gap Always replace them if damaged Check each fiber reed for white stress marks or missing material Replace if necessary 2 Remove cylinder head cover and inspect O rings an...

Page 90: ...g pistons 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 Place support block under piston and remove piston pins using pin puller 7 Remove water pump cover from front of engine Piston Pin Puller PN 2870386 Support Block PN 2870390 ...

Page 91: ...eel puller Use drive clutch puller T handle or a wrench to hold puller 10 Before removing stator plate note where ignition timing marks are located or scribe additional marks for reference upon reassembly 11 Mark or note location of engine mount straps and remove Flywheel Puller PN 2871043 T Handle PN 5020326 ...

Page 92: ...out of lower case 14 If pump shaft removal is necessary remove retaining pin from crankcase using a diagonal cutter or similar tool 15 Tap out the drive shaft using a center punch and hammer Locate the center punch in the centering hole on the oil pump end of the shaft Be careful not to damage the bearing This will remove the oil seal and the mechanical seal from the crankcase Pin ...

Page 93: ...e is no hole in the bushing S Measure depth of the retaining pin hole in the old bushing S Using the retaining pin hole as a guide carefully drill a hole in the new bushing to the same depth 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 i...

Page 94: ...aft assembly aligning seals and snap ring with grooves in case 11 Apply a thin coating of 3 Bond 1215 sealant 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 being careful to...

Page 95: ...new base gasket Be sure gasket surface is clean and free of nicks burrs or scratches 22 Lubricate and install piston rings on piston withmark on end of ring facing upward 23 Place piston support under skirt and lubricate pistons and cylinders thoroughly 24 Align ring end gaps with locating pins and compress rings Install cylinder carefully with a gentle front to rear rocking motion Install cylinde...

Page 96: ...s and install 28 Torque head bolts to specification outlined in beginning of this chapter in proper sequence 29 Torque 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 1 2 3 4 5 6 7 8 9 10 11 12 Cylinder Base 6 8 4 5 1 7 3 2 Washer 10 3x14x1mm 10 ft lbs 14 Nm Washer 325x 7...

Page 97: ...ssembly 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...

Page 98: ...8 Use flywheel holder to hold flywheel and torque nut to specification found in beginning of this chapter 39 Install recoil hub and recoil housing Torque bolts to 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 lb...

Page 99: ...7 3 56 for gen eral inspection procedures Disassembly 1 Remove oil pump 2 Remove recoil housing 3 Remove recoil hub Inspect waterpump drive belt for missing cracked or broken drive cogs Replace if worn Measure the belt at 4 different points as shown Re place if width is less than 250 6 35mm Nominal new width is 345 8 75mm Refer to Chapter 2 Mainte nance for water pump belt installation Replace if ...

Page 100: ...ve 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 ...

Page 101: ...ankcase Loosen hose clamp and remove housing 10 Inspect water pump weep hole for signs of leakage or blockage 11 Remove crankshaft seal from housing by driving seal to inside of housing Replace seal if removed 12 Remove water pump cover bolts Hose Clamp 1 2 3 4 Inspect Weephole ...

Page 102: ...new mechanical seal in cover with spring sleeve toward impeller housing Install seal guide over end of shaft and apply a light film of grease to seal guide Carefully install shaft and bearings in cover Assemble 10x14mm washer impeller washer and nut Torque impeller nut to specification Water Pump Mechanical Seal Installa tion Tool 600 700 800 RMK domestic engines 8 9mm PN 2872389 Impeller Nut Torq...

Page 103: ... If clearance is excessive DO NOT attempt to reverse the reeds to reduce the air gap Always replace them if damaged Check each fiber reed for white stress marks or missing material Replace if necessary 18 Remove cylinder head Note condition and placement of both cylinder head O rings 19 Loosen cylinder base nuts and remove cylinders Reed Pedal Clearance 015 38 mm max Exaggerated for illustration ...

Page 104: ...ng piston pin in place 21 Remove piston pin using piston pin puller and adaptor 22 Remove water manifold by removing both retainer brackets 23 Remove bottom crankcase bolts and separate crankcase halves Piston Pin Puller PN 2870386 Adaptor PN 5130971 Remove Clamps ...

Page 105: ...s are critical for proper bearing clear ance 3 Set crankshaft in lower crankcase Lubricate seal lips with Premium All Season Grease Make sure seals are positioned properly with lip and spring facing inward toward crankshaft Install snap rings with gap facing upward toward upper case half NOTE When installing a crankshaft on a 800 twin en gine apply Loctitet 609 to the PTO bearing surfaces and bear...

Page 106: ...gether Torque bottom crankcase bolt to specification in the proper sequence found in the beginning of this chapter 7 Install new O rings on water manifold Grease O rings and install manifold 8 Install pistons and rings Make sure C clips are firmly seated in grooves NOTE Keystone ring bevel must be up Marking near ring end gap faces upward Lower Crankcase Stud Height 121 124 mm 4 76 4 88 from crank...

Page 107: ...king motion Loosely install cylinder nuts 10 Install new cylinder head O ring and install cylinder head Make sure O ring is properly seated in groove 11 Torque cylinder base bolts in proper sequence Refer to specifications in the beginning of this chapter 12 Torque head bolts in proper sequence Refer to specifications in the beginning of this chapter Make sure O rings are properly seated in groove...

Page 108: ...n housing Spring and seal lip must face inward toward crankshaft 15 Apply 3 Bondä sealant to pump housing crankcase mating surface and carefully install onto crankcase Tighten water pump to engine hose clamp and torque bolts to specification 16 Align timing marks and install stator Install Seal Apply 3 Bond Hose Clamp 1 2 3 4 Ignition Water Pump Housing Torque 22 Ft lbs 30 4 Nm ...

Page 109: ...lt and recoil hub NOTE See domestic twin water pump belt installation in chapter 2 Maintenance for correct belt installation 19 Install recoil cover and oil pump Make sure oil pump drive slot mates properly with water pump shaft 20 Install reed valve reed stuffer and reed cover Flywheel Holder PN 8700229 Recoil Hub Bolt Torque 96 108 in lbs 11 12 5 Nm ...

Page 110: ... carbon 4 Carbon deposits can be removed from valve with a Scotch Britet pad or similar soft abra sive brush 5 Lubricate exhaust valve with Polaris Premium Gold 2 cycle engine lubricant Install valve in cylinder and move it through the entire travel range to check for free movement without bind ing If the valve sticks anywhere in the travel range check the valve and valve bore in the cyl inder for...

Page 111: ...sing gasket 2 Install washer beveled side out and bellows 3 Apply Loctitet 262 to threads of valve and install valve cap Torque to specification 4 Install spring valve cover and adjuster nut Torque exhaust valve cover bolts to specifica tion Valve Cap Torque 6 Ft lbs 8 3 Nm Valve Cover Bolt Torque 4 Ft lbs 5 5 Nm ...

Page 112: ...re spring pressure S Allows exhaust valve to open at slower rate S For applications such as drag racing 2 Turning spring adjuster out S Creates less spring pressure S Allows exhaust valve to open at faster rate S For applications such as trail riding Riders can fine tune the VES to suit their riding con ditions and power delivery characteristics Base setting is with adjuster screw flush with housi...

Page 113: ...5 7041704 03 PINK 4 7 7 1 1 734 046 7041704 04 PURPLE 3 1 4 7 1 726 040 7041704 05 YELLOW 2 4 3 6 1 734 037 7041705 06 WHITE 1 6 2 8 1 537 036 These springs will change the timing characteristics of the exhaust valve opening A heavier spring will keep the valve in the closed position longer while a lighter spring will allow the valve to open sooner NOTE If making any changes to the valve springs m...

Page 114: ... glazing If cylinder wear or damage is minimal hone the cylin der lightly with finish stones following the procedure outlined on page 3 52 Honing To Oversize If cylinder wear or damage is excessive it will be nec essary to oversize the cylinder using a new oversize piston and rings This may be accomplished by either boring the cylinder and then finish honing to the final bore size or by rough honi...

Page 115: ...ately 1 2I 1 3 cm beyond the bore at the end of each stroke Release the hone at regular intervals to inspect bore size and finish Port Chamfering Remove the sharp edges at the bottom and top of each port whenever boring or honing is performed Make sure there are no sharp edges IMPORTANT Cleaning the Cylinder After Honing It is very important that the cylinder be thoroughly cleaned after honing to ...

Page 116: ...ing information outlined in this chapter for specific procedures Refer to the specifications section in chapter 1 for Target Clearance when re boring cylinder or Service Limit specifications to determine if piston requires replacement Piston to Cylinder Clearance Refer to specifications in chapter 1 for specific models Piston Ring Installed Gap Refer to specifications in chapter 1 for specific mod...

Page 117: ...case when the case is inverted or if the crankcase bearing surface is severely galled or damaged the case should be replaced Crankshaft Main Bearing Inspection 1 Clean crankshaft thoroughly and oil main and connecting rod bearings with Polaris Premium 2 engine oil Carefully check each main bearing on the shaft NOTE Due to extremely close tolerances the bearings must be inspected visually and by fe...

Page 118: ...eedle bearings if worn or cracked and always replace them if piston damage has occurred 3 Visually inspect piston pin for damage discoloration or wear Run your fingernail along the length of the pin and replace it if any rough spots galling or wear is detected Connecting Rod Small End Inspection 1 Clean small end of connecting rod and inspect inner bore with a magnifying glass Look for any surface...

Page 119: ...ously straightened areas to verify truing Refer to the illustrations below Crankshaft Alignment Fixture PN 2870569 Crankshaft Runout Inspection When checking the crankshaft runout it is important to measure with a dial indicator in the correct position When measuring on the flywheel side SMeasure runout 1 2 12 7mm from the bearing flat When measuring from the PTO side SMeasure runout where the tap...

Page 120: ...ct a situation like the one shown in the illustration at right squeeze the crankshaft at point A Use tool from alignment kit 7 If the crank rod pin location is 180_ from the dial indicator opposite that shown above it will be necessary to spread the crankshaft at the A position as shown in the illustration at right When rebuilding and straightening a crankshaft straightness is of utmost importance...

Page 121: ...ed ing with the following steps 1 Securely fasten a degree wheel on the flywheel or PTO end of crankshaft Use a large degree wheel for more accuracy and make sure it is mounted concentrically with the crankshaft center line 2 Sharpen a coat hanger or section of welding rod and anchor it to a convenient spot Point the sharpened end at the outer perimeter of the degree wheel 3 Install a dial indicat...

Page 122: ...tting on the mag end cylinder simply read the wheel and dial indicator 8 Remove the dial indicator and install in cylinder 2 or center cylinder Repeat steps4 and5 Note thedegree wheel indication when the dial indicator reads 100 ATDC It should be 180 or 120 2 from cylinder 1 Repeat procedure on PTO cylinder 3 where applicable Cylinder 3 should also be 120 á 2 from cylinder 1 Symptoms of an out of ...

Page 123: ... with a telescoping gauge or a dial bore gauge Measure the bore 1 2 from the top of the cylinder in line with the piston pin and 90 to the pin to determine if the bore is out of round Repeat the measurements at the middle of the cylinder and the bottom of the cylinder to determine taper or out of round at the bottom Record all measurements Cylinder Head Warp Service Limit 003 08mm Top Middle Botto...

Page 124: ...learance exceeds the service limit the cylinder should be re bored and new pistons and rings installed Piston Ring Installed Gap 1 Position ring 1 2I 1 3 cm from the top of the cylinder using the piston to push it squarely into place Measure installed gap with a feeler gauge at both the top and bottom of the cylinder NOTE A difference in end gap indicates cylinder taper The cylinder should be meas...

Page 125: ...retors 3 Place oil feed lines with their check valves away from the clutch area Start the engine and let it idle at normal idle RPM 4 Lift oil pump control lever up to its maximum flow position 5 Drops of oil should be visible from the banjo check valves after the engine is idled one to two minutes with a drop occurring approximately every few seconds 6 If oil does not flow from one of the check v...

Page 126: ...l should flow from beneath the screw head to indicate the pump is free of air 3 Tighten bleed bleed screw securely Oil Pump Bushing End Play Adjustment Fuji If the oil pump crankcase or any pump drive component is replaced inspect the drive gear bushing end play us ing the following procedure 1 Assemble oil pump drive gear assembly Be sure the bushing is fully seated in the crankcase 2 Measure dis...

Page 127: ...ms and subtract from total bushing end play determined in step 3 6 Add or subtract shims as required to provide specified end play 7 Lightly grease a new O ring and install it on the pump Install pump engaging slot in shaft with drive gear Apply Loctiteä 242 to bolts and torque evenly to 78 in lbs 9 Nm Measurement B End Play 008 016 203 406 mm Optional Shims PN 3083671 006 15mm PN 3083672 012 3mm ...

Page 128: ...without throttle engagement See figures 3 and 4 5 Torque cable locknuts to 10 20 in lbs NOTE Use a mirror when aligning the oil pump marks whenever the oil pump is difficult to view Mikuni Flatslide Carburetors 1 Verify that carburetor slides are within 1 16 of each other when passing the top of the carburetor throat See figure 2 2 Set engine idle speed as outlined in the specifications listed in ...

Page 129: ... air will remain trapped in system which may result in overheating Filling and Bleeding Procedure If the cooling system should become low in the reservoir tank and or filler neck the system should be bled of any trapped air using the following procedure Domestic Twins Bleeding Procedure 1 Fill cooling system Leave pressure cap off 2 With engine running at specified idle speed loosen bleed screw on...

Page 130: ...cap pres sure Refer to filling and bleeding procedure on page 3 61 Hose tee to brake cooler Hose tee to pump in Hose bulkhead to rear extrusion Hose brake cooler to rear extrusion Hose tee to bottle 500 SKS Euro only ENGINE COOLANT BOTTLE CENTER EXCHANGER TUNNEL EXCHANGERS BRAKE COOLER BY PASS REAR CLOSEOFF EXCHANGER Euro Only THERMOSTAT ...

Page 131: ...efer to filling and bleeding procedure on page 3 61 Hose tee to brake cooler Hose tee to pump in Hose engine out to bottom close off Hose bulkhead to rear extrusion Hose brake cooler to rear extrusion Hose tee to bottle Bypass Hose Not Shown Protective conduit ENGINE BRAKE COOLER COOLANT BOTTLE CENTER COOLER TUNNEL EXCHANGERS BY PASS THERMOSTAT ...

Page 132: ...edure on page 3 61 Hose Bottle Pump Hose Cooler Center Hose Gripper Cooler Center Hose Gripper Brake Cooler Hose Brake Cool er Bypass Rear Exchanger Hose Gripper Rear Close off Gripper De Icer Cooling Extrusions Cooler Center 3 outlet Hose Engine Out Front ENGINE BRAKE COOLER COOLANT BOTTLE CENTER EXCHANGER TUNNEL ROLL EXCHANGER REAR CROSSOVER EXCHANGER BY PASS THERMOSTAT ...

Page 133: ...1 Hose Gripper Center Cooler Gripper De Icer Hose Gripper Rear Closeoff Rear Exchanger Hose Gripper Brake Cooler 151 and Longer only Rear Cooler Plate Hose Tee Brake Cooler Hose Engine Out Hose Tee to Engine Hose Center Cooler Tee Hose Cooler Bottle Cooler Center Colant Flow ENGINE BRAKE COOLER COOLANT BOTTLE CENTER EXCHANGER TUNNEL ROLL EXCHANGERS REAR CROSSOVER EXCHANGER BY PASS THERMOSTAT ...

Page 134: ...chet side of reel 4 Pass end of rope through rope guide and slide reel down onto shaft and spring NOTE Make sure reel tab engages hook on end of spring 5 Reinstall ratchet pawl onto reel face NOTE Ratchet spring must hold ratchet in retracted position 6 Reinstall friction plate with one end of friction spring in hole on end of ratchet pawl 7 Reinstall flange nut and torque to 5 ft lbs 6 9 Nm 8 Pul...

Page 135: ...HiFax overheating Engine not running on all cylinders Engine runs but fails to idle Incorrect air mixture setting Throttle stop screw incorrectly adjusted Restricted pilot jet Low compression Tight belt Piston damage Enricher plunger not seating properly Engine runs but overloads with fuel Enricher plunger are not seating properly Fuel pump diaphragm is ruptured caused by engine backfiring Carbure...

Page 136: ...taillight if headlight works short is in taillight wiring or taillight Unit fails to pro pel itself Check belt center distance Check clutch Check chain Check drive sprocket assembly Track frozen or stuck Track wears un evenly Check tension Check for proper alignment Check for loose bent or broken suspension parts Chaincase overheating Check oil level Check chain tension and Check track tension for...

Page 137: ......

Page 138: ...w 4 8 4 9 Gasoline Volatility 4 10 Float Chamber Venting 4 11 Fuel System Overview 4 12 Mikuni VM TM Carburetor Operation 4 13 4 18 Component Effect Charts 4 19 VM Carburetor Disassembly Inspection Assembly 4 20 4 23 Throttle Synchronization 4 24 TM Carburetor Disassembly Inspection Assembly 4 25 4 29 TM Throttle Synchronization 4 30 4 31 Choke Adjustments 4 32 Fuel Pumps 4 33 Sediment Trap 4 34 T...

Page 139: ......

Page 140: ...T NO PART NO 25 3130064 60 3130071 30 3130065 35 3130066 40 3130067 45 3130068 50 3130629 55 3130070 Mikuni Mikuni HEX HEAD HEX HEAD MAIN JET NO PART NO MAIN JET NO PART NO 80 3130099 250 3130128 510N 3131400 85 3130100 260 3130129 520N 3131401 90 3130101 270 3130130 530N 3131402 95 3130102 280 3130131 540N 3131408 100 3130103 290 3130132 550N 3131409 105 3130104 300 3130133 560N 3131410 110 31301...

Page 141: ...art Numbers Mikuni NEEDLE JET NO PART NO NEEDLE JET NO PART NO P 4 159 3130162 P 6 247 3130655 P 2 166 3130460 P 8 247 3130382 P 4 166 3130348 Q 0 247 3130414 P 4 166 3130499 Q 2 247 3130165 P 6 166 3130160 Q 4 247 3130603 P 8 166 3130421 Q 8 247 3130485 Q 2 166 3130376 R 0 247 3130477 O 4 169 3130166 P 0 286 3130607 O 4 169 3130409 P 2 286 3130608 O 6 169 3130358 O 4 286 3130635 O 6 169 3130469 O...

Page 142: ...Pilot Air Jet 0 9 3130777 Piston Valve 4 0 3130793 Pilot Air Jet 1 0 3130778 New Main Jets Pilot Air Jet 1 1 3130779 Main Jet 510N 3131400 Pilot Air Jet 1 2 3130780 Main Jet 520N 3131401 Pilot Air Jet 1 3 3130781 Main Jet 530N 3131402 Pilot Air Jet 1 4 3130782 N Series main jets are designated N for the flow characteristics Pilot Air Jet 1 5 3130783 characteristics The 510N flows the same as the 5...

Page 143: ...irst letter designates the taper angle of the top section closest to the grooves and the second letter designates the angle of the bottom ta per The taper angles are graduated in 15 15 minute incre ments The jet needle marked 9DH01 57 would have a top taper of 1_0 and a bottom taper of 2_0 The number follow ing the letters on the jet needle is the manufacture s lot num ber and it varies with indiv...

Page 144: ...ottle slide Needle Jet D The needle jet is press fit into carbs and is not replaceable Piston Valve E The piston valve operates in the same manner as Mikuni VM carburetor round slide valves Main Jet and Pilot Jet F The main jets hex and pilot jets air bleed type are identical in style and function as the Mikuni VM carbs There is washer on main jet Do not lose washer upon disassembly Fuel Screw G T...

Page 145: ...lunger Piston Valve Jet Needle Plate Lever Ring Adjustment Screw O ring Funnel Pilot Air Jet Pin Main Jet Drain Plug Float Bowl Float Needle Seat Asm Starter Jet Pilot Jet Spring Adjuster Cap Check Valve Plate Spring Packing E Ring Ring Mikuni TM 38 TM 40 Exploded View ...

Page 146: ...e Spring Plunger Cap Plunger Spring Plunger Throttle Plate E Ring Jet Needle Throttle Valve Needle Jet Cap Air Screw Spring Throttle Stop Screw Spring Pilot Jet Ring Main Jet Gasket Float Drain Plug Needle Seat Float Pin Float Arm Packing Plate Mikuni VM 34SS Exploded View ...

Page 147: ...tor System ACCS Do not change calibration setting or serious engine damage may result ACCS Valve ACCS Valve ACCS valves cannot be interchanged between models When replacing a faulty valve be sure the identification number stamped on the valve body is correct ...

Page 148: ...e plunger to the left and closing off some of the passageways through the ACCS valve see Ill 2 This prevents atmospheric pres sure from reaching the float bowl allowing the vacuum line to reduce the pressure in the float bowl This reduces the amount of fuel sup plied through the carburetor preventing the mixture from becoming too rich NOTE The ACCS valve is calibrated specifi cally for the model i...

Page 149: ...g a large volume of fuel will normally have the correct blend to work well at all times throughout the year in their local area When the weather is very cold gasoline must be able to vaporize very quickly in order for an engine to start and warm up properly If summer blend fuel is being used in the winter little or no vaporization will occur Droplets will form causing flooding and very hard starti...

Page 150: ... This pro vides a more consistent pressure difference between the carburetor venturi and the float bowl as the vacuum inside the airbox changes For example if the airbox foam filter becomes restricted with snow when riding in pow der the airbox vacuum increases Without airbox venting the pressure difference would increase substantially choking or flooding the engine With airbox venting the pressur...

Page 151: ...l Line Impulse Line Crank Seal Check Valves Impulse Fitting at Crankcase Crank Seal Cylinder Base Gasket Carb Mounts Vent Lines Water Traps Fuel Lines Fuel Pump Violet Fuel Line Red Fuel Line No filter on 2001 and earlier models NOTE Some models use fuel filters are located inside the fuel tank To inspect replace filter S Remove fuel cap S Using a long clean wire bend into a fish hook shape Pull t...

Page 152: ...nger area mixes again with air coming from the air intake port for starting and is delivered to the engine through the fuel discharge nozzle in the optimum air fuel ratio The starter is opened and closed by means of the starter plunger The starter type carburetor is constructed to utilize the negative pressure of the inlet pipe so it is important that the throttle valve is closed when starting the...

Page 153: ...of air is increased Pilot Jet From idling to low speeds the fuel supply is metered by the pilot jet There are several air bleed openings in the sides of the pilot jet which reduce the fuel to mist The number stamped on the jet is an indication of the amount of fuel in cc s which passes through the jet during a one minute inter val under a given set of conditions Pilot Air Screw The pilot air screw...

Page 154: ...er will be stamped into the bottom of the valve e g 2 5 indicating the size of the cutaway The higher the number the steeper the angle Leaner mixture Throttle Valve The throttle valve controls the rate of engine air intake by moving up and down inside the main bore At small throttle openings air flow control is performed chiefly by the cutaway By controlling air flow the negative pressure over the...

Page 155: ...t right shows the variation of fuel flow based on the height of the E ring Needle Jet Fig 2 The needle jet works in conjunction with the jet needle to regulate fuel flow rate An air bleed opening in the side of the needle jet brings in air measured by the air jet This air initiates the mixing and atomizing process inside the needle jet Mixing is augmented by a projection at the needle jet outlet c...

Page 156: ...ditions Larger numbers give a greater flow resulting in a richer mixture Main jets are screwed directly into the needle jet base Jetting Guidelines Changes in altitude and temperature affect air density which is essentially the amount of oxygen available for combustion In low elevations and cold temperatures the air has more oxygen In higher elevations and higher temperatures the air is less dense...

Page 157: ...uretors The Mikuni carburetor has varying operations de pending upon varying driving conditions It is constructed of a float system pilot system main system and starter system or initial starting de vice Float System The float system is designed to maintain a constant height of gasoline during operation When the fuel flowing from the fuel pump into the float chamber through the needle valve reache...

Page 158: ...alve Cut Away Jet Needle Needle Jet Throttle Position 0 start idle 1 4 1 2 3 4 Full starter jet choke plunger air jet pilot outlet bypass throttle valve needle jet jet needle main jet needle valve fuel screw 100 100 Main Slow Start Polaris TM 38 TM 40 Mikuni component effect versus throttle opening chart ...

Page 159: ...cking 3 Remove jet needle by compressing return spring toward top cap and removing throttle plate which rests on top of needle E clip Note the E clip position and inspect needle taper for wear An indication of wear would be an hourglass shape or polished spots somewhere along the taper 4 Remove enricher choke plunger Check condition of seal on tip of plunger Any nicks or cuts will cause leakage an...

Page 160: ...ect enricher choke fuel supply passage in bowl for obstruction 8 Use a spring loaded automatic center punch to remove float arm pin Remove inlet needle and seat assembly 9 Inspect needle for wear and replace sealing washers upon reassembly CAUTION Do not bend float arm during disassembly Do not use exces sive force to remove float arm pin The float pin tower cast ings are very easily damaged and a...

Page 161: ...air or cleaning solvents Review all fuel system warnings found on page 4 1 before proceeding 12 Remove pilot air screw and clean all passages in the carburetor body with carburetor cleaner Dry all passages and jets with compressed air Replace gaskets and any parts which show wear or damage 13 Reassemble carburetor adjusting float level before installing float bowl Refer to page 4 23 for float leve...

Page 162: ...g inlet needle CAUTION Never bend the float arm itself Leak Testing Needle and Seat 1 Be sure float level is adjusted properly 2 Invert carburetor 3 Install float chamber and connect pressure tester PN 2870975 to fuel inlet fitting Pressure Tester PN 2870975 4 Apply approximately 5 PSI pressure and wait for one minute The needle and seat should hold pressure indefinitely If the pressure drops rapi...

Page 163: ...quired until a slight drag can be felt on the gauge or tool 6 Securely tighten throttle cable synchronization lock nut 7 Repeat steps 3 through 5 on remaining carburetor Idle Gap Synchronization 8 Referring to chart in the Specifications section chapter 1 select correct diameter Idle Gap drill gauge for the engine 9 Slightly lift throttle slides with throttle lever and insert idle gap drill gauge ...

Page 164: ... thoroughly with solvent CAUTION Do not use compressed air to dry at this time The float chamber could become pressurized resulting in damage to the floats or inlet needle and seat Do not soak carburetors in carb cleaner Clean only with aerosol cleaner 2 Remove top caps 3 Remove four screws on funnel 4 Turn throttle shaft so slide opens all the way NOTE You may have to turn out slide stop screw fo...

Page 165: ...op of carb loosen allen head screw holding needle in position Slide holding plate to side 7 Reach into top of carb with a long nose pliers and remove needle 8 Inspect needle for wear 9 Remove E rings packing plate spring and rings connecting slide to lever ...

Page 166: ...oat body will not come off unless water trap drain plug which is threaded and screws into main jet housing is removed 12 Remove 2 screws holding float needle seat assembly in position Remove float needle seat assembly 13 Inspect needle for wear NOTE Needles are not available separately If needle is worn or damaged you must replace float needle seat as sembly ...

Page 167: ...etor Disassembly 1 Remove main jet starter jet pilot jet and idle screw 2 Clean all passages in carburetor body with carburetor cleaner Dry all passages and jets with compressed air Replace gaskets and any parts which show wear or damage ...

Page 168: ...ld hold pressure indefinitely If the pressure drops carefully inspect the needle and the needle seat The needle can be replaced needle comes with float and seat 5 Carefully inspect float bowl gasket and replace if necessary Install float bowl on carburetor 6 Install float body 7 Install air adjusting screw 8 Install throttle slide 9 Install jet needle 10 Install funnel 11 Install carburetors on sn...

Page 169: ...buretor on twins have a non adjustable set screw on the throttle shaft Thiscarbu retor is what the other carb s is synchronized to 1 Remove airbox 2 Remove top caps on all carburetors 3 Hold throttle wide open and view position of carburetor slide on base carburetor Middle carb on triples PTO carb on twins 4 With throttle held wide open turn the slide stop screw with screwdriver until slide is flu...

Page 170: ...ors 5 On remaining carb s loosen phillips head screw inside the offset nut 6 When screw is loose hold throttle to wide open Turn offset nut clockwise to raise or counterclockwise to lower until throttle slide is in same position as base carburetor 7 Tighten phillips head screw 8 Replace top caps ...

Page 171: ...r kit is available This allows replacement of the lever assembly rather than the entire cable assembly Installation instruc tions are included with the kit Adjustment Procedure 1 Flip choke toggle to full off position 2 Loosen adjustment locknut A on carburetor s 3 Turn cable sleeve adjusting nut B clockwise on carburetor s until 1 4 6 cm or more choke toggle free play is evident 4 Turn cable slee...

Page 172: ... pressure in the fuel pump chamber This causes the inlet valve in the pump to close and the outlet valve to open filling the float bowl in the carburetor When the float level in the carburetor reaches its standard level the needle valve will close prevent ing more fuel from entering the carburetor even though the fuel pump continues to try to provide the carburetor with fuel Maintenance The impuls...

Page 173: ...oline powered engine exhaust fumes are poison ous and can cause loss of consciousness and death in a short time 1 Turn fuel valve off 2 Remove air silencer 3 Position a shop cloth or container below drain plug and water trap plug 4 Remove drain plug and sealing O Ring or slide clamp upward and remove water trap plug 5 Drain water fuel Clean trap with electrical contact cleaner and dry with compres...

Page 174: ...CONDITION SYMPTOMS Mixture Too Rich Black spark plug tip plug fouling Heavy exhaust smoke Engine runs worse after warm up Engine loads up Mixture Too Lean Spark plug electrodes white Fluctuation in engine speed Power loss Engine overheats Cylinder scoring Holing pistons Backfiring detonation Throttle diagnostic opening check points Poor Fuel Mileage Incorrect ignition timing Improper track tension...

Page 175: ...hrottle S Main jet incorrect size or clogged lean S Needle jet damaged or loose S Needle jet jet needle worn rich S E clip position incorrect for altitude and temperature Troubleshooting Tips Full Throttle S Main jet size rich or lean S Fuel filter blocked lean S Fuel vent lines or check valves plugged S Exhaust system plugged S Air box restricted S Fuel pump weak S Exhaust leaking into engine com...

Page 176: ...e Clutch Installation 5 20 Spider Indexing 5 21 Driven Clutch Removal 5 22 Driven Clutch Disassembly 5 23 5 24 Driven Clutch Assembly 5 25 5 27 Driven Clutch Installation 5 28 Drive Belt Part Numbers Applications 5 29 Drive Belt Inspection 5 30 Drive Belt Deflection 5 31 Drive Belt Deflection Measurements 5 32 Clutch Offset Inspection and Adjustment 5 33 Clutch Alignment and Inspection 5 34 Drive ...

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Page 178: ...he Polaris parts department The part number is 9915235 Description Part Number Offset Alignment Tool 21 32 1 7 cm P 90 Clutches 2870914 Offset Alignment Tool 5 8 1 6 cm P 85 Clutches 2870426 T Handle Drive Clutch Puller Large Shaft ID 2870506 Drive Clutch Puller 550 Fuji Engines 2872084 Strap Wrench 2870336 Replacement Strap for 2870336 2870389 Spider Spanner Nut Driver Jam Nut 2870338 Spider Remo...

Page 179: ...t 34á1 PN 5630107 02 Gram Weight 49á1 PN 5630225 O Gram Weight 51 PN 5610088 Gram Weight 53á1 PN 5630174 W W Gram Weight 37 5á1 PN 5630109 03 03 Gram Weight 32 5á1 PN 5630227 04 04 Gram Weight 57 5á1 PN 5630229 1 M1 Modified Gram Weight 46 0á1 PN 5630301 M K1 K1 Gram Weight 39á1 PN 5630144 P1 P1 Gram Weight 42á1 PN 5630089 ...

Page 180: ... 07 Gram Weight 52á1 PN 5630244 08 Gram Weight 47 5á1 PN 5630245 15 15 Gram Weight 55 5á1 PN 5630274 10 10 Bushed Gram Weight 51 5á1 PN 1321526 10 M W 10M W Bushed Gram Weight 46á1 PN 1321527 10M 10M Bushed Gram Weight 49 5á1 PN 1321528 10M B 10M Blue Bushed Gram Weight 47 5á1 PN 1321529 10M R 10M Red Bushed Gram Weight 44á1 PN 1321530 ...

Page 181: ...21586 10 60 Bushed Gram Weight 60 PN 1321587 10 58 Bushed Gram Weight 58 PN 1321588 10A Bushed Gram Weight 55 PN 1321589 10 A L 10 AL Bushed Gram Weight 53á1 PN 1321531 10 56 10 56 Bushed Gram Weight 56 1 PN 1321684 10 54 10 54 Bushed Gram Weight 54 1 PN 1321685 53B S53B Gram Weight 49 1 PN 1321730 S53R Gram Weight 51 1 PN 1321731 53R 55R S55R Gram Weight 53 1 PN 1321759 ...

Page 182: ...ed 207 4 29 165 310 7042083 Black Green 218 3 38 120 340 CAUTION Never shim a drive clutch spring to increase its compression rate This may result in complete stacking of the coils and subsequent clutch cover failure Maximum efficiency of the variable speed drive system is dependent upon many factors Included in these are converter offset and alignment belt tension belt to sheave clearance and int...

Page 183: ...ta tion in s 7041198 Red 0 170 4 00 21 45 38 85 7041296 Blue 0 192 3 43 29 64 60 133 7041499 Silver 0 188 3 45 25 54 5 53 119 7041646 Silver Blue 0 183 3 45 42 75 53 119 7041782 Black 0 177 3 60 24 49 44 99 7041501 Gold 0 188 3 60 24 49 44 99 7042022 Blue Orange 0 192 3 50 56 90 60 133 67 150 Driven Spring Charts Blue Silver Gold and Black Red 0 20 40 60 80 2 5 1 375 Compression Distance in Load i...

Page 184: ...pacer Weight w Bushing Weight Pin Sleeve Bushing Moveable Insert Fixed Sheave Moveable Sheave Spider Roller Pin Do not lubricate drive clutch components Replacement clutches come complete and balanced without clutch weights and clutch spring The clutch cover spider and sheaves cannot be purchased separately as replacement parts P 85 Drive Clutch ...

Page 185: ... Washer Stationary Sheave Pin Adjustment Cam Screw Driven Cap Do not lubricate driven clutch components except inside of ramp helix hub to reduce fretting and corrosion Replacement driven clutches come complete with ramp and spring The moveable and station ary sheaves cannot be ordered as separate service parts P 85 Driven Clutch ...

Page 186: ...y authorized special tools and service procedures Any unauthorized modifications to clutches such as adding or removing weights will voidthe warranty Relationship Between Drive Clutch Weights And Spring In Maintaining Operating RPM The drive clutch is an RPM and torque sensing unit designed to transfer the maximum amount of horsepower from the engine to the ground This is accomplished by weights a...

Page 187: ...ng rate too low the engine RPM will be low and the drive clutch will upshift too fast keeping the engine out of its power band 9000 8000 7000 6000 5000 4000 3000 ENGINE OPERATING RANGE 250 RPM ENGAGEMENT RPM If the weights and spring are matched properly the engine RPM will go to the desired range and remain there on both upshift and backshift ...

Page 188: ...n clutch is increased and becomes greater than the torque delivered from the engine the driven clutch becomes dominant and overrides the drive clutch The driven clutch downshifts into a ratio which will match the increased load Because the driven clutch can sense and shift into the proper ratio engine RPM will remain within the specified range Driven Clutch Adjustments The driven clutch has a prov...

Page 189: ...re than required to remove galling or scoring Never use power tools to ream taper of drive clutch CAUTION Never use an air impact wrench for installing or removing a drive clutch It will loosen the spider torque value and could cause engine crankshaft damage Identification This number indicates internal clutch component varia tion for individual engines For easy identification refer to the three n...

Page 190: ...enly remove cover attaching bolts Do not allow side loading or misalignment of cover or bushing may be damaged Remember there is spring tension on the cover Inspect cover bushing for wear See page 5 36 for inspection and repair procedure 3 Mount drive clutch securely in the holding fixture On models equipped with a spider jam nut P 85 Clutches remove jam nut in a counterclockwise direction standar...

Page 191: ...e page 5 38 for inspection and repair procedure 7 Using an 1 8 Allen wrench with a 3 8 combination wrench remove drive clutch fly weights Note direction of weight pin with nut on trailing side Inspect each weight Surface shouldbe smooth with no waves or galling Place bolt inside weight to check flyweight bushing and pin surface for wear NOTE The weight bushing is not a service part and both weight...

Page 192: ... 2 Place spider on a vise or in an arbor press Using a pin punch drive out the roller pin Roller Installation 1 Start a replacement roller on each leg driving a pin in 100 125 25 32 cm beyond the first land of the spider leg A Remove any aluminum burrs from pin protruding from spider 2 Install one washer onto pin Spider Button Removal Tool PN 2870985 ...

Page 193: ...CAUTION Use care to start the pin straight Aluminum burrs could pass through into the roller bushing causing it to bind and stick Also use care to make sure the roller remains aligned when the pin is driven through The roller bushing could be damaged causing premature wear and roller fail ure Spider Button Shimming 1 Determine how many shims are to be used NOTE A shim kit is available which contai...

Page 194: ... 3 Install spider buttons using a soft face hammer 4 Record width of spider buttons on each leg 5 Add shims beneath trailing side spider button to obtain specified button to tower clearance when assembled Button to Tower Clearance P 85 P 90 002 05 mm Use Dial Caliper Measure tower width at bottom of travel Measure each leg and record ...

Page 195: ... or removing washers from under the spider and the sheaves were marked before disassembly follow in dexing procedure on page 5 21 3 Torque spider to specification 4 Torque jam nut to specification P 85 Clutches Install weights with weight pin nut on trailing side Use new nuts to ensure proper retention Torque nut to 30 in lbs Spider Torque P85 and P90 Spider Removal Tool PN 2870341 200 ft lbs 276 ...

Page 196: ...ng a tapered reamer Place reamerin a vise and lubricate with cutting oil Clean taper by manually rotating clutch clockwise 2 Check crankshaft taper for galling or scoring If necessary clean taper evenly with 200 grit emery cloth 3 Both clutch taper and crankshaft taper should be clean and dry NOTE Do not use harsh cleaners which may cause clutch taper to corrode during use This will cause diffi cu...

Page 197: ...e parts manual for type and placement of retaining bolt components 6 Torque retaining bolt to specifications Hold clutch with strap wrench NOTE Re torque clutch to specification after first period of operation such as a test ride Drive Clutch Bolt Torque Large ID Shaft 3 4 40 45 ft lbs 55 2 62 1 Nm Drive Clutch Bolt Torque Small ID Shaft 14mm 7 16 50 ft lbs 69 Nm ...

Page 198: ...shers are available for fine tuning 4 Install spider washer s and spider aligning Xs Notice as the spider seat location is changed the sheave marks made before disassembly no longer align There are two ways to bring the sheave marks into alignment S Vary the amount and thickness of spacer washers Washer thickness may vary slightly S Re index marked spider leg to another tower This can be done beca...

Page 199: ...85 clutches externally adjustable can be removed using a 3 point flywheel or steering wheel puller and the 1 4 20 adjustment bolt holes Use a suitable spacer on the end of the jackshaft 3 Inspect jackshaft keyway for wear or damage NOTE Notice the number and thickness of shim washers between driven clutch and jackshaft bearing These must be replaced to maintain proper offset alignment ...

Page 200: ...h a soft faced hammer Remove snap ring and washer 3 Allow sheaves to return and force the helix out Before removing helix note driven clutch spring position Remove helix 4 Inspect helix ramps and movable buttons and for wear or damage P 85 buttons can be removed by applying heat to the button housing or drill button with an 1 8 drill bit The ramp buttons should be replaced when worn See Maintenanc...

Page 201: ...heave off and inspect sheave surfaces for wear or grooving Note size and number of shim washers between sheaves 7 Note condition of moveable sheave bushing Install helix into bushing It should slide freely without binding See page 5 39 for bushing replacement 8 Polish helix with a fine emery cloth to remove any sharp edges or build up which may cause sticking Tabs Aligned ...

Page 202: ...le sheave and 4 holes in the helix NOTE The driven clutch helix moveable assembly has several different spring locations which affect clutch shift ing and RPMs Tighter spring tension will raise engine RPMs during clutch upshift and allow quicker downshift when pulling or negotiating a hill The lighter tension posi tions will tend to have a slower downshift and a harder up shift 4 Align inner keywa...

Page 203: ... 5131013 42 36 34 P 85 36 5 5130383 36 5 P90 40 38 36 5131161 40 38 36 P90 38 36 5131162 38 36 P90 38 36 34 5131163 38 36 34 P90 34 5131164 34 P90 5 Hold fixed sheave and turn movable sheave 1 4 turn counterclockwise 6 Force helix down into place exposing snap ring groove The helix spring should always be adjusted within its limits before a helix change is performed The normal rate of change betwe...

Page 204: ...of snap ring when clutch is removed Pry lightly to remove retainer and gain access to snap ring Refer to illustration below 8 Allow sheaves to close Test clutch by pre loading movable sheave 1 4 turn counterclockwise and releasing Sheave should open and close smoothly with a positive stop Some helix ramps have more than one washer beneath the snap ring NOTE Always install snap ring with chamfer to...

Page 205: ...e shaft The bearing should be greased at 1000 mile 1600 km intervals and before storage NOTE Spacer washers between driven clutch and jack shaft bearing set the offset Refer to adjustment proce dure on page 5 33 to adjust offset between the drive and driven clutch 2 Lightly grease jackshaft keyway or spline With square key in place P 85s slide clutch onto jackshaft 3 Install spacer bolt and washer...

Page 206: ...52mm 28 12 00 47 625 Double cog Good for short runs on higher horsepower engines Drag Racers Good for lower horsepower trail riding 3211075 1 438 36 52mm 28 12 00 47 625 Double cog CVT 3211080 1 438 36 52mm 28 11 50 46 625 Double cog CVT version of PN 3211078 3211078 1 438 36 52mm 28 11 50 46 625 Standard Drive Belt Belt dimensions given are nominal dimensions There is a variance for all critical ...

Page 207: ...e aggressively for short durations for initial cold drive away Towing another machine at or about engagement RPM When possible do not go in deep snow when towing another ma chine Use fast effective throttle to engage the clutch Not all ma chines are intended for pulling heavy loads or other machines Spinning track while vehicle is stuck high RPM low vehicle speed high ambient temp Example 8000 RPM...

Page 208: ...erformance loss This is due to the belt rising too high in the drive clutch sheaves upon en gagement Not enough belt deflection belt too tight If thedrive belt is too short or the center distance too long the ratio will again be incorrect In addition the machine may creep when the engine idles causing damage to the in ternal face of the drive belt Belt too high on initial engagement ...

Page 209: ...djusting Belt Deflection P 85 Belt deflection can be adjusted without removing the clutch from the jackshaft 1 Pull belt into driven clutch to slightly open sheaves 2 Loosen three bolts on adjustment cam 3 Turn cam counterclockwise to reduce distance between sheaves Do not rotate past 1 position 4 Torque bolts to specification 1 1 4 3 2 cm Straight Edge Production washer is usually 075 thick with ...

Page 210: ...ch to float on the jackshaft After adjusting offset add or remove shim washers from the retaining bolt to provide a 030 060 75 1 5mm of float on jackshaft This will prevent side loads on the jackshaft bearing NOTE On models with driven clutch snap ring retainer the clutch is mounted firmly on the shaft without float NOTE When checking electric start models use a straight edge as shown in Ill 2 If ...

Page 211: ...h Alignment Adjustment 1 Loosen all 4 engine mounting bolts 2 Adjust engine torque stop until clutches are in proper alignment 3 Tighten engine mounts securely 4 Recheck both clutch offset and alignment 5 Verify proper torque stop adjustment Torque Stop Adjustment NOTE There are two types of torque stops currently used Refer to the illustrations below for adjustment of each type 1 After aligning c...

Page 212: ...E Measure total belt to sheave clearance with a new belt 2 Install feeler gage between other sheave and belt Belt to Sheave Clearance Adjustment Belt to sheave clearance can be adjusted in two ways 1 Try several new belts to achieve proper clearance 2 Can add or remove shims from under the spider to increase or decrease belt to sheave clearance See Spider indexing on page 5 21 NOTE Spider indexing...

Page 213: ...Removal Bridge 8 1 Main Puller Adapter 5020632 9 1 Adapter Reducer 5010279 10 1 Number Two Puller Adapter 5020633 11 1 Instruction 9912260 You will need to supply Piston pin puller PN 2870386 Bench vise Soft face hammer for P 85 Driven Moveable Small scribe or pick for Cover Bushing Removal Hand held propane torch for P 90 Driven Loctite RC 680 Retaining Compound 2870584 P 85 Drive Clutch Cover Bu...

Page 214: ... bushing and bushing removal tool from puller Discard bushing P 85 Drive Clutch Cover Bushing Installation 1 On Garmaxä style bushings PN 3576516 apply Loctite 680 retaining compound PN 2870584 to the outer surface of the bushing Do not lubricate bushings or premature wear will result 2 Working from inside of cover insert bushing and bushing installation tool into center of clutch cover 3 With mai...

Page 215: ...from inside adapter and set aside P 85 Drive Clutch Movable Sheave Bushing Installation 1 Place main adapter Item 8 on puller 2 Push new bushing into center of sheave by hand 3 Insert installation tool Item 1 into center of sheave and with towers pointing toward vise slide sheave onto puller rod 4 Install nut on puller rod and hand tighten Turn barrel to apply additional tension if needed 5 Turn s...

Page 216: ...outside insert thumb through center of sheave Using downward pressure hold bushing removal tool tightly in place 5 With back side toward vise slide sheave onto puller 6 Install nut onto puller rod and hand tighten Slowly align clutch with bridge and turn puller barrel to increase tension if needed 7 Turn sheave counterclockwise until bushing is removed and sheave comes free 8 Remove nut from pulle...

Page 217: ...ll 4 13 Slide clutch sheave onto puller with back side away from vise 14 Turn puller barrel until rod extends past back side of sheave 15 Insert large installation tool for DU bushing onto rod 16 Install nut onto puller rod and hand tighten Turn puller barrel to increase tension as needed 17 Turn clutch sheave counterclockwise until bushing is seated 18 Remove nut from puller rod and set aside 19 ...

Page 218: ...ive drive clutch button tower clearance Bearing failure chaincase jackshaft or front drive shaft Drive chain loose or worn sprocket teeth broken Driven clutch bushing worn excessively or spring broken Drive chain adjustment too tight too loose Drive belt surface flat spots Inspect replace Install new buttons or shim out existing buttons Inspect replace Inspect adjust or replace Inspect replace Ins...

Page 219: ... specified operating range a Incorrect drive clutch spring too high spring rate b Drive clutch shift weights incorrect for application too light c Drive clutch binding d Driven clutch binding e Converter sheaves greasy belt slippage f Improper driven clutch setup a Install proper spring b Install proper shift weights c Disassemble and clean clutch inspecting shift weights and buttons Reassemble wi...

Page 220: ... mph indicated on speedometer Lower the gear ratio Remove windage plates from driven clutch If possible move to better snow condi tions and reduce RPM Avoid riding in very high am bient temperatures Ice and snow piled up between track and tunnel overnight or after stopping for a long period of time enough to re freeze the snow Break loose snow and ice under tunnel Allow longer than normal warmup A...

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Page 222: ...0 6 11 Handlebar Centering 6 12 Toe Adjustment 6 13 6 14 XTRA CRC XC 10 Steering Alignment 6 15 CRC Steering Adjustment 6 16 CRC Camber Adjustment 6 17 Carbide Placement 6 18 Ski Spindle Bushing Removal Replacement 6 19 6 20 Steering Arm Orientation 6 21 Ski Skag Removal Installation 6 22 Ski Installation 6 23 Torsion Bar Removal Installation 6 24 Handlebar Torque Sequence 6 25 Seat Removal Instal...

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Page 224: ...ations A 28 30 ft lbs 38 41 Nm B 35 40 ft lbs 47 54 Nm C 40 45 ft lbs 45 62 Nm D 45 50 ft lbs 61 68 Nm E 55 60 ft lbs 76 83 Nm Apply Premium All Season Grease PN2871322 3oz to all grease zerks located on suspension assemblies z Replace locking fasteners if removed D E A A A A A ...

Page 225: ...ations A 17 19 ft lbs 24 26 Nm B 28 30 ft lbs 39 41 Nm C 35 40 ft lbs 48 55 Nm D 40 45 ft lbs 55 62 Nm E 45 50 ft lbs 62 69 NM Apply Premium All Season Grease PN2871322 3oz to all grease zerks located on suspension assemblies z Replace locking fasteners if removed A C E A B B B C ...

Page 226: ...ean D E A B C A A B B B C C Torque Specifications A 17 19 ft lbs 24 26 Nm B 28 30 ft lbs 39 41 Nm C 35 40 ft lbs 48 55 Nm D 40 45 ft lbs 55 62 Nm E 45 50 ft lbs 62 69 NM Apply Premium All Season Grease PN2871322 3oz to all grease zerks located on suspension assemblies ...

Page 227: ...ations A 17 19 ft lbs 23 26 Nm B 28 30 ft lbs 38 41 Nm C 35 40 ft lbs 47 54 Nm D 40 45 ft lbs 55 62 Nm E 45 50 ft lbs 61 68 Nm Apply Premium All Season Grease PN2871322 3oz to all grease zerks located on suspension assemblies z Replace locking fasteners if removed A A B D B B ...

Page 228: ...locking fasteners if removed Torque Specifications A 28 30 ft lbs 38 41 Nm B 35 40 ft lbs 47 54 Nm C 54 66 ft lbs 75 91 Nm D 135 165 ft lbs 187 228 Nm Apply Premium All Season Grease PN2871322 3oz to all grease zerks located on suspension assemblies A A A D A A A A B A C A ...

Page 229: ...guidelines on page 6 8 before making adjustments The following components must be inspected at this time NOTE Always follow rod end engagement guidelines found on page 6 7 Maximum setup width must be checked whenever front suspension components are adjusted or replaced Tie rods and tie rod ends Radius rods and radius rod ends Torsion bar and bushings linkage where applicable Handlebars and steerin...

Page 230: ...ght Hold tie rod or radius rod and tigh ten jam nut If possible support the edge of the rod end as shown to keep it from rotating out of position until jam nut is tight When tie rod ends are properly tightened the tie rod should rotate freely approxi mately 1 8 turn Rod End Engagement Guidelines All IFS Positive Negative and Neutral 0 Camber Front View Incorrect Correct Tie Rod End Mounting Surfac...

Page 231: ... 2 11 80cm TOE OUT 38 X 7 37 60 95 50cm 13 16 3 4 2 08 80cm 38 X 7 Widetrak LX 37 60 95 50cm 13 16 3 4 2 08 80cm At Normal Ride 41 Indy Xtra Sport Tour Sport Tour E S 39 10 99 31cm 0 5 16 0 80cm At Normal Ride Height Sport Tour Sport Tour E S Sport Tour Euro 39 10 99 31cm 0 5 16 0 80cm 42 5 Indy Xtra 50 Classic Touring Trail Touring 40 44 102 72cm 0 5 16 0 80cm 42 5 X 10 CRC 600 Classic Touring 40...

Page 232: ...apter for procedure This will be used as a reference point for final toe out measurement 2 Support the front of the machine 1 2 2 5 5 1 cm off the floor 3 Remove skis and ski pivot bushings 4 Disconnect adjustable torsion bar linkage where applicable 5 Measure spindle to chassis centering as shown and record measurement Both spindles should be an equal distance 1 8 3 mm from the center of the chas...

Page 233: ...d camber distance Measurement should be taken from top of alignment bar to top of ski pivot bushing hole in spindle bushing removed Radius rod must be re attached to trailing arm before measuring CAMBER INSPECTION All Models Elevate Front End Shocks Installed Refer to specifications for SIFS type SSpecified amount of camber Attaching Bolts Radius Rod End Jam Nuts Suspension Free Hanging With IFS S...

Page 234: ... 0 the bar should slide freely through both spindles tolerance CAUTION Radius rod ends must remain parallel to the bulkhead after rod end jam nuts are tightened to specified torque See illustration at right 4 Tighten all jam nuts Torque radius rod attaching bolts to specification WARNING After camber adjustment is complete be sure to measure set up width outlined on page 6 9 and compare to specifi...

Page 235: ...ment bar cannot be installed through spindles On these models the pitman and idler arm Fig II or bellcrank on non CRC models should be pointed straight forward 6 Lubricate ski pivot bushings with Polaris Premium All Season Grease and install in spindle Torque ski bolts to specification Install new cotter pin in castle nut 7 Perform Toe Adjustment on page 6 13 Fig I Drag Link Fig II Pitman Arm Idle...

Page 236: ...oid rough concrete asphalt or carpet which may cause carbide skags to grab or catch and restrict movement SERVICE HINT Before final measurement is taken skis should be pushed together lightly at the tips to re move play in the steering components This will help achieve accurate measurement If a strap is used be sure it is not too tight or it will alter measurement this is most important on models ...

Page 237: ...oth tie rods Turn tie rod as required to adjust toe 4 Hold tie rod and tighten jam nuts Be sure to position inner and outer tie rod ends parallel to their respective mounting surface as shown When tie rod ends are properly tightened the tie rod should rotate freely approximately 1 8 turn 10 10 Toe Measurement CRC Incorrect Correct Tie Rod End Mounting Surface Support Edge Tie Rod Jam Nut Torque 8 ...

Page 238: ...ntal kit PN 2872949 includes 14 34 travel location bars that fit 2000 XC 10 CRC models Kit components are also available separately See tool catalog for tool ordering information Refer to the chart below for travel bar application for width camber and toe adjustments on XTRA CRC and XC 10 CRC models See text on following pages for specific procedures XTRA CRC and XC 10 CRC Models When Measuring Se...

Page 239: ...d ends If the suspension is set too wide the torsion bar can come loose and interfere with steering Do not attempt to set the suspension wider than the specified Maximum Set Up Width Camber Adjustment XTRA CRC and XC 10 CRC 5 Remove IFS shocks and install appropriate travel location bars The travel location bars will locate the IFS at a given point of travel where the camber should be neutral 0 6 ...

Page 240: ...tion 11 Re check set up width and compare to specifications Handlebar Centering CRC 12 With alignment bar in spindles and tie rod ends disconnected center the steering rack by pointing the pitman arm and idler arm straight forward 13 Center the handlebars by adjusting drag link length Tighten jam nuts to 24 25 ft lbs 33 35 Nm 14 The steering arms should be parallel to the ski centerline or slightl...

Page 241: ...ing IFS shocks will allow the driver to make adjustments to the compression valving of the front shocks by turn ing the screws located near the base of the shocks By turning the screw clockwise the compression of the shock is in creased stiffening the ride Byturn ing counter clockwise the com pression is decreased softening the ride The factory setting is in the softest position Screw all the way ...

Page 242: ...sembly Note direction of steering arm bolt and remove 2 Remove steering arm 3 Slide spindle and ski assembly out bottom of trailing arm Inspect spindle for wear or damage 4 Remove old bushings and washer from bottom of spindle tube with a drift punch Inspect condition of washer and replace if worn Install new bushings tapered end first Washer Bushings ...

Page 243: ...n Grease 6 Install spindle into trailing arm with grease fitting facing rearward 7 With ski facing straight forward attach steering arm Align with marks made in step 1 8 Install steering arm bolt and torque to specification All Season Grease PN 2871322 3 oz PN 2871423 14 oz Spindle Bolt Torque 28 30 ft lbs 38 6 41 4 Nm ...

Page 244: ... Always mark steering arms and spindles before removal for reference upon reassembly When installing new parts or after steering arm installation refer to the illustrations and text below Always verify proper steering operation after completing adjustments or repairs 1 Reinstall torsion bar linkage where applicable Torque attaching bolts to specification 2002 EDGE RMK 75 ...

Page 245: ...frees the skag for removal from the ski Ski Skag Installation 1 Push skag forward then up into position 2 Reinstall nuts and torque to specification Ski Skag Removal EZ Steer 1 Remove the three nuts from the skag 2 Pull down and rearward to remove the skag Ski Skag Installation EZ Steer 1 Install flat bar as shown 2 Install IFS carbide skag 3 Reinstall nuts and torque to specification Ski Skag Ret...

Page 246: ...support The 90_ flat portion of stop should face toward the front of the ski Long saddle skis with this type of ski stop will require the metal support The 90_ flat portion of stop should face toward the front of the ski Install ski over spindle slightly in front of ski saddle with ski pointing outside METAL SKI INSTALLATION Slide ski forward until spindle is just behind ski saddle and turn to the...

Page 247: ... the rivets 4 Punch out the rivet body 5 Remove support and torsion bar 6 Repeat procedure for second torsion bar Torsion Bar Installation 1 Rivet support in place using Polaris PN 7621449 rivets NOTE These high strength Q rivets are the only replacement rivets recommended for this application 2 Reinstall torsion bar 3 Reinstall trailing arm assembly 4 Check camber and toe adjustments Torsion Bar ...

Page 248: ...throttle lever operate smoothly and do not hit the fuel tank windshield or any other part of the machine when turned fully to the left or right IMPORTANT When adjusting the handlebar be sure the serrations in handlebar and adjuster block match be fore torquing 4 Torque the handlebar adjuster block bolts to specification following sequence shown The gap should be equal at front and rear 5 Replace h...

Page 249: ...pump and plug line to prevent fuel spillage from tank See photo one at right 6 Roll front tank hold down spring forward off tank saddle 7 If machine is equipped with a fuel gauge connector this should be unplugged 8 Remove two bolts holding rear of seat to tunnel 9 Slide seat rearward enough to gain access to taillight connector at RH side of fuel tank Unplug connector Slide seat off machine and s...

Page 250: ...re to the center strap This will allow you to pull the center strap back through the foam and into the storage box 4 Place the seat foam on the seat base assembly as shown in Ill 1 5 Drape the seat cover over the seat foam 6 Insert and pull the two seat bucket hold down straps attached to the seat cover through the two holes in the seat foam and the routed out holes located in the storage box area...

Page 251: ...over to the plastic seat base in each corner Use two or three staples per corner 10 Now that the seat cover is correctly positioned and tacked to the plastic seat base in four places turn the assembly over and inspect it If the seat cover seems to fit correctly and everything looks straight including the tool compartment flap continue with step 11 11 Staple the remainder of the unattached seat cov...

Page 252: ...Models 17 Trim excess vinyl from the bottom around the back of the seat area only after a satisfactory fit is obtained 18 Reinstall seat by reversing disassembly steps as they apply to your particular model Hood Repair Currently there is no procedures or materials recommended by Polaris for repairing hoods Hoods for 2001model snowmobiles are made of Thermoplastic Olefin TPO and cannot be repaired ...

Page 253: ...s 3 Install new taillight assembly and rivet into place 4 Connect taillight wire harness NOTE Taillight harness wires must be routed away from any possible contact with seat cover staples to prevent electrical shorts 5 Pull seat cover tightly and evenly into position and re staple to seat pan 6 Inspect cover for a wrinkle free finish before reinstalling on the snowmobile ...

Page 254: ...NOTE The rivet for polyethylene nosepans is PN 7621467 NOTE Rivet holes may require drilling into the bulkhead NOTE 1 When transfer drilling holes do not force pan into a position which is not uniform with the other side Use the same method to drill both sides 2 Rivet holes across from one another in unison 3 Liquid cooled models will have recesses on both sides like reference A Fan cooled models ...

Page 255: ...cles represent rivets installed from the under side of nosepan through to the top NOTE The rivet for polyethylene nosepans is PN 7621467 NOTE Rivet holes may require drilling into the bulkhead NOTE 1 When transfer drilling holes do not force pan into a position which is not uniform with the other side Use the same method to drill both sides 2 Rivet holes across from one another in unison Tipped In...

Page 256: ...filled in circles represent rivets installed from the under side of nosepan through to the top NOTE The rivet for polyethylene nosepans is PN 7621467 NOTE Rivet holes may require drilling into the bulkhead NOTE 1 When transfer drilling holes do not force pan into a position which is not uniform with the other side Use the same method to drill both sides 2 Rivet holes across from one another in uni...

Page 257: ...pe off 2 Carefully remove decal backing and apply new decal 3 If decal does not have a pre mask apply additional soapy water solution to top of decal after it is in position 4 Holding decal in position remove all trapped air and soapy water solution from under decal using a clean soft rubber squeegee to prevent scratching of decal surface 5 If decal has a pre mask carefully remove NOTE If the deca...

Page 258: ...e freeplay Steering bellcrank bushing worn or loose Drag link worn or loose Steering post loose Steering post bushings worn Tie rod ends worn Spindle bushings worn Tighten or replace if necessary Tighten or replace if necessary Tighten as needed Replace if necessary Tighten as needed Replace if necessary Front end bounces or sags IFS shock spring preload too soft Improper shock charge or valving i...

Page 259: ......

Page 260: ... Suspension Information EDGE RMK 7 11 EDGE RMK Exploded View 7 12 Suspension Adjustment 7 13 7 16 Front Suspension Adjustment 7 17 Limiter Strap Adjustment 7 18 Compression Damping Adjustable Shocks 7 19 How to Adjust Rear Suspensions 7 20 Rear Suspension Springs 7 21 IFS Springs Xtra 10 Xtra Lite EDGE RMK 7 22 Stock Shock Valving 7 23 7 24 Foxt Overview 7 25 Foxt Valving Part Numbers 7 26 Foxt Ma...

Page 261: ......

Page 262: ...s the extension of the front of the suspension reducing the angle of the torque arm and increasing ski pressure during acceleration Length ening the strap allows the front of the suspension to extend further increasing the angle of the torque arm and decreasing ski pressure during acceleration Limiter strap adjustment has a great affect on weight transfer LImit er straps only affect acceleration I...

Page 263: ...ss it one inch 300 pounds of force would compress it two inches 450 pounds of force would compress it three inches etc S Progressively wound spring the rate of the spring increases as it is compressed For example a 100 200 in rate spring requires 100 pounds of force to compress the first one inch but requires 200 additional pounds to compress the last one inch When a bump is encountered by the sus...

Page 264: ...f the things that you have to consider when tuning a suspension On new machines or whenever new suspension parts are installed the sled should be ridden for at least one tank of fuel to allow moving parts in the shocks and suspension to wear in The shock springs will also take their initial set and the setup will be more accurate Soft Tension Long End to Front Medium Tension Short End Up Firm Tens...

Page 265: ...d for high and low speed damping characteristics On Indy Select shocks the compression damping can be changed by turning the adjuster screw On Ryde FX shocks the compression damping can be changed by adjust ing the adjustment cam to the left or right Refer to shock section in this chapter for adjustment NOTE When we refer to high and low speed we are referring to the speed of the shock shaft or va...

Page 266: ... position for maximum lift and floatation n Ski Stance Narrow position for maximum maneuverability n Front Torque Arm standard position for overall handling and speed over snow n Ski Stance Set to rider preference n Front Torque Arm High position for increased control and less transfer n Ski Stance Wide position for maximum stability More detailed instructions and options are found on troubleshoot...

Page 267: ...ension from machine NOTE Some models may allow Hi Fax to be removed by sliding it through track windows with the suspension mounted in the machine 2 Remove front Hi Fax retaining bolt 3 Use a block of wood or a drift punch and hammer to drive Hi Fax rearward off the slide rail 4 With Hi Fax material at room temperature install new Hi Fax by reversing steps 1 3 NOTE Lightly coat Hi Fax track clip a...

Page 268: ...Nm 3 8 suspension mounting bolts 35 40 ft lbs 49 55 Nm 7 16 suspension mounting bolts 55 60 ft lbs 76 83 Nm Shock rod bolts do not over torque 12 ft lbs 17 Nm Shock rods must pivot freely after torquing L L L L L L L LUBRICATION POINTS XTRA 10 Grease at fittings Forward L LUBRICATION POINTS XTRA LITE L Grease at fittings L L Forward L L Both sides ...

Page 269: ...SUSPENSIONS 7 8 Rear Suspension Exploded View XTRA Lite Front Torque Arm Rear Torque Arm Front track shock spring preload washers PN 5210953 ...

Page 270: ...l Rail Bumper Rear Track Shock Front Track Shock Front Torque Arm Front Track Spring Torsion Spring Bogie Wheel Rear Torque Arm Rear Pivot Arm Idler Wheel Rail Bumper Slide Rail Rear Track Shock Bogie Wheel Rail Bumper Hi fax Rail Tip XTRA Lite Rear Suspension ...

Page 271: ...ck Shock Front Track Shock Limiter Strap Rear Torsion Spring Forward Rear Track Shock Rear Track Shock Idler Wheel Slide Rail Hi fax Rail Bumper Pivot Arm Shaft Pivot Arm Shaft Bogie Wheel Front Torque Arm Carrier Wheel Rear Limiter Strap XTRA 10 Rear Suspension ...

Page 272: ...ing bolts 35 40 ft lbs 49 55 Nm Shock rod bolts do not over torque 12 ft lbs 17 Nm Shock rods must pivot freely after torquing L L L L L L L L L L L L L L L L L L L L L L L L Torsion Spring Bogie Wheel Slide Rail Rail Bumper Rail Tip Front Track Shock Rear Track Shock Idler Wheel Front Torque Arm Rear Torque Arm ...

Page 273: ...SUSPENSIONS 7 12 EDGE RMK Exploded view Front Torque Arm Rear Torque ARm ...

Page 274: ...amping on Ryde FX or Indy Select rear track shock Adjustment Procedures It is a good idea to break the suspension in for approximately 150 miles 240 km and re grease all suspension parts before fine tuning adjustments are made All settings will vary from rider to rider depending on rider weight vehicle speed riding style and trail conditions We recommend starting with factory settings and then cus...

Page 275: ...mpromise or trade off A machine set up to perform well in the moguls would not suit the preference of a groomed trail rider Adjustable Features and Adjustment Options Independent Front Suspension IFS S Front shock spring preload some models require washers S Optional springs S Indy Select shock on some models Rear Suspension S Rear torsion springs S Front rear scissor stop FRSS S Rear rear scissor...

Page 276: ... rear suspension As the front torque arm FTA hits the bump it forces the rear scissor to collapse a predetermined amount depending on the FRSS block position This accomplishes two important things it allows a lighter spring rate on the FTA because it can borrow spring rate from the rear torsion springs and it prepares the rear portion of the suspension for the bump reducing secon dary kick back Th...

Page 277: ...justment on both sides Be sure rear scissor stop face is square with the face of the scissor arm to ensure complete contact Rear Spring Tension Rear spring tension adjustments are made by rotating the eccentric spring block A as shown with the engine spark plug tool The block provides three spring tension positions This adjustment is easier if the long spring leg is lifted over the roller and repl...

Page 278: ...hock with occa sional light bottoming CAUTION If the plastic nut is unscrewed from the threaded body the nut will break Always leave one thread showing above the plastic nut or the spring coils will stack resulting in damage For the best ride the spring preload should be as low as pos sible Set the preload to use the full travel of the ski shock with occasional light bottoming To determine if your...

Page 279: ...is may also be affected Front Torque Arm Limiter Strap Adjustment XTRA 10 One method of changing ski to snow pressure is to change the length of the front torque arm limiter straps The limiter strap is normally mounted in the fully extended position S Lengthening the straps decreases ski pressure under accelera tion S Shortening the straps increases ski pressure under acceleration To adjust models...

Page 280: ...t IFS If the suspension is bottoming tighten the compression screw clockwise in 1 2 turn increments until the bottom ing stops Backing off 1 4 turn counter clockwise at this point should give you the best possible ride ensuring use of the full travel of the suspension The opposite procedure should be used if the suspension is too stiff upon initial set up If bottoming continues after the screw is ...

Page 281: ... upon initial set up If bottoming continues after the screw is turned in full clockwise the torsion spring should be adjusted using the adjustment block Back the screw out to the original starting position after torsion spring preload has been in creased Riding conditions are ever changing Keep in mind the Indy Select Ryde FX shocks can be adjusted at any time to achieve the best possible ride in ...

Page 282: ...LH 359 Sq Diameter x 77_ 7041630 067 RH 359 Sq Diameter x 77_ 7041631 067 LH 375 Sq Diameter x 77_ 7041632 067 RH 375 Sq Diameter x 77_ 144 151 156 EDGE RMK Optional Suspension Set Ups See Suspension Tuning Decal Un der Hood Torsion Spring Part No Wire Dia Degrees 7042081 067 L H 347 Sq Diameter x 47_ 7042082 067 R H 347 Sq Diameter x 47_ 7042068 067 L H 359 Sq Diameter x 47_ 7042069 067 R H 359 S...

Page 283: ...9 2 91 Yes Fox 7041574 067 10 32 140 00 10 25 331 1 89 1 89 2 91 Yes Fox 7041575 067 10 36 120 00 11 42 331 1 89 1 89 2 87 Yes Fox 7041576 067 9 55 100 00 10 80 306 1 89 1 89 2 86 Yes Fox 7041591 067 12 79 80 00 12 25 306 1 89 1 89 2 75 Yes 7041598 067 9 71 105 00 9 33 312 1 89 2 25 2 894 Yes 7041613 067 14 01 75 00 11 88 295 1 89 1 89 2 62 Yes Fox 7041668 067 6 94 70 00 4 00 219 1 89 1 89 2 34 No...

Page 284: ...08 2C 900x 008 900x 006 1C 1 300x 006 1 250x 010 1C 1 300x 006 1 300x 012 Orifice 086 086 Orifice 070 076 1R 1 250x 010 1 250x 010 1R 1 250x 010 1 250x 012 2R 1 100x 010 1 000x 008 2R 1 100x 012 1 100x 010 3R 1 000x 008 900x 008 3R 1 000x 010 1 000x 010 Rebound S 4R 900x 008 800x 008 Rebound S 4R 900x 010 900x 010 Stack 5R 800x 008 700x 008 Stack 5R 800x 010 800x 010 6R 6R 700x 010 700x 010 7R 7R ...

Page 285: ...ength in Collapsed Length in Stroke in Shock Rod in IFP Depth in Shaft Part PSI 7041968 16 61 10 97 5 64 0 49 2 25 1700183 200 7041982 16 61 10 97 5 64 0 49 6 71 200 IFS Shocks IFS Track Shocks Shock PN Extended Length in Collapsed Length in Stroke in Shock Rod in IFP Depth in Shaft Part PSI 7041976 16 25 11 00 5 25 0 49 6 56 1700010 280 7041978 16 17 10 75 5 42 0 49 6 52 1700154 200 7042059 17 25...

Page 286: ...aution should be observed while handling and working with high pressure service equipment Wear a face shield safety glasses and ear protection during service of these shocks Care should be observed while handling the inflater needle and pressure gauges Maintain your equipment and keep it in good condition If injury should occur consult a physician immediately Extreme cleanliness is of utmost impor...

Page 287: ...059 1 000 x 0 012 1500030 1 300 x 0 008 1500058 0 900 x 0 012 1500051 1 250 x 0 008 1500057 0 800 x 0 012 1500031 1 100 x 0 008 1500056 0 700 x 0 012 1500032 1 000 x 0 008 1500087 1 300 x 0 015 1500033 0 900 x 0 008 1500086 1 250 x 0 015 1500028 0 800 x 0 008 1500085 1 100 x 0 015 1500029 0 700 x 0 008 1500084 1 000 x 0 015 1500062 1 300 x 0 010 1500083 0 900 x 0 015 1500026 1 250 x 0 010 1500082 ...

Page 288: ... shock pressure valve Depress safety pin on safety needle and push gauge and needle assembly slowly toward shock inserting needle Be sure to push needle completely into shock valve Release nitrogen in a safe direction away from everyone by turning T handle clockwise if equipped or by depressing Schrader valve pin CAUTION It is possible for some residual pressure to remain in the shock regardless o...

Page 289: ...l shock rod and piston straight out to avoid seal or valve damage Be prepared to catch piston ring when removing the damper rod valve piston 7 Remove shock from vise and dispose of used oil properly in suitable container Set shock body aside 8 Mount damper rod in soft jawed vise Loosen valve nut and clean the valve piston and valving washers with electrical contact cleaner Dry thoroughly with comp...

Page 290: ...ain seal and O ring out of bearing cap Use care to avoid scratching the seal cavity 3 Clean seal cavity and inspect bushing for wear or damage and replace bearing cap if necessary 4 Lubricate new seals and O ring with Polaris shock oil and install Be sure the seals are seated completely in the seal cavity 5 Inspect jounce bumper where applicable and replace if damaged 6 Inspect damper rod for nick...

Page 291: ... 10 Inspect O ring in body cap for damage 11 Note location of Allen screw in internal floating piston IFP for reassembly in body tube Remove IFP through body cap end external threaded end using IFP tool Be prepared to catch piston ring and piston as it comes out Remove Allen screw from center of piston Inspect bleeder screw O ring and IFP sealing O ring for wear or damage Replace O rings upon reas...

Page 292: ...y cap externally threaded end of shock body 2 Compress flexible piston ring around valve piston and install piston into shock body 3 Screw in bearing cap by hand until O ring is fully seated 4 Invert shock and mount bearing cap flats lightly in vise Caution Be sure damper rod is fully extended 5 Fill with shock fluid to approximately 1 2 54cm from end of body ...

Page 293: ...ort shock and strike body cap end 2 3 times with a soft faced hammer to remove all air trapped inside the valve piston Allow shock to stand for 3 5 minutes CAUTION Do not over tighten vise or bearing cap may be damaged 9 Unscrew body cap and remove 10 Remove IFP bleeder screw 11 Set IFP tool to specified depth with a dial caliper as shown Remove IFP Tool PN 2871351 ...

Page 294: ... the tool to prevent the IFP from turning Pour out excess oil It is not necessary to completely clean all oil from the nitrogen chamber a small amount of oil will lubricate the IFP Verify the proper IFP depth to within 025 63mm with a dial caliper Be sure to measure to the flat portion of the IFP not to the tapered outer edge 15 Reinstall body cap with a new O ring and tighten by hand Mount shock ...

Page 295: ...d and remove from the pressurizing valve while holding the pressure hose on the fitting Do not insert the needle again to check pressure as the volume inside the gauge will reduce pressure in the shock 19 As a final check push the damper rod through a full stroke The damper rod must bottom out at full travel and then slowly rise to full extension Shaft movement must be smooth and consistent throug...

Page 296: ...stalling IFS shocks tighten top mount first Pivot shock body into lower mount and determine if spacer washers are necessary to prevent twist or side loading of shock Suspension assemblies should always be moved through entire travel without springs to verify free movement and proper alignment of all components Shock Eyelet Replacement If shock eyelet is removed for damper rod replacement clean thr...

Page 297: ...700122 0 008 1 000 1700126 0 010 1 000 1700127 0 012 1 000 1700128 0 015 1 000 1700129 0 006 1 100 1700130 0 008 1 100 1700131 0 010 1 100 1700132 0 012 1 100 1700133 0 015 1 100 1700134 0 006 1 250 1700135 0 008 1 250 1700136 0 010 1 250 1700137 0 012 1 250 1700138 0 015 1 250 1700139 0 006 1 300 1700140 0 008 1 300 1700141 0 010 1 300 1700142 0 012 1 300 1700143 0 015 1 300 Tool Part numbers Gas...

Page 298: ...ixed lower retainer the use of a proper spring compressor should be used to avoid risk of bodily injury Wash the shock body in parts cleaner then dry with compressed air to remove sand and dirt WARNING When using compressed air to dry com ponents protective eyewear should be worn to avoid risk of injury Remove bearing sleeve and or bushings from lower shock mount eyelet Secure the lower mount of t...

Page 299: ...essure to escape be fore proceeding with the removal of the pressure valve assembly Pressurized gas and shock oil could eject the valve assembly from the cylinder resulting in bodily injury Using a slotted screwdriver remove the pressure valve assembly from the lower end mount Account for an O ring PICTURE 5 Using an adjustable face spanner PN PS45262 fully loosen and remove cylinder head assembly...

Page 300: ...ial attention should be paid the order of the Rebound and Compression disc shim stacks ensuring that they are in the same order prior to disassembly Tighten the lock nut to 15 20 ft lb of torque PICTURE 10 CAUTION DO NOT OVER TORQUE If exces sive torque is applied damage to the piston and valves will occur Secure the shock body by its lower mount in vise The use of soft jaws is recommend to preven...

Page 301: ...to the pressure valve port counter bore through 360 Degrees where the pressure valve assembly O ring meets Screw the pressure valve assembly into the valve port by hand with a slotted head screwdriver and tighten to 100 110 in lb of torque PICTURE 15 Fill the shock body with shock oil A Internal Floating Piston Shocks Fill the shock body with shock oil to the bottom of the threadwith in the cylind...

Page 302: ...oil overflow Fast installation of the piston rod and assembly may displace the floating piston from its original position This must not oc cur if the damper is expected to perform as de signed Using an open face spanner wrench tighten cylin der head securely into the shock cylinder PIC TURE 18 Pressurize the shock through the pressure valve with nitrogen gas to the specified pressure PIC TURE 19 I...

Page 303: ... clockwise WARNING Nitrogen gas is under extreme pressure Use caution when releasing nitrogen gas from shock Protective eyewear should be worn to avoid risk of injury CAUTION Allow all the gas pressure to escape before proceeding with the removal of the pressure valve assembly Pressurized gas could eject the valve assembly from the cylinder resulting in bodily injury Once the shock is completely d...

Page 304: ...is recommend to prevent damage or marks to the shock CAUTION It is important that the gas shock be retained in the vise by the lower mount Any othermeth od of securing the shock body during these procedures may deform the shock body cylinder Apply a thin film of oil onto the floating piston wear band and O ring and set aside ready for use Fill the reservoir to its top with shock oil Once filled im...

Page 305: ...ts original posi tion This must not occur if the damper is expected to perform as designed Using an open face spanner tighten cylinder head securely into the shock cylinder Pressurize the shock reservoir through the pressure valve with nitrogen gas to the specified gas pres sure NOTE Adjust gas pressure to 200psi After being compressed the piston rod should fully extend from the shock once the sho...

Page 306: ... rider on machine Make sure spindles and all steering components are free turning Make sure skags are straight on skis Check hi fax and replace if worn Reduce ski pressure DIncrease front track spring preload DReduce IFS spring preload if shims have been added DReduce rear torsion spring preload Front end pushes Check for worn skags Check for binding suspension shafts and grease all pivot points I...

Page 307: ...perly straight forward with rider on machine Make sure spindles and all steering components are free turning Make sure skags are straight on skis Check hi fax and replace if worn Reduce ski pressure DIncrease front track spring preload requires shims DReduce IFS spring preload by adjusting cam DReduce rear torsion spring preload DLengthen front limiter strap Front end pushes Check for worn skags C...

Page 308: ...SUSPENSIONS 7 47 Suspension Troubleshooting EDGE RMK ...

Page 309: ......

Page 310: ...8 10 Master Cylinder Removal Installation 8 11 8 19 Brake Pad Replacement 8 20 8 21 Hydraulic Caliper Removal Installation 8 22 8 24 Drive System Removal Installation 8 25 Rear Suspension Removal 8 25 8 26 Chaincase Jackshaft Driveshaft Removal 8 27 8 28 Chaincase Jackshaft Driveshaft Installation 8 29 8 31 Track Installation 8 32 Final Assembly 8 33 8 36 Reverse Maintenance Adjustment 8 37 8 38 C...

Page 311: ......

Page 312: ...y 600 EDGE RMK 15 x 136 1 75 Indy 700 EDGE RMK 15 x 136 15 x 144 15 x 151 1 75 2 0 2 0 Indy 800 EDGE RMK 15 x 144 15 x 151 15 x 156 2 0 2 0 2 0 2002 Chaincases Model Chaincase Version Indy 500 SKS 7 05 17 91cm Indy 700 SKS 7 05 17 91cm Indy Trail RMK 7 05 17 91cm Indy 500 RMK 7 05 17 91cm Indy 600 EDGE RMK 7 92 20 12cm Indy 700 EDGE RMK 7 92 20 12cm Indy 800 EDGE RMK 7 92 20 12cm ...

Page 313: ...BRAKES FINAL DRIVE 8 2 ...

Page 314: ...BRAKES FINAL DRIVE 8 3 ...

Page 315: ...BRAKES FINAL DRIVE 8 4 ...

Page 316: ... Pitch Part Number 66P 3224071 68P 3224070 70P 3224069 Bottom Sprockets For 3 4 HYVOt Drive Systems Standard Bottom Sprockets Reverse Sprockets 37T 2900010 38T 2900011 39T 2900012 39T 1341243 40T 2900013 40T 1341227 41T 2900014 41T 1341228 42T 2900015 43T 2900016 HYVO Lightweight Cut Metal Gears are also avaiable Please look these Part Numbers up in your High Performance Manual PN 9917367 or the Q...

Page 317: ...41 68 17 35 64 NOT RECOMMENDED 17 37 66 17 39 68 NOT RECOMMENDED 17 40 68 17 41 68 18 35 66 NOT RECOMMENDED 18 37 66 18 39 68 NOT RECOMMENDED 18 40 68 18 41 68 19 35 66 19 37 66 NOT RECOMMENDED 19 39 68 19 40 68 19 41 70 NOT RECOMMENDED 20 35 66 20 37 68 NOT RECOMMENDED 20 39 68 20 40 70 NOT RECOMMENDED 20 41 70 NOT RECOMMENDED 21 35 66 21 37 68 21 39 70 NOT RECOMMENDED 21 40 70 NOT RECOMMENDED 21...

Page 318: ...0 16 39 72 NOT RECOMMENDED 16 40 72 16 41 72 17 35 70 NOT RECOMMENDED 17 37 70 17 39 72 17 40 72 17 41 72 18 35 70 18 37 72 NOT RECOMMENDED 18 39 72 18 40 72 18 41 74 NOT RECOMMENDED 19 35 70 19 37 72 NOT RECOMMENDED 19 39 72 19 40 74 NOT RECOMMENDED 19 41 74 20 35 70 20 37 72 20 39 74 NOT RECOMMENDED 20 40 74 20 41 74 21 35 72 NOT RECOMMENDED 21 37 72 21 39 74 NOT RECOMMENDED 21 40 74 21 41 74 22...

Page 319: ... the brakes to feel spongy Compensating Port Located within the master cylinder is a small compensating port C which is opened and closed by the master cylinder piston assembly The port is open when the brake lever is released and the piston is outward As the temperature within the hydraulic system changes this port compensates for fluid expansion caused by heat or contraction caused by cooling Du...

Page 320: ... end in a clean container Be sure the hose fits tightly on fitting NOTE Fluid may be forced from compensation port B when brake lever is pumped Place diaphragm C in reservoir to prevent spills Do not install cover 7 Slowly pump lever D until pressure builds and holds 8 While maintaining lever pressure open bleeder screw Close bleeder screw and release brake lever Do not release lever before bleede...

Page 321: ...utting into service Check for proper braking action and lever reserve With lever firmly applied lever reserve should be no less than 1 2 1 3 cm from handlebar 14 Check brake system for fluid leaks Brake Lever Reserve Limit Not less than 1 2 1 3 cm from handlebar No Closer Than 1 2 1 3 cm ...

Page 322: ... release Hayest Master Cylinder Removal 1 Position clean shop cloths to catch spilled fluid CAUTION Brake fluid will damage finished surfaces Do not allow brake fluid to come in contact with finished surfaces 2 Remove the handlebar protector pad from the outlet end of the handlebar master cylinder to access the brake fluid line connector SRemove handlebar cover strips SRemove two screws SRemove ho...

Page 323: ...be sure you have thoroughly read and under stand Hydraulic Brake Operation page 8 8 1 Thoroughly clean all brake parts with isopropyl alcohol and either wipe dry with a clean lint free cloth or lightly blow dry with an air hose Examine all parts carefully for signs of excessive wear damage or corrosion Replace any parts found to be damaged Check park lever spring for breakage Replacing Cartridge S...

Page 324: ... housing bore with alcohol Inspect bore for scratches dents cuts or digs that might cause a leak Replace housing if severe damage is found 6 Paint housing bore and cartridge o rings with D O T 3 brake fluid 7 Align slots in cartridge with tabs in housing bore and insert cartridge Push cartridge through until outlet end of cartridge snaps into place Polaris DOT 3 Brake Fluid PN 2870990 ...

Page 325: ... 10 Apply thread sealant install brake line and tighten snug 11 Mount the master cylinder and switch pack to the handlebars making sure the wires are not pinched or twisted NOTE Start all four screws prior to tightening Tighten top two screws first followed by bottom two Do not over tighten This will create a gap approximately 050 100 between LH control and master cylinder at the bottom of the ass...

Page 326: ...d 14 Bleed brakes as outlined on pages 8 10 and 8 11 Check entire system for leaks and fill reservoir to fluid level line 15 Install master cylinder reservoir cover and gasket Torque screws to 15 18 in lbs 1 7 2 0 Nm Brake Line Torque 1 ft lb 1 4 Nm plus 2 turns Polaris DOT 3 Brake Fluid PN 2870990 Cover Screw Torque 15 18 in lb 1 7 2 0 Nm ...

Page 327: ...ned on pages 8 11 and 8 12 2 Squeeze the lever handle and actuate the parking brake lever enough distance for the head of the pivot pin to clear the park brake lever 3 Squeeze the two spring tabs on the end of the pivot pin at the same time pushing the pivot pin up through the hole 4 Remove the pivot pin and the lever ...

Page 328: ...nough distance for the head of the pivot pin to clear the park brake lever 2 Align the lever pivot hole with the housing pivot hole 3 Squeeze the two spring tabs on the end of the pivot pin at the same time pushing the pivot pin down through the hole until the pivot pin snaps into place 4 Reinstall master cylinder assembly ...

Page 329: ...river lift long spring arm out of its notch in the housing 3 While pulling in an upward direction with the brake lever slightly activated gently wiggle the park brake lever and spring from its pivot hole Park Brake Lever and or Spring Installation 1 Place the spring on the upper pivot post of the park lever with the formed spring arm fit into its position on the outer part of the park lever The st...

Page 330: ...Release the straight arm of the spring and push the park lever pivot post down into position 4 With a small screwdriver push the straight spring arm down until it snaps into the notch in the housing 5 Fill reservoir Replace the master cylinder cover and screws Torque screws to 15 18 in lbs 1 7 2 0 Nm Cover Screw Torque 15 18 in lb 1 7 2 0 Nm Pivot Hole Rotate ...

Page 331: ... rope guide NOTE Donot disconnect brake line 3 Lift bracket and brake assembly off vehicle Remove all dirt from caliper assembly using brake cleaner and clean shop cloths 4 Use a drop cloth to protect surfaces from brake fluid spillage Remove reservoir cover from master cylinder assembly Using a large hardwood dowel or a C clamp vise grip on the center of the old pads apply pressure toward the cal...

Page 332: ...iston is not compressed far enough into the caliper Caliper assembly must fit freely onto disc and chaincase 10 Replace 3 8 bolts washers and rope guide Torque to specification 11 Actuate brake several times to set brake pads to proper operating position 12 Check for proper fluid level in master cylinder and replace cover Torque cover bolts to specification 13 Inspect entire system for leaks and r...

Page 333: ...ain brake fluid from caliper assembly into appropriate container Dispose of properly CAUTION Protect eyes from brake fluid at all times 5 Slide brake assembly out of bracket and remove old pads and clips 6 Place caliper on bench with piston down 7 Remove piston from caliper using a caliper piston pliers commercially available orby coveringthe pistonwith a shop cloth and applying compressed air to ...

Page 334: ...rasive cloth 4 Check piston to see if it is pitted scored or worn If so discard and replace the piston CAUTION Do not attempt to polish or sand piston 5 Clean piston with denatured alcohol and wipe dry with a clean lint free cloth Using compressed air blow dry 6 Check inlet and bleeder hole threads for damage Be sure bleeder screw is clear 7 Inspect brake line seat for damage and replace caliper i...

Page 335: ...material type code number as the old set 5 Connect hose or line to caliper 6 Place new pads with friction material facing each other into housing Hold in place using clips 7 Slide brake assembly into bracket until both clips snap into grooves in bracket 8 Separate pads for installation over disc 9 Place brake assembly over disc and push bracket into chaincase 10 Replace 3 8 bolts rope guide and wa...

Page 336: ...ace drip pan under chaincase and remove drain plug Dispose of used chaincase oil properly 2 Turn fuel valve off 3 Remove drive belt and driven clutch Note position of washers for controlling drive to driven offset A and washers to control clutch free floating B 4 Loosen jackshaft bearing lock set screws if equipped NOTE Some models are equipped with set screw or Skwez loct style jackshaft bearings...

Page 337: ...Remove third jackshaft flangette attaching bolt Tip machine back to upright and support rear with jack stand 2 Remove chaincase cover attaching bolts and remove cover 3 Remove cotter pin and nut 4 Loosen chain adjustment bolt and remove chain tensioner assembly 5 Remove bottom sprocket attaching bolt chain and sprockets 6 Remove two bolts securing caliper carrier bracket to chaincase NOTE Inspect ...

Page 338: ...toward snap ring side of chaincase when removing Inspect chaincase for any damage and replace if required Jackshaft Removal 1 Remove O Ring seal sleeve and brake disc by tapping on jackshaft end with a soft face hammer 2 Remove jackshaft 3 For set screw and Skwez loc bearings inspect drive shaft and jackshaft in bearing contact area If diameter is 001 025 mm less than non contact area shafts shoul...

Page 339: ... the bulkhead then pulling driveshaft toward you 3 After drive shaft has been removed inspect condition of drive sprockets and replace if required NOTE On models with pressed bearings on drive shaft S If bearings are loose internally or rough they should be replaced S If bearings are loose on the shaft the shaft must be replaced ...

Page 340: ...nd grease 2 Install jackshaft installation tool on the threads of the jackshaft 3 Insert jackshaft through bearing in chaincase 4 Install jackshaft alignment tool and secure with castle nut and flat washer Tighten jackshaft nut securely to ensure positive bearing and jackshaft seating to chaincase NOTE Use of a standard nut and flat washer for this align ment process will simplify the process as w...

Page 341: ...case 7 Install jackshaft flangette gasket and bolts Align grease hole A in bearing with hole or fitting in flangette B to within 100 to ensure greasability Torque nuts to specification Do not lock set screws on retainer ring if so equipped Driveshaft Installation 1 Tip machine back on its left side Set track into machine making note of correct direction of travel Most tracks have an arrow pointing...

Page 342: ...hain at the same time Finger tighten the top sprocket nut and turn in bottom sprocket bolt until snug NOTE On Hyvot sprockets the beveled side goes toward the chaincase bearing 6 Install chain tensioner Finger tighten adjustment bolt 7 Install brake caliper assembly in chaincase CAUTION On models with hydraulic brakes make sure caliper piston is fully retracted into caliper to prevent brake bindin...

Page 343: ...r ease of installation turn the front rear scis sor stops FRSS to low position This allows the rear torque arm to move forward more to line up holes 4 Torque suspension mounting bolts to specification 5 Return front rear scissor stops FRSS to original position 6 Install suspension springs 7 Align track outlined in suspension section and tighten adjuster and rear shaft bolts to specification 3 8 Su...

Page 344: ...o hold jackshaft while torquing 5 To obtain correct chain tension place a slight reverse tension on the chain as indicated in the illustration at right 6 There should be approximately 1 4 3 8 6 95 cm total deflection on the chain at point B Loosen adjuster bolt locknut and turn adjuster bolt C until correct chain deflection is obtained Polaris Premium All Season Grease PN 2871423 Bottom Chaincase ...

Page 345: ...il to the chaincase Verify proper level with dipstick 10 Torque jackshaft bearing set screws to specification if so equipped 11 Lubricate bearings with Polaris Premium All Season grease Chaincase Cover Bolt Torque 8 10 ft lbs 11 14 Nm Polaris Synthetic Gearcase Lube PN 2871477 Gallon PN 2871478 12 ounces Driveshaft and Jackshaft Bearing Set Screw Torque 80 in lbs 9 2 Nm Polaris Premium All Season ...

Page 346: ...er washers PN 7555734 to the clutch retaining bolt When properly adjusted the driven clutch will have 020 100 5 2 5 mm float CAUTION Incorrect float can cause jackshaft bearings to be side loaded resulting in premature bearing failure 14 Torque driven clutch retaining bolt to specification Clutch Alignment Tool P90 PN 2870914 P85 PN 2870426 P90 Offset 21 32 P90 Electric Start Off set 1 28 straight...

Page 347: ... attach ground cable last to prevent sparks 17 Replace exhaust system 18 Install hood if removed aligning with marks made during disassembly Ensure proper hood closure and readjust if necessary 19 Test ride the unit to ensure all components are functioning properly before putting into service Hood Bolt Torque 8 10 ft lbs 11 14 Nm ...

Page 348: ...tall chain top sprocket bottom option sprocket and wide face pinion gear into case at the same time S When installing case cover be sure that shift fork has slipped into fork groove of reverse gear Forward Position Reverse Position Top Sprocket Chain Pinion Gear Narrow Face Spur Pinion Gear Shift Fork Groove Drive Coupler Reverse Kit Option Sprocket Chain Pinion Gear Wide Face Drive Chain Chain Pi...

Page 349: ...uster bolt slightly about one turn out 4 Tighten adjuster to specified torque 5 Loosen adjuster bolt 1 2 turn 6 Hold adjuster bolt in position and tighten locknut securely Chain Retention Bracket Screw Pinion Shaft Washer O Ring Pinion Gear Spur Washer Pinion Gear Drive Washer Drive Coupler Reverse Gear Compression Spring Bolt Drive Coupler Retainer Adjuster Bolt Torque 20 in lbs 2 3 Nm ...

Page 350: ...ith the shifter in the forward position 1 Pull shift lever slowly while observing shift arm on transmission 2 If adjustment is correct the sprocketswill meshfully when the lever is pulled and no grinding will occur indicating incomplete engagement If incomplete engagement is suspected perform the following steps 1 Move lever to forward position 2 Loosen jam nuts on linkage rod 3 Adjust linkage rod...

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Page 352: ...ed View 9 7 700 800 EDGE RMK Electrical Exploded View 9 8 Timing Procedure 9 9 Preparing a New Battery 9 10 Load Test 9 11 Dynamic Testing 9 12 Static Testing 9 13 Starter Assembly Exploded View 9 14 Unregulated Voltage 9 15 9 16 Regulated Voltage 9 16 2 6 Pulse Alternators 9 17 2002 Flywheels 9 17 Electrical Systems Testing 9 18 9 23 TPS Testing Adjustment 9 24 9 27 Troubleshooting 9 28 ...

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Page 354: ...d by it Test Method 1 Connect black lead to Com meter terminal 2 Connect red lead to VW meter terminal 3 Turn selector dial to V setting 4 Connect test leads parallel with test component The polarity of the leads is not important Usage S Test unregulated voltage output of a stator coil S Test regulated voltage to the lights and handwarm ers V Volts DC measuring battery voltage volt drop etc Used t...

Page 355: ...al to W setting 4 Isolate test component from the rest of the electrical circuit by disconnecting wires from harness 5 Connect test leads to the circuit to be tested Usage S Testing coil resistance S Testing switch operation S Testing wire continuity A Amps AC used to test lighting coil output Used to test the power of an alternator coil Test Method 1 Connect black lead to Com meter terminal 2 Con...

Page 356: ...und wire s from battery terminal 3 Connect red meter lead to battery terminal 4 Connect black meter lead to harness ground wires and cable CAUTION Do not operate electric starter if equipped or meter damage may occur Usage S Testing key off current draw S Testing key on current draw S Testing charging system break even RPM S Testing DC current flow direction is battery charging NOTE When using the...

Page 357: ...aft by hand while observing the dial indicator As the piston touches the indicator plunger the dial will begin to rotate Find the point where the pointer stops rotating and reverses direction This will be TDC Top Dead Center 3 While holding the crankshaft with the piston at TDC zero the indicator by rotating the bezel until the 0 on the dial and the pointer align 4 Rotate the crankshaft opposite t...

Page 358: ...on Chart If the ignition timing specification is listed in degrees only convert to either inches or mm BTDC and use a dial indicator to verify timing marks NOTE Due to differing rod lengths and engine strokes consult the engine model list for correct engine ...

Page 359: ...tor Assembly Wiring Harness NOTE Always verify timing of engine at room temperature only 68 F 20 C Refer to ignition timing procedure on page 9 9 Flywheel Rotation Acceptable Variance Flywheel Lines Stationary Pointers NOTE Acceptable variance is usually one line on either side of the dial indicated timing mark ...

Page 360: ...s Water Pump Pulley NOTE Always verify timing of engine at room temperature only 68 F 20 C Refer to ignition timing procedure on page 9 9 Flywheel Rotation Acceptable Variance Flywheel Lines Stationary Pointers NOTE Acceptable variance is usually one line on either side of the dial indicated timing mark ...

Page 361: ...r Lighting Coil Flywheel Water Oil Pump Drive Belt NOTE Always verify timing of engine at room temperature only 68 F 20 C Refer to ignition timing procedure on page 9 9 Flywheel Rotation Acceptable Variance Flywheel Lines Stationary Pointers NOTE Acceptable variance is usually one line on either side of the dial indicated timing mark ...

Page 362: ...the crankshaft center line note the relative position between the marked flywheel line andthe stationary pointer If the stationary pointer is aligned with the mark made in Step 2 or within the acceptable variance the timing is correct 7 If the pointer is outside the variance the stator will have to be rotated either with crankshaft rotation to retard the timing or against rotation to advance it NO...

Page 363: ...ble If the battery is stored or used in a partially charged condition hard crystal sulfation will form on the plates reducing their efficiency and possibly ruining the battery Open Circuit Voltage Test OCV Battery voltage should be checked with a digital multitester Readings of 12 6 or less requirefurther batterytesting and charging Specific Gravity Test A tool such as the battery hydrometer PN 28...

Page 364: ...nto enter the battery or the acid will be neutralized 2 Using a wire brush or knife remove any corrosion from the cables and terminals 3 Make sure the electrolyte is at the proper level Add distilled water if necessary 4 Charge at a rate no greater than 1 10 of the battery s amp hr capacity until the electrolyte s specific gravity reaches 1 270 or greater 5 The battery may be stored either in the ...

Page 365: ...t Repair or replace any defective parts Reconnect solenoid connect tester black lead to battery positive terminal and red tester lead to sole noid end of battery to solenoid cable B Page 9 13 Turn key to start position The reading must be less than 1V DC Is it No Yes Clean battery to solenoid cable ends or replace cable Connect black tester lead to solenoid end of battery to solenoid cable and red...

Page 366: ...ectrical contact cleaner and or a non metallic grit sandpaper Replace brush assembly when worn to 5 16 8 cm or less Starter Housing and Field Coil Inspection 1 Using a digital multitester measure resistance between starter input terminal and insulated brushes The reading should be 3 ohms or less 2 Measure resistance between insulated brushes and field coil housing The reading should be infinite 3 ...

Page 367: ...ngs slide brush plate down onto the commutator 5 While holding positive brush springs to the side slide positive brushes into their holders and correctly position the springs on top of the brushes 6 Using a non petroleum grease lubricate brush end bushing and slide it onto end of armature 7 Align threaded holes in brush plate and install dust cover and screws 8 Reinstall through bolts and properly...

Page 368: ...rom reading NOTE 0 3 to 0 5 ohms may be less than the internal resistance of your meter leads or meter Before measuring the stator resistance short the meter leads together and read the display and record this measurement Subtract this reading from the stator resistance readings EXAMPLE Short meter leads together meter reads 0 7 ohms Measure stator resistance meter reads 1 10 ohms Subtract 0 7 ohm...

Page 369: ... Readings should be above 5 amps Refer to Amps AC on page 9 2 Regulated Voltage 1 Connect the alternator to main harness connector 2 Insert one of the tester leads along the side of the yellow regulator wire connector between the insulation and the terminal 3 Ground the other tester lead 4 Start engine and observe headlight output Increase engine RPM If the headlights seem dim above 3500 RPM let t...

Page 370: ...Fuji twin cylinder 6 pulse Tachometers Tachometers for snowmobiles will have an identification marking on the back side For example The tachometer for a 600 RMK will have 6 pulse or 6P written on it 2002 Flywheels The flywheels used on model year 2002 snowmobiles will not work correctly if used on earlier build models The 2002 flywheel is calibrated specifically for 2002 CDI boxes and will not fit...

Page 371: ...Move one of the tester leads from the green to the red switch wire The multitester should now read less than 4 ohms 6 Turn the Hi Lo Switch back to the Lo beam position and the meter should again read an open circuit OL Seat Harness Troubleshooting 1 Remove the taillight lens 2 Remove the two taillight bulbs and the brakelight bulb 3 Separate the seat harness from the main harness by unplugging th...

Page 372: ... wire colors and connections 1 Disconnect wires Set the multitester dial to the ohms W position 2 With the key in the off position check the resistance between the G Ground brown terminal and the M Mag black terminal This reading must be less than 4 ohms 3 Turn the key to the on position The multitester should now read an open circuit OL 4 Move the tester lead from the G terminal to the switch hou...

Page 373: ...onnect the lamp wire 3 Connect one test probe to the switch terminal and the other to engine ground Themeter shouldshow anopen circuit OL This indicates a normally open switch If the switch were heated to approximately 205 F the contact in the switch would close and the reading would be less than 4 ohms CAUTION If attempting to heat the sensor to close the contacts heat only in a water bath Never ...

Page 374: ...e event the carburetor or controls malfunction and allow the throttle cable to become slack the circuit will close both switch plungers out grounding the ignition system and causing the engine to stop Speed Control Assurance Adjustment Throttle lever free play must always provide a specified clearance between throttle lever and throttle block This clearance is controlled by the throttle cable slee...

Page 375: ...y from the throttle block With the switchplung ers outward and the auxiliary shut off switch in the ON posi tion the multitester must read less than 4 ohms resistance Inspect wires and repair if damaged or replace switch as sembly Test 3 Auxiliary Shut Off The multitester should read less than 4 ohms in the OFF position and an open circuit in the the ON position Inspect wires and repair if damaged...

Page 376: ...e the multitester ohmmeter to test the resistance of the fuel sender Position Ohms Range Empty 95 W 90 97 5 W Full 7 W 4 5 13 W The supply voltage to the gauge should be 13 5 VAC Fuel Gauge Diode Fuse 0 2A Pur Wh Brn Yel ...

Page 377: ...same position as removal Polaris has developed a TPS test kit for aid in setting the Throttle Position Sensor to specification TPS Testing 1 Illustration at right shows the TPS sensor kit PN 2201519 2 Make sure your 9 volt battery is in good condition by inserting the black volt meter probe from your Fluket meter in the black terminal and the red probe into the pink terminal Voltage should read 4 ...

Page 378: ...NOTE The fluke meter will change scales and show O L momentarily when throttle is opening 6 Voltage at yellow terminal should be 4 0 to 4 2 volts at Wide Open Throttle for domestic engines and 3 77 volts for Fuji engines 800 XCR If not the TPS must be adjusted to this specification TPS Volts at Wide Open Throttle Polaris Domestic Engines 4 0 to 4 2 volts TPS Volts at Wide Open Throttle Fuji 800 XC...

Page 379: ...n the TPS clockwise to decrease voltage or counterclockwise to increase voltage 3 When the TPS is set to the desired voltage tighten the holding screws and verify voltage is 4 0 to 4 2 volts at Wide Open Throttle for Polaris domestic engines and 3 77 volts for Fuji engines 800 XCR Decrease Increase ...

Page 380: ...ontinued 4 When the TPS is set and voltage is verified remove the tester and re install the snowmobile TPS harness 5 When storing the TPS tester remove the red terminal of the tester and insert it in the blank terminal of the harness ...

Page 381: ...resistances look for pinched or bare harness wires or replace the coil Condition Incorrect Advance Retard Follow the engine timing procedure for checking running timing at recommended RPM Is the timing within limits No Yes Adjust the ignition timing by rotating the stator plate to correct the timing After adjusting the recommended RPM timing continue with operating RPM timing if poor performance e...

Page 382: ...ELECTRICAL 9 29 Notes ...

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Page 384: ...CHAPTER 10 WIRING DIAGRAMS ...

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Page 386: ...spection 3 51 Coolant Level 2 11 Cooling System 3 62 Cooling System Bleeding 2 11 3 62 Cooling System Diagram 3 64 3 65 3 66 Crankcase Inspection 3 50 Crankshaft Bearing Inspection 3 50 Crankshaft Indexing 3 54 3 55 Crankshaft Truing 3 52 Cylinder Cleaning 3 48 Cylinder Deglazing 3 47 Cylinder Head Inspection 3 56 Cylinder Honing 3 47 Cylinder Measurement 3 56 D Decal Installation 6 34 Decal Remov...

Page 387: ...nt 2 17 Handlebar Centering 6 12 Handlebar Centering CRC 6 17 Handlebar Torque 6 25 Headlight Adjustment 2 16 Headlight Bulb Filament Continuity Test 9 18 Headlight Bulbs 2 16 Helix Ramps 5 26 Hi Lo Beam Switch Testing 9 18 HiFax Inspection Replacement 7 6 HiFax Removal 7 6 Hone Selection 3 47 Honing Procedure 3 48 Honing to Oversize 3 47 Hood Repair 6 29 Hydraulic Caliper Disassembly 8 22 I IFS S...

Page 388: ...shing Replacement 6 19 6 20 Spark Plugs 2 14 Specific Gravity Test 9 10 Speed Control Assurance Adjustment 9 21 Speed Control Assurance Replacement 9 22 Spider Button Shimming 5 16 5 17 Spider Indexing 5 21 Spider Roller Removal 5 15 Spindle Centering 6 9 Spindle to Chassis Centering CRC 6 16 Spring Tension Rear Xtra 10 Style 7 16 Sprocket Chain Combinations 8 6 8 7 Starter Installation 9 15 Start...

Page 389: ...3 Track Tension Data 2 13 Troubleshooting Drive Driven Clutches 5 41 5 42 Troubleshooting Oil Pump 3 58 Troubleshooting Seat Harness 9 18 Troubleshooting Suspension Xtra 10 7 43 7 44 Troubleshooting Suspension Xtra Lite 7 42 U Unregulated Voltage 9 15 9 16 W Water Pump Belt Tension Domestic Engines 2 7 ...

Page 390: ...WIRING DIAGRAMS 10 1 TRAIL RMK ...

Page 391: ...ELECTRICAL 10 2 INDY 500 RMK 500 SKS EURO ...

Page 392: ...WIRING DIAGRAMS 10 3 INDY 700 SKS INDY 600 700 800 EDGE RMK ...

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