Polaris 650 MATRYX INDY VR1 129 2021 Page 294 Manual Download

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3.140

9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual

AIR INTAKE PLENUM REMOVAL

1. Remove the side panels and hood.

2. Remove the console. See Console Removal page

9.23.

3. Remove the push rivets

retaining the intake tube to

the intake plenum.

4. Remove the edge clip

retaining the wiring harness

to the intake plenum.

5. Disconnect the ECU connectors

from the wiring

harness or remove the ECU mounting fasteners.

6. Remove the intake plenum

AIR INTAKE PLENUM INSTALLATION

1. Install the intake plenum

2. Connect the ECU connectors

to the wiring harness

or install the ECU mounting fasteners.

ENGINE / COOLING / EXHAUST

Summary of Contents for 650 MATRYX INDY VR1 129 2021

Page 1: ...zed dealer for service We value your input and appreciate any assistance you can provide in helping make these publications more useful Please provide any feedback you may have regarding this manual Authorized dealers can submit feedback using Ask Polaris Click on Ask Polaris and then click on Service Manual Service Literature Question Consumers please provide your feedback in writing to Polaris I...

Page 2: ...on which if not avoided WILL result in death or serious injury WARNING SAFETY ALERT WARNING indicates a hazardous situation which if not avoided COULD result in death or serious injury CAUTION SAFETY ALERT CAUTION indicates a hazardous situation which if not avoided COULD result in minor to moderate injury NOTICE NOTICE provides key information by clarifying instructions IMPORTANT IMPORTANT provid...

Page 3: ...y Vac Registered Trademark of Neward Enterprises Inc Torx Registered Trademark of Textron Hilliard Trademark of the Hilliard Corporation Warn Trademark of Warn Industries FOX Registered Trademark of FOX RACING SHOX RydeFX Registered Trademark of ArvinMeritor Some Polaris factory publications can be downloaded from www polarisindustries com purchased from www purepolaris com or by contacting the ne...

Page 4: ...haft Position Sensor CPS specification Revised PBR Update Replacement procedure FEEDBACK FORM A feedback form has been created for the technician or consumer to provide Polaris with an overall satisfaction rating for this service manual provide comments on your experience or upload pictures video This feedback form is viewable on a mobile device by scanning the QR code or by clicking HERE if viewi...

Page 5: ...er Summary CHAPTER 1 GENERAL INFORMATION CHAPTER 2 MAINTENANCE CHAPTER 3 ENGINE COOLING EXHAUST CHAPTER 4 ENGINE ELECTRICAL CHAPTER 5 FUEL SYSTEM CHAPTER 6 FINAL DRIVE BRAKE SYSTEMS CHAPTER 7 PVT SYSTEM CHAPTER 8 STEERING SUSPENSIONS CHAPTER 9 CHASSIS CHAPTER 10 BATTERY ELECTRICAL ...

Page 6: ......

Page 7: ...SAULT 146 CLUTCH SETTINGS 1 14 850 SWITCHBACK ASSAULT 146 CLUTCH SETTINGS 1 14 MISC SPECIFICATIONS AND CHARTS 1 15 MASTER TORQUE TABLE 1 15 CONVERSION TABLE 1 21 SAE TAP DRILL SIZES 1 22 METRIC TAP DRILL SIZES 1 22 DECIMAL EQUIVALENTS 1 23 FUEL RECOMMENDATION 1 24 FUEL SYSTEM DEICERS 1 24 SERVICE PRECAUTIONS 1 25 GENERAL DIAGNOSTICS 1 26 DIAGNOSTIC TROUBLE CODES DTC 1 26 DIAGNOSTIC TROUBLE CODES D...

Page 8: ...MER RESET 1 55 OIL PUMP ENRICHMENT MODE TIMER RESET 1 57 EV ACTUATOR LEARN PROCEDURE 1 58 FUEL PUMP PRIME PROCEDURE 1 61 GEARING CHANGE REPROGRAMMING 1 63 ELECTRONIC OIL PUMP PRIME PROCEDURE 1 64 DIGITAL WRENCH ECU REPROGRAMMING REFLASH 1 66 DIGITAL WRENCH VEHICLE IDENTIFICATION INFORMATION 1 70 POLARIS MOBILE DIGITAL WRENCH PMDW 1 72 PVT SYSTEM DIAGNOSTICS 1 73 DRIVE BELT 1 73 DRIVE CLUTCH 1 73 D...

Page 9: ...etermine Digital Wrench calibration VEHICLE IDENTIFICATION NUMBER VIN DESIGNATION 2017 Example SN1CBA8G0G3000000 WORLD MFG ID VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS MAK E LINE TYPE ENGINE SIZE ENGINE MODIFIER CHECK DIGIT MODEL YEAR MFG LOCATION INDIVIDUAL SERIAL NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 S N 1 C B A 6 G 0 G 3 0 0 0 0 0 0 Model Year H 2017 J 2018 K 2019 L 2020 M 2021 TUNNEL DECA...

Page 10: ... of the tunnel and printed on the tunnel VIN label q Certification Label e Emissions Certification w Tunnel VIN Model Number Label Stamp IMPORTANT If installing an aftermarket tunnel wrap do not cover the tunnel certification tunnel VIN or emissions certification labels with the wrap If the tunnel wrap doesn t provide an opening for these labels remove the section of wrap where the labels are loca...

Page 11: ...l Performance Crossover Snowmobile Service Manual Copyright Polaris Inc 1 5 ENGINE SERIAL NUMBER LOCATION The engine serial number is located on the identification label q on the engine case next to the recoil cover GENERAL INFORMATION 1 ...

Page 12: ...278 68 4010278 PUBLICATION PART NUMBERS 2021 YEAR MODEL MODEL NUMBERS OWNER S MANUAL 2021 650 MATRYX INDY XC 129 850 MATRYX INDY XC 129 S21TKP6RS S21TKP6RE S21TKP8RS S21TKP8RE 9931271 650 MATRYX INDY VR1 129 850 MATRYX INDY VR1 129 S21TKV6RS S21TKV6RE S21TKV8RS S21TKV8RE 650 MATRYX INDY XC 137 850 MATRYX INDY XC 137 S21TDP6RS S21TDP6RE S21TDP8RS S21TDP8RE 650 MATRYX INDY VR1 137 850 MATRYX INDY VR...

Page 13: ...e of the tools listed or depicted are mandatory while other tools may be substituted with a similar tool if available Polaris recommends the use of Polaris Special Tools when servicing any Polaris product Dealers may order special tools through the Polaris official tool supplier Bosch Automotive Service Solutions 1 800 345 2233 or https polaris service solutions com GENERAL INFORMATION 1 ...

Page 14: ...NUMBERS MODEL IMAGE 650 INDY XC Launch Edition 129 850 INDY XC Launch Edition 129 S21TKP6RS S21TKP6RE S21TKP8RS S21TKP8RE 850 INDY XC 129 SHOWN 650 INDY VR1 129 850 INDY VR1 129 S21TKV6RS S21TKV6RE S21TKV8RS S21TKV8RE 850 INDY VR1 129 SHOWN 650 INDY XC Launch Edition 137 850 INDY XC Launch Edition 137 S21TDP6RS S21TDP6RE S21TDP8RS S21TDP8RE 850 INDY XC 137 SHOWN GENERAL INFORMATION ...

Page 15: ...t Polaris Inc 1 9 MODEL MODEL NUMBERS MODEL IMAGE 650 INDY VR1 137 850 INDY VR1 137 S21TDV6RS S21TKV6RE S21TDV8RS S21TKV8RE 850 INDY VR1 137 SHOWN 650 SWITCHBACK ASSAULT 146 850 SWITCHBACK ASSAULT 146 S21TLC6RS S21TLC6RE S21TLC8RS S21TLC8RE 850 SWITCHBACK ASSAULT 146 SHOWN GENERAL INFORMATION 1 ...

Page 16: ...t 3 5 L Cooling System Capacity 4 0 qt 3 8 L Brake Fluid DOT 4 ENGINE 650 MODELS 850 MODELS Engine Type Patriot Liquid Cooled Case Reed Induction Patriot Liquid Cooled Case Reed Induction Model Number S6095 6544 LO6R S6186 8444 LO8R Displacement 650 cc 840 cc Number of Cylinders 2 2 Bore Stroke 74 8 x 74 mm 85 x 74 mm Operating RPM 150 8250 8250 Idle RPM 200 1600 1800 Engagement RPM 200 3800 3000 ...

Page 17: ...come from the factory with the stud protection installed Stud protection kits are designed to work with studded tracks that have no greater than 0 375 in 0 953 cm of stud penetration that is distance of the stud above the lug tip Polaris does not recommend studding anything above a 1 352 in 3 43 cm Cobra track although the stud protection will work on a 1 6 in 4 06 cm Cobra track on 146 models PVT...

Page 18: ...k Walker Evans Comp Adj 2 Piggyback Rear Track Shock RTS Walker Evans Velocity Walker Evans Velocity Walker Evans Velocity Rear Travel 16 2 in 41 1 cm 16 2 in 41 1 cm 16 0 in 40 6 cm Reference Steering Suspension chapter for shock settings ELECTRICAL 650 MODELS 850 MODELS Alternator Output Operating Voltage Watts 13 5 VDC Total 13 5 14 5 VDC 500w 5000 rpm Idle Ignition Timing Variable Based on RPM...

Page 19: ...ngs Use 2 gram lighter shift weights when operating in temperatures above 40 F 5 C Drive Clutch Bolt Torque 80 ft lbs 108 Nm Re torque after running engine 850 INDY XC INDY VR1 129 137 CLUTCH SETTINGS CLUTCH SETTINGS ALTITUDE meters feet DRIVE CLUTCH DRIVEN CLUTCH CHAINCASE Shift Weight Clutch Spring Clutch Spring Driven Helix Gearing Pitch 0 600 0 2000 10 72 1322428 Almond Gold 7041645 Black 155 ...

Page 20: ...gram lighter shift weights when operating in temperatures above 40 F 5 C Drive Clutch Bolt Torque 80 ft lbs 108 Nm Re torque after running engine 850 SWITCHBACK ASSAULT 146 CLUTCH SETTINGS CLUTCH SETTINGS ALTITUDE meters feet DRIVE CLUTCH DRIVEN CLUTCH CHAINCASE Shift Weight Clutch Spring Clutch Spring Driven Helix Gearing Pitch 0 600 0 2000 10 72 1322428 Almond Gold 7041645 Black 155 222 7043063 ...

Page 21: ...8 x 1 25 x 50 24 ft lbs 32 N m Apply VES oil under fastener head and to threads prior to installation Crankcase Fasteners M8 x 1 25 x 80 24 ft lbs 32 N m Apply VES oil under fastener head and to threads prior to installation ENGINE ITEM TORQUE Stator Fasteners M6 x 1 0 x 32 12 ft lbs 16 N m Flywheel Flange Nut M14 x 1 50 90 ft lbs 122 N m CPS Fasteners M5 x 0 8 x 10 53 in lbs 6 N m Recoil Starter ...

Page 22: ...uel Rail Mounting Fasteners First Pass 5 ft lbs 6 5 N m Second Pass 15 ft lbs 20 N m Front Seat Mount Fastener 36 in lbs 4 N m PFA Nut 28 ft lbs 38 N m FUEL SYSTEM ITEM TORQUE Fuel Tank Support Mounting Nuts 9 ft lbs 12 N m Tank Studs 18 in lbs 2 N m FINAL DRIVE BRAKES ITEM TORQUE Brake Disc Fastener 40 ft lbs 54 N m Chaincase Cover Fasteners 12 ft lbs 16 N m Chaincase Fill Plug 4 ft lbs 6 N m Cha...

Page 23: ...4 ft lbs 60 N m Pitman Idler Arm to Bracket Fasteners 30 ft lbs 41 N m Tie Rod End Nut 37 ft lbs 50 N m Tie Rod Jam Nut 11 ft lbs 15 N m STEERING FRONT SUSPENSION ITEM TORQUE Control Arm Pivot Stud Flange Nuts 30 ft lbs 41 N m Front Lower Control Arm Pivot Screw Nut 40 ft lbs 54 N m Control Arm to Spindle Fastener 40 ft lbs 54 N m Ski to Spindle Fastener 37 ft lbs 50 N m Front Ski Toe Fastener 8 f...

Page 24: ...Jounce Bumper Fastener Torque until screw protrudes 5mm out of nut Wheel Mount Block Fastener 9 ft lbs 12 N m Front Torque Arm Bumper Fasteners 4 ft lbs 6 N m IGX 146 REAR SUSPENSION ITEM TORQUE Rail Plate Reinforcement Fasteners 17 ft lbs 23 N m Spring Roller Shaft Fastener 17 ft lbs 23 N m Bogie Wheel Fastener 10 ft lbs 14 N m Front Cross Shaft Fastener 33 ft lbs 45 N m FTS Mounting Shaft Fasten...

Page 25: ...e Fasteners 9 ft lbs 12 N m Rear Lower Over Structure Stud Plate Fasteners 40 in lbs 4 5 N m Upper Over Structure Fasteners 12 5 ft lbs 17 N m CHASSIS BODY ITEM TORQUE Hood Cap Fasteners 18 in lbs 2 N m Hood Trim Fasteners 11 in lbs 1 25 N m Display Door Latch Fastener 15 in lbs 1 7 N m Display Fasteners 53 in lbs 6 N m Fender Fasteners 36 in lbs 4 N m Side Panel Trim Fasteners 10 in lbs 1 1 N m C...

Page 26: ...0 850 Matryx Trail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc ELECTRICAL ITEM TORQUE Starter Motor Pinion Fasteners 7 ft lbs 10 N m Starter Motor Clip Bracket Nuts 8 ft lbs 11 N m GENERAL INFORMATION ...

Page 27: ...x 2 54 cm mile mi x 1 6 km km x 0 6214 mile ounces oz x 28 35 grams g fluid ounces fl oz x 29 57 cubic centimeters cc cubic centimeters cc x 03381 fluid ounces grams g x 0 035 ounces pounds lb x 0 454 kg kilogram kg x 2 2046 lbs cubic inches cu in x 16 387 cc cubic centimeters cc x 0 061 cubic inches US quarts x 0 946 liters L liters L x 1 057 US quarts US gallons x 3 785 liters L liters L x 0 264...

Page 28: ...12 24 17 1 1 2 12 1 27 64 12 28 4 6 mm 1 3 4 5 1 9 16 1 4 20 7 1 3 4 12 1 43 64 1 4 28 3 2 4 1 2 1 25 32 5 16 18 F 2 12 1 59 64 5 16 24 I 2 1 4 4 1 2 2 1 32 3 8 16 O 2 1 2 4 2 1 4 3 8 24 Q 2 3 4 4 2 1 2 7 16 14 U 3 4 2 3 4 7 16 20 25 64 METRIC TAP DRILL SIZES TAP SIZE DRILL SIZE DECIMAL EQUIVA LENT NEAREST FRACTION 3 x 50 39 0 0995 3 32 3 x 60 3 32 0 0937 3 32 4 x 70 30 0 1285 1 8 4 x 75 1 8 0 125...

Page 29: ... 25 64 0 3906 10 mm 0 3937 13 32 0 4063 27 64 0 4219 11 mm 0 4331 7 16 0 4375 29 64 0 4531 15 32 0 4688 12 mm 0 4724 31 64 0 4844 1 2 0 500 13 mm 0 5118 33 64 0 5156 17 32 0 5313 35 64 0 5469 14 mm 0 5512 9 16 0 5625 37 64 0 5781 15 mm 0 5906 19 32 0 5938 39 64 0 6094 5 8 0 625 16 mm 0 6299 FRACTION DECIMAL MM TO INCHES 41 64 0 6406 21 32 0 6563 17 mm 0 6693 43 64 0 6719 11 16 0 6875 45 64 0 7031 ...

Page 30: ...ETHANOL mode INTERNATIONAL FUEL For peak performance POLARIS recommend the use of 95 octane E10 gasoline or higher octane If lower octane is used some engine performance will be lost and fuel economy will decrease Do not use gasoline with higher ethanol rating than E10 REQUIRE MENT 650 MODELS 850 MODELS Minimum Fuel 95 RON E10 95 RON E10 Maximum Performance Fuel 95 RON E0 95 RON E0 REQUIRE MENT 65...

Page 31: ...age to fasteners CAUTION Always follow torque specifications as outlined throughout this manual Incorrect torquing may lead to serious machine damage or as in the case of steering components can result in injury or death for the rider s IMPORTANT If a torquing sequence is indicated for nuts bolts or screws start all fasteners in their holes and hand tighten Following the manual exactly tighten to ...

Page 32: ...rometric Sensor Circuit Voltage High 108 3 P2229 This Trouble Code Sets if the Barometric Pressure Sensor Signal Circuit is Open or Shorted to Battery Voltage Can be caused by Damaged Wiring Connections a Faulty Ambient Pressure Sensor or ECU Barometric Sensor Circuit Voltage Low 108 4 P2228 This Trouble Code Sets if the Barometric Pressure Sensor Signal Circuit is Shorted to Ground Can be caused ...

Page 33: ...nsor or ECU Connections Fuel Temperature Sensor Voltage Low 174 4 P1323 This trouble code sets if the Fuel Temperature Sensor Voltage is Below 0 01V Can be caused by Damaged Wiring a faulty Fuel Pressure Sensor or ECU Connections ECU Memory Checksum Error 628 13 P0601 This Trouble Code Sets if an Internal Memory Fault is detected in the Engine Controller Can only be caused by a defective ECU Crank...

Page 34: ...ions a Faulty Oil Pump Connections or Faulty ECU Connections Oil Pump Driver Circuit Fault 3589 12 P16BC This Trouble Code Sets if a Failure is Detected in the Oil Pump Driver Circuit Can be caused by Damaged Wiring Connections a Faulty Oil Pump Connections or Faulty ECU Connections Injector Output Supply 2 Voltage High 3598 3 P16A9 This Trouble Code sets if the Injector Output Supply 2 Voltage is...

Page 35: ...s Trouble Code sets if the ECU Supply Voltage is below 10 00V Can be based by faulty wiring faulty regulator or ECU Connections Critical Supply Voltage High 520175 3 P1343 This Trouble Code sets if the Critical Supply Voltage is above 17 00V Can be based by faulty wiring faulty regulator or ECU Connections Critical Supply Voltage Low 520175 4 P1344 This Trouble Code sets if the Critical Supply Vol...

Page 36: ...onnections a Faulty Charge Relay or ECU Charge Relay Driver Circuit Open 520220 5 P163C This Trouble Code Sets if the Charge Relay Driver Circuit is Open Can be caused by Damaged Wiring Connections a Charge Relay or ECU Oil Pump or Fuel Injector Offset not Programmed 520241 13 P1278 This Trouble Code Sets if Either the Fuel Injector or Oil Injection Pump Calibration has Not Been Programmed Update ...

Page 37: ...ctuator Internal IC Over Current Over Temp 523957 6 P3029 This trouble code sets if the ECU has detected a Exhaust Valve Actuator internal IC current above 2A or 200C Can be caused by a faulty ECU Exhaust Valve Actuator Internal IC Communication Loss 523957 19 P3032 This trouble code sets if the ECU loses communication with the Exhaust Valve Actuator IC Can be cause by a faulty ECU Exhaust Valve A...

Page 38: ...uit near console Right grip heater current falls below current limit hystersis 5 C110B Right Grip Heater Driver Under Current Right grip heater measured current below current limit value Continue normal operation Check right grip heater for damage or an open circuit Check right grip heater wiring for broken wire near console Right grip heater current rises above current limit hystersis 6 C110C Rig...

Page 39: ...tput state control to test the fuel pump function ECU must command the fuel pump to turn on when using Output State Control testing Fuel Pressure Fuel Pressure using a fully charged 12V battery connected to fuel pump prime connectors 650 Models 42 to 49 psi 292 to 336 kPa 850 Models 57 to 62 5 psi 393 to 431 kPa Fuel Pump Pick Up Sock Inspect the fuel pump pick up sock Replace the sock if it is co...

Page 40: ...he rider drives aggressively and at sustained high speeds Also during the break in time the full shift RPM may be 200 300 RPM lower than when fully broken in Step 1 Document the Basics Document the specific concern Determine when the concern occurs conditions speed throttle position etc Transfer these notes directly to the Ask Polaris case Ask the rider what type of two stroke engine oil they have...

Page 41: ... Never clean a drive belt with anything more than a solution of warm soapy water and then allow the belt to air dry If chemicals have been used to clean the clutches verify the clutch bushings are not sticking on the stationary shafts If you find tacky belt residue in or around the bushings disassemble the clutch and clean thoroughly Step 4 Inspect Rear Suspension Track Verify the rail sliders are...

Page 42: ...e Replace reset Throttle Position Sensor TPS SmartWarmer heater calibration when replacing heater elements NOTICE If the snowmobile is equipped with a fully charged battery it can be used to supply power to the test connectors If using a stand alone service battery do not place the battery in the tunnel footwells Place the battery on the floor next to the engine compartment DIGITAL WRENCH SPECIAL ...

Page 43: ...le Digital Wrench Update 3 If a newer update is available it should be downloaded before using Digital Wrench DIGITAL WRENCH UPDATING SOFTWARE Updates are released for Digital Wrench via the Internet at http polaris diagsys com The Digital Wrench website can also be accessed through the dealer website at www polarisdealers com NOTICE Only authorized Polaris dealers and distributors can access the ...

Page 44: ...ur PC before running the install 8 When the update is complete the version shown on the right side of the Digital Wrench start up screen should match the update you just downloaded NOTICE Versions and updates are subject to change DIGITAL WRENCH COMMUNICATION ERRORS If you experience problems connecting to a vehicle or any Digital Wrench related problem visit the Digital Wrench Knowledge Base for ...

Page 45: ...n View sensor and ECU information in a grid meter or chart format Enter customer and vehicle information and view ECU Identification View information from the main ECU sensors Load the Vehicle Home Page Set up data capture and record functions Open the Software Configuration Screen Perform specialized testing and adjustment functions service reports Run the Help System Open the ASSERT ASK form Pri...

Page 46: ...orts w Select preferred language e Select displayed units of measurement US or Metric r Select PC Laptop COM port Use this drop down menu if the SmartLink cable is not recognized by the PC Laptop t Debugging Mode Use when instructed by Polaris Service to determine Digital Wrench vehicle communication issues y Help Balloons Auto Update Turn these features on off based on preference If auto updates ...

Page 47: ... the engine running Run the engine on a test stand in a well ventilated area as specified to attempt to set active code DIGITAL WRENCH DTC DISPLAY REF DESCRIPTION q DTC P Code w Controller providing the code ECU or Instrument Cluster e Description of DTC r Status Current or Historic t Number of occurrences y Detailed DTC explanation guided diagnostics if available u Clear DTC list Clicking on the ...

Page 48: ... list Click or to add or subtract data fields Up to 14 items can be displayed on the screen at one time Click the save button to save the current view as a custom data map Click the folder button to display more preset data lists or create a customized data list NOTICE Some components require the engine to be running or power supplied to the CRITICAL PWR test connector to display data For example ...

Page 49: ...r e List of either data items if data item is selected as the trigger or trouble codes if trouble code is selected as the trigger r Enable or reset trigger recording In the example shown below TPS Volts was selected as the Data Item Trigger Digital Wrench prompts the user to select the Comparison t and the Value In this case the Comparison was set to Greater Than and the Value was set to 3 50 volt...

Page 50: ...se functions has guided step by step instructions DIGITAL WRENCH VEHICLE HISTORICAL INFORMATION Vehicle Historical Information is located under the Special Tests Menu The screen will show the user total engine run time number or engine overheat and shut down events and total TPS or engine RPM history in hours DIGITAL WRENCH VEHICLE HISTORICAL INFORMATION REF DESCRIPTION q Event Counter This table ...

Page 51: ...utton to initiate the test IMPORTANT Verify there is a sufficient amount of fuel in the fuel tank to prevent fuel pump damage when performing the fuel pump test NOTICE Test items may appear different than what is shown and are vehicle specific Some test items require battery power to be connected to the DC PWR Test connector For example When testing the chassis relay Load Shed battery power must b...

Page 52: ...ccurate Polaris dealer number is entered on the Digital Wrench Configurations Screen After creating a Service Report scroll up and down through the report to verify all of the data items are present NOTICE To obtain the most accurate data information run the engine on a test stand in a well ventilated area Remember to supply power to the instrument cluster if you want instrument cluster informatio...

Page 53: ...nected to the internet prior to performing the ECU replacement procedure NOTICE Service replacement ECUs are formatted as no start ECUs and will not allow the engine to run or the user to set fuel injector color oil pump flow offset etc until the ECU is set with the correct vehicle engine model number The ECU replacement procedure copies the original ECU s vehicle information to the PC laptop and ...

Page 54: ...op 8 Select the model year product line and vehicle description by selecting the Change Vehicle Type icon 9 Select the Special Tests icon Select ECU Injector Oil Pump Replacement 10 On the following screen select ECU Replacement 11 The next screen will prompt the user to verify the defective ECU is connected to the vehicle and the Chassis Power Up harness is connected Click Done Continue to procee...

Page 55: ... ECU REPLACEMENT PROCEDURE 1 Follow steps 1 through 11 in the ECU replacement procedure 2 Digital Wrench will notify the user that it is unable to communicate with the ECU Click on Done Continue 3 The next screen asks the user to enter the vehicle model number and serial number Enter the correct model and serial numbers for the vehicle into the data fields and then click on Continue IMPORTANT The ...

Page 56: ...fset number can be found on the oil pump housing decal or the original ECU s information decal Click on Continue after entering the offset number IMPORTANT Severe engine damage may occur if the wrong oil pump offset number code is entered 7 Digital Wrench will display the model number and serial number the user entered at step 3 Verify these numbers are accurate before clicking Continue 8 Disconne...

Page 57: ...ed at the base of each fuel injector When replacing fuel injectors reference this color band to ensure the right fuel map is selected using Digital Wrench 1 Obtain a fully charged 12 volt battery and the Chassis Power Up Harness Chassis Power Up Harness PS 47296 B 2 Open the left engine compartment panel 3 Connect the Next Gen Service Power Harness to the diagnostic connector on the wiring harness...

Page 58: ...hicle Click Done Continue to proceed 11 Digital Wrench will scan the ECU and display the current fuel injector color code on the screen If the fuel injectors installed on the engine are a different color than what is shown click on the correct color box on the right side of the screen Click on Continue 12 Digital Wrench will set the fuel injector setting in the ECU After this process is completed ...

Page 59: ... and not used 1 Verify the most current update has been downloaded and loaded into Digital Wrench 2 Obtain a fully charged 12 volt battery and the Chassis Power Up Harness Chassis Power Up Harness PS 47296 B 3 Open the left engine compartment panel 4 Connect the Next Gen Service Power Harness to the diagnostic connector on the wiring harness Next Gen Service Power Harness PS 52573 5 Connect one of...

Page 60: ...n select Oil Pump Replacement 12 The next screen will display the current offset value at the top This number must match the number on the oil pump and the ECU label If the offset number on the oil pump does not match what is shown on the screen enter the correct three digit number into the New Oil Pump Offset field Click Continue to proceed 13 After setting the correct oil pump flow offset number...

Page 61: ...ANT This procedure must be performed when new fuel injectors are installed on the engine 1 Obtain a fully charged 12 volt battery and the Chassis Power Up Harness Chassis Power Up Harness PS 47296 B 2 Open the left engine compartment panel 3 Connect the Next Gen Service Power Harness to the diagnostic connector on the wiring harness Next Gen Service Power Harness PS 52573 4 Connect one of the Chas...

Page 62: ...ink cable to the vehicle and PC laptop 7 Start Digital Wrench and select the appropriate vehicle 8 Select the Special Tools Tool Box menu and then Service Procedures 9 The next screen will prompt the user to select the desired operation Select Break In Timer Reset 10 On the next screen click on Fuel Break In Reset GENERAL INFORMATION ...

Page 63: ... Harness PS 47296 B 2 Open the left engine compartment panel 3 Connect the Next Gen Service Power Harness to the diagnostic connector on the wiring harness Next Gen Service Power Harness PS 52573 4 Connect one of the Chassis Power Up harness leads to the ECU PWR diagnostic test connector on the Next Gen Service Power Harness 5 Connect the power up harness to the battery NOTICE If the snowmobile is...

Page 64: ...t be performed whenever the following occurs EV actuator is replaced EV actuator cable is replaced or removed from the tie bar Any exhaust valve upper or lower is replaced Cylinder is replaced The EV Actuator Learn Procedure does not need to be performed if the actuator cable is removed from the actuator and actuator jam nut bracket NOTICE The EV Actuator Learn Procedure will not work if the batte...

Page 65: ...nnect the power up harness to the battery NOTICE If the snowmobile is equipped with a fully charged battery it can be used to supply power to the test connectors If using a stand alone service battery do not place the battery in the tunnel footwells Place the battery on the floor next to the engine compartment 6 Connect the SmartLink cable to the vehicle and PC laptop 7 Start Digital Wrench and se...

Page 66: ...the procedure The instrument cluster or PIDD will turn on and off each time the relay is closed and opened This is normal and critical to the completing the learning procedure The actuator will also be heard moving back and forth as the ECU sets the travel limits 13 At the end of the procedure the software will check for any faults that may have occurred 14 If no faults are encountered this screen...

Page 67: ...tem in the event the fuel tank was run dry and the engine is difficult to re start after re filling the fuel tank 1 Obtain a fully charged 12 volt battery and the Chassis Power Up Harness Chassis Power Up Harness PS 47296 B 2 Open the left engine compartment panel 3 Connect the Next Gen Service Power Harness to the diagnostic connector on the wiring harness Next Gen Service Power Harness PS 52573 ...

Page 68: ...e user to select the desired operation Select Fuel Pump Prime 10 Click Done Continue after reading the following screen 11 The fuel pump will run and prime the fuel system Use fuel pump prime to perform the following tests Verify the ECU can activate the fuel pump Purge the fuel system of air if the fuel tank was run dry or the fuel system was disassembled Test fuel system pressure Non ES models t...

Page 69: ...rness PS 52573 4 Connect one of the harness leads to the ECU PWR test diagnostic connector 5 Connect the power up harness to the battery NOTICE If the snowmobile is equipped with a fully charged battery it can be used to supply power to the test connectors If using a stand alone service battery do not place the battery in the tunnel footwells Place the battery on the floor next to the engine compa...

Page 70: ... prevent surplus oil from accumulating in the crankcase The Oil Pump Prime procedure is used to purge the engine oil supply lines of air and to verify the ECU can drive the oil pump NOTICE Fill the oil tank with oil prior to starting this procedure Verify the engine oil supply lines are connected to the engine and the oil pump supply hose is connected to the pump and oil tank The Oil Pump Prime Pr...

Page 71: ... supply power to the test connectors If using a stand alone service battery do not place the battery in the tunnel footwells Place the battery on the floor next to the engine compartment 6 Connect the SmartLink cable to the vehicle and PC laptop 7 Start Digital Wrench and select the appropriate vehicle 8 Select the Special Tools Tool Box menu and then Service Procedures 9 The next screen will prom...

Page 72: ... in several applications around the dealership is more likely to cause a reprogramming problem than one dedicated to Digital Wrench diagnostics only OBTAINING THE LATEST UPDATE Reprogramming updates are provided periodically and contain the most recent calibrations CLOSE NON ESSENTIAL PROGRAMS Polaris recommends that you DO NOT install non essential programs on a Service Department laptop Camera d...

Page 73: ...ct the power up harness to the battery NOTICE If the snowmobile is equipped with a fully charged battery it can be used to supply power to the test connectors If using a stand alone service battery do not place the battery in the tunnel footwells Place the battery on the floor next to the engine compartment 7 Connect the SmartLink cable to the vehicle and PC laptop 8 Start Digital Wrench on the la...

Page 74: ...ick on ReFlash Authorization from the Service and Warranty drop down menu 14 Enter or paste the Request Code into the box 15 Select the same file type from the list that you selected previously while in Digital Wrench Enter the VIN along with the customer s name and address When completed click the Authorize button once to proceed 16 An Authorization Key will appear in the upper left corner of the...

Page 75: ...n Do not touch the vehicle or PC during the process 19 Once the ECU reprogramming procedure is complete click Continue Cycle the power to the ECU by disconnecting the Chassis Power Up Harness connector from the ECU PWR Test connector 20 Wait for 10 seconds 21 Reconnect the Chassis Power Up Harness connector to the ECU PWR Test connector GENERAL INFORMATION 1 ...

Page 76: ...is Power Up harness leads to the ECU PWR diagnostic test connector on the Next Gen Service Power Harness 5 Connect the power up harness to the battery NOTICE If the snowmobile is equipped with a fully charged battery it can be used to supply power to the test connectors If using a stand alone service battery do not place the battery in the tunnel footwells Place the battery on the floor next to th...

Page 77: ... part number of the ECU and should match the number in the vehicle s parts catalog Item t is the ECU calibration software part number This number must match the number provided by Digital Wrench when performing the ECU Reflash procedure and referenced if new ECU calibration files are released INSTRUMENT CLUSTER INFORMATION The drop down menu q will display what information is shown Click to select...

Page 78: ... DEVICES Minimum operating system Android 3 1 Honeycomb or higher Android 4 0 or higher preferred NOTICE The PMDW app will not work on Microsoft Windows 8 or Apple IOS products Dual core processor 2 GB internal memory external micro SD 32 or 64 GB slot 500 MB RAM Rear facing camera with minimum 3 0 mega pixel resolution with auto continuous focus Video microphone and voice to text capable Internet...

Page 79: ...n use for extended periods of time should be inspected for glazing at 1 000 mile intervals Replace as required CORD POP OUT Inspect drive driven clutch alignment motor mounts and deflection Set the driven clutch float Remove the belt during off season storage period DRIVE CLUTCH PREMATURE WEAR Verify the correct clutch weight spring package is installed Inspect the spider rollers bushings for dama...

Page 80: ...MPH indicated on speedometer Lower the gear ratio Remove windage plates from the driven clutch If possible move to better snow conditions and reduce RPM Avoid riding in very high ambient temperatures Ice and snow piled up between the 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 the tunnel Allow a longer than norm...

Page 81: ...hock This thin film of oil lubricates the Seal to ensure low friction and reduces the corrosion rate of the Piston Rod Vehicle operating conditions have a high impact on how much shock oil might be present on the seal and shock body i e road conditions and operating temperature It is important to properly identify the difference between normal operation weepage or misting and a shock that has a le...

Page 82: ...ters beside a DMM will only work in one scenario and slight variables can provide you with misleading results The testing practices described in this chapter are more certain and rely only on the DMM and your knowledge STATIC AND DYNAMIC TESTING There are many methods for testing a DC circuit These methods fall into one of two categories either static or dynamic STATIC TESTING The two most common ...

Page 83: ...onnector is held upside down this is an indication that the female connector in the harness has insufficient tension and will cause connection issues You can either replace that harness or service it by replacing the terminal or attempting to adjust tighten the tang in the female terminal For a video demonstration scan the QR code below or right click it and select open in new tab BACK PROBING Bac...

Page 84: ...r way to return to ground B so much more of it can flow than the circuit is designed for This causes the circuit s protection device either a fuse or circuit breaker to open protecting the circuit from damage There are many possible causes of a short to ground here are some The harness rubbing against a component that is grounded such as the frame chassis component or engine A component s internal...

Page 85: ...uity of the circuit Testing Continuity Resistance page 1 78 4 Ensure you have checked for a short to ground Testing For A Short To Ground page 1 78 5 Ensure that neither end of the circuit is connected 6 Set your DMM to DC volts 7 Connect one meter lead securely to the battery negative post 8 Connect the other lead to either end of the disconnected circuit Ensure you are using the correct adapter ...

Page 86: ...plished with either heat guns or cold air guns WARNING Always exercise caution when using these tools and use them for short periods of time when changing the temperature of an area Failure to do so can lead to serious injury and or damage to the machine TESTING CURRENT FLOW AMPERAGE Performing a current flow test requires the meter leads be inserted into the correct cavities in the meter and be p...

Page 87: ...ound you will be measuring available voltage This is a static test and not dynamic voltage drop testing Refer to Static and Dynamic Testing page 1 76 The measurement of voltage is the DIFFERENCE in electrical pressure between the two points your DMM leads are touching Most circuits will have one load The load is the component in the circuit that uses the current flow to do work such as move a sole...

Page 88: ...1 82 9850064 R03 2021 650 850 Matryx Trail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc NOTES GENERAL INFORMATION ...

Page 89: ...2 10 LUBRICANTS SERVICE PRODUCTS 2 15 50 50 EXTENDED LIFE ENGINE ANTIFREEZE 2 17 HOOD SIDE PANEL SERVICE 2 18 SIDE PANEL REMOVAL 2 18 SIDE PANEL INSTALLATION 2 18 HOOD REMOVAL 2 19 HOOD INSTALLATION 2 19 ENGINE MAINTENANCE 2 20 THROTTLE LEVER FREEPLAY INSPECTION 2 20 THROTTLE LEVER FREEPLAY ADJUSTMENT 2 20 SPARK PLUG MAINTENANCE 2 21 SPARK PLUG WIRE CAP MAINTENANCE 2 21 COOLING SYSTEM MAINTENANCE ...

Page 90: ...ISER ANGLE ADJUSTMENT 2 42 LEFT HAND CONTROL ADJUSTMENT 2 43 FRONT SUSPENSION 2 44 FRONT SUSPENSION INSPECTION WIDE FIXED CAMBER 2 44 CONTROL ARM PIVOT ADJUSTMENT 2 45 SKI ALIGNMENT TOE ADJUSTMENT 2 45 SKI SKAG INSPECTION SKAG REPLACEMENT 2 46 REAR SUSPENSION 2 48 REAR SUSPENSION INSPECTION PRO CC 2 48 REAR SUSPENSION INSPECTION IGX 146 2 49 RAIL SLIDER INSPECTION 2 50 TRACK INSPECTION 2 50 TRACK ...

Page 91: ...2 61 CONTROLS 2 62 AUXILIARY ENGINE STOP SWITCH 2 62 THROTTLE RELEASE SWITCH TRS 2 62 OFF SEASON STORAGE 2 63 TREATING THE FUEL SYSTEM 2 63 FOGGING THE ENGINE 2 63 DRIVE BELT STORAGE 2 63 BATTERY ELECTRICAL SYSTEM STORAGE 2 64 CHAINCASE 2 64 CLEANING THE SNOWMOBILE 2 65 LUBRICATE THE PIVOTS 2 65 STORING THE SNOWMOBILE 2 65 MAINTENANCE ...

Page 92: ... the Service Manual which is available to your qualified service technician Reverse if equipped must not be engaged during engine tune ups NON IONIZING RADIATION This vehicle emits some electromagnetic energy People with active or non active implantable medical devices such as heart monitoring or controlling devices should review the limitations of their device and the applicable electromagnetic s...

Page 93: ...ard over 1 4 turn mount and tilt the tool kit container until the bracket detaches from the bumper tube 5 Pull the container out of the compartment 6 When reinstalling the drive belt into the container fold the belt as shown Verify that the belt loop at the rear of the container is positioned slightly higher than the front loop Forward 7 Carefully lift the hood upward over 1 4 turn mount and slide...

Page 94: ...with each other Drive with extra caution during the break in period Perform regular checks on fluid levels lines and all other important areas of the snowmobile Always check and fill the oil bottle when refueling IMPORTANT Serious engine damage can occur without the proper lubrication Check the oil bottle level often during the first tank of fuel If the oil level doesn t go down inspect oil inject...

Page 95: ...maintenance checks and adjustments several pre ride pre season and storage inspections operational checks are required PRE RIDE INSPECTION The following items should be inspected pre ride ITEM INSPECTION CHECK Drive Driven Clutch Inspect the drive belt condition runout Engine Check for proper coolant level Brake System Inspect brake lever Inspect parking brake Electrical System Inspect auxiliary s...

Page 96: ...n Clutch Condition C Drive Belt Tension I Engine Engine Mounts I Recoil Handle Rope Function I Spark Plugs I Exhaust Pipe I Exhaust System Retaining Springs I Coolant Level I Cooling Hoses Pipes I Brake System Brake Lever Hose Condition Routing I Fluid Level Leaks Fluid Condition I Brake Pads Brake Disc I Brake System I Fuel System Throttle Lever Throttle Cable I Fuel Vent Hoses I Oil Hoses I Air ...

Page 97: ...e System I Chassis Suspension Ski Fasteners C Hood Side Panel Fasteners I Drive Chain Tension If Equipped I Chaincase Oil If Equipped I Track Alignment Track Tension I Front Limiter Strap I Rail Slide Condition I Rear Shock Threads L Bogie Wheel Condition Fastener Bolts I Rear Idler Wheel Bolts I Rear Idler Adjuster Bolt Jam Nuts I Cooling Fins and Shroud I Handlebar Centering I Hood Seat Chassis ...

Page 98: ...rs 60 40 Coolant If applicable Replace every 2 years Throttle Lever Throttle Cable Inspect or Adjust Air Box Inspect or Adjust Hood Side Panel Fasteners Inspect or Adjust Drive Chain Tension If Equipped Inspect or Adjust Chaincase Oil If Equipped Inspect or Adjust Track Alignment Track Tension Inspect or Adjust Front Limiter Strap Inspect or Adjust Rail Slide Condition Inspect or Adjust Bogie Whee...

Page 99: ...djust Fuel Vent Hoses Inspect or Adjust Air Box Inspect or Adjust Ski Toe Alignment Inspect or Adjust Hood Side Panel Fasteners Inspect or Adjust Drive Chain Tension If Equipped Inspect or Adjust Chaincase Oil If Equipped Replace Track Alignment Track Tension Inspect or Adjust Front Limiter Strap Inspect or Adjust Rail Slide Condition Inspect or Adjust Bogie Wheel Condition Fastener Bolts Inspect ...

Page 100: ...5 years 60 40 Coolant If applicable Replace every 2 years Cooling Hoses Pipes Inspect or Adjust Hose Condition Routing Inspect or Adjust Fluid Level Leaks Fluid Condition Inspect or Adjust Brake Pads Brake Disc Inspect or Adjust Throttle Lever Throttle Cable Inspect or Adjust Fuel Vent Hoses Inspect or Adjust Oil Hoses Inspect or Adjust Air Box Inspect or Adjust Ski Toe Alignment Inspect or Adjust...

Page 101: ...ce Exhaust Pipe Inspect or Adjust Exhaust System Retaining Springs Inspect or Adjust 50 50 Extended Life Coolant Replace every 5 years 60 40 Coolant If applicable Replace every 2 years Cooling Hoses Pipes Inspect or Adjust Hose Condition Routing Inspect or Adjust Fluid Level Leaks Fluid Condition Inspect or Adjust Brake Pads Brake Disc Inspect or Adjust Brake Fluid Replace Throttle Lever Throttle ...

Page 102: ...S MORE OFTEN FOR VEHICLES SUBJECTED TO SEVERE USE D HAVE AN AUTHORIZED POLARIS DEALER PERFORM THESE SERVICES E EMISSION CONTROL SYSTEM SERVICE CODE ITEM ACTION Rear Idler Wheel Bolts Inspect or Adjust Rear Idler Adjuster Bolt Jam Nuts Inspect or Adjust Cooling Fins and Shroud Inspect or Adjust Camber Alignment Inspect or Adjust MAINTENANCE ...

Page 103: ... Gallon 2883734 55 Gallon 2883735 330 Gallon 2883736 Synthetic Chaincase Lubricant Quart 2873105 Gallon 2873106 2 5 Gallon 2872952 50 50 Extended Life Antifreeze Quart 2880514 Gallon 2880513 55 Gallon 2880512 Shock Oil 5W Walker Evans 2874522 Shock Oil 5W Fox Quart 2870995 2 5 Gallon 2872279 Shock Oil 5W RydeFX Arvin 2873716 Brake Fluid DOT 4 2872189 Fogging Oil Aerosol 2870791 Premium All Season ...

Page 104: ... 12 oz 2881416 2 5 Gallon 2881417 Scented Advanced 5 1 Fuel Stabilizer 3 pack 1 oz Packet 2881421 Strawberry 1 oz Packet 2881419 Mint 1 oz Packet 2881418 Unscented 1 oz Packet 2881420 Three Bond Sealant 5 oz 2871557 Shock Adjusting Lubricant PRO RIDE AXYS Progressive Rear Track Shock Only 2878018 Cleaners Polishes Instant Shine Detailer 2830204 Polaris Polish 2830207 Mud Shield Pre Treat 2830208 N...

Page 105: ...ifreeze However mixing the two will affect the service interval To receive the full 5 year service interval benefit the cooling system must be fully drained and replenished with the Extended Life antifreeze To determine if a vehicle is using 60 40 or 50 50 Extended Life antifreeze note the color 60 40 antifreeze is green while 50 50 Extended Life antifreeze is yellow 50 50 EXTENDED LIFE ANTIFREEZE...

Page 106: ...rely latched before starting the engine unless instructed to do so for servicing reasons 1 Rotate the three 1 4 turn fasteners q at the front and rear of the panel 2 Open the side panel then pull the panel outward to release the tabs at the bottom SIDE PANEL INSTALLATION 1 Align the tabs on the side panel with the slots q in the fender and console Left side shown right side similar 2 Carefully ins...

Page 107: ...Remove the left and right side panels 2 Rotate the 1 4 turn fasteners q at the rear corners of the hood 3 Pull hood over 1 4 turn mounts before lifting on hood 4 Disconnect the hood wire harness connector w 5 Remove the hood assembly from the vehicle HOOD INSTALLATION 1 Install the hood q by inserting the front of the hood into the nosepan 2 Lay the hood down onto the overstructure 3 Reconnect the...

Page 108: ...mage for reference only MEASUREMENT Throttle Lever Freeplay 009 029 in 0 25 0 76 mm 4 Adjust freeplay if the gap does not meet specification THROTTLE LEVER FREEPLAY ADJUSTMENT WARNING Do not operate the snowmobile if throttle cable freeplay is too tight Adjust throttle lever freeplay using the in line throttle cable adjuster NOTICE Image for reference only 1 Move protective sheath to expose the in...

Page 109: ...y be running rich Inspect the engine fuel system and lubrication system for problems Set the electrode gap to specification before installing a new spark plug MEASUREMENT NGK BPR9ES Gap 027 in 0 70 mm When installing spark plug s install clean and dry Torque to specification TORQUE Spark Plug 22 ft lbs 30 N m SPARK PLUG WIRE CAP MAINTENANCE Inspect the spark plug wires and caps when performing spa...

Page 110: ...react adversely with the metals in the engine and cooling system COOLANT BOTTLE LEVEL CHECK CAUTION Cooing system under pressure Steam and hot liquids will cause burns to your skin Never bleed the cooling system or remove the pressure cap when the engine is warm or hot Wear eye protection when servicing the cooling system The engine coolant level is controlled by the recovery system The recovery s...

Page 111: ...1 Open the side panels and remove the hood 2 Close the side panels 3 Fill the coolant bottle to the COLD FILL mark 4 Install the coolant bottle cap to the first lock Do not tighten to the fully seated position 5 Lock the parking brake 6 Start the engine and allow it to run at a fast idle for several minutes until the heat exchangers are warm to the touch IMPORTANT Keep the coolant level in the coo...

Page 112: ... threaded hole in the outer sheave of the clutch 7 Turn the wrench clockwise until the sheaves open far enough to remove the belt 8 Firmly grasp the belt w midway between the clutches and pull upward and rearward to remove it from the driven and then drive clutch NOTICE The fender console can be spread apart as needed to access the driven clutch DRIVE BELT INSTALLATION NOTICE Always clean the driv...

Page 113: ...ch counterclockwise to tighten the sheaves Work the belt around the clutches as you remove the L wrench Doing so will set the belt in low gear 5 Reinstall the wrench q to the wrench bracket to secure the fender to the console 6 Reinstall the left side panel 7 When installing a new belt follow the belt break in procedures MAINTENANCE ...

Page 114: ...ction 1 25 in 3 2 cm ADJUSTMENT 1 Loosen the 11 mm jam nut on the belt width adjuster screw 2 Using a 3 mm Allen wrench turn the set screw inward clockwise to increase the distance between the sheaves increase deflection or outward counter clockwise to decrease the distance decrease deflection 3 Lightly tighten the jam nut q while holding the set screw stationary 4 Using the L wrench open the driv...

Page 115: ...l Clutch Alignment Tool PS 51607 The Clutch Alignment tool is designed with the specified alignment angle and offset When installed into the drive clutch and placed on top of the driven clutch the technician can immediately determine if any adjustments are required PROCEDURE 1 Open the left engine compartment door 2 Remove the drive belt 3 Install the alignment tool e into the drive clutch Verify ...

Page 116: ...he jackshaft IMPORTANT Always verify the driven clutch floats on the jackshaft The jackshaft bearing will fail from side loading if the driven clutch is not allowed to float 5 Apply a light film of Polaris Premium grease to the jackshaft Install the driven clutch and push it tight toward the bulkhead 6 Install the driven clutch bolt q flat washer w original float washers e and r and spacer t Torqu...

Page 117: ... 2 29 CLUTCH CLEANING Periodically inspect clutch sheaves for damage wear or belt residue To maintain optimum performance clean with non oil based cleaners such as isopropyl alcohol IMPORTANT Do not lubricate the clutch bushings or any internal clutch components Clutch bushings are self lubricating MAINTENANCE ...

Page 118: ... lines regularly for signs of deterioration or damage Always check fuel line condition after periods of storage Normal deterioration from weather and fuel compounds may occur Replace worn or damaged fuel lines promptly IMPORTANT Kinking the fuel lines or using a pliers or similar tools to remove fuel lines may cause damage to the lines If a fuel line has been damaged or kinked replace it promptly ...

Page 119: ...f you use non ethanol fuel sometimes labeled non oxygenated POLARIS recommends the regular use of isopropyl based fuel system deicer Add 1 2 ounces per gallon 8 16 ml per liter of gasoline to prevent damage resulting from fuel system icing Never use deicers or additives containing methanol POLARIS recommends the use of Carbon Clean IMPORTANT If you use fuel with up to 10 ethanol sometimes labeled ...

Page 120: ...onator Do not remove EGT from resonator if replacement is not required Disconnect the Exhaust Gas Temperature EGT Sensor e wire connectors when removing pipe r Do not remove EGT from pipe if replacement is not required 1 Inspect springs t Replace if missing broken or stretched 2 Inspect gasket y and pipe socket seal u The gasket and socket seal may weep during break in period Weeping should subsid...

Page 121: ...am nut q 5 Finger tighten the adjuster bolt w until it can no longer be adjusted by hand then back off 1 4 turn 6 Tighten the jam nut to specification while holding the adjuster bolt TORQUE Drive Chain Tensioner Jam Nut 21 ft lbs 28 N m 7 Reinstall the side panels Release the parking brake CHAINCASE OIL LEVEL CHECK 1 Position snowmobile on a flat level surface 2 Remove the fill plug q Maintain the...

Page 122: ... 4 Extract the oil from the chaincase 5 Lower the snowmobile 6 Using a funnel slowly add the recommended oil until the fluid begins to overflow FLUID CAPACITY Maximum Fluid Capacity 10 5 oz 310 mL 7 Clean the area with a clean dry shop towel 8 Reinstall the fill plug Torque plug to specification TORQUE Chaincase Fill Plug 4 ft lbs 6 N m CHAINCASE OIL CHANGE COVER DRAIN METHOD 1 Position snowmobile...

Page 123: ...asteners 12 ft lbs 16 N m 9 Remove the fill plug Clean all metal shavings off the plug 10 Using a funnel slowly add the recommended oil until the fluid begins to overflow FLUID CAPACITY Maximum Fluid Capacity 10 5 oz 310 mL 11 Clean the area with a clean dry shop towel 12 Reinstall the fill plug Torque fill plug to specification TORQUE Chaincase Fill Plug 4 ft lbs 6 N m 13 Reinstall the screws sec...

Page 124: ...rakes may cause a complete loss of brakes which could result in serious injury or death Have the brakes serviced at the first sign of abnormal feel or performance CALIPER PAD COMPONENTS Brake pads must be replaced when the brake pad material becomes thinner than the backing plate approximately 1 16 in 1 5 mm A kit is available for replacing brake pads WARNING Brake failure during operation can res...

Page 125: ...nt slits allow for diaphragm movement and if they become plugged movement of brake fluid below the diaphragm may be restricted altering brake function Inspect the reservoir to be sure it contains the correct amount of fluid Use only Polaris DOT 4 high temperature brake fluid Change fluid every 2 years or whenever the fluid is dark or contamination is suspected Position the handlebars so the brake ...

Page 126: ...rating the vehicle with a spongy brake lever can result in loss of brakes which could cause an accident and lead to serious injury or death Never operate the vehicle with a spongy feeling brake lever CAUTION Hot exhaust system parts can cause burns Allow adequate time for the exhaust system to cool Never perform this procedure with the engine running During the bleeding procedure keep the brake re...

Page 127: ...ull stroke Then unscrew the bleeder valve y 3 4 turn to release air 6 Close the bleeder valve and release the brake lever 7 Repeat steps 5 and 6 until fluid flows from the bleeder valve in a solid stream free of air bubbles WARNING Overfilling the master cylinder leaves no room for fluid expansion and may cause the brakes to lock resulting in serious injury or death Always add brake fluid to the p...

Page 128: ...BAR COMPONENT FASTENERS q Left Handlebar Control Block 20 in lbs 2 3 N m DO NOT MOVE THE LH CONTROL BLOCK WITHOUT FIRST LOOSENING THE SCREWS t Throttle Lever Block Cover Screws 6 in lbs 0 7 N m w Brake Lever Master Cylinder 60 80 in lbs 6 8 9 N m y Throttle Lever Block Set Screw 27 in lbs 3 1 N m e Upper Lower Riser Clamps 11 ft lbs 15 N m Hand Guards if applicable Hand Guard Arm Fasteners Tighten...

Page 129: ... LOCATIONS Refer to the following illustration and measurements to position handlebar components at factory specified locations NOTICE Do not attempt to move handlebar components without first loosening the affected component s screws q 9 25 in 235 mm e 0 078 in 2 mm To grip end w 0 078 in 2 mm To grip end r 6 30 in 160 mm MAINTENANCE ...

Page 130: ...proper torque MEASUREMENT Short Riser 60 mm 26 5 3 Tall Riser 85 mm 31 5 3 IMPORTANT Do not stretch wires while adjusting the controls Stretching the wires could damage the handwarmers 3 Tighten the fasteners to specification TORQUE Handlebar Riser Fasteners 11 ft lbs 15 N m HANDLEBAR RISER ANGLE ADJUSTMENT Riser angle can be adjusted to suit rider preference The factory desired setup angles are s...

Page 131: ...ke master cylinder mounting screws q and move it away from left hand control IMPORTANT Use care when moving brake master cylinder Do not damage the brake light signal wire NOTICE If applicable hand guards may need to be loosened or removed to access and move the brake master cylinder 2 Loosen the four left hand control mounting screws w 3 Move the control block to the desired position 4 Torque con...

Page 132: ...ower control arms Spindles Skis ski loops ski stops skags carbides Tie rods rod ends tie rod boots Sway bar sway bar linkage Fasteners q Upper Lower Control Arm Nuts 30 ft lbs 41 N m u Ski Bolt Nuts 37 ft lbs 50 N m w Lower Control Arm Front Pivot Bolt Nut 40 ft lbs 54 N m i Ski Skag Fasteners 8 ft lbs 11 N m e Sway Bar Fasteners 20 ft lbs 27 N m o Lower Control Arm Spindle Nuts 40 ft lbs 54 N m r...

Page 133: ...e the ski alignment or toe adjustment The skis on your snowmobile are set with a small amount of toe out at the factory You can inspect and adjust the toe setting by following the procedures below SKI TOE SETTING INSPECTION NOTICE Toe alignment is measured at ride height 1 Rock the front end of the vehicle up and down and then set it down gently This will set the front suspension at ride height Pl...

Page 134: ... this point verify the handlebar is centered with the skis 8 Turn both tie rods equally to set ski toe When finished measurement q should be 1 8 1 4 in 3 6 mm wider than measurement w NOTICE If setting toe on each ski using the alignment bar as a reference point q should be 1 16 1 8 in 1 6 3 mm wider than measurement w 9 Torque steering tie rod jam nuts and spindle fasteners to specification TORQU...

Page 135: ...EMENT NOTICE Always replace ski skags in pairs 1 Raise and support the front of the snowmobile so the skis are approximately 6 in 15 2 cm from the ground 2 Remove the attaching nuts q and pry the skag w downward 3 Reverse the steps to install a skag Tighten nuts to specification TORQUE Ski Skag Nuts 8 ft lbs 11 N m MAINTENANCE ...

Page 136: ...t lbs 45 N m Apply Loctite 263 to fastener o Rear Torque Arm to Tunnel Fastener 33 ft lbs 45 N m w Front Torque Arm to Tunnel Fastener 46 ft lbs 63 N m a Rear Cross Shaft Fastener 33 ft lbs 45 N m Apply Loctite 263 to fastener e FTS Mounting Fasteners 33 ft lbs 45 N m s Rear Pivot Arm Fastener 56 ft lbs 76 N m r Front H Bracket Fastener 56 ft lbs 76 N m d Rear Torque Arm to Rear Pivot Arm Fastener...

Page 137: ...rs Track q Front Cross Shaft Fastener 33 ft lbs 45 N m Apply Loctite 263 to fastener i Rear Torque Arm to Rear Pivot Arm Fastener 17 ft lbs 23 N m w Front Torque Arm to Tunnel Fastener 50 ft lbs 68 N m o Rear Idler Fastener 33 ft lbs 45 N m e FTS Mounting Shaft Fastener 50 ft lbs 68 N m Apply Loctite 263 to fastener a RTS Mounting Fasteners 33 ft lbs 45 N m r Front Torque Arm to Rail Fastener 46 f...

Page 138: ...perate the snowmobile if slide thickness measures less than 7 16 in 1 1 cm Worn rail sliders can be removed from the suspension without removing the track Raise the rear suspension off of the ground Loosen the track tension Rotate the track to access the screw securing the slider at the front of the beam Apply spray lubricant to the rail beam Use a small pry bar to drive the slider rearward until ...

Page 139: ...t and tighten the right adjusting bolt 4 After adjustments are complete verify the track tension is set to specification 5 Tighten the lock nuts 6 Tighten the idler shaft bolts to specification TORQUE Rear Idler Fastener 33 ft lbs 45 N m TRACK TENSION INSPECTION Track adjustment is critical for proper handling Always maintain correct tension and alignment NOTICE Closely monitor track tension durin...

Page 140: ...g screws w to provide equal adjustment on both sides of the track 4 Repeat the measurement on the other side of the track NOTICE Check more frequently when the snowmobile is new or if studs are installed 5 Remove the weight Start the engine and slowly rotate the track at least five revolutions Let the track come to a stop do not apply brakes 6 Check track alignment and adjust as necessary 7 Tighte...

Page 141: ... y y Preferred Maximum Rear Idler Fastener Torque e e Weight Measurement Location r r PRO CC 7 8 1 1 8 in 2 2 2 6 cm IMPORTANT If the track is studded Polaris recommends maintaining 7 8 in 2 2 cm track tension setting at all times Rear Idler Fasteners 33 ft lbs 45 N m 10 lb 4 54 kg 16 in 40 cm ahead of rear idler shaft IGX 146 NOTICE Image for reference only MAINTENANCE ...

Page 142: ...rom the vehicle and store the battery in a cool dry location Continue to maintain the battery with the BatteryMINDer 2012 AGM 2 AMP charger and inspect the battery every 60 days LEAD ACID LOW MAINTENANCE BATTERY MAINTENANCE Recharge the battery to its full capacity every 30 to 60 days If the battery is stored or used in a partially charged condition hard crystal sulfation will form on the plates r...

Page 143: ...ing 1 Remove the right side panel 2 Remove the plastic rivet q and fastener w securing the console panel to the chassis 3 Remove the plastic rivet e securing the fender to the chassis 4 Disconnect the black negative battery cable r first 5 Disconnect the red positive cable t last 6 Pull the fender away from the battery compartment to gain better access 7 Remove the battery hold down strap y 8 Remo...

Page 144: ...g harness do not come into contact with the brake disc Move the wiring harness cables behind the chassis tube and away from the brake disc IMPORTANT Route the BROWN harness ground wires e and BLACK main battery ground cable r as shown in the image Both are routed up and over the rubber strap If the ground wires cable are routed down the side of the battery they may interfere with the rear side pan...

Page 145: ...the battery IMPORTANT Do not remove the sealing strip until ready to activate the battery 2 Remove the top strip of caps on the electrolyte package NOTICE Retain this strip of caps for battery sealing after it has been filled WARNING DO NOT pierce or otherwise open the foil seals on the electrolyte container or attempt to separate the individual electrolyte containers 3 Place the electrolyte conta...

Page 146: ...to the top of the battery NOTICE Only install caps by hand DO NOT use a hammer or excessive force IMPORTANT Ensure the sealing caps are flush with the battery NOTICE Maximum battery performance and longevity depends on following the rest and charging activation steps 7 Allow battery to stand for 1 2 hours This allows the electrolyte to permeate the plates for optimal performance 8 Charge the batte...

Page 147: ... SEASON STORAGE Whenever the vehicle is not used for a period of two months or more remove the battery from the vehicle ensure that it is fully charged and store it out of the sun in a cool dry place Check battery voltage each month during storage and or recharge as needed to maintain a full charge NOTICE Battery charge can be maintained by using a Polaris battery tender charger or by charging onc...

Page 148: ...ptics are always powered when engine is running Selecting high beam adds the high beam optics to the array If equipped with electric start and 7S display accent optics will be powered when key is in the on position Lights are powered by the display when not running so they will go off when the display dims or times out to low power mode The taillight w assembly features LED elements and are not se...

Page 149: ...boards 3 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height w 4 Start the engine Move the headlight switch to low beam 5 Observe the headlight aim on the wall There should be a distinct horizontal line on the wall from the low beam That line should align with the mark on the wall w ADJUSTMENT 1 Shut off engine WARNING To prevent seriou...

Page 150: ...E SWITCH TRS The throttle release switch TRS is designed to stop the engine if all pressure is removed from the throttle lever and the throttle cable or throttle plates do not return to the normal closed position WARNING If the throttle release switch does not shut off the engine during a throttle system malfunction immediately push down the auxiliary engine stop switch Do not start the engine aga...

Page 151: ...abel 4 Position the snowmobile outside in a well ventilated area 5 Start and run the engine for 10 15 minutes to distribute the treated fuel throughout the fuel system NOTICE On Carbureted engines 550cc 120 Youth run the engine for 10 15 minutes and then turn the fuel shut off valve to OFF Continue to run the engine until the engine stalls and turns off Doing this drains the carburetors of fuel FO...

Page 152: ...he battery 3 Inspect the electrical connections and wire harnesses throughout the snowmobile If damage is found make a note of the damage so that you and your authorized Polaris dealer can address the concern CHAINCASE Never leave used lubricant in the chaincase during the storage season Doing so may leave water present in the chaincase which may cause corrosion and rust 1 Follow the Owner s Manua...

Page 153: ...ed metal components such as the exhaust pipe silencer shock shafts and suspension springs pivots IMPORTANT Do not spray metal protectant on the drive or driven clutches LUBRICATE THE PIVOTS After washing the snowmobile it is important to use Polaris Premium All Season grease to lubricate the various suspension steering pivot points Doing so forces any water accumulated within the joints out which ...

Page 154: ...2 66 9850064 R03 2021 650 850 Matryx Trail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc NOTES MAINTENANCE ...

Page 155: ...HECK VALVE TESTING 3 16 CROSS SHAFT OIL GALLERY OUTLET CHECK VALVE REPLACEMENT 3 16 ELECTRONIC OIL PUMP RESISTANCE CHECK 3 22 ELECTRONIC OIL PUMP PRIME PROCEDURE 3 22 ELECTRONIC OIL PUMP MANUAL PRIME PROCEDURE 3 24 DIGITAL WRENCH ELECTRONIC OIL PUMP FLOW OFFSET 3 25 ELECTRONIC OIL PUMP TROUBLE CODES PROTECTION MODE 3 27 CRANKCASE WEEP HOLE 3 27 OIL TANK 3 28 OIL TANK ASSEMBLY VIEW 3 28 OIL TANK RE...

Page 156: ...INDER HEAD REMOVAL 3 75 CYLINDER HEAD INSPECTION 3 76 CYLINDER REMOVAL 3 77 CYLINDER INSPECTION 3 78 CYLINDER HONING 3 79 PISTON REMOVAL 3 80 PISTON MARKINGS 3 81 PISTON INSPECTION 3 81 PISTON RING MARKINGS 3 82 PISTON RING INSTALLED GAP 3 82 PISTON NEEDLE BEARING 3 83 ENGINE DISASSEMBLY INSPECTION BOTTOM END 3 84 GENERAL INFORMATION BOTTOM END 3 84 CRANKCASE DISASSEMBLY 3 84 CRANKSHAFT REMOVAL 3 ...

Page 157: ... DIGITAL WRENCH DATA DISPLAY 3 123 EV ACTUATOR LEARN PROCEDURE 3 124 EV ACTUATOR MOUNTING 3 127 EV ACTUATOR WIRE HARNESS CONNECTOR 3 128 EV ACTUATOR CONNECTOR PINOUT 3 128 COOLING SYSTEM 3 129 COOLING SYSTEM ASSEMBLY VIEW 3 129 COOLANT BOTTLE ASSEMBLY VIEW 3 130 COOLING HOSE HOT SIDE ROUTING RETENTION 3 131 COOLING HOSE COLD SIDE ROUTING RETENTION 3 133 COOLANT BOTTLE THERMOSTAT REMOVAL 3 135 COOL...

Page 158: ...3 4 9850064 R03 2021 650 850 Matryx Trail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc EXHAUST MANIFOLD INSTALLATION 3 154 EXHAUST INSTALLATION 3 155 ENGINE COOLING EXHAUST ...

Page 159: ...To reset the Oil Pump Enrichment Mode Timer see Oil Pump Enrichment Mode Timer Reset page 1 57 BREAK IN FUNCTION ENGINE RUN TIME DURATION DESCRIPTION Fuel Injectors 2 hours 2 additional fuel Oil Pump Enrichment Period 10 Hours 15 additional enriched oil supply to engine Total engine run time above 3 500 RPM The Electronic Oil Pump Prime procedure MUST be performed using Digital Wrench whenever the...

Page 160: ...Manual Copyright Polaris Inc SPECIAL TOOLS PU 52498 Heavy Duty Flywheel Puller PS 51732 A E VES Guillotine Alignment Tool PS 52573 Next Gen Service Power Harness PU 52602 Flywheel Holding Tool PU 52497 33mm Drive Clutch Taper Reamer 2870390 Piston Support Block ENGINE COOLING EXHAUST ...

Page 161: ...Pick Set PU 45431 Depth Micrometer Set PV 34673 Precision Straight Edge PV 3009 75 100 mm Micrometer PU 45149 Hose Pincher 2870852 14 mm Compression Gauge 2870630 Battery Powered Timing Light PV 43554 V Block Set Special tools may be required while servicing this vehicle Some of the tools listed or depicted are mandatory while other tools may be substituted with a similar tool if available Polaris...

Page 162: ...rogrammed into the ECU A flow offset number is assigned to each oil pump at the time of manufacture The part number label q on the oil pump housing will have the three digit offset number w printed on it The seven digit number preceding the is the Polaris part number and subject to change Item e is the manufacturing serial number and not used If replacing the electronic oil pump with a new part no...

Page 163: ...il pump housing label is missing or damaged flow offset identification can be determined by noting the number and location of the pin stamp s on the plastic housing In the image there is one pin stamp in location q The flow code would be 001 OIL PUMP FLOW OFFSET CODE PIN STAMPS Offset Code q q w w e e 001 X 002 X 003 X 004 X X 005 X X X ENGINE COOLING EXHAUST ...

Page 164: ...3 2021 650 850 Matryx Trail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc OIL PUMP LINE CONNECTIONS Match the oil line and fittings as shown when installing the oil pump ENGINE COOLING EXHAUST ...

Page 165: ...e Injector e Low LO 11 02 in 280 mm CTR Crank Bearing r High HI 9 45 in 240 mm MAG Lower Case Injector t Low LO 9 45 in 240 mm MAG Crank Bearing y Oil Supply Hose Connects to Oil Tank 18 11 in 460 mm N A IMPORTANT High HI ports connect to Lower Case Injectors ONLY NOTICE Perform Oil Pump Prime procedure in Digital Wrench if engine oil supply lines have air bubbles larger than 1 in 2 54 cm or the l...

Page 166: ... check valve fitting the two wires of the clamp q have to be around the center barb on the fitting w IMPORTANT If an oil supply hose falls off of a check valve the check valve must be pressure tested to ensure it works properly If the center crankcase waterpump cross shaft oil supply hose falls off of the check valve the internal outlet check valve must be pressure tested ENGINE COOLING EXHAUST ...

Page 167: ...laris Inc 3 13 OIL SUPPLY HOSE ROUTING NOTICE Images for reference only 1 From the electronic oil pump route the oil supply hose up to the oil hose support and secure with a panduit strap q 2 Continue routing the oil supply hose up to the oil tank fitting and secure with clamp w ENGINE COOLING EXHAUST ...

Page 168: ...and sealed the external center gallery check valve pop off pressure can vary between 3 17 psi 20 7 117 2 kPa because of the level of oil in the center gallery cavity When pressure testing the external center gallery check valve verify oil is not leaking from the crankcase weep hole IMPORTANT Always replace a check valve that fails to achieve the minimum opening pressure of 3 psi 20 7 kPa before op...

Page 169: ... is installed in the snowmobile the box end of a long ratchet extension can placed over the end Check Valve Fitting Press Tool to install the PTO oil check valve fitting into the crankcase NOTICE Image for reference only Be careful not to damage any wiring when sliding the ratchet extension down behind the air intake side tube q Ratchet Extension e PTO Oil Check Valve Fitting w Check Valve Fitting...

Page 170: ...weep hole If the test results are outside if the specifications listed above the external center gallery check valve and cross shaft oil gallery outlet check valve must be replaced CROSS SHAFT OIL GALLERY OUTLET CHECK VALVE REPLACEMENT 1 Follow the following Engine Disassembly Inspection Top End procedures Remove the cylinder head See Cylinder Head Removal page 3 75 Remove the cylinder See Cylinde...

Page 171: ...eal about a 1 8 1 6 in 3 17 4 23 mm bolt gap 7 Once loosened carefully and lightly tap on the fasteners to separate the crankcase halves 8 Finish removing the outer crankcase fasteners 9 Carefully lift straight up and remove the lower crankcase half e NOTICE Crankcase ring land damage in the area shown is caused by improper crankcase separation ENGINE COOLING EXHAUST ...

Page 172: ...er crankshaft removal 11 Discard the PTO and MAG crankshaft seals 12 With the upper crankcase half removed remove the oil check valve fitting t using a punch to extract it from the top side NOTICE Note the orientation of the fitting to ensure proper installation 13 Apply a drop of green Loctite 603 to the new oil check valve fitting barrel y IMPORTANT Be careful not to drip any Loctite on the inle...

Page 173: ...using a foam brush to the PTO bearing cavity of the upper crankcase half in the locations shown NOTICE Do not over apply Loctite in oil injector area Doing so may block the oil passage Keep Loctite out of the snap ring groove 16 Install the crankshaft i into the upper crankcase using two new crankcase seals STOP During installation make sure the PTO bearing snap ring o is installed in the groove o...

Page 174: ...nkcase mating surface following the details outlined in the crankcase sealant path procedure See Crankcase Sealant Path page 3 55 NOTICE Do not over apply sealant in oil injector area Doing so may block the oil passage 21 Install the lower crankcase f NOTICE Ensure water pump cross shaft turns and indexes with crankshaft during assembly STOP During installation make sure the PTO bearing snap ring ...

Page 175: ...ligns with the notch in the water pump cover 25 Install the water pump cover and cover fasteners Torque fasteners to specification TORQUE Water Pump Cover Fasteners 9 ft lbs 12 N m Torque in sequence page 3 50 26 Follow the Stator Flywheel Service procedures Install the stator See Stator Installation page 3 67 Install the flywheel See Flywheel Installation page 3 68 27 Install the Recoil See Recoi...

Page 176: ...re is used to purge the engine oil supply lines of air and to verify the ECU can drive the oil pump NOTICE Fill the oil tank with oil prior to starting this procedure Verify the engine oil supply lines are connected to the engine and the oil pump supply hose is connected to the pump and oil tank The Oil Pump Prime Procedure is a Service Procedure performed with Digital Wrench The procedure must be...

Page 177: ...equipped with a fully charged battery it can be used to supply power to the test connectors If using a stand alone service battery do not place the battery in the tunnel footwells Place the battery on the floor next to the engine compartment 6 Connect the SmartLink cable to the vehicle and PC laptop 7 Start Digital Wrench and select the appropriate vehicle 8 Select the Special Tools Tool Box menu ...

Page 178: ...btain a fully charged 12 volt battery and the Chassis Power Up Harness Chassis Power Up Harness PS 47296 B 2 In addition to the Chassis Power Up Harness the oil pump manual prime procedure requires the Dual Power Up Adapter to allow for three connectors to be powered Dual Power Up Adapter PS 50805 3 Open the left engine compartment panel 4 Connect the Next Gen Service Power Harness to the diagnost...

Page 179: ... The seven digit number preceding the is the Polaris part number and subject to change Item e is the manufacturing serial number and not used 1 Verify the most current update has been downloaded and loaded into Digital Wrench 2 Obtain a fully charged 12 volt battery and the Chassis Power Up Harness Chassis Power Up Harness PS 47296 B 3 Open the left engine compartment panel 4 Connect the Next Gen ...

Page 180: ... select Oil Pump Replacement 12 The next screen will display the current offset value at the top This number must match the number on the oil pump and the ECU label If the offset number on the oil pump does not match what is shown on the screen enter the correct three digit number into the New Oil Pump Offset field Click Continue to proceed 13 After setting the correct oil pump flow offset number ...

Page 181: ...tected in the Oil Pump Driver Circuit Can be caused by Damaged Wiring Connections a Faulty Oil Pump Connections or Faulty ECU Connections If either DTC is set by the ECU the ECU will enable a reduced engine power mode The driver should turn off the engine immediately to prevent serious engine damage Ensure that the wire harness connector is connected and secured to the oil pump housing and the wir...

Page 182: ...ile Service Manual Copyright Polaris Inc OIL TANK OIL TANK ASSEMBLY VIEW q Oil Cap y Oil Tank Mounting Fasteners 7 ft lbs 9 N m w Fitting u Washer e Flanged Grommet i Clutch Guard r Oil Tank o Clutch Guard Fasteners 8 ft lbs 10 N m t Oil Level Switch ENGINE COOLING EXHAUST ...

Page 183: ... connector q 3 Remove the oil tank mounting fasteners w and washers e 4 Slide the oil tank forward and tilt it on its side to gain access to the oil line fitting 5 Slide the springband clamp r down the oil line 6 Remove the oil line t from the fitting y and quickly plug the fitting hole NOTICE Place a rag under the fitting to catch any spilled oil 7 Remove the oil tank u ENGINE COOLING EXHAUST ...

Page 184: ...tch any spilled oil 2 Secure the oil line with the springband clamp r 3 Slide the oil tank into position and align mounting holes with the mounting brackets on the clutch guard 4 Install washers e and oil tank mounting fasteners w Torque fastener to specification TORQUE Oil Tank Mounting Fasteners 7 ft lbs 9 N m 5 Connect the oil level sender q 6 Verify the oil tank has the specified amount of flu...

Page 185: ...e Exhaust Removal page 3 152 NOTICE The strain relief retaining the wiring harness to the intake plenum will be cut during resonator removal 4 Remove the console See Console Removal page 9 23 5 If the vehicle is equipped with a battery disconnect the battery negative terminal at this time 6 Draw the recoil slowly then tie a knot in the rope near the recoil housing to secure the rope 7 Remove the r...

Page 186: ...illed oil 13 Remove the oil tank u 14 Remove the fasteners i retaining the rear of the clutch guard o and remove the clutch guard by sliding the front out of the fender 15 Remove the push rivets a retaining the intake tube to the intake plenum 16 Remove the cable tie s securing the upper intake tube to the chassis 17 Remove the diagnostic connector d from the cap 18 Remove the fastener f retaining...

Page 187: ... remove the intake plenum assembly k 23 Remove the drive belt drive clutch and driven clutch See the following procedures for removal Drive Belt Removal page 2 24 Drive Clutch Removal page 7 14 Driven Clutch Removal page 7 26 24 Remove the fasteners l retaining the PTO side cross brace 1 Remove the PTO side cross brace NOTICE The PTO side chassis cross brace can either be removed completely or rem...

Page 188: ...val 27 Remove spark plugs 2 from engine to aid in engine removal 28 Tape the holes for the spark plugs shut to prevent debris form entering the cylinders 29 Disconnect the PBR connectors 2 and Stator connector 2 from the PBR 30 Remove the fasteners 2 securing the PBR and remove the PBR 31 Cut the cable tie 2 and disconnect the T MAP sensor harness connector 2 32 Cut the cable tie of the routing cl...

Page 189: ...aust valve assembly a Do not remove the actuator cable 3 off of the actuator pin The cable will remain installed b Remove the four exhaust valve base fasteners 3 retaining the electronic variable exhaust system c Turn the handlebars to the right d Pull the EV cable taut to bring the valves to the full open position and remove the exhaust valve assembly 3 from the engine e With the exhaust valve as...

Page 190: ...r installation 37 Remove the stator connector 3 from the wiring harness 38 Remove the cable ties 3 from the wire supports NOTICE Do not remove the cable tie securing the support to the coolant hose 39 Remove the fuel injector harness 3 and oil pump connector 3 from the wiring harness Remove the connectors from the connector placement bracket NOTICE Do not attempt to disconnect the fuel injectors f...

Page 191: ...otor See Starter Motor Flex Drive Removal page 10 91 43 If cooling system was not previously drained place a drain pan under the engine 44 Remove the coolant bottle cap 45 Drain the coolant system by removing the coolant hose from the water pump cover 46 Remove the coolant hose 4 from the cylinder head 47 Place a rag under the fuel line connectors 4 and disconnect the fuel lines on the mag side of...

Page 192: ...outing clips securing the fuel injector harness to the throttle body Loosen the two gear clamps 51 Remove the left side engine mounting bolts 4 52 Remove the right rear engine mounting bolt 4 53 54 Lift oil pump out of bracket as it needs to come out with the engine 55 The engine can now be removed by lifting the intake side of the engine up Pull the engine up and back slightly and remove it on th...

Page 193: ...CE Apply Loctite 262 to 4 6 threads in middle of threaded section of the fastener prior to installation 5 Loosely install the washer and right rear engine mounting bolt 4 NOTICE Apply Loctite 262 to 4 6 threads in middle of threaded section of the fastener prior to installation 6 Loosely install the fasteners 4 securing the right front engine mount from the bottom of the clip 7 Torque all the engi...

Page 194: ...nect locks on the lines IMPORTANT Perform a push pull test on the fuel line connections with at least 5 lbs of force Connections should NOT disengage during push pull test 12 Install the coolant hose 4 onto the cylinder head 13 If the water pump cover was removed install it at this time TORQUE Water Pump Cover Fasteners 9 ft lbs 12 N m Torque in sequence page 3 50 14 Install the coolant line s on ...

Page 195: ...he wiring harness Install the connectors on the connector placement bracket 18 Route the fuel injector harness oil pump jumper harness and TPS harness into and along the side of the wire support securing the harness with new cable ties 4 19 Route and secure the stator harness and fuel injector harness in the stator wire support Continue to route the stator harness and secure in the throttle cable ...

Page 196: ...ht b Pull the EV cable taut to bring the valves to the full open position and install the EV assembly 3 c Loosely install the fasteners 3 retaining the electronic variable exhaust system Torque to specification NOTICE The shorter exhaust valve base fasteners should be positioned in the outer mounting holes TORQUE Exhaust Valve Base Fasteners 9 ft lbs 12 N m Torque in sequence page 3 50 d Verify th...

Page 197: ...TICE If the ignition coils were removed reinstall the ignition coils and torque fasteners to specification TORQUE Air Box Coil Fasteners 36 in lbs 4 N m 25 Install new cable tie on air box routing clip 2 to secure the stator wiring harness and throttle cable 26 Connect the T MAP Sensor 2 to the wiring harness and install new cable tie 2 to secure wiring 27 Install the PBR and fasteners 2 Torque fa...

Page 198: ...he wire harness and install the spark plug caps 2 onto the spark plugs NOTICE Make sure the spark plug wires snap into place Be sure the MAG and PTO plug wires are correct 31 Install the fasteners l that retain the support brace 1 TORQUE Left Support Brace Fasteners 22 ft lbs 30 N m 32 Install the drive clutch driven clutch and drive belt See the following procedures for installation Drive Clutch ...

Page 199: ...ing the wiring harness to the intake plenum 35 Connect the ECU to the wiring harness h 36 Carefully install the intake tube assembly g NOTICE Ensure the intake tube is properly seated to the air box and properly aligned with the intake plenum 37 Install the fastener f retaining the lower intake tube Torque the fastener to specification TORQUE Lower Intake Tube Fastener 36 in lbs 4 N m ENGINE COOLI...

Page 200: ...tube to the chassis 40 Install the push rivets a retaining the intake tube to the intake plenum 41 Slide the front of the clutch guard o into the body work Install the fasteners i at the rear of the clutch guard TORQUE Clutch Guard Nuts 8 ft lbs 10 N m 42 Install the oil tank u by quickly installing the oil line t onto the fitting y NOTICE Place a rag under the fitting to catch any spilled oil ENG...

Page 201: ... Verify the oil tank has the specified amount of fluid 48 Draw the recoil slowly then untie the knot in the rope near the recoil housing Pull rope through the console 49 Install the recoil handle 50 Install the console See Console Installation page 9 25 51 If the vehicle is equipped with a battery connect the battery negative terminal at this time 52 Install the resonator and tuned pipe See Exhaus...

Page 202: ...n 129 137 S6095 6544 LO6R 650 Indy VR1 129 137 650 Switchback Assault 146 ENGINE SPECIFICATIONS ENGINE MODEL NUMBER RANGE HEAD SQUISH MM INCHES PISTON TO CYLINDER CLEARANCE MM INCHES PISTON RING END GAP MM INCHES TRIGGER TO FLYWHEEL GAP MM INCHES ALL ENGINES MINIMUM 1 290 mm 0 051 in 0 121 mm 0 004 in 0 45 mm 0 017 in 0 36 mm 0 014 in NOMINAL 0 9 mm 0 035 in MAXIMUM 1 630 mm 0 064 in 0 139 mm 0 00...

Page 203: ...nch Edition 129 137 S6186 8444 LO8R 850 Indy VR1 129 137 850 Switchback Assault 146 ENGINE SPECIFICATIONS ENGINE MODEL NUMBER RANGE HEAD SQUISH MM INCHES PISTON TO CYLINDER CLEARANCE MM INCHES PISTON RING END GAP MM INCHES TRIGGER TO FLYWHEEL GAP MM INCHES ALL ENGINES MINIMUM 1 290 0 051 0 145 0 0057 0 40 0 016 0 36 0 014 NOMINAL 0 9 0 035 MAXIMUM 1 630 0 064 0 155 0 0061 0 50 0 020 1 34 0 052 ENG...

Page 204: ... Snowmobile Service Manual Copyright Polaris Inc COMPONENT TORQUE SEQUENCES Certain engine components must be torqued in sequence Refer to this section for fastener torque sequences while servicing the engine CYLINDER HEAD MONOBLOCK CYLINDERS ENGINE COOLING EXHAUST ...

Page 205: ...3 9850064 R03 2021 650 850 Matryx Trail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc 3 51 ELECTRONIC VARIABLE EXHAUST VALVE COVER EXHAUST MANIFOLD ENGINE COOLING EXHAUST ...

Page 206: ...3 52 9850064 R03 2021 650 850 Matryx Trail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc INTAKE CRANKCASE ENGINE COOLING EXHAUST ...

Page 207: ...3 9850064 R03 2021 650 850 Matryx Trail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc 3 53 RECOIL HOUSING WATERPUMP COVER ENGINE COOLING EXHAUST ...

Page 208: ... 650 850 Matryx Trail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc COMPONENT ORIENTATION VIEWS q DET Sensor 60 10 toward PTO Side q Orient Throttle Body Clamps at 6 O Clock 10 ENGINE COOLING EXHAUST ...

Page 209: ...es must be cleaned using a gasket scraper and then wiped clean with Acetone Maximum case sealant working time is 10 minutes Crankcase halves must be installed and fasteners torqued to specification within 10 minutes of initial sealant application After the proper torque has been applied to the crankcase fasteners allow crankcase sealant to cure for at least 1 hour before proceeding with engine rea...

Page 210: ...n or smeared using a finger to flatten the bead but must be biased toward the outer edges of the case mating surface The desired sealant coverage is when a very thin layer of sealant is covering the entire mating surface with ZERO sealant near the inner edges of the water pump cross shaft gallery between the two seal grooves q ENGINE COOLING EXHAUST ...

Page 211: ...s 31 N m u Cylinder Base Gasket w Spark Plug i Cylinder Fasteners M10 x 1 50 x 127 40 ft lbs 54 N m Apply VES oil under fastener head and to threads prior to installation e Cylinder Head o Cylinder Fasteners M10 x 1 50 x 83 40 ft lbs 54 N m Apply VES oil under fastener head and to threads prior to installation r O Ring a Throttle Body Coolant Hose t O Ring s Springband Clamp y Cylinder ENGINE COOL...

Page 212: ...ase Fasteners M8 x 1 25 x 80 24 ft lbs 32 N m Apply VES oil under fastener head and to threads prior to installation w Check Valve Oil Fitting u Dowel Pin e Lower Crankcase i Flanged Seal r Flanged Seal o Hollow Dowel t Crankcase Fasteners M8 x 1 25 x 50 24 ft lbs 32 N m Apply VES oil under fastener head and to threads prior to installation ENGINE COOLING EXHAUST ...

Page 213: ...le Service Manual Copyright Polaris Inc 3 59 PISTON CRANKSHAFT ASSEMBLY VIEW q Piston Ring y Crankshaft Assembly w Piston u Bearing PTO Snap Ring e Piston Pin i Bearing PTO Bearing is slip fit r Piston Circlip o Bearing t Bearing MAG a Woodruff Key ENGINE COOLING EXHAUST ...

Page 214: ...TATOR FLYWHEEL ASSEMBLY VIEW q Stator t Recoil Starter Pulley w Stator Fasteners M6 x 1 0 x 32 12 ft lbs 16 N m y Flywheel Flange Nut M14 x 1 50 90 ft lbs 122 N m e Flywheel u Stator Wire Retainer r Recoil Starter Pulley Fasteners 10 ft lbs 13 N m i CPS Fasteners M5 x 0 8 x 10 53 in lbs 6 N m ENGINE COOLING EXHAUST ...

Page 215: ...1 25 18 ft lbs 24 N m w Front PTO Engine Mount u Rear MAG Engine Mount Bracket Mount Bracket to be retained while mount nut is torqued e Rear PTO Engine Mount i Rear MAG Engine Mount r Engine Mount Fasteners M8 x 1 25 x 20 18 ft lbs 24 N m o Front MAG Engine Mount t Rear PTO Engine Mount Bracket Mount Bracket to be retained while mount nut is torqued a Front MAG Engine Mount Bracket Mount Bracket ...

Page 216: ...ater to cross shaft prior to seal assembly at seal shaft interface w Water Pump Cover i Oil Seal Install with spring towards intake side of engine e Water Pump Cover Seal o Retaining Ring r Water Pump Driven Shaft Nut M8 x 1 25 9 ft lbs 12 N m a Ball Bearing t Water Pump Impeller s Water Pump Driven Shaft Ensure cross shaft turns and indexes with crankshaft during assembly y D Washer d Ball Bearin...

Page 217: ...3 9850064 R03 2021 650 850 Matryx Trail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc 3 63 ENGINE COOLING EXHAUST ...

Page 218: ...x Trail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc REED VALVE ASSEMBLY VIEW q Reed Throttle Body Adapter Fasteners 12 ft lbs 16 N m e Throttle Body Adapter w Gear Clamps r Reed Assemblies ENGINE COOLING EXHAUST ...

Page 219: ...ove the recoil starter pulley fasteners q and recoil starter pulley w from the flywheel NOTICE The recoil fan is balanced and can only be installed on the flywheel one way because of an asymmetrical hole pattern 5 Secure the flywheel using the Flywheel Holding tool e Start by aligning all the mounting holes and install the two shoulder bolts e into the flywheel until they bottom out Then install t...

Page 220: ...rews into the magneto stator located behind the flywheel 9 Turn the puller center bolt in until the flywheel o pops off of the crankshaft STATOR REMOVAL INSPECTION 1 Remove the flywheel See Flywheel Removal Inspection page 3 65 2 Remove the fasteners q securing the trigger coils 3 Remove the stator wire retainer w that prevents the trigger coil wires from contacting the flywheel 4 Remove the three...

Page 221: ...res will be pulled through the cutout in the crankcase STATOR INSTALLATION 1 Carefully install the magneto stator q into the crankcase NOTICE The stator wires will be pulled through the cutout in the crankcase 2 Align the magneto stator mounting holes and install the three stator fasteners w Torque fasteners to specification TORQUE Stator Fasteners 12 ft lbs 16 N m 3 During assembly route the stat...

Page 222: ...installation 2 Secure the flywheel using the Flywheel Holding tool Start by aligning all the mounting holes and install the two shoulder bolts into the flywheel until they bottom out Then install three of the fasteners from the recoil starter pulley into the crankcase Flywheel Holding Tool PU 52602 NOTICE Ensure there is a little play and the flywheel is able to move freely when all fasteners are ...

Page 223: ...d section Torque fasteners to specification TORQUE Recoil Starter Pulley Fasteners 10 ft lbs 13 N m NOTICE The recoil fan is balanced and can only be installed on the flywheel one way because of an asymmetrical hole pattern 5 Install the recoil housing and fasteners Torque fasteners to specification TORQUE Recoil Housing Fasteners 9 ft lbs 12 N m Torque in sequence page 3 50 6 Reinstall the exhaus...

Page 224: ... The following components will need to be removed or disconnected for reed valve inspection Side panels and hood Resonator Oil tank Air box Throttle body Refer to the applicable sections of the service manual for removal procedures 1 Remove the throttle body adapter fasteners q and then remove the throttle body adapter 2 The throttle body adapter w uses integrated stuffers Inspect and replace adap...

Page 225: ...ired REED PETAL REPLACEMENT INSPECTION If the engine becomes hard to start idle RPM is higher than normal throttle response deteriorates or a lean operating condition is encountered the throttle body adapter and reed valve assemblies should be inspected Inspect each reed petal There should be no cracks or chipping on any of the petals Inspect the reed cages for damage Make sure the rubber tips are...

Page 226: ...s Reed valve disassembly tool 1 Insert the supplied reed cage disassembly tool q between the reed and reed stop Push the tool firmly to release the tabs 2 Remove the inner cage w from the outer flange e 3 Remove and discard the two outer reed petals r 4 Use a small flat blade screw driver to pry the inner reed retainers t out of the inner cage Discard the retainers 5 Remove and discard the two inn...

Page 227: ...it 3 Place the two inner reeds into the center of the inner reed cage making sure they are at the bottom 4 Separate the inner reeds with your finger and then place a new retainer bar e on an upward angle making sure it fits between the inner reeds 5 Slide the retainer bar into the inner cage making sure it is parallel to the cage base and that it engages the reed locating tabs 6 Install a new reta...

Page 228: ...cage assembly t into the outer flange y as shown until the locating tabs snap into their openings When assembled correctly the inner cage should be flush with the outer flange 10 When installing each reed assembly back into the engine verify the model number A is at the bottom and MOTOTASSINARI B is at the top ENGINE COOLING EXHAUST ...

Page 229: ...nk Air intake tube assembly Intake plenum Fuel injector harness from main harness Steering post Exhaust manifold High tension wires and spark plugs DET and coolant temp sensor from main harness Drain coolant Outlet cooling hose Refer to the applicable sections of the service manual for removal procedures IMPORTANT Use Digital Wrench to reset the oil pump enrichment mode timer if the piston s cylin...

Page 230: ...bly 6 Inspect the cylinder head combustion domes for any damage Measure cylinder head flatness Replace cylinder head if required CYLINDER HEAD INSPECTION The engine cylinder head must be flat to properly seal Use a precision straight edge and a feeler gauge to inspect cylinder head for warping MEASUREMENT Cylinder Head Warp Limit 0 006 in 015 mm Replace cylinder head if warping exceeds specificati...

Page 231: ...then remove the six cylinder fasteners w 4 Carefully pull the cylinder e upward taking care not to drop the piston and rod abruptly against the crankcase NOTICE The space between the cylinder studs and over structure is limited Be careful not to damage the over structure during cylinder removal 5 Remove the cylinder base gasket r Clean the gasket residue from the crankcase and cylinder bases 6 Ins...

Page 232: ...to the pin Y to determine if the bore is out of round Repeat the measurements at a point just above the exhaust port and at a point below the transfer port Use the chart below and record all measurements CYLINDER MEASUREMENT WORKSHEET q TOP Measured 0 78 in 20 mm from top of cylinder X Y w MIDDLE Measured above exhaust port X Y e BOTTOM Measured below transfer port X Y Out of Round Top X Top Y and...

Page 233: ... hone in cylinder and tighten stone adjusting knob until stone contacts the cylinder walls DO NOT OVERTIGHTEN 4 Apply honing oil to the stones and cylinder walls Wet honing removes more material faster and leaves a more distinct pattern in the bore 5 Using a 1 2 in 13 mm drill motor rotating at a speed of 300 500 RPM run the hone in and out of the cylinder rapidly until cutting tension decreases R...

Page 234: ...piston slightly with a heat gun if pin cannot be removed by hand IMPORTANT Do not apply heat to the piston ring The ring may lose radial tension If needed the piston can also be removed using a Piston Puller and the correct Pin Puller Adapter Piston Pin Puller PU 45255 Pin Puller Adapter PS 47055 5 Remove the piston from the connecting rod 6 Carefully remove top compression ring e by hand or using...

Page 235: ... is the only recommended tool to accurately measure piston diameter Check piston for scoring or cracks in piston crown or pin area Excessive carbon buildup below the ring lands is an indication of piston ring or cylinder wear Using a micrometer measure the piston outside diameter at a 90 angle to the direction of the piston pin and at the specified measuring pointq MEASUREMENT Piston Measuring Poi...

Page 236: ...xcessive taper and out of round Replace rings if the installed end gap exceeds the service limit Always check piston ring installed gap after re boring a cylinder or when installing new rings 1 Position the ring q 0 79 in 20 mm from the top of the cylinder using the piston to push it squarely into place 2 Position the ring below the transfer port using the piston to push it squarely into place MEA...

Page 237: ...needle bearing and pin in connecting rod 4 Rotate pin slowly and check for rough spots or any resistance to movement 5 Slide pin back and forth through bearing while rotating and check for rough spots 6 With pin and bearing centered in rod twist ends back and forth in all directions to check for excessive axial play 7 Pull up and down evenly on both ends of pin to check for radial play 8 Replace p...

Page 238: ...MPORTANT Use Digital Wrench to reset the oil pump enrichment mode timer if the piston s cylinder s or crankshaft are serviced replaced CRANKCASE DISASSEMBLY 1 Remove the ten inner crankcase fastenersq from the locations indicated below NOTICE The inner crankcase fasteners are longer than the outer crankcase fasteners 2 Loosen the seven outer crankcase fasteners w to reveal about a 1 6 1 8 bolt gap...

Page 239: ...ation 6 Thoroughly clean the two crankcase mating surfaces with acetone Flush out the crankcase galleries after the crankshaft and water pump shaft have been removed CRANKSHAFT REMOVAL NOTICE If crankshaft replacement is required the crankshaft must be replaced as an assembly 1 Remove the crankshaft q by pulling it straight up and out Inspect as required NOTICE Crankcase ring land damage in the ar...

Page 240: ...to easily be removed LOWER CRANKCASE CROSS SHAFT GAL LERY INSPECTION Inspect the lower crankcase cross shaft gallery q for any residual crankcase sealant particles Clean out residual sealant particles by cleaning lower crankcase and lower crankcase cross shaft gallery with brake cleaner or kerosene NOTICE Do not use Acetone or another cleaner After cleaning with brake cleaner or kerosene flush the...

Page 241: ...ay in rod by supporting rod against one thrust washer and alternately applying up and down pressure Replace bearing pin and thrust washers if side clearance is excessive or if there is any up and down movement detectable in the big end bearing MAIN BEARING INSPECTION Clean the crankshaft oil main and connecting rod bearings thoroughly with Polaris engine oil Carefully check each main bearing q on ...

Page 242: ... bearing is a slip fit bearing The bearing can be re used if it passes inspection 1 Inspect the outer races q for signs of damage or overheating 2 Inspect rollers w and roller cage e for damage 3 Inspect the snap ring r for damage If slip fit bearing passes inspection clean cured green Loctite 603 from outer race using acetone ENGINE COOLING EXHAUST ...

Page 243: ...ires striking with a hammer support crankshaft to prevent bearing damage and re check previously straightened areas to verify trueing Refer to the illustrations below Crankshaft Alignment Kit 2870569 NOTE The rod pin position in relation to the dial indicator tells you what action is required to straighten the shaft CRANKSHAFT TRUING EXAMPLES High at point q If point q measures high strike the sha...

Page 244: ...ection MEASUREMENT Crankshaft Runout Limit 0 0025 in 0 030 mm CRANKSHAFT INDEX Polaris crankshafts are pressed together The connecting rod journal center lines are indexed 180 apart from each other It is sometimes necessary to check multi cylinder crankshafts to verify that one cylinder has not been forced out of position relative to the other cylinder Symptoms of an out of index crankshaft can in...

Page 245: ... by tipping the engine Remaining coolant may also be removed using a fluid transfer pump or wet dry vac 2 Remove the water pump cover fasteners q and cover w 3 Discard the water pump cover seal e 4 Remove the impeller nut r impeller t and washer y from the water pump drive shaft 5 To remove the mechanical seal u use Water Pump Seal Remover Start by removing the fastener and seal remover body from ...

Page 246: ...removal 8 Turn the Seal Remover tool center bolt until the mechanical portion of the mechanical seal is removed Carefully disassemble any remaining pieces of the mechanical seal until just the mechanical seal body is remaining 9 Remove both seal remover body fasteners from the tool and rotate the seal remover body halves so the tapered end is on the outside Reinstall the fastener on one side 10 In...

Page 247: ...3 Twist a screw into the oil seal i and remove the oil seal from the crankcase Discard the seal IMPORTANT Do not pry on the water pump mating surface or bore as crankcase damage may occur 14 Remove the snap ring o IMPORTANT Do not pry on the water pump mating surface or bore as crankcase damage may occur 15 The crankcase will need to be split and the crankshaft removed in order to remove the water...

Page 248: ...RTANT Use care during installation to prevent damaging the water pump bore 3 Once the water pump drive shaft assembly and snap ring have been installed the crankshaft and crankcase can be re installed See Crankshaft Installation and Crankcase Assembly NOTICE Ensure the water pump cross shaft turns and indexes with the crankshaft during assembly 4 Install the seal r NOTICE It is recommended to use ...

Page 249: ...ft Torque nut to specification TORQUE Water Pump Driven Shaft Nut 9 ft lbs 12 N m 7 Install new water pump seal o on water pump cover NOTICE Ensure the seal tab aligns with the notch in the water pump cover 8 Install the water pump cover a and cover fasteners s Torque fasteners to specification TORQUE Water Pump Cover Fasteners 9 ft lbs 12 N m Torque in sequence page 3 50 ENGINE COOLING EXHAUST ...

Page 250: ... a light coat of green Loctite 603 using a foam brush to the PTO bearing cavity of the upper crankcase half in the locations shown NOTICE Do not over apply Loctite in oil injector area Doing so may block the oil passage Keep Loctite out of the snap ring groove 2 Install the crankshaft q into the upper crankcase using two new crankcase seals STOP During installation make sure the PTO bearing snap r...

Page 251: ...t bearings NOTICE Do not fill the water pump cross shaft gallery between the two seal grooves with VES VES Extreme oil 4 Apply VES VES Extreme oil into the two connecting rod bearings t 5 With the outer race of the PTO bearing against the standoff feature of the seal apply a light coat of green Loctite 603 using a foam brush to the exposed half of the PTO bearing in the locations shown NOTICE Do n...

Page 252: ...lation make sure the outer race of the PTO bearing is against the standoff feature of the seal Do NOTallow the bearing to slide against the crankshaft 3 Loosely install the crankcase fasteners then torque fasteners in sequence to specification After the proper torque has been applied to the fasteners allow crankcase sealant to cure for at least 1 hour before proceeding TORQUE Crankcase Fasteners 2...

Page 253: ...Warm the piston to 100 130 F 38 54 C for assembly to connecting rod 2 Install the piston onto the connecting rod 3 Install the piston pin q into piston 4 Install the piston circlips w in the correct orientation 5 Install the cylinder See Cylinder Installation page 3 100 6 Install the cylinder head See Cylinder Head Installation page 3 101 ENGINE COOLING EXHAUST ...

Page 254: ...When installing a piston into a cylinder verify each piston ring opening is located at each piston ring locating pin 4 Install the six cylinder fasteners e and torque to specification NOTICE The longer cylinder fasteners should be positioned in the exhaust side mounting holes TORQUE Cylinder Fasteners 40 ft lbs 54 N m Torque in sequence page 3 50 Apply VES oil under fastener head and to threads pr...

Page 255: ...ylinder head o rings q NOTICE Apply lube as required to retain o rings during cylinder head installation 2 Install the cylinder head w 3 Install the cylinder head fasteners e and torque to specification TORQUE Cylinder Head Fasteners 23 ft lbs 31 N m Torque in sequence page 3 50 4 Install the throttle body coolant hose onto the cylinder head and slide the springband clamp r up to secure the coolan...

Page 256: ... RECOIL ASSEMBLY VIEW q Recoil Housing Fasteners 9 ft lbs 12 N m i Recoil Spacer w Recoil Housing o Recoil Friction Spring e Slide Plate a Recoil Ratchet r Recoil Spring s Friction Plate t Recoil Reel d Washer y Recoil Return Spring f Recoil Friction Plate Fastener 15 ft lbs 20 N m u Recoil Washer ENGINE COOLING EXHAUST ...

Page 257: ...ousing fasteners Note the location of the hose support for installation 3 Remove the housing e from the engine and move to work bench NOTICE If the recoil assembly is severely damaged consider replacing the complete recoil housing assembly as a service part The new service part assembly is completely assembled with the rope RECOIL HOUSING DISASSEMBLY 1 Remove the recoil housing See Recoil Housing ...

Page 258: ...the housing 2 Lubricate the center shaft and spring with Polaris Premium grease 3 If installing a new recoil rope on the reel use a utility knife to remove the silicone from the knot housing on the reel 4 Remove the old rope and replace with new Use a double overhand stopper knot to secure the new rope to the reel 5 After tieing the knot push the knot into the housing so that it is flush with the ...

Page 259: ...r a Torque fastener to specification NOTICE Apply Loctite 242 to fastener prior to installation TORQUE Recoil Friction Plate Fastener 15 ft lbs 20 N m 15 Pull rope out to its full extension and align pulley notch with rope hole in housing 16 Using a needle nose pliers or hooked wire pull a loop of rope through the notch in the reel 17 Prevent the rope from being retracted by tying a knot in the ro...

Page 260: ... Install the recoil housing q and align mounting holes 2 Install the recoil housing fasteners w and torque fasteners to specification using the specified pattern NOTICE The coolant hose support e is secured by one of the recoil housing fasteners TORQUE Recoil Housing Fasteners 9 ft lbs 12 N m Torque in sequence page 3 50 ENGINE COOLING EXHAUST ...

Page 261: ...ust first consider the characteristics of a two stroke engine The height of the exhaust port in a two stroke engine cylinder has an effect on the total power output of an engine as well as the RPM at which the power occurs Exhaust systems are tuned by design to match engine exhaust port configuration and desired power delivery characteristics Engines with relatively high exhaust ports and exhaust ...

Page 262: ...imately 6 000 to 7 200 RPM At this stage the upper valves are establishing the effective exhaust port height for each cylinder Stage 3 High Port Upper Lower Valves Fully Retracted Stage 3 valve position is set at approximately 7 200 RPM At this stage the lower valves engage the steps in the upper valves and retract the upper valves out of the exhaust ports NOTICE Exhaust valve stage positions give...

Page 263: ...t Valve Tiebar Fasteners M6 x 1 0 x 16 14 ft lbs 19 N m i Cylinder Exhaust Valve Base Seal e Exhaust Valve Tiebar o Exhaust Valve Spring r EV Valve Push Pull Cable Fastener M6 x 1 0 x 12 9 ft lbs 12 N m a Upper Exhaust Valve Guillotine t Exhaust Valve Base Fasteners M6 x 1 0 x 50 9 ft lbs 12 N m s Lower Exhaust Valve Guillotine y Exhaust Valve Base Fasteners M6 x 1 0 x 30 9 ft lbs 12 N m ENGINE CO...

Page 264: ...d continue to work without issue Only Diagnostic Trouble Codes DTCs P1403 Hardware Fault and P1409 Actuator Overheat indicate the need to replace the actuator with a new part All other DTCs associated with the E VES system should be diagnosed by inspecting the wiring wiring connectors or performing the E VES re learn procedure Always inspect the actuator s wire harness connector and verify the loc...

Page 265: ...el angle does not fall into the allowable range diagnostic code P1402 Learn Failure is generated After the actuator motor performs an acceptable learn sequence it cycles the valves in the following order stage 1 stage 2 stage 3 stage 2 and then stage 1 E VES Maintenance There is no periodic maintenance interval for inspection and or valve cleaning for the E VES system E VES guillotines are articul...

Page 266: ...il residue will accumulate on the guillotine blades springs and shafts as the E VES assembly is extracted from the cylinder The two photos are of a guillotine assembly removed from an engine with over 5 000 miles 8 046 KM on it The engine oil used during break in and subsequent driving was VES oil Top View ENGINE COOLING EXHAUST ...

Page 267: ...ans may find more or less deposits but the net result is that these deposits have no effect on E VES operation After removing the E VES assembly from the cylinder use a clean shop towel to simply wipe these deposits away from the components verify the cylinder slots are clean and that no foreign material has entered the combustion chambers IMPORTANT Never use harsh abrasives wire brushes or files ...

Page 268: ... Actuator Learn Procedure does not need to be performed if the actuator cable is removed from the actuator and actuator jam nut bracket NOTICE The EV Actuator Learn Procedure will not work if the battery cannot supply the required voltage to the actuator Do not perform this procedure with a partially charged battery Verify the battery provides a minimum of 12 5 volts before attempting procedure Ve...

Page 269: ...nents for damage or wear and replace as required E VES II DISASSEMBLY 1 Remove the E VES assembly from the cylinder See E VES II Removal page 3 114 2 Remove the exhaust valve tiebar fastenersq 3 Slide the guillotine valves out of the exhaust valve base Separate the lower w and upper e exhaust valve guillotines for inspection NOTICE The exhaust valve springs r will be removed as the guillotine valv...

Page 270: ...ve tie bar fasteners w 2 Install the E VES Guillotine Alignment Tool on the guillotine valves E VES Guillotine Alignment Tool PS 51732 A 3 Torque the exhaust valve tie bar fasteners to specification TORQUE Exhaust Valve Tiebar Fasteners 14 ft lbs 19 N m 4 Remove E VES Guillotine Alignment Tool 5 Install the upper guillotine valves e 6 Insert the springs q between the upper guillotine valves and ba...

Page 271: ...valve base fasteners e and cover screws to hand tightness NOTICE The shorter exhaust valve base fasteners should be positioned in the outer mounting holes 4 Torque the exhaust valve base fasteners u per the sequence to specification TORQUE Exhaust Valve Base Fasteners 9 ft lbs 12 N m Torque in sequence page 3 50 5 Perform the E VES actuator learn procedure with Digital Wrench See EV Actuator Learn...

Page 272: ... sets if the Exhaust Valve Actuator Position is less than 45 0 when trying to achieve Mid position This can be caused by a faulty Exhaust Valve Actuator Broken Cable or Broken Exhaust Valve Assembly 520180 16 P2631 EV Actuator Position High in Closed Position This Trouble Code sets if the Exhaust Valve Actuator Position is greater than 30 0 when trying to achieve Closed position This can be caused...

Page 273: ...pen Check the following Inspect EV relay for corrosion or loose terminals If no problems found Replace EV Relay Actuator Diagnostic 520334 31 P1409 EV Actuator Overheat Condition This Trouble Code sets if Actuator Circuit board too hot Internal short circuit Check the following Check for heat sources close to actuator If no problems found Replace EV actuator 520335 3 P1406 EV Actuator Position Dri...

Page 274: ...sed by Feedback Set signal wire is short to ground short to power or open circuit 7 P1316 Exhaust Valve Actuator Feedback Position Fault This Trouble Code sets if the Exhaust Valve Actuator Feedback Signal is missing or erratic This can be caused by Feedback signal wire is short to ground short to power or open circuit 8 P1319 Exhaust Valve Actuator Feedback Signal Missing This Trouble Code sets i...

Page 275: ...nut IMPORTANT Do not damage the Exhaust Gas Temperature EGT sensor wire 4 The rod end of the actuator cable sits on a pin To remove lift the rod end up and off of the pin 5 Hold the actuator cable as shown 6 The rod end can be pushed in and pulled out to test cable valve travel The full in to full out travel distance should meet specification MEASUREMENT E VES Cable Full In to Full Out Travel Appr...

Page 276: ...not travel the specified full in full out distance sticks or is damaged E VES service is recommended See Engine chapter for more information 10 To reinstall the actuator cable verify the cable q is routed over the bulkhead cross tube w NOTICE Exhaust pipe removed in image for clarity 11 Install the cable rod end back onto the servo motor lever pin e 12 Install cable staked nut into bracket Verify ...

Page 277: ... to the ECU PWR test and Critical PWR test connectors The data display image shows the four data items for the E VES system Digital Wrench is connected to the snowmobile with the engine off NOTICE Create a custom data list display to show the E VES data items E VES DIGITAL WRENCH DATA DISPLAY DATA ITEM DESCRIPTION q EXHAUST VALVE ACTUAL POSITION 0 0 Valves Closed 55 0 60 0 Valves at Mid Position 1...

Page 278: ...cedure with a partially charged battery Verify the battery provides a minimum of 12 5 volts before attempting procedure Verify all wires are in good condition and connectors are connected to the actuator and ECU IMPORTANT Do not attempt to increase battery voltage by connecting batteries in series EV actuator damage will occur if battery power supply exceeds 16 volts 1 Obtain a fully charged 12 vo...

Page 279: ... learn procedure by checking for faults If the software determines there is insufficient battery voltage to complete the process it is here when the software will stop and instruct the user to charge the battery 12 If no faults are encountered and there is sufficient battery voltage to proceed the learn procedure will commence NOTICE The ECU will command the EV actuator relay to open and close sev...

Page 280: ...return to the main menu 15 If a fault were to occur an error screen will appear describing what the fault was and how to resolve the issue Typically the fault will be caused by a partially charged battery or loose wire connector as noted by this error screen 16 If an error screen appears charge the battery and check for obvious mechanical issues Check all associated wires and wire connectors Click...

Page 281: ...EV actuator TORQUE EV Actuator Mount Fasteners 9 ft lbs 12 N m When installing the push pull cable e push the cable end onto the lever pin r Install the jam nuts into the actuator cable bracket t Torque to specification TORQUE E VES Actuator Cable Jam Nut 13 ft lbs 18 N m Route the push pull cable over the bulk head support tube y NOTICE The EV Actuator Learn Procedure must be performed whenever t...

Page 282: ... onto the actuator A click should be heard Then push the lock into the connector When the lock is pushed in a second click should be heard NOTICE The position of the connector lock mechanism should be checked if you are experiencing diagnostic trouble codes related to the E VES system or if the EV Learn Procedure fails due to insufficient battery voltage and the battery is supplying at least 12 5 ...

Page 283: ...ant system q Coolant Bottle o Panduit Strap w Hose Tunnel Bottle a Hose Throttle Cable Support e Springband Clamp s Fuel Oil Line Support r Hose Throttlebody Coolant Bottle d Hose Bypass t Hose Front Cooler Feed f Stator Wire Support y Hose Support Mounted on recoil housing g Asm Hose Coolant Bottle Engine u Hose Bottle Tunnel h Hose Support Mounted to upper crankcase half i Hose Electrical Wires ...

Page 284: ...ris Inc COOLANT BOTTLE ASSEMBLY VIEW q Coolant Bottle y Coolant Bottle Mounting Fasteners 7 ft lbs 9 N m w Pressure Cap u Plastic Push Rivet e Coolant Bottle Vent Line i Connector Placement Bracket r Coolant Bottle Bracket o Edge Clip t Coolant Bottle Bracket Fasteners 7 ft lbs 9 N m ENGINE COOLING EXHAUST ...

Page 285: ...l Performance Crossover Snowmobile Service Manual Copyright Polaris Inc 3 131 COOLING HOSE HOT SIDE ROUTING RETENTION Cooling hose is secured in 2 locations as shown q Cooling hose is secured in 2 locations as shown q ENGINE COOLING EXHAUST ...

Page 286: ... COOLING HOSE HOT SIDE ROUTING RETENTION CONTINUED Cooling hose is secured in 2 locations as shown q Orientation of panduit strap q on the hose throttle cable support should be pointing toward downward Orientation of panduit strap w on the stator wire support should be pointing toward upside ENGINE COOLING EXHAUST ...

Page 287: ...erformance Crossover Snowmobile Service Manual Copyright Polaris Inc 3 133 COOLING HOSE COLD SIDE ROUTING RETENTION Cooling hoses are secured in 3 locations as shown q Cooling hoses are secured in 3 locations as shown q ENGINE COOLING EXHAUST ...

Page 288: ...Performance Crossover Snowmobile Service Manual Copyright Polaris Inc COOLING HOSE COLD SIDE ROUTING RETENTION CONTINUED Cooling hoses are secured in 3 locations as shown q Cooling hose is secured in 3 locations as shown q ENGINE COOLING EXHAUST ...

Page 289: ...nd clamp securing the coolant hose to the coolant bottle 5 Drain the coolant 6 Remove the brake caliper mounting fasteners q and move the brake caliper to the side Discard caliper mounting fasteners 7 Remove the two plastic rivets w securing the connector placement bracket 8 Remove the two fasteners e securing the coolant bottle to the footrest 9 Slide the springband clamps r down the coolant hose...

Page 290: ...nt Bottle Mounting Fasteners 7 ft lbs 9 N m 4 Install the two plastic rivets w to secure the connector placement bracket to the coolant bottle 5 Install the fuel tank 6 Install new brake caliper mounting fasteners r and torque fasteners to specification TORQUE Brake Caliper Mounting Fasteners 40 ft lbs 54 N m 7 Install the fuel tank See Fuel Tank Installation page 5 29 8 Install the console See Co...

Page 291: ... Service Manual Copyright Polaris Inc 3 137 COOLANT BOTTLE OVERFLOW LINE ROUTING NOTICE Image for reference only 1 Secure the coolant overflow line routing in the locations shown below and make sure the coolant overflow line passes through the bracket ENGINE COOLING EXHAUST ...

Page 292: ... test below to verify proper thermostat operation 1 Remove the coolant bottle thermostat assembly 2 Fill a pot with distilled water 3 Place the pot on a commercially available hot plate 4 Place the coolant bottle thermostat assembly in the distilled water 5 Heat the water using a thermometer to monitor the temperature of the water IMPORTANT Heating the coolant bottle thermostat assembly excessivel...

Page 293: ...N m s Air Box w RH Intake Screen d Lower Intake Foam e RH Intake Vent f Seal Foam r RH Intake Vent Mount g Narrow Band Clamp t Intake Assembly h Dart Clip y U Clip j Lower Intake Tube Fastener 36 in lbs 4 N m u ECU Mounting Fasteners 5 ft lbs 7 N m k Drain Plug i LH Intake Vent Mount l Cable Tie o LH Intake Vent 1 Drain Plug a LH Intake Screen 2 Plastic Push Rivet ENGINE COOLING EXHAUST ...

Page 294: ...he push rivets q retaining the intake tube to the intake plenum 4 Remove the edge clip w retaining the wiring harness to the intake plenum 5 Disconnect the ECU connectors e from the wiring harness or remove the ECU mounting fasteners 6 Remove the intake plenum r AIR INTAKE PLENUM INSTALLATION 1 Install the intake plenum r 2 Connect the ECU connectors e to the wiring harness or install the ECU moun...

Page 295: ...be to the intake plenum 5 Install the console See Console Installation page 9 25 6 Install the hood and side panels AIR INTAKE TUBE REMOVAL 1 Remove the side panels and hood 2 Remove the cable tie q securing the upper intake tube to the chassis 3 Remove the fastener w retaining the lower intake tube 4 Remove the push rivets e retaining the intake tube to the intake plenum 5 Remove the diagnostic c...

Page 296: ...n assembly 2 Install the diagnostic connector into the cap on the intake tube assembly 3 Install the push rivets e retaining the intake tube to the intake plenum 4 Install the fastener w retaining the lower intake tube Torque the fastener to specification TORQUE Lower Intake Tube Fastener 36 in lbs 4 N m 5 Install a new cable tie q to secure the upper intake tube to the chassis 6 Install the hood ...

Page 297: ...uring the oil tank to the clutch guard Pull the oil tank away from the clutch guard just enough to access the intake tube screw IMPORTANT Do not damage the oil supply hose when moving the oil tank 5 Remove the fasteners e retaining the rear of the clutch guard r and remove the clutch guard by sliding the front out of the fender 6 Remove the push rivets y retaining the intake tube to the intake ple...

Page 298: ... the wiring harness to the intake plenum 13 Carefully remove the intake plenum assembly d 14 Remove the fasteners f retaining the PTO side cross brace g Remove the PTO side cross brace NOTICE The PTO side chassis cross brace can either be removed completely or remove the back bolt only and swing the tube forward This makes air box removal much easier 15 Remove the fasteners h securing the PBR and ...

Page 299: ... l from the wire harness and remove the spark plug caps 1 from the spark plugs 18 Cut the cable tie of the routing clip 2 securing the stator wiring harness and throttle cable to the air box 19 Loosen the two gear clamps 2 securing the air box to the throttle body 20 Carefully remove the air box 2 NOTICE If removal is difficult and additional space is needed remove the ignition coils from the air ...

Page 300: ...NOTICE If the ignition coils were removed reinstall the ignition coils and torque fasteners to specification TORQUE Air Box Coil Fasteners 36 in lbs 4 N m 2 Install new cable tie on air box routing clip 2 to secure the stator wiring harness and throttle cable 3 Connect the ignition coil connectors l to the wire harness and install the spark plug caps 1 onto the spark plugs 4 Connect the T MAP Sens...

Page 301: ...torque to specification TORQUE PBR Fasteners 6 ft lbs 8 N m 6 Install the fasteners f that retain the support brace g Torque the fasteners to specification TORQUE Left Support Brace Fasteners 22 ft lbs 30 N m 7 Carefully install the intake plenum assembly d into place 8 Install the edge clip s retaining the wiring harness to the intake plenum 9 Connect the ECU to the wiring harness a ENGINE COOLIN...

Page 302: ...air box and properly aligned with the intake plenum 11 Install the fastener i retaining the lower intake tube Torque the fastener to specification TORQUE Lower Intake Tube Fastener 36 in lbs 4 N m 12 Install the diagnostic connector u into the cap 13 Install the cable tie y securing the upper intake tube to the chassis 14 Install the push rivets t retaining the intake tube to the intake plenum ENG...

Page 303: ... 8 ft lbs 10 N m 16 Re install oil tank and align mounting hole Install washers w and oil tank mounting fasteners q Torque fasteners to specification TORQUE Oil Tank Mounting Fasteners 7 ft lbs 9 N m 17 Install the driven clutch and drive belt See the following procedures for installation Driven Clutch Installation Drive Belt Installation 18 Install the console See Console Installation page 9 25 1...

Page 304: ... last to install e Exhaust Spring SS i Exhaust Spring r Exhaust Seal Socket Inspect replace if damaged o Exhaust Spring t EGT Sensor s 32 ft lbs 44 N m Apply Loctite 767 64 Anti Seize as required When removing the resonator or tuned pipe disconnect the EGT sensor s from the wiring harness DO NOT REMOVE the EGT probe from the resonator or pipe if it is not necessary a Exhaust Seal Socket Inspect re...

Page 305: ...ce Crossover Snowmobile Service Manual Copyright Polaris Inc 3 151 EXHAUST MANIFOLD ASSEMBLY VIEW q Exhaust Manifold Fasteners First Pass 11 ft lbs 15 N m Second Pass 22 ft lbs 30 N m e Exhaust Manifold Gasket w Exhaust Manifold ENGINE COOLING EXHAUST ...

Page 306: ...r and the tuned pipe 3 Remove the exhaust spring w connecting the front of the resonator to the chassis 4 Remove the exhaust spring e connecting the rear of the resonator to the chassis 5 Cut the cable tie r that secures the EGTsensor to the main harness 6 Disconnect the EGTsensor t 7 Remove the exhaust spring y connecting the tuned pipe to the chassis 8 Carefully separate the resonator and tuned ...

Page 307: ...the tuned pipe to the exhaust manifold 10 From the right side of the snowmobile remove the bottom exhaust spring i connecting the tuned pipe to the exhaust manifold NOTICE An extended length exhaust spring tool aids in lower exhaust spring removal 11 Cut the routing clip o that secures the EGTsensor to the load center 12 Disconnect EGTsensor a 13 Remove the tuned pipe ENGINE COOLING EXHAUST ...

Page 308: ...d w NOTICE Discard the Exhaust Manifold gasket e EXHAUST MANIFOLD INSTALLATION 1 Prepare the engine and exhaust manifold surfaces for exhaust manifold gasket installation 2 Install the exhaust manifold and gasket torque the fasteners in sequence TORQUE Exhaust Manifold Fasteners First Pass 11 ft lbs 15 N m Second Pass 22 ft lbs 30 N m Torque in sequence page 3 50 NOTICE Image for reference only 3 ...

Page 309: ...Set the tuned pipe in place 4 From the right rear of the bellypan install the bottom exhaust spring w that connects tuned pipe to exhaust manifold NOTICE Stainless steel gray springs connect the tuned pipe to the exhaust manifold An extended length exhaust spring tool aids in lower exhaust spring removal installation 5 Install the upper exhaust springs e NOTICE Stainless steel gray springs connect...

Page 310: ...r routing clip with a new cable tie t 8 Install the Exhaust Seal Socket y NOTICE Inspect replace if damaged 9 Inspect the upper and lower resonator mounts 10 Set the resonator in place NOTICE Ensure the resonator is properly positioned on the resonator mounts 11 Install the exhaust spring u securing the rear of the resonator in place 12 Install the exhaust spring i fastening the front of the reson...

Page 311: ...ings a securing the tuned pipe to the resonator 15 Connect the EGTsensor s to the wiring harness 16 Properly route and secure the slack in the EGT sensor wire to the main harness with a new cable tie d 17 Install the EGTsensor s if removed Torque to specification TORQUE EGT Sensor 32 ft lbs 44 N m Apply Loctite 767 64 Anti Seize as required 18 Install the hood and side panels 19 Verify proper oper...

Page 312: ...3 158 9850064 R03 2021 650 850 Matryx Trail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc NOTES ENGINE COOLING EXHAUST ...

Page 313: ...MPERATURE EGT SENSOR 4 7 AIR TEMPERATURE PRESSURE SENSOR T MAP 4 8 CRANKSHAFT POSITION SENSORS CPS 4 8 CRANKSHAFT POSITION SENSOR AIR GAPS 4 9 IGNITION COIL PACKS 4 10 ENGINE COOLANT TEMPERATURE ECT SENSOR 4 10 KNOCK DET SENSOR 4 11 FUEL PRESSURE SENSOR 4 11 ELECTRONIC CONTROL UNIT ECU 4 12 ECU CNA 34 PIN CONNECTOR PINOUT 4 12 ECU CNB 34 PIN CONNECTOR PINOUT 4 13 ECU LABEL INFORMATION 4 14 ECU LOC...

Page 314: ...r all DC chassis components including hand warmers and thumb warmer RD WH BRN Circuits Gauge PWR Connect 12 VDC battery voltage to power instrument cluster lights and to supply power to EV actuator when viewing data list items and the engine is off RD BK BRN Circuits Critical PWR Connect 12 VDC battery voltage to this connector to power fuel pump and oil pump Also provides the power to the EV Lear...

Page 315: ...or LED is illuminated drive slowly and stop the engine frequently to allow it to cool down Continued engine operation with the engine hot LED illuminated may cause serious engine damage If the ECU determines serious engine damage may occur the hot lamp will flash and the engine will be shut down The ECU will also register and accumulate count the number of occurrences DTCs 110 0 or 110 16 if the e...

Page 316: ...tion cannot be controlled by normal means and further operation may cause engine damage the check engine LED will flash the instrument cluster will display DET or DETONATION and the ECU will either limit the maximum engine speed or shut off the engine If the ECU limits RPM the limit will remain active until the driver turns off and restarts the engine MODEL CHECK ENGINE LED GAUGE DISPLAY PROTECTIO...

Page 317: ...cuit is at 22 VDC via P1347 code when engine is running Faulty plugged fuel injector Use Digital Wrench to troubleshoot Exhaust valve system malfunction Verify valves are not stuck open vent hoses are not frozen or plugged Use Digital Wrench to troubleshoot Knock sensor malfunction Verify knock sensor screw torque is set to specification Air leaks Verify air intake system is sealed Check throttle ...

Page 318: ...osition and diagnostic signal The PWM converter changes these two PWM signals to analog signals and returns them to the ECU The ECU uses these signals to verify the position of the exhaust valves and system faults Throttle Position Sensor TPS The TPS relays the position of the throttle plates operator throttle input to the ECU Engine Coolant Temperature ECT Sensor Relays the engine temperature to ...

Page 319: ...nsor w is screwed into the center section of the exhaust pipe Test the sensor s using Digital Wrench The EGT will not return reliable resonator pipe temperatures when the engine is at idle speed For this reason test drive the snowmobile to bring the exhaust system up to operating temperature EXHAUST TEMPERATURE SENSOR Resistance Values 349 5Ω 392 F 200 C 767 3Ω 1562 F 850 C When removing the reson...

Page 320: ...sors are used to determine engine direction ignition fuel injection angles and engine speed The 2 tooth CPS q picks up 2 inner flywheel teeth and determines crank angle The 5 tooth CPS w picks up 5 outer flywheel teeth and determines the following Judge direction of rotation forward and backward Ignition advance angle control Injector drive angle control Excess advance ignition control at reverse ...

Page 321: ...ioned directly underneath the sensor being measured 2 Insert the blade of a 030 feeler gauge between the rib and sensor face If there is no drag felt on the feeler gauge the CPS must be adjusted 3 To adjust a CPS use an 8 inch pry bar to carefully deflect the sensor 4 Place the tip of the small pry bar between the back of the sensor and crankcase insert a 012 feeler gauge between the sensor face a...

Page 322: ...Plug Cap Resistance 5kΩ 15 68 F 20 C Test each ignition coil pack for resistance using a digital multimeter Replace the coil pack if measurements do not match specifications The high tension wires are not serviceable If the wires are damaged replace the complete coil pack ENGINE COOLANT TEMPERATURE ECT SENSOR OPERATING TEMPERATURE RANGE 22 248 F 30 120 C Resistance 2 4 2 6KΩ 68 F 20 C Measure in s...

Page 323: ...Use Digital Wrench the fuel pump prime test connector or start the engine to power the fuel pump Compare pressure results to specification NOTICE If additional information is needed on fuel pump prime see If using a battery to power the fuel pump verify the battery is fully charged Fuel Pressure 650 Models 42 to 49 psi 292 to 336 kPa 12 14 VDC Fuel Pump Power 850 Models 57 to 62 5 psi 393 to 431 k...

Page 324: ...Hard Stop Hard Stop 11 GY Left Hand Controls Reverse Signal 12 VT Oil Level Oil SW 13 OG BK Brake Switch Splice Brake SW 14 OG RD Load Center Cooling Fan Relay Control 17 DG Ignition Switch Starter Lockout 18 OG DG Load Center Battery Charge Relay Control 20 PK RD Fuel Sensor Fuel Temperature 21 DG YE Fuel Sensor Fuel Pressure 22 DG RD Ground Speed Sensor Ground Speed Signal 23 RD WH Splice Chassi...

Page 325: ...D Splice Ignition MAG 9 YE BK Ignition Coil MAG IGN MAG 10 RD DB Injector PWR Splice Injector PWR 11 GY TMAP Sensor Intake Air Pressure Signal 12 PK TMAP Sensor Intake Air Temp Signal 13 BU TPS Sensor TPS Signal 14 VT Detonation Sensor DET Signal 15 BK WH Detonation Sensor DET Sensor GND 16 BK DB Ignition GND Splice Ignition PTO 17 OG YE Ignition Coil PTO IGN PTO 18 BN WH Splice PBR Ground 1 ECU G...

Page 326: ...l injectors are replaced during service to parts with different color bands the ECU must be set to the new color code using Digital Wrench and the technician should mark the label with the new color code Likewise if the oil pump is replaced with one with a different flow offset number the ECU must be set to the new oil pump flow offset and the technician should mark the label with the new offset n...

Page 327: ... used after completing the ECU installation process Digital Wrench will transfer the original ECU s data files to the new ECU using the ECU replacement procedure 1 Reinstall the fasteners securing the ECU to the intake plenum Torque fasteners to specification TORQUE ECU Mounting Fasteners 5 ft lbs 7 N m 2 Verify the ECU wire harness connectors are clean and dry Reconnect the two ECU connectors Ver...

Page 328: ...t pulling on the throttle plate cam Turn the throttle cable in line adjuster clockwise to loosen the cable If the cable continues to pull on the throttle plate cam readjust the throttle cable threaded barrel on the throttle body All engine management sensors switches must be connected to obtain accurate TPS voltage readings Use a fully charged 12VDC battery to power the engine management system TH...

Page 329: ...er in and out The return signal line should change without any erratic jumps or gaps If erratic jumps or gaps are encountered inspect the wiring and connector pins at the sensor and ECU connector If the signal return is erratic and no wiring issues are found and the TPS is securely mounted to the throttle body replace the TPS ENGINE ELECTRICAL ...

Page 330: ...ation replace the entire throttle body assembly For additional information regarding throttle body removal see the following procedures Throttle Body Removal Throttle Body Installation NOTICE Anytime the throttle body is serviced follow the TPS wire lead routing information below 1 From the throttle position sensor TPS route the TPS wire lead back along the sensor and secure the wire lead to the s...

Page 331: ...e TPS wire lead upward toward the coolant bottle and secure on the outside of the hose electrical support with a panduit e Continue to route the TPS wire lead upward and secure in the hose electrical support with a panduit r 4 Complete routing by connecting TPS connector t to the main harness connector Secure the TPS connector to the connector placement bracket using the Christmas tree clip on the...

Page 332: ...ne when the RPM is at the lowest RPM point 4 Slowly apply throttle until the sled starts to move in reverse and carefully direct the sled in the direction that you want NOTICE Maximum RPM in reverse is 5 000 6 000 RPM If the engine stops running or is shut off while in reverse The engine will start in forward gear PERC FORWARD OPERATION NOTICE When servicing clutches ensure that the vehicle is in ...

Page 333: ...FUEL INJECTORS FUEL RAIL THROTTLE BODY 5 8 FUEL RAIL THROTTLE BODY ASSEMBLY VIEW 5 8 FUEL HOSE QUICK DISCONNECT FITTINGS 5 9 THROTTLE BODY REMOVAL 5 9 THROTTLE BODY INSTALLATION 5 14 FUEL RAIL FUEL INJECTOR REMOVAL 5 19 FUEL RAIL FUEL INJECTOR INSTALLATION 5 21 FUEL INJECTORS 5 23 FUEL INJECTOR SERVICE 5 23 FUEL TANK SERVICE 5 25 FUEL TANK ASSEMBLY VIEW 5 25 FUEL TANK REMOVAL 5 26 FUEL TANK INSTAL...

Page 334: ...othing immediately wash it off with soap and water and change clothing WARNING Gasoline is extremely flammable and explosive under certain conditions EFI components are under high pressure Verify system pressure has been relieved before disassembly Never drain the fuel system when the engine is hot Severe burns may result Do not overfill the tank The tank is at full capacity when the fuel reaches ...

Page 335: ...0 87 ETHANOL mode INTERNATIONAL FUEL For peak performance POLARIS recommend the use of 95 octane E10 gasoline or higher octane If lower octane is used some engine performance will be lost and fuel economy will decrease Do not use gasoline with higher ethanol rating than E10 REQUIRE MENT 650 MODELS 850 MODELS Minimum Fuel 95 RON E10 95 RON E10 Maximum Performance Fuel 95 RON E0 95 RON E0 REQUIRE ME...

Page 336: ... left engine compartment panel 3 Connect the Next Gen Service Power Harness to the diagnostic connector on the wiring harness Next Gen Service Power Harness PS 52573 4 Connect one of the Chassis Power Up harness leads to the ECU PWR and Chassis PWR diagnostic test connectors on the Next Gen Service Power Harness 5 Connect the power up harness to the battery NOTICE If the snowmobile is equipped wit...

Page 337: ...lowing screen 11 The fuel pump will run and prime the fuel system Use fuel pump prime to perform the following tests Verify the ECU can activate the fuel pump Purge the fuel system of air if the fuel tank was run dry or the fuel system was disassembled Test fuel system pressure Non ES models that have been run out of gas and cannot be re started FUEL SYSTEM ...

Page 338: ... engine starts 7 Turn off the engine and continue to re fuel the snowmobile MODELS WITH RECOIL START MANUAL 1 Position the snowmobile on flat level ground 2 Fill the fuel tank with minimum 2 gal 7 6 L of fuel 3 Reinstall the fuel cap verify the Engine Stop Switch is reset and turn the ignition key to START 4 Position yourself on the left side of the snowmobile and grip the handlebars q 5 Carefully...

Page 339: ...a 4 Press and release the SET button to toggle through available options until the desired fuel type is displayed in the information display area 5 To exit Options Menu Press and release the MODE button until EXITappears in the information display area 6 Press and release the SET button to exit The fuel type being displayed is the active fuel type FUEL TYPE SELECTION 7S DISPLAY Change the fuel typ...

Page 340: ... o Fuel Injector Service Harness e Throttle Body Assembly Service part includes TPS a Fuel Hose Supply Supply Quick Connect Fittings RED r Fuel Rail Mounting Fasteners First Pass 5 ft lbs 6 5 N m Second Pass 15 ft lbs 20 N m s Cable Tie t Fuel Injectors Individual fuel injectors are not serviceable Replace both fuel injectors with fuel injector service harness O rings and bushing are serviceable d...

Page 341: ... Do not apply excessive pressure to fuel fittings or clips Verify proper operation of the fitting and clip by lightly pulling on fitting to ensure it is secure before completing repair THROTTLE BODY REMOVAL 1 Remove the side panels and hood 2 Remove the console See Console Removal page 9 23 3 Remove the drive belt and driven clutch See the following procedures for removal Drive Belt Removal Driven...

Page 342: ...ke plenum 7 Remove the cable tie y securing the upper intake tube to the chassis 8 Remove the diagnostic connector u from the cap 9 Remove the fastener i retaining the lower intake tube 10 Carefully remove the intake tube assembly o 11 Disconnect the ECU connectors a form the wiring harness 12 Remove the edge clip s retaining the wiring harness to the intake plenum FUEL SYSTEM ...

Page 343: ...emoved completely or remove the back bolt only and swing the tube forward This makes air box removal much easier 15 Remove the fasteners h securing the PBR and carefully move the PBR to the side 16 Cut the cable tie j and disconnect the T MAP sensor harness connector k 17 Disconnect the ignition coils connectors l from the wire harness and remove the spark plug caps 1 from the spark plugs 18 Cut t...

Page 344: ...he ignition coils from the air box assembly 21 Pinch off the throttle body coolant hoses using hose pincher tools Hose Pincher PU 45149 22 Remove the hoses 2 from the throttle body 23 Cut the cable ties 2 that secure the fuel injector harness to the throttle body 24 Disconnect the TPS sensor connector2 from the wiring harness and remove the connector from the connector placement bracket NOTICE Not...

Page 345: ...n the engine NOTICE Do not remove the cable tie securing the support to the coolant hose 26 Loosen the two gear clamps 2 that secure the throttle body to the reed valve manifold assembly 27 Pull the throttle body out of the reed valve manifold assembly 28 Loosen the throttle cable lock nut 2 and remove the cable from the throttle body 29 Remove the throttle body from the vehicle FUEL SYSTEM ...

Page 346: ...ification NOTICE Turn the throttle cable in line adjuster to full length clockwise prior to cable installation TORQUE Throttle Cable Lock Nut 44 in lbs 5 N m 3 Reinstall the throttle body into the reed valve manifold assembly Tighten gear clamps 2 to specification TORQUE Throttle Body Gear Clamps 11 in lbs 1 24 N m 4 Properly route TPS harness and secure the harness with new cable ties 2 to the wi...

Page 347: ...ss to the throttle body using new cable ties 2 7 Reinstall the throttle body coolant supply and return hoses 2 8 Carefully install the air box 3 into the snowmobile 9 Tighten air box to throttle body gear clamps 2 to specification TORQUE Air Box to Throttle Body Gear Clamps 11 in lbs 1 24 N m NOTICE If the ignition coils were removed reinstall the ignition coils and torque fasteners to specificati...

Page 348: ...ctors l to the wire harness and install the spark plug caps 1 onto the spark plugs 12 Connect the T MAP Sensor k to the wiring harness and install new cable tie j to secure wiring 13 Slide the PBR back onto bracket and align mounting holes Install the two fasteners h and torque to specification TORQUE PBR Fasteners 6 ft lbs 8 N m 14 Install the fasteners f that retain the support brace g TORQUE Le...

Page 349: ...ining the wiring harness to the intake plenum 17 Connect the ECU to the wiring harness a 18 Carefully install the intake tube assembly o NOTICE Ensure the intake tube is properly seated to the air box and properly aligned with the intake plenum 19 Install the fastener i retaining the lower intake tube Torque the fastener to specification TORQUE Lower Intake Tube Air Box Fastener 36 in lbs 4 N m FU...

Page 350: ...rd r into the body work Install the fasteners e at the rear of the clutch guard TORQUE Clutch Guard Nuts 8 ft lbs 10 N m 24 Re install oil tank and align mounting hole Install washers w and oil tank mounting fasteners q Torque fasteners to specification TORQUE Oil Tank Mounting Fasteners 7 ft lbs 9 N m 25 Install the driven clutch and drive belt See the following procedures for installation Driven...

Page 351: ...cro dampers and fuel hoses attached to the rail are not serviceable IMPORTANT Do not touch fuel injector inlets outlets Leave protective caps in place while handling NOTICE Fuel rail fasteners must be replaced each time they are removed or loosened 1 Follow the procedure for air box removal The throttle body can remain installed in the adapter plate 2 Disconnect the fuel return q and supply w quic...

Page 352: ...erify the two rubber bushings are not inside the fuel injector bores Remove with a soft tipped pick if bushings did not come out with injectors Discard the bushings 7 If the fuel injector harness assembly needs to be replaced remove the fuel injector harness u from the wiring harness and remove the connector from the connector placement bracket NOTICE Do not attempt to disconnect the fuel injector...

Page 353: ...st be replaced each time they are removed or loosened 1 To reassemble fuel injectors install a new blue O ring q new green O ring w and new rubber bushing e on each fuel injector Apply a light film of engine oil on the rubber bushings and O rings NOTICE Note the rubber bushings are installed cone side into bore 2 Carefully pass the MAG fuel injector harness lead r between the fuel supply and retur...

Page 354: ...sconnect fittings Wipe away any spilled fuel using a clean shop towel Firmly pull on each hose connection to verify the hoses are secured IMPORTANT Do not apply excessive pressure to fuel fittings or clips Verify proper operation of the fitting and clip by lightly pulling on fitting to ensure it is secure before completing repair 8 If removed re install the throttle body See throttle body installa...

Page 355: ...e may occur if the incorrect fuel injector calibration is loaded on the ECU The MAG and PTO fuel injectors are noted with labels q Install the fuel injectors in their correct locations RED BLUE or YELLOW color bands w are located at the base of each fuel injector When replacing fuel injectors reference this color band to ensure the right fuel map is selected using Digital Wrench PINS WIRE COLOR IN...

Page 356: ...il Performance Crossover Snowmobile Service Manual Copyright Polaris Inc 3 When fuel injector is ready for installation ensure the rubber bushing e is properly oriented with the cup side of the bushing facing the injector as shown FUEL SYSTEM ...

Page 357: ...at Mount f LH Tank Mount Foam r Fuel Pump Position the alignment arrow on the tank assembly between the alignment line s and the raised rib on the pump flange assembly g Fuel Tank Support t PFA Gasket h T slot Fastener y PFA Nut 28 ft lbs 38 N m PFA nut must not contact the PFA neck surface j Washer u Fuel Tank Cap k Fuel Tank Support Mounting Nuts 9 ft lbs 12 N m i O ring l Studs 18 in lbs 2 N m ...

Page 358: ...ehicle to sit for a period of one hour after shutting off the engine before servicing the fuel line This allows the exhaust to cool and fuel pressure to drop 1 Rotate the three 1 4 turn latches q and remove the side panel w by pulling the panel outward to release the tabs at the bottom Repeat this step to remove the side panel from opposite side of the snowmobile 2 Rotate the 1 4 turn fasteners e ...

Page 359: ...ntake plenum 8 Remove the two fasteners i push pin rivet o and clutch tool a that secure the lower portion of the console 9 Remove fuel cap s and plastic fuel filler neck nut d 10 Lift up the center of the console and disconnect the key switch connector f from the key switch NOTICE If needed the switch panel may be removed to disconnect the key switch connector and any accessory connections 11 Car...

Page 360: ... l securing the fuel tank to the fuel tank support 15 While holding a clean shop rag around the fuel line connectors at the fuel pump disconnect the fuel supply and return hose connectors 1 from the fuel pump flange assembly NOTICE Note the position of the supply and return fuel hoses Disconnect the 5 16 connector from the 5 16 fitting on the pump flange and disconnect the 3 8 connector from the 3...

Page 361: ...t on the over structure and aligning the rear tank tabs with the studs of the fuel tank support 3 Route fuel pump wire harness under the return fuel line and to the main harness on the left side of the fuel tank Reconnect the fuel pump wire harness connector 2 IMPORTANT Ensure proper routing 4 Reconnect the fuel supply and return hose connectors 1 at the fuel pump flange assembly NOTICE Note the p...

Page 362: ...s to specification TORQUE Rear Tank Trim Nuts 44 in lbs 5 N m 8 Place console near its installed position and connect the main harness key switch connector f to the key switch NOTICE If not previously removed the switch panel may be removed to aid in connecting the key switch connector and any accessory connections Reinstall the switch panel once all connections are made 9 Remove the fuel cap and ...

Page 363: ...ion TORQUE Console Fasteners 71 in lbs 8 N m 11 Install the two push pin rivets u that secure the front of the console to the lower intake plenum 12 Install the two fasteners y that secure the console and lower intake plenum to the over structure Torque fastener to specification TORQUE Console Fasteners 71 in lbs 8 N m 13 Install the seat and secure with 1 4 turn latch 14 Install the hood t by ins...

Page 364: ...clean and dry prior to assembly 16 Rotate the 1 4 turn fasteners e at the rear corners of the hood to secure the rear of the hood to the console 17 Align the tabs at the bottom of the side panel w with the slots in the fender and carefully insert 18 Close the side panel w and secure by rotating the three 1 4 turn latches q Repeat this step to install the side panel onto opposite side of the snowmo...

Page 365: ... battery verify battery is fully charged and can supply required voltage to fuel pump FUEL LEVEL SENSOR RESISTANCE VALUES FLOAT POSITION GAUGE READING RESISTANCE Ω 68 F 20 C Full 2 0 1 0 1 2 39 9 Empty 102 25 2 0 PICKUP FILTER MEDIA Primary Screen 200 Microns Filter 10 Microns FUEL PUMP REMOVAL WARNING Gasoline is extremely flammable and explosive under certain conditions Do not smoke or allow ope...

Page 366: ...k fuel system 1 Dampen a clean rag with isopropyl alcohol and clean the surface of the tank in the pump mounting area the tank side of the PFA flange and the upper sealing surface of the PFA neck Dry all surfaces with a clean rag Allow adequate drying time for the alcohol 2 Dampen a clean rag with alcohol and thoroughly remove any contaminants from the supplied gasket 3 Install the new pump flange...

Page 367: ...lange Nut 28 ft lbs 38 N m 7 Verify the foam pads on the tunnel are installed and not damaged 8 Install the fuel tank t by carefully hooking the fuel tank mounting tab onto the fuel tank bracket on the over structure and aligning the rear tank tabs with the studs of the fuel tank support 9 Reconnect the fuel supply and return hose connectors y at the fuel pump flange assembly NOTICE Note the posit...

Page 368: ...the amount of time required to reach 5 PSI Use the optional Schrader valve listed in the tools list if desired If you use a larger volume pump be sure to monitor the pressure on the gauge constantly so that 6 PSI is never exceeded IMPORTANT DO NOT USE SHOP COMPRESSED AIR 15 Saturate the PFA nut area with the soap solution 16 Inspect for leaks under the PFA nut around the top perimeter of the pump ...

Page 369: ...aris Inc 5 37 FUEL PUMP WIRE HARNESS ROUTING 1 Route the fuel pump wire harness q under the return fuel line and along the left side of the fuel toward the fuel pump connector of the main harness 2 Connect the fuel pump wire harness connector w to the fuel pump connector of the main harness FUEL SYSTEM ...

Page 370: ...OUTING NOTICE Images for reference only 1 The fuel supply line q should be connected to the fuel pump flange assembly in location shown below 2 The fuel supply line should route down the front of the fuel tank The supply line should be secured in the foam block w and connect to the corresponding line e from the fuel rail in the locations shown below FUEL SYSTEM ...

Page 371: ...ges for reference only 1 The fuel return line q should be connected to the fuel pump flange assembly in location shown below 2 The fuel return line should route down the front of the fuel tank The return line should be secured in the foam block w and connect to the corresponding line e from the fuel rail in the locations shown below FUEL SYSTEM ...

Page 372: ...er Snowmobile Service Manual Copyright Polaris Inc SUPPLY RETURN LINE ROUTING RETENTION NOTICE Image for reference only 1 With both fuel supply and return line properly routed secure both fuel lines together with a panduit q at the location shown below FUEL SYSTEM ...

Page 373: ...CASE COVER TORQUE PATTERN 6 13 RIGHT FENDER CHAINCASE ACCESS SCREWS 6 13 CHAINCASE DISASSEMBLY 6 13 CHAINCASE COVER SERVICE 6 16 CHAINCASE ASSEMBLY 6 16 CHAINCASE HOUSING REMOVAL 6 19 CHAINCASE HOUSING INSTALLATION 6 21 CHAINCASE VENT LINE ROUTING 6 24 DRIVESHAFT SERVICE 6 25 DRIVESHAFT ASSEMBLY VIEW 6 25 DRIVESHAFT REMOVAL 6 26 DRIVESHAFT INSTALLATION 6 27 JACKSHAFT SERVICE 6 28 JACKSHAFT ASSEMBL...

Page 374: ...2021 650 850 Matryx Trail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc BRAKE LINE ROUTING 6 46 TRACK STUDDING LUG HEIGHT 6 48 TRACK STUDDING 6 48 STUD PROTECTION 6 48 FINAL DRIVE BRAKE SYSTEMS ...

Page 375: ...O PM 3221102 25T 3 4W 15 SPL HYVO PM 3222127 26T 3 4W 15 SPL HYVO PM 3222126 36T 3 4W 15 SPL HYVO PM 3222125 37T 3 4W 15 SPL HYVO PM 3222108 39T 3 4W 15 SPL HYVO PM 3222099 40T 3 4W 15 SPL HYVO PM 3222101 41T 3 4W 15 SPL HYVO PM 3222192 42T 3 4W 15 SPL HYVO PM 3221188 43T 3 4W 15 SPL HYVO PM 3222239 44T 3 4W 15 SPL HYVO PM 3222146 45T 3 4W 15 SPL HYVO PM DRIVE CHAINS PART NUMBER DESCRIPTION 322111...

Page 376: ...l Wrench no provision is made in the event a larger or smaller diameter driveshaft is installed in the vehicle Only the factory installed driveshaft is used in the speedometer offset logic IMPORTANT Do not use upper lower sprocket combinations that are not listed on the table Non recommended sprocket and chain combinations may cause severe chaincase damage CHAINCASE SPROCKET RATIO SPEED CHART 7 06...

Page 377: ...s Inc 6 5 CHAINCASE SPROCKET RATIO SPEED CHART 7 063 179 4 MM CHAINCASE UPPER SPROCKET LOWER SPROCKET CHAIN LENGTH RATIO THEORETICAL VEHICLE SPEED MPH AT 1 1 SHIFT RATIO RPM 8050 8250 8450 22 44 72 2 00 86 88 90 22 45 72 2 05 84 86 88 20 42 70 2 10 82 84 86 19 40 68 2 11 82 84 86 FINAL DRIVE BRAKE SYSTEMS ...

Page 378: ...rockets on the snowmobile do not match the model specifications in the table Digital Wrench must be used to re calibrate the speedometer offset 850 CHAINCASE GEARING STOCK SETTINGS 2021 MODEL YEAR MODEL TRACK TOP GEAR BOTTOM GEAR CHAIN PITCH 2020 850 Indy XC VR1 129 1 25 23 37 68 1 3 23 37 68 1 5 22 41 70 850 Indy XC VR1 137 1 25 23 37 68 1 3 23 37 68 1 5 22 41 70 850 SWITCHBACK ASSAULT 146 1 3 23...

Page 379: ...ness PS 52573 4 Connect one of the harness leads to the ECU PWR test diagnostic connector 5 Connect the power up harness to the battery NOTICE If the snowmobile is equipped with a fully charged battery it can be used to supply power to the test connectors If using a stand alone service battery do not place the battery in the tunnel footwells Place the battery on the floor next to the engine compar...

Page 380: ...ch limits the top sprocket teeth numbers to 19 26 and the bottom sprocket teeth numbers to 36 45 Future Digital Wrench updates will limit the teeth numbers to match the Polaris specified acceptable sprocket combinations IMPORTANT Entering incorrect top and bottom sprocket values will result in inaccurate vehicle speed display 12 Digital Wrench will re program the ECU with the required speedometer ...

Page 381: ... 6 N m e Brake Disc d Lower Sprocket Fastener 29 ft lbs 40 N m 2 O Ring r Seal Sleeve f Domed Washer Install dome side out 2 Vent Fitting t Oil Seals Install with lips facing centerline of snowmobile g Lower Sprocket 2 Vent Hose y Cover Bearing h HYVO Chain 2 Seal u Cover Fasteners 12 ft lbs 16 N m j Snap Rings Install sharp edge facing out 2 Drive Chain Tensioner Jam Nut 21 ft lbs 28 N m i Cover ...

Page 382: ...hten the adjuster bolt w until it can no longer be adjusted by hand then back off 1 4 turn 6 Tighten the jam nut to specification while holding the adjuster bolt TORQUE Drive Chain Tensioner Jam Nut 21 ft lbs 28 N m 7 Reinstall the side panels Release the parking brake CHAINCASE OIL LEVEL CHECK 1 Position snowmobile on a flat level surface 2 Remove the fill plug q Maintain the oil level at the bas...

Page 383: ...ract the oil from the chaincase 5 Lower the snowmobile 6 Using a funnel slowly add the recommended oil until the fluid begins to overflow FLUID CAPACITY Maximum Fluid Capacity 10 5 oz 310 mL 7 Clean the area with a clean dry shop towel 8 Reinstall the fill plug Torque plug to specification TORQUE Chaincase Fill Plug 4 ft lbs 6 N m CHAINCASE OIL CHANGE COVER DRAIN METHOD 1 Position snowmobile on fl...

Page 384: ...metal shavings off the plug 10 Using a funnel slowly add the recommended oil until the fluid begins to overflow FLUID CAPACITY Maximum Fluid Capacity 10 5 oz 310 mL 11 Clean the area with a clean dry shop towel 12 Reinstall the fill plug Torque fill plug to specification TORQUE Chaincase Fill Plug 4 ft lbs 6 N m 13 Reinstall the screws securing the fender to the chaincase 14 If equipped with a bat...

Page 385: ...chaincase assembly CHAINCASE DISASSEMBLY CAUTION Exhaust system components can cause serious burns Allow exhaust system to cool completely 1 Remove the left and right engine compartment door panels 2 Remove the hood assembly 3 If the vehicle is equipped with a battery remove the battery and battery bracket 4 Remove the exhaust resonator 5 Drain the chaincase oil using the cover drain method When p...

Page 386: ...a pair of flat blade screwdrivers or soft jawed pliers to carefully pry the seal sleeve t out of the cover 11 Locate the O ring y on the end of the jackshaft inside the cover Use a pick and carefully remove the O ring Inspect O ring and discard if damaged or torn 12 Remove the remaining cover fasteners u NOTICE Two fasteners secure the fender to the bottom of the chaincase housing Remove the screw...

Page 387: ... smoothly Replace the seal if damaged 16 Remove the lower gear fastener o and washer a Note the beveled washer orientation 17 Loosen the chain adjuster jam nut s and bolt d 18 Remove the spacer f on the jackshaft 19 Remove the upper sprocket g chain h and lower sprocket j as an assembly 20 Inspect the sprockets for wear and replace as required Inspect the chain for frozen links and damage Replace ...

Page 388: ...ect the bearing by feel Replace if bearing feels rough or freewheels 4 Install a new bearing into the cover using an Arbor press or similar tool Press only on the bearing s outer race 5 Install a new oil seal into the front of the cover Apply a light film of oil to the seal lips to aid installation Press only on the outer circumference of the seal Note that the oil seal spring lip faces in Press s...

Page 389: ...ghten the tensioner adjuster bolt until there is 1 8 in 3 175 mm chain deflection on the backside of the drive chain 8 Verify the adjuster bolt seal is seated against the chaincase Torque jam nut to specification TORQUE Drive Chain Tensioner Jam Nut 21 ft lbs 28 N m 9 Inspect the cover gasket Replace if damaged Verify the gasket is installed in the cover groove as shown 10 Install the cover making...

Page 390: ...rs 12 ft lbs 16 N m 12 Install the two fender to chaincase housing screws Torque screws hand tight 13 Inspect the jackshaft O ring y Replace if worn or damaged Install O ring onto jackshaft Verify the O ring is seated in the jackshaft groove 14 Install the seal sleeve t with the groove facing outward 15 Clean the brake disc r with brake cleaner and then install on to jackshaft 16 Loosely install t...

Page 391: ...thetic Chaincase Lubricant SCL Tighten fill plug to specification TORQUE Chaincase Fill Plug 4 ft lbs 6 N m 20 If the snowmobile is equipped with electric starter reinstall the battery bracket and battery 21 Reinstall the exhaust resonator 22 Reinstall the hood and side panels CHAINCASE HOUSING REMOVAL NOTICE The chaincase housing and right bulkhead support are one piece and bonded to the chassis ...

Page 392: ...using to the tunnel closeoff 8 Obtain a propane torch Wear protective gloves clothing and eye wear Apply even heat to the rear housing flange and front spar where it mounts to the bulkhead clip arrows in image IMPORTANT Keep flame away from flammable materials Use propane torch in well ventilated area Only apply heat to area that requires adhesive bond separation Do not apply heat to areas of adhe...

Page 393: ...e chaincase to tunnel mating surfaces All residual bonding adhesive MUST be removed Use a putty knife and wire brush to remove material 16 After removing residual adhesive wash in solution of warm soapy water and allow to air dry CHAINCASE HOUSING INSTALLATION Verify all traces of adhesive residue have been removed from the housing tunnel and bulkhead clip Wash all mating surfaces with a solution ...

Page 394: ...se housing to the vehicle 5 Reference Adhesive Applicator Kit and Adhesive Application sections in Chassis chapter NOTICE The Bonded Component Service section in Chapter 9 outlines the adhesive applicator tools and the adhesive application procedure required to properly install bonded components 6 Apply adhesive to the housing s rear mounting flanges and front spar as shown in the illustration r 7...

Page 395: ...fasteners are loosely installed torque the nuts and fasteners to specifications TORQUE Chaincase Rear Mounting Nuts 9 ft lbs 12 N m Chaincase Side Support Fasteners 26 ft lbs 35 N m Tube Brace Fastener 22 ft lbs 30 N m 13 Install the speed sensor a and fastener s onto the housing Torque fastener to specification TORQUE Speed Sensor Fastener 7 ft lbs 9 N m 14 Reinstall the chaincase components Foll...

Page 396: ... Route the chaincase vent line q from the chaincase vent fitting and under the coolant hose Secure the chaincase vent line in the hose electrical support with a panduit w 2 Route the chaincase vent line behind the coolant bottle and toward the rear of the vehicle The chaincase vent line should terminate in the coolant bottle bracket e as shown below FINAL DRIVE BRAKE SYSTEMS ...

Page 397: ...al Copyright Polaris Inc 6 25 DRIVESHAFT SERVICE DRIVESHAFT ASSEMBLY VIEW q Bearing Cover Flangette Fasteners 18 ft lbs 25 N m r Bearing Flangette Clinch Nuts w Bearing Cover t Driveshaft Assembly Not Serviceable e Bearing Press on inner race until fully seated FINAL DRIVE BRAKE SYSTEMS ...

Page 398: ...eshaft assembly r out of the chaincase housing Tilt the driveshaft out of the tunnel once it is clear of the chaincase Remove the driveshaft from the tunnel 8 Inspect the track drivers for damage The drivers cannot be serviced If driver damage is found replace the driveshaft assembly NOTICE A driveshaft assembly is supplied with a new bearing and bearing cup 9 Remove the track NOTICE The arrows on...

Page 399: ...ned end of the driveshaft into the chaincase 4 Install the bearing cover and align mounting holes 5 Loosely install the three outer fasteners w securing the bearing cover to the tunnel 6 Loosely install the three fasteners q securing the driveshaft bearing flange to the tunnel bearing cover 7 Torque the bearing cover fasteners to specification TORQUE Driveshaft Bearing Cover Fasteners 18 ft lbs 25...

Page 400: ...ce Crossover Snowmobile Service Manual Copyright Polaris Inc JACKSHAFT SERVICE JACKSHAFT ASSEMBLY VIEW q Jackshaft Bearing Flange Fasteners 18 ft lbs 25 N m r Bearing w Bearing Flange t Bearing Deflector e Jackshaft Asm y O ring FINAL DRIVE BRAKE SYSTEMS ...

Page 401: ... bearing flange w 6 Extract the jackshaft e out of the tunnel 7 Inspect the splines on the jackshaft for abnormal wear Inspect the bearing q by feel Replace bearing if it does not roll smoothly 8 A deflector w is located between the bearing q and machined step in the jackshaft When installing a new bearing press on the inner race of the bearing Press until bearing is installed at the specified dis...

Page 402: ...all the bearing flange w 3 Loosely install all three fasteners q Torque fasteners to specification TORQUE Jackshaft Bearing Flange Fasteners 18 ft lbs 25 N m 4 Reinstall the clutch guard and oil tank assembly 5 Reinstall the driven clutch assembly 6 Follow the procedure for chaincase reassembly FINAL DRIVE BRAKE SYSTEMS ...

Page 403: ... IMPORTANT Pressure bleeding is not recommended When fluid surges through the fittings it is possible to cavitate the fluid and create air in the system In addition the fluid stored in a pressure bleeder may be contaminated Always use fresh DOT 4 brake fluid from a sealed container Keep these points in mind when bleeding hydraulic brakes The master cylinder reservoirs have limited capacities It is...

Page 404: ...Y VIEW q Brake Line u Brake Pads w Banjo Bolt 240 260 in lbs 27 30 N m i Piston Seals e Sealing Washers o Pistons r Bleeder Fitting 100 135 in lbs 11 15 N m a Caliper Mounting Fasteners 40 ft lbs 54 N m Discard and replace with new fasteners when removed t Caliper Assembly s Washers y Brake Pad Retaining Pin FINAL DRIVE BRAKE SYSTEMS ...

Page 405: ...in lbs 0 68 0 90 N m y Pivot Pin w Reservoir Cover Gasket u Brake Light Switch Guard Fastener Until Fully Seated e Reservoir Assembly Includes reservoir fastener and o ring Inner Reservoir Fastener 6 8 in lbs 0 68 0 90 N m i Brake Light Switch r Master Cylinder Clamp Fastener 60 80 in lbs 6 8 9 N m o Park Lever Assembly t Piston Assembly a Brake Lever FINAL DRIVE BRAKE SYSTEMS ...

Page 406: ...omplete loss of brakes which could result in serious injury or death Have the brakes serviced at the first sign of abnormal feel or performance CALIPER PAD COMPONENTS Brake pads must be replaced when the brake pad material becomes thinner than the backing plate approximately 1 16 in 1 5 mm A kit is available for replacing brake pads WARNING Brake failure during operation can result in serious inju...

Page 407: ...s allow for diaphragm movement and if they become plugged movement of brake fluid below the diaphragm may be restricted altering brake function Inspect the reservoir to be sure it contains the correct amount of fluid Use only Polaris DOT 4 high temperature brake fluid Change fluid every 2 years or whenever the fluid is dark or contamination is suspected Position the handlebars so the brake fluid r...

Page 408: ...the vehicle with a spongy brake lever can result in loss of brakes which could cause an accident and lead to serious injury or death Never operate the vehicle with a spongy feeling brake lever CAUTION Hot exhaust system parts can cause burns Allow adequate time for the exhaust system to cool Never perform this procedure with the engine running During the bleeding procedure keep the brake reservoir...

Page 409: ...oke Then unscrew the bleeder valve y 3 4 turn to release air 6 Close the bleeder valve and release the brake lever 7 Repeat steps 5 and 6 until fluid flows from the bleeder valve in a solid stream free of air bubbles WARNING Overfilling the master cylinder leaves no room for fluid expansion and may cause the brakes to lock resulting in serious injury or death Always add brake fluid to the proper l...

Page 410: ...cation q MEASUREMENT Phantom Brake Pad Minimum Thickness 1 16 in 1 5 mm 5 Replace brake pads as a set if one or both pads do not meet the minimum specification IMPORTANT Always replace brake pads as a set 6 Install the brake pads back into the caliper 7 Reinstall the retaining pin 8 Test brake system prior to returning vehicle to service BRAKE LEVER MASTER CYLINDER SERVICE NOTICE The brake switch ...

Page 411: ...h washers 6 Move the master cylinder lever assembly to a clean workspace on a work bench 7 Remove the cover fasteners t cover y and damper u Drain any residual brake fluid out of the reservoir into a suitable container 8 Remove the fastener i securing the reservoir to the valve body Remove the reservoir o 9 Note the O ring a on the top side of the valve body The O ring must be replaced if damaged ...

Page 412: ...e brake switch g is secured to the valve body using two plastic pins Remove the brake switch by carefully prying it up using a small flat blade screwdriver NOTICE The brake switch can be removed without master cylinder removal or disassembly 12 The piston valve and valve body are not serviceable The piston valve g is retained in its bore by O ring pressure It can be removed to clean it and the bor...

Page 413: ...ard make sure the wire is secured in the routing tab of the brake switch guard TORQUE Brake Switch Guard Fastener Until Fully Seated 4 Verify the O ring is installed on the top side of the valve body 5 Install reservoir r and inner reservoir fastener t Torque fastener to specification TORQUE Inner Reservoir Fastener 6 8 in lbs 0 68 0 90 N m 6 The master cylinder assembly should resemble what is sh...

Page 414: ...the banjo bolt and install into master cylinder 12 Orient the brake hose fitting as shown Torque banjo bolt i to specification TORQUE Brake Line Banjo Bolt 240 260 in lbs 27 30 N m 13 Add new DOT 4 brake fluid to the reservoir Perform the brake bleeding procedure NOTICE After filling with brake fluid and bleeding air out of system check all fluid joints with clean dry shop rag to determine if any ...

Page 415: ...container NOTICE Discard the two crush washers e 2 Remove and discard the brake caliper mounting fasteners r 3 Remove the brake pad retaining pin y and brake pads u 4 Hold the caliper over a jar or suitable container and then push the pistons back into the caliper This will push the brake fluid inside the caliper out of the banjo fitting hole IMPORTANT NEVER RE USE BRAKE FLUID USED BRAKE FLUID MAY...

Page 416: ...mpressed air or a lint free rag 11 Inspect the caliper bores and pistons for pitting heavy scoring or corrosion Replace parts if heavily scored or pitted 12 To assemble the caliper lubricate two new piston seals with new brake fluid Install each seal by inserting one point of the seal into the bore groove and then work the seal around the groove with your index finger Do not twist or rip the seals...

Page 417: ...he brake hose 8 Remove the brake disc r from the jackshaft 9 Measure brake disc and compare to specifications MEASUREMENT Lateral Run Out Service Limit 010 in 0 254 mm Service Limit Thickness 030 in 0 762 mm less than nominal Nominal Thickness 197 005 in 5 127 mm 10 Prior to disc installation clean the brake disc with brake cleaner Dry with compressed air or lint free towel 11 Install brake disc o...

Page 418: ...secured to the brake caliper with banjo bolt route the brake line q up toward the connector placement bracket located behind the coolant bottle Secure the brake line with a routing clip w to the connector placement bracket 2 Continue to route the brake line upward along the over structure tube Secure the brake line with a routing clip e to the fuel tank bracket FINAL DRIVE BRAKE SYSTEMS ...

Page 419: ...50 Matryx Trail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc 6 47 3 Complete the process by routing the brake line up to the brake master cylinder and secure with banjo bolt r FINAL DRIVE BRAKE SYSTEMS ...

Page 420: ...ion and vehicle braking Adding studs to the outer rows is generally considered for drivers who desire a high degree of traction but can sacrifice track durability Studs placed on the outer rows are more susceptible to being ripped out of the track Polaris does not recommend studs on the outside band of the Storm 150 track Damage will occur Adding studs may require the use of longer more aggressive...

Page 421: ... mm w Stud Size e Track Lug Height r Track Belt Thickness MAXIMUM PENETRATION POLARIS Studs Stud Length 1 25 Inch 3 2 cm Track 1 352 Inch 3 4 cm Cobra Track Overall Installed Height Recommended for Matryx models in cm in cm in cm in cm Signature Series 1 325 3 4 375 95 27 7 1 58 4 0 YES Signature Series 1 45 3 7 1 7 4 3 NO FINAL DRIVE BRAKE SYSTEMS ...

Page 422: ...6 50 9850064 R03 2021 650 850 Matryx Trail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc NOTES FINAL DRIVE BRAKE SYSTEMS ...

Page 423: ...H WEIGHTS 7 6 PERC TEAM LWT DRIVEN HELIXES 7 7 TEAM RAMP ANGLES 7 7 TEAM DRIVEN SPRINGS 7 8 DRIVE BELT 7 9 DRIVE BELT SPECIFICATIONS 7 9 BELT INSPECTION 7 9 DRIVE BELT REMOVAL 7 10 DRIVE BELT INSTALLATION 7 11 DRIVE CLUTCH 7 12 DRIVE CLUTCH IDENTIFICATION 7 12 DRIVE CLUTCH ASSEMBLY VIEW 7 13 DRIVE CLUTCH REMOVAL 7 14 DRIVE CLUTCH DISASSEMBLY 7 14 ROLLER REMOVAL 7 16 ROLLER INSTALLATION 7 17 SPIDER...

Page 424: ...CH ASSEMBLY VIEW TEAM LWT 7 25 DRIVEN CLUTCH REMOVAL 7 26 DRIVEN CLUTCH DISASSEMBLY 7 26 DRIVEN CLUTCH ASSEMBLY 7 27 DRIVEN CLUTCH INSTALLATION 7 28 PVT SYSTEM ADJUSTMENTS 7 29 BELT DEFLECTION INSPECTION ADJUSTMENT 7 29 CLUTCH ALIGNMENT OFFSET PS 51607 7 30 CLUTCH OFFSET FLOAT ADJUSTMENT 7 31 CLUTCH CLEANING 7 32 PVT SYSTEM ...

Page 425: ...ring with a lower pre load rate will result in a lower engagement RPM speed while installing a spring with a higher pre load rate will result in a higher engagement RPM CLUTCH WEIGHT The clutch weights generate centrifugal force as the drive clutch rotates The force generated changes in relation to the engine RPM and with the specified weight of each clutch weight When changing only the clutch wei...

Page 426: ...ARING The final drive gear ratio plays an important role in how much vehicle load is transmitted back to the helix A tall gear ratio lower numerical number typically results in lower initial vehicle acceleration but a higher top end vehicle speed A lower gear ratio higher numerical number typically results in a higher initial vehicle acceleration but a lower top end vehicle speed Choosing the prop...

Page 427: ...10 111 7041922 Almond Blue 218 3 75 150 310 122 7041988 Almond Red 207 4 27 165 310 110 7042083 Black Green 218 3 38 120 340 168 7043681 Black 3681 225 3 327 120 310 145 7043829 Black 3829 218 3 48 140 330 145 7043076 Black 3076 225 2 67 40 340 229 7043120 Black 3120 225 2 78 60 340 213 7043121 Black 3121 255 3 05 100 340 183 7042287 Black 2287 207 3 40 110 290 137 7041148 Gold 207 3 25 100 275 13...

Page 428: ... Replacement is required IMPORTANT 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 SERIES 10 DRIVE CLUTCH WEIGHTS SERIES 10 WEIGHTS WEIGHT GRAMS 1 GR GRAMS 1 GR PART NUMBER 10M R 44 1321530 10M W 46 1321527 10M B 47 5 1321529 10M 49 5 1321528 10 51 1321526 10A L 52 3 1321531 10 54 54 1321685 10A...

Page 429: ...46 65 42 36 TEAM RAMP ANGLES The angles and length of the transition between the first and final angle is stamped on the back of the helix The first number A designates the starting angle of the ramp The second number B designates the finish angle The last number C is the transition distance in inches between the starting and finish angles IMPORTANT Do not install a non ER helix on a PERC equipped...

Page 430: ... Yellow 4 40 11 2 100 150 45 7043057 Red Blue 4 767 12 1 140 200 54 7043063 Black Subs to 7043150 P2 Non Tabbed 7043064 Blue Black Subs to 7043152 P2 Non Tabbed 7043060 Red White 4 95 12 5 100 200 91 7043069 Red Pink 3 50 8 9 140 260 110 7043363 Black Purple 4 50 11 4 160 240 72 7043252 Black 160 280 3 70 9 4 160 280 109 7043254 Black 140 300 3 20 8 1 140 300 146 7043255 Black 160 300 3 50 8 9 160...

Page 431: ... adjusted properly The belt cord line should be flush with or slightly above the outer circumference of the driven clutch sheaves The belt will seat itself in the driven clutch during the break in period Adjust the belt ride out after the break in period by re adjusting belt deflection The break in period for a new drive belt is 30 50 miles During this time vary the throttle position under 50 and ...

Page 432: ...perating in a forward motion 2 Turn the ignition key off Wait for the engine to come to a complete stop 3 Rotate the driven clutch counter clockwise 1 4 turn by hand to ensure forward engagement 4 Lock the parking brake 5 Remove the left side panel 6 Retrieve the L wrench q Install the wrench into the open threaded hole in the outer sheave of the clutch 7 Turn the wrench clockwise until the sheave...

Page 433: ...elt over the drive clutch and pull back the slack The belt cord line should be flush with or slightly above the outer circumference of the driven clutch sheaves 3 Hold the belt down between the sheaves and roll the bottom portion over the outer clutch sheave Work the belt to the outer edge of the sheave 4 Turn the L wrench counterclockwise to tighten the sheaves Work the belt around the clutches a...

Page 434: ...olaris Inc DRIVE CLUTCH DRIVE CLUTCH IDENTIFICATION Every clutch will have the last three digits of the clutch part number etched on to the cover q The X w marking is an index mark where the clutch cover e clutch spider r and the stationary sheave t should line up when the clutch is assembled PVT SYSTEM ...

Page 435: ...5 in lbs 3 N m t Drive Clutch Spring j Moveable Sheave y Jam Nut 290 330 ft lbs 394 447 N m Apply Loctite 243 to Threads k Bearing Sleeve u Spider 280 300 ft lbs 380 406 N m Apply Loctite 243 to Threads l Moveable Insert i Guide Button 1 Stationary Sheave o Roller Pin 2 Starter Ring Gear Applicable to electric start models a Washers 2 Starter Ring Gear Fasteners Applicable to electric start models...

Page 436: ...inue to tighten the clutch puller and repeat this step IMPORTANT Do not use an impact wrench to remove or install the clutch bolt or clutch puller Damage to the clutch and or crankshaft can occur DRIVE CLUTCH DISASSEMBLY NOTICE Sheaves must be marked to provide a reference point for clutch balance and spider indexing If the sheaves are not marked and the spider washers are changed or misplaced the...

Page 437: ... jam nut r in a counterclockwise direction standard thread using the drive clutch spider nut socket Drive Clutch Spider Nut Socket 2870338 10 Install the spider removal tool and remove the spider t in a counterclockwise direction standard thread Spider Tool 2870341 11 Measure the total thickness of the spacer washers that are installed on top of the clutch spacer Record the thickness of these spac...

Page 438: ...htly in the roller 20 Replace the roller and pin if roller fails to roll smoothly no flat spots or if the bushing is loose or worn ROLLER REMOVAL q Spider r Shim w Button t Roller e Roller Pin y Washers 1 With the spider in a vise start removing the spider buttons by drilling a 0 18 hole in the center of a button on one side of the spider 2 Place a pin punch through the drilled hole in the button ...

Page 439: ... 6 Install the pin centering tool Pin Centering Tool 2870401 7 Drive the roller pin through the second land of the spider 8 Repeat the process for the other two rollers 9 Install new spider buttons on each leg using a soft faced hammer SPIDER BUTTON INSTALLATION 1 A shim kit is available which contains an assortment of shims Drive Clutch Shim Kit 2200387 2 Measure the width of the moveable sheave ...

Page 440: ...e 3 Install the main adapter onto the puller 4 Working from inside of the moveable sheave insert the moveable sheave removal tool q into the center of the sheave Slide the sheave onto the puller tool with towers facing upward 5 Secure the puller nut Turn the puller barrel to increase tension on the sheave if required 6 Turn the sheave counterclockwise on the puller rod until it comes free 7 Remove...

Page 441: ...ise until the bushing is removed and the cover comes free 7 Remove the tools and discard the bushing BUSHING INSTALLATION 1 To install a new cover bushing apply Loctite 648 to the leading edge of the new bushing Insert the new bushing and bushing installation tool from the inside of the cover NOTICE Verify no retaining compound is deposited on the I D of the bushing 2 With the main adapter install...

Page 442: ...ht Pin Nut 25 in lbs 3 N m 5 Place the moveable sheave r onto the stationary sheave 6 Place the same number of spacers t onto the shaft of the stationary sheave IMPORTANT Spacers must be kept in alignment and on center with the shaft as the spider is being torqued or the clutch will be out of balance 7 Thread the spider y onto the stationary sheave shaft 8 Index the spider See Spider Indexing page...

Page 443: ...haft and torque it to specification TORQUE Spider Jam Nut Torque 290 330 ft lbs 394 447 N m Apply Loctite 243 to Threads 11 Place the drive spring i on the shaft 12 Place the cover o onto the clutch and torque the cover fasteners a to specification TORQUE Clutch Cover Fasteners 100 in lbs 11 N m Use cross pattern NOTICE Do not allow the side loading or misalignment of the cover or the bushing may ...

Page 444: ...le turning 33 mm Tapered Reamer PU 52497 2 Check crankshaft taper for galling or scoring If necessary clean the taper evenly with 200 grit emery cloth 3 Clean clutch and crankshaft tapers with isopropyl alcohol Dry completely prior to clutch installation Do not use harsh cleaners which may cause clutch taper to corrode or damage the crank seal 4 Slide clutch onto crankshaft taper 5 Install the bol...

Page 445: ...ght against one of the drive clutch sheaves Measure the opposite side gap using a feeler gauge 3 A slight drag should be felt when inserting the feeler gauge between the belt and sheave face 4 Compare the measured gap to specification The distance between the moveable and stationary clutch sheaves and thus the belt to sheave clearance is determined by the number and thickness of the washer s insta...

Page 446: ... washer thickness may vary slightly Re index the marked spider leg to another tower This can be done because the spider has little effect on overall clutch balance Re indexing the spider 1 3 turn clockwise or 1 leg will allow the realignment of the moveable and stationary sheaves as previously marked t For EXAMPLE 0 020 or 0 032 in 0 5 0 8 mm washer removed re index spider clockwise 1 3 turn NOTIC...

Page 447: ...olaris Inc 7 25 DRIVEN CLUTCH DRIVEN CLUTCH ASSEMBLY VIEW TEAM LWT q Belt Deflection Screw 145 in lbs 16 N m i Roller w Stationary Sheave o Washer e Deflection Spacer a Retaining E Ring r Moveable Sheave s Snap Ring t Spring Cup d Helix y Spring f Helix Fasteners 110 in lbs 12 N m u Spider PVT SYSTEM ...

Page 448: ...location of the offset washers y and u bushing i located behind the driven clutch 5 Inspect the jackshaft and driven clutch splines for damage Replace components as required DRIVEN CLUTCH DISASSEMBLY 1 Remove the screws q from the helix then carefully pry the helix w out of the moveable sheave 2 Install the clutch in the clutch compressor fixture Clutch Compressor Fixture PU 50518 CAUTION Driven s...

Page 449: ...d DRIVEN CLUTCH ASSEMBLY 1 To assemble the clutch slide the components back on to the stationary sheave shaft 2 Align the notch in the roller assembly q with row of double splines on the shaft Slowly compress the spring and roller assembly down on to the shaft Install the snap ring w making sure it is fully seated in the groove 3 Install the helix e by aligning the rollers with the ramps Push the ...

Page 450: ...set washers bushings are installed on the jackshaft that were present when the clutch was removed 2 Apply a light film of Polaris Premium Grease to the jackshaft splines and shaft 3 Install the driven clutch 4 Install spacer q float washers w and e flat washer r and driven clutch bolt t 5 Torque bolt to specification TORQUE Driven Clutch Bolt 18 ft lbs 25 N m PVT SYSTEM ...

Page 451: ...NT Belt Deflection 1 25 in 3 2 cm ADJUSTMENT 1 Loosen the 11 mm jam nut on the belt width adjuster screw 2 Using a 3 mm Allen wrench turn the set screw inward clockwise to increase the distance between the sheaves increase deflection or outward counter clockwise to decrease the distance decrease deflection 3 Lightly tighten the jam nut q while holding the set screw stationary 4 Using the L wrench ...

Page 452: ... Clutch Alignment Tool PS 51607 The Clutch Alignment tool is designed with the specified alignment angle and offset When installed into the drive clutch and placed on top of the driven clutch the technician can immediately determine if any adjustments are required PROCEDURE 1 Open the left engine compartment door 2 Remove the drive belt 3 Install the alignment tool e into the drive clutch Verify i...

Page 453: ... the jackshaft IMPORTANT Always verify the driven clutch floats on the jackshaft The jackshaft bearing will fail from side loading if the driven clutch is not allowed to float 5 Apply a light film of Polaris Premium grease to the jackshaft Install the driven clutch and push it tight toward the bulkhead 6 Install the driven clutch bolt q flat washer w original float washers e and r and spacer t Tor...

Page 454: ... Inc CLUTCH CLEANING Periodically inspect clutch sheaves for damage wear or belt residue To maintain optimum performance clean with non oil based cleaners such as isopropyl alcohol IMPORTANT Do not lubricate the clutch bushings or any internal clutch components Clutch bushings are self lubricating PVT SYSTEM ...

Page 455: ...8 13 FRONT SWAY BAR ASSEMBLY VIEW 8 14 STEERING FRONT SUSPENSION SERVICE 8 15 STEERING POST SERVICE 8 15 STEERING POST REMOVAL 8 15 STEERING POST INSTALLATION 8 16 SKI SERVICE 8 19 SKI REMOVAL 8 19 SKI INSTALLATION 8 19 SPINDLE SERVICE 8 20 SPINDLE REMOVAL 8 20 SPINDLE INSTALLATION 8 21 CONTROL ARM SERVICE 8 23 LOWER CONTROL ARM REMOVAL 8 23 LOWER CONTROL ARM INSTALLATION 8 23 UPPER CONTROL ARM RE...

Page 456: ... 8 47 GENERAL SETUP ADJUSTMENTS ALL MODELS 8 48 CONTROLS HANDLEBAR 8 48 HANDLEBAR COMPONENT FASTENERS 8 48 HANDLEBAR COMPONENT LOCATIONS 8 49 HANDLEBAR ANGLE ADJUSTMENT 8 50 HANDLEBAR RISER ANGLE ADJUSTMENT 8 50 LEFT HAND CONTROL ADJUSTMENT 8 51 TWO PIECE THROTTLE CONTROL REMOVAL 8 52 TWO PIECE THROTTLE CONTROL INSTALLATION 8 54 FRONT SUSPENSION 8 56 CONTROL ARM PIVOT ADJUSTMENT 8 56 SKI ALIGNMENT...

Page 457: ...GS 8 73 REAR TRACK SHOCK FACTORY CLICKER SETTINGS 8 73 SHOCKS 8 74 GENERAL 8 74 SHOCK REBUILDING TOOLS 8 74 2021 SHOCK SPECIFICATIONS 8 76 WALKER EVANS SHOCKS 8 82 GENERAL INFORMATION 8 82 SHOCK MAINTENANCE OVERVIEW 8 82 WALKER EVANS SHOCK VALVE PART NUMBERS 3 8 I D 8 83 WALKER EVANS SHOCK VALVE PART NUMBERS 7 16 I D 8 84 WALKER EVANS PISTON VALVE ARRANGEMENT 8 86 WALKER EVANS PISTON VALVE ORIENTA...

Page 458: ...the following components must be checked Tie rods tie rod ends Sway bar bushings linkage Spindles Skis Ski Skags Pitman Idler Arms Control Arms Pivots Shocks Springs and Retainers Component Fastener Torques Front Rear Torque Arms Track Condition Alignment Tension Bogie Idler shafts and Wheels Handlebar Fasteners Component Locations ROD END ALIGNMENT All rod ends in the front suspension and steerin...

Page 459: ...bile Service Manual Copyright Polaris Inc 8 5 MAXIMUM WIDTH TOE CAMBER SPECIFICATIONS FRONT SUSPENSION MAXIMUM SETUP WIDTH CAMBER IN MM TOE OUT IN MM AT RIDE HEIGHT OVERALL Matryx Wide Fixed Camber Not Adjustable Not Adjustable 1 8 1 4 in 3 0 6 0 mm STEERING SUSPENSIONS ...

Page 460: ...eering Post w Plugs a Flange Nuts 20 ft lbs 27 N m Replace with new when removed e Hand Grips s Steering Post Bushings Apply Premium Grease r Handlebar Riser Clamp Fasteners 11 ft lbs 15 N m d Steering Bushing Seal Apply Premium Grease t Upper Handlebar Clamp f Spacers y Front Handlebar Wire Clamp g Steering Strap u Back Handlebar Wire Clamp h Upper Steering Post Mount Fasteners i Riser STEERING S...

Page 461: ...ver Snowmobile Service Manual Copyright Polaris Inc 8 7 HAND GUARD ASSEMBLY VIEW q Hand Guards r Mounting Clamps w Hand Guard Mounting Arms t Hand Guard Clamp Fasteners 18 in lbs 2 N m e Hand Guard Arm Fasteners Tighten Until Fully Seated STEERING SUSPENSIONS ...

Page 462: ... m 2 Fixed Drag Link to Pitman Arm Fastener 20 ft lbs 27 N m r Washer f Rod End 2 Pitman Idler Arm to Bracket Fasteners 30 ft lbs 41 N m t Nut 44 ft lbs 60 N m g Nut 11 ft lbs 15 N m 2 Pivot Shaft y Steering Strap h Tie Rod 2 Pivot Bushing u Lower Steering Post Bushing Mount Fasteners 20 ft lbs 27 N m j Nut 11 ft lbs 15 N m 2 Nut i Nut 37 ft lbs 50 N m k Rod End 2 Idler Arm o Nut 20 ft lbs 27 N m ...

Page 463: ...nuts f Washer e Nut 40 ft lbs 54 N m g Lower Spherical Bearing r Nut 30 ft lbs 41 N m h Retaining Ring Retaining ring must be fully seated t Washer j Lower Control Arm to Spindle Fastener y Pivot Bushing k Spindle u Lower Control Arm l Washer i Upper Control Arm 1 Nut 40 ft lbs 54 N m o Upper Control Arm Pivot Shaft Push forward to remove all clearance prior to torquing nuts 2 Bushing a Retaining ...

Page 464: ...50 Matryx Trail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc FRONT SHOCK MOUNTING ASSEMBLY VIEW XC q Upper Mounting Fastener e Nut 37 ft lbs 50 N m w Bushing r Lower Mounting Fastener STEERING SUSPENSIONS ...

Page 465: ... Trail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc 8 11 FRONT SHOCK MOUNTING ASSEMBLY VIEW VR1 q Upper Mounting Fastener r Spacer w Bushing t Lower Mounting Fastener e Nut 37 ft lbs 50 N m STEERING SUSPENSIONS ...

Page 466: ... Performance Crossover Snowmobile Service Manual Copyright Polaris Inc FRONT SHOCK MOUNTING ASSEMBLY VIEW SWITCHBACK ASSAULT 146 q Upper Mounting Fastener r O ring w Bushing t Lower Mounting Fastener e Nut 37 ft lbs 50 N m STEERING SUSPENSIONS ...

Page 467: ...right Polaris Inc 8 13 SKI ASSEMBLY VIEW q Ski o Washer w Washer a Nut 6 ft lbs 8 N m e Ski to Spindle Fastener s Nut 8 ft lbs 11 N m r Ski Toe Fastener d Ski Toe t Carbide f Nut 37 ft lbs 50 N m y Washer g Rubber Ski Stop u Nut 8 ft lbs 11 N m h Bushing i Ski Toe Fastener STEERING SUSPENSIONS ...

Page 468: ...le Service Manual Copyright Polaris Inc FRONT SWAY BAR ASSEMBLY VIEW q Sway Bar Link Fastener t Bushings w Sway Bar Link y Bushing Clamps e Nut 20 ft lbs 27 N m Replace with new when removed u Sway Bar r Nut 7 ft lbs 10 N m Replace with new when removed STEERING SUSPENSIONS ...

Page 469: ...eners q and lower handlebar clamps w and carefully move the handlebar controls as an assembly away from the upper steering post NOTICE The throttle cable handlebar wiring harness and brake line will remain connected 5 Remove the flange nut e securing the lower steering post to the fixed link r Discard the flange nut 6 Remove the two fasteners t securing the lower steering post clamp to the steerin...

Page 470: ...pper post bushings Discard the split seal f Bushings h Split Seal g Spacers STEERING POST INSTALLATION NOTICE The lower steering post bushings control the amount of vertical movement in the steering post Install new bushings if they are damaged or show signs of excessive wear 1 Install the steering post o back into the vehicle 2 Install a new split seal h onto the upper steering post NOTICE Instal...

Page 471: ... 27 N m 4 Assemble the lower steering post bushings s spacers d and strap a to the lower steering post mount Apply a light film of Polaris Premium Grease to the bushings 5 Install fasteners t that secure the lower steering post clamp to the steering post mount Torque fasteners to specification TORQUE Lower Steering Post Bushing Mount Fasteners 20 ft lbs 27 N m Do not over torque 6 Reconnect the lo...

Page 472: ...t Install the lower handlebar clamps w and fasteners q to secure the handlebar Torque fasteners to specification TORQUE Handlebar Clamp Fasteners 11 ft lbs 15 N m 8 Reinstall the exhaust pipe and resonator SeeExhaust Installation page 3 155 9 Install the air intake plenum See Air Intake Plenum Installation page 3 140 10 Reinstall the hood assembly and side panels STEERING SUSPENSIONS ...

Page 473: ... and ski bumper t NOTICE Note the orientation of the ski bumper 4 Remove the pivot bushing from the spindle Clean the pivot bushing to remove any corrosion foreign material 5 Inspect the ski bumper Replace if damaged SKI INSTALLATION 1 Install the rubber ski stop t into the ski and reinstall the ski r to the spindle 2 From outside of ski install fastener w washers e and new flange nut q Torque new...

Page 474: ...nd washers e from ski NOTICE Note the orientation of the fastener and washers 3 Remove the ski r and ski bumper t NOTICE Note the orientation of the ski bumper 4 Remove the nut y washer u and steering tie rod end i from the spindle Discard the flange nut NOTICE Note the position of the washer under the rod end 5 Remove the nut o washers a and upper control arm spherical bearing s Discard the flang...

Page 475: ... of the washers and fastener orientation 7 Remove the spindle h SPINDLE INSTALLATION 1 Loosely install the spindle lower control arm spindle fastener d washers f and new flange nut g 2 Loosely install the upper control arm spherical bearing s washers a and new flange nut o 3 Torque lower control arm and upper control arm spindle nuts to specification TORQUE Upper Lower Control Arm Spindle Nuts 40 ...

Page 476: ...ify the washer is installed under the rod end flange TORQUE Steering Tie Rod End Spindle Nut 37 ft lbs 50 N m 5 Install the rubber ski stop t into the ski and reinstall the ski r to the spindle 6 From outside of ski install fastener w washers e and new flange nut q Torque new ski flange nut to specification NOTICE Verify the washers are installed dome side out TORQUE Ski Fastener Flange Nuts 37 ft...

Page 477: ...lange nuts Remove the lower control arm assembly u LOWER CONTROL ARM INSTALLATION 1 Reinstall the control arm assembly u Secure control arm pivot onto the bulkhead studs using new flange nuts t Torque flange nuts to specification NOTICE The lower control arm front pivot is secured with a screw y and flange nut Install this screw from the right side of the vehicle TORQUE Control Arm Pivot Stud Flan...

Page 478: ...ndle See spindle installation procedure 5 If the ski assembly was removed reinstall the ski UPPER CONTROL ARM REMOVAL 1 Remove the spindle and ski as an assembly 2 Remove the sway bar link fastener q and nut w 3 Remove the fastener e and nut r securing the shock to the lower control arm Discard the flange nut 4 Remove the four flange nuts t that secure the pivot shafts to the bulkhead Discard the ...

Page 479: ...QUE Control Arm Pivot Stud Flange Nuts 30 ft lbs 41 N m 2 Install the shock fastener e and new flange nut r to secure the shock to the lower control arm Torque nut to specification TORQUE Shock Mounting Fasteners 37 ft lbs 50 N m 3 Reinstall the sway bar link fastener q and nut w Torque nut to specification TORQUE Sway Bar Link Control Arm Fastener 20 ft lbs 27 N m 4 Reinstall the spindle See spin...

Page 480: ...ts shown Upper control arm pivots similar When installing or adjusting the control arm pivots push the rear pivots forward prior to tightening the control arm pivot flange nuts SPHERICAL BEARING REPLACEMENT 1 Remove the lower control arm 2 Remove the retaining ring q from the bearing bore 3 Using an Arbor press press the bearing w out of the bore 4 Obtain a new bearing Use an Arbor press to press ...

Page 481: ... Idler Fastener 33 ft lbs 45 N m w Front Cross Shaft f Washer e Front H Bracket Fastener g Idler Wheel r Washer h Idler Spacer t Rear H Bracket Fastener 46 ft lbs 63 N m j Bushing y Rear Cross Shaft k Center Idler Spacer u Rear Pivot Arm l Idler Shaft i Rear Pivot Arm Shaft 1 Nut 56 ft lbs 76 N m o Washer 2 H Bracket a Rear Pivot Arm Fastener 2 H Bracket Shaft s Rear Cross Shaft Fastener 33 ft lbs...

Page 482: ... Mount y Washer k Rail Plate Reinforcement 2 Pivot Arm Bumper Fastener u Jounce Bumper Fastener Head of screw to be on same side of rail as adjuster block l Front Torque Arm Bumper 2 Rail Plate Reinforcement Fasteners 17 ft lbs 23 N m i Wheel Mount Block Fastener 1 Front Torque Arm Bumper Fasteners 4 ft lbs 6 N m 3 Spring Roller Shaft Fastener 17 ft lbs 23 N m o Wheel Mount Block Wheel block goes ...

Page 483: ...850 Matryx Trail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc 8 29 PRO CC BOGIE WHEEL ASSEMBLY VIEW q Nut 10 ft lbs 14 N m e Bogie Wheel Asm w Offset Washer r Bogie Wheel Fastener STEERING SUSPENSIONS ...

Page 484: ...ener 46 ft lbs 63 N m i Limiter Strap Assembled with cloth compound side wrapped around shaft rubber to the outside w Washer o Limiter Strap Fastener e Pivot Bushing a Front Torque Arm r Pivot Shaft s Washer t Nut d Front Torque Arm to Rail Fastener 56 ft lbs 76 N m Apply Loctite 263 to fastener prior to assembly y Nut 12 ft lbs 16 N m f FTA Mount Tapped u Washer STEERING SUSPENSIONS ...

Page 485: ... to Rear Pivot Arm Fastener l Washer t Rear Torque Arm Shaft 1 Plain Carrier Wheel y Spacer 2 RTS Mounting Fasteners u Roller Spring Adjuster Adjust spring roller to medium position 2 Shock Pivot Arm to H Bracket Fastener i Push On Clip 2 Shock Pivot Arm Bushing o Rear Mounting Arm Fasteners 2 Nut 24 ft lbs 33 N m a Nut 33 ft lbs 45 N m 2 Shock Pivot Arm s Washer 2 Nut 17 ft lbs 23 N m d Nut 24 ft...

Page 486: ... prior to assembly d Idler Wheel w Front Cross Shaft f Idler Spacer e Washer g Bushing r FTS Mounting Shaft Fastener 50 ft lbs 68 N m Apply Loctite 263 to fastener prior to assembly h Center Idler Spacer t Rear Pivot Arm j Idler Shaft y Rear Pivot Arm Shaft k Nut 6 ft lbs 8 N m u Washer l Nut 33 ft lbs 45 N m i Rear Pivot Arm Fastener 1 FTS Mounting Shaft o RTA Scissor Stop Guide Fastener 2 Shock ...

Page 487: ...i Fax 146 y Washer 2 Adjustment Fastener u Jounce Bumper Fastener Head of screw to be on opposite side of rail as adjuster block 2 Nut i Wheel Mount Block Fastener 2 Idler Adjustment Spacer o Wheel Mount Block Wheel block goes in front hole on the LH rail asm Wheel block goes in rear hole on the RH rail asm 2 Idler Adjustment Block a Nut 9 ft lbs 12 N m 2 Rivet s Hitch Pin 2 Rail Plate Reinforceme...

Page 488: ...50 850 Matryx Trail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc IGX 146 BOGIE WHEEL ASSEMBLY VIEW q Nut 10 ft lbs 14 N m e Bogie Wheel Asm w Offset Washer r Bogie Wheel Fastener STEERING SUSPENSIONS ...

Page 489: ...sher w Washer d Nut 46 ft lbs 63 N m e Pivot Bushing f Pivot Shaft r Pivot Shaft g Shock Pivot Fastener t Nut h Shock Pivot y Nut 12 ft lbs 16 N m j Lubrication Fitting u Washer k RTS Pivot Bushing i Limiter Strap Assembled with cloth compound side wrapped around shaft rubber to the outside l Nut 24 ft lbs 33 N m o Limiter Strap Fastener 1 Front Torque Arm to Rail Fastener a Front Torque Arm STEER...

Page 490: ...Plain Carrier Wheel r Nut 17 ft lbs 23 N m j Torsion Spring Sleeve t Rear Torque Arm to Rear Pivot Arm Fastener k Torsion Spring y Rear Torque Arm Shaft l Upper Shock Rod Fastener u Roller Spring Adjuster 1 RTS Threaded Bushing i Push On Clip 2 Bushing o Set Screw 2 Lower RTS Fastener 33 ft lbs 45 N m a Rear Torque Arm to Tunnel Fastener 46 ft lbs 63 N m 2 RTS Bushing s Washer 2 Shock Rod d Washer...

Page 491: ...ARING SERVICE 1 Wear eye protection when removing snap ring Use a snap ring pliers to remove the snap ring from the bearing bore Note the sharp side of the snap ring faces out 2 Press the bearing out of the bogie wheel 3 Install a new bearing into the bogie wheel by pressing on the bearing s outer race 4 Install the snap ring Verify the snap ring is fully seated in the groove BOGIE WHEEL ASSEMBLY ...

Page 492: ...the shock rod to the front torque arm Discard the lock nut 5 Remove the fastener securing the shock body to the H bracket Discard the lock nut FRONT TRACK SHOCK FTS INSTALLATION 1 Install the FTS and align mounting holes 2 Install the fastener securing the shock body to the H bracket Use new lock nut Torque fastener to specification TORQUE FTS Mounting Fasteners 33 ft lbs 45 N m 3 Install the fast...

Page 493: ... of the fasteners washers and nuts 4 Remove the lower fastener securing the shock to the shock pivot arm REAR TRACK SHOCK RTS INSTALLATION 1 Install the lower fastener securing the shock to the shock pivot arm Use new lock nut Torque fastener to specification TORQUE Rear Track Shock Shock Rod Fasteners 17 ft lbs 23 N m 2 Install the upper fastener securing the shock to the rear torque arm Use new ...

Page 494: ...hown in the stock upper hole position 2 Raise the rear of the snowmobile off of the ground using a dedicated track stand or similar device 3 To access the FTS lower cross shaft rail beam screws remove the left and right bogie wheels Note the orientation of the screws washers and nuts 4 Measure the shock preload setting Loosen the spring preload by turning the preload adjuster clockwise 5 Remove th...

Page 495: ... rail beams If the holes are elongated the rail s must be replaced 2 Installation of the FTS is the reverse of removal 3 Clean the cross shaft rail beam fastener threads and apply Loctite 263 to the threads 4 Use new lock nuts where applicable 5 Verify the cross shaft washers q are installed between the cross shaft and rail beams 6 To secure the limiter strap lower the front of the track onto a fl...

Page 496: ...dicated track stand or similar device 2 Remove the fasteners securing the shock to the rear torque arm 3 Remove the fasteners securing the shock to the lower mount REAR TRACK SHOCK RTS INSTALLATION Installation of the rear track shock RTS onto the snowmobile is the reverse of removal Use new lock nuts when installing the shock Torque fasteners to specifications TORQUE Rear Track Shock Fasteners 33...

Page 497: ...e rear idler shaft bolts q 2 Loosen the jam nuts w on each rear idler adjuster e Push the rear idler shaft idler wheel assembly forward 3 Remove the two upper carrier fasteners r and nuts t NOTICE Right side shown 4 Remove the front torque arm to tunnel mount bolts y and washers u NOTICE Right side shown 5 Carefully pull the rear suspension i from the track and remove rear suspension from the tunn...

Page 498: ...e rear suspension i back into the tunnel and track 3 Loosely install the washers u and front torque arm to tunnel mount bolts y NOTICE Right side shown 4 Loosely the two upper carrier fasteners r and nuts t NOTICE Right side shown 5 When all four rear suspension mounting bolts are installed torque all to specifications TORQUE Front Torque Arm to Tunnel Mount Fasteners 46 ft lbs 63 N m Upper Carrie...

Page 499: ...spension may exhibit some side to side play between the rear torque arm mounting arm and tunnel suspension mounting points The play is normal and necessary for the proper operation of the rear suspension Do not shim or re arrange bushings at this mounting point in an effort to tighten the gap s present at these locations as bushing wear may occur STEERING SUSPENSIONS ...

Page 500: ...er shaft bolts q 2 Loosen the jam nuts w on each rear idler adjuster e Push the rear idler shaft idler wheel assembly forward 3 Remove the two upper carrier fasteners r spring washers t and washers y NOTICE Right side shown 4 Remove the front torque arm to tunnel mount bolts u and washers i NOTICE Right side shown 5 Carefully pull the rear suspension o from the track and remove rear suspension fro...

Page 501: ...nsion o back into the tunnel and track 3 Loosely install the washer i and front torque arm to tunnel mount bolts u NOTICE Right side shown 4 Loosely install the washers y spring washers u and two upper carrier fasteners r NOTICE Right side shown 5 When all four rear suspension mounting bolts are installed torque all to specifications TORQUE Front Torque Arm to Tunnel Mount Fasteners 50 ft lbs 68 N...

Page 502: ...R COMPONENT FASTENERS q Left Handlebar Control Block 20 in lbs 2 3 N m DO NOT MOVE THE LH CONTROL BLOCK WITHOUT FIRST LOOSENING THE SCREWS t Throttle Lever Block Cover Screws 6 in lbs 0 7 N m w Brake Lever Master Cylinder 60 80 in lbs 6 8 9 N m y Throttle Lever Block Set Screw 27 in lbs 3 1 N m e Upper Lower Riser Clamps 11 ft lbs 15 N m Hand Guards if applicable Hand Guard Arm Fasteners Tighten U...

Page 503: ...TIONS Refer to the following illustration and measurements to position handlebar components at factory specified locations NOTICE Do not attempt to move handlebar components without first loosening the affected component s screws q 9 25 in 235 mm e 0 078 in 2 mm To grip end w 0 078 in 2 mm To grip end r 6 30 in 160 mm STEERING SUSPENSIONS ...

Page 504: ...r torque MEASUREMENT Short Riser 60 mm 26 5 3 Tall Riser 85 mm 31 5 3 IMPORTANT Do not stretch wires while adjusting the controls Stretching the wires could damage the handwarmers 3 Tighten the fasteners to specification TORQUE Handlebar Riser Fasteners 11 ft lbs 15 N m HANDLEBAR RISER ANGLE ADJUSTMENT Riser angle can be adjusted to suit rider preference The factory desired setup angles are shown ...

Page 505: ...ster cylinder mounting screws q and move it away from left hand control IMPORTANT Use care when moving brake master cylinder Do not damage the brake light signal wire NOTICE If applicable hand guards may need to be loosened or removed to access and move the brake master cylinder 2 Loosen the four left hand control mounting screws w 3 Move the control block to the desired position 4 Torque control ...

Page 506: ...le lever 2 Loosen the throttle block set screw q 3 Remove the e clip w the throttle lever pin e and adjustment washers r Note the number of washers 4 Remove the throttle lever t and remove the wiring from the clip on the throttle block NOTICE The throttle lever will just be moved to the side as the wiring is part of the handlebar wiring harness 5 Remove the screw y from the auxiliary stop switch b...

Page 507: ...d cover o 7 Remove the throttle release switch a from the throttle block s Note the orientation of the switch during removal NOTICE The throttle release switch will just be moved to the side as the wiring is part of the handlebar wiring harness 8 Slide the lower block d out of the upper block f Remove the throttle blocks from the handlebar STEERING SUSPENSIONS ...

Page 508: ...hrottle release switch a into the throttle block s NOTICE Make sure the switch is properly oriented 3 Install the throttle block cover o and throttle block cover screws i Torque fasteners to specification TORQUE Throttle Cover Screws 6 in lbs 0 7 N m 4 Install or reposition the stop switch assembly u and install the screw y into the auxiliary stop switch block Torque fastener to specification TORQ...

Page 509: ...tle lever t and reinstall the wiring into the clip on the throttle block 6 Install the adjustment washers r the throttle lever pin e and e clip w 7 Torque the throttle block set screw q to specification TORQUE Throttle Block Set Screw 27 in lbs 3 1 N m 8 Reinstall the throttle cable barrel into the throttle lever STEERING SUSPENSIONS ...

Page 510: ...ange the ski alignment or toe adjustment The skis on your snowmobile are set with a small amount of toe out at the factory You can inspect and adjust the toe setting by following the procedures below SKI TOE SETTING INSPECTION NOTICE Toe alignment is measured at ride height 1 Rock the front end of the vehicle up and down and then set it down gently This will set the front suspension at ride height...

Page 511: ...s point verify the handlebar is centered with the skis 8 Turn both tie rods equally to set ski toe When finished measurement q should be 1 8 1 4 in 3 6 mm wider than measurement w NOTICE If setting toe on each ski using the alignment bar as a reference point q should be 1 16 1 8 in 1 6 3 mm wider than measurement w 9 Torque steering tie rod jam nuts and spindle fasteners to specification TORQUE Ti...

Page 512: ...NOTICE Always replace ski skags in pairs 1 Raise and support the front of the snowmobile so the skis are approximately 6 in 15 2 cm from the ground 2 Remove the attaching nuts q and pry the skag w downward 3 Reverse the steps to install a skag Tighten nuts to specification TORQUE Ski Skag Nuts 8 ft lbs 11 N m STEERING SUSPENSIONS ...

Page 513: ...ot operate the snowmobile if slide thickness measures less than 7 16 in 1 1 cm Worn rail sliders can be removed from the suspension without removing the track Raise the rear suspension off of the ground Loosen the track tension Rotate the track to access the screw securing the slider at the front of the beam Apply spray lubricant to the rail beam Use a small pry bar to drive the slider rearward un...

Page 514: ...tighten the right adjusting bolt 4 After adjustments are complete verify the track tension is set to specification 5 Tighten the lock nuts 6 Tighten the idler shaft bolts to specification TORQUE Rear Idler Fastener 33 ft lbs 45 N m TRACK TENSION INSPECTION Track adjustment is critical for proper handling Always maintain correct tension and alignment NOTICE Closely monitor track tension during the ...

Page 515: ...crews w to provide equal adjustment on both sides of the track 4 Repeat the measurement on the other side of the track NOTICE Check more frequently when the snowmobile is new or if studs are installed 5 Remove the weight Start the engine and slowly rotate the track at least five revolutions Let the track come to a stop do not apply brakes 6 Check track alignment and adjust as necessary 7 Tighten t...

Page 516: ...Preferred Maximum Rear Idler Fastener Torque e e Weight Measurement Location r r PRO CC 7 8 1 1 8 in 2 2 2 6 cm IMPORTANT If the track is studded Polaris recommends maintaining 7 8 in 2 2 cm track tension setting at all times Rear Idler Fasteners 33 ft lbs 45 N m 10 lb 4 54 kg 16 in 40 cm ahead of rear idler shaft IGX 146 NOTICE Image for reference only STEERING SUSPENSIONS ...

Page 517: ...strap is set at position 1 Polaris recommends leaving the limiter strap length at position 1 to maintain the optimum ride characteristics of the snowmobile Riders who desire less ski pressure and more weight transfer toward the rear of the snowmobile can lengthen the limiter strap by changing to position 2 TORQUE Limiter Strap Nuts 12 ft lbs 16 N m STEERING SUSPENSIONS ...

Page 518: ...the torsion spring preload or increase the front track shock spring preload Step 3 Adjust shock clickers if equipped for ride quality For models equipped with monotube shocks always adjust the rear torsion spring preload to enhance bottoming resistance For models with shock clickers you can adjust the clickers to control bottoming and adjust ride comfort Turn a clicker counter clockwise to decreas...

Page 519: ...tance Compression damping can be adjusted at the front suspension and at the front and rear track shock Make adjustments in increments then test ride When adjusting the front suspension always adjust both clickers equally To stop bottoming of the front or rear suspension stiffer ride rotate the clicker s clockwise two clicks as viewed from the top of the clicker then test ride Repeat the adjustmen...

Page 520: ...o may affect handling and require a spring rate change TORSION SPRING SETTING RECOMMENDED USAGE Low Rider s and gear 140 180lb If less than 140 use the optional spring chart for softer springs Medium Rider s and gear 180 220lb High Rider s and gear 220 260lb If above 260 use the optional spring chart for heaver springs OPTIONAL SPRINGS If the correct balance cannot be obtained by adjusting the sto...

Page 521: ...being adjusted Always verify the spring collars retainers are tight and holding the spring s in position IMPORTANT The factory installed length of the IFS Shock Spring is equal to the maximum installed free length FACTORY SPRING FACTORY INSTALLED LENGTH MINIMUM INSTALLED LENGTH INDY XC 10 75 in 27 3 cm 9 75 in 24 8 cm INDY VR1 10 75 in 27 3 cm 9 75 in 24 8 cm IFS FACTORY CLICKER SETTINGS MODEL CLI...

Page 522: ...r than the minimum length as shown in the following chart Damage to the suspension could result When decreasing preload make sure at least two turns of preload are holding the retainer against the spring FACTORY SPRING MAXIMUM INSTALLED LENGTH MINIMUM INSTALLED LENGTH INDY XC 1 62 in 4 1 cm 1 38 in 3 5 cm INDY VR1 2 25 in 5 7 cm 1 75 in 4 5 cm NOTICE Spring preload is measured between edge of shoc...

Page 523: ... the torsion spring preload or increase the front track shock spring preload Step 3 Adjust shock clickers if equipped for ride quality For models equipped with monotube shocks always adjust the rear torsion spring preload to enhance bottoming resistance For models with shock clickers you can adjust the clickers to control bottoming and adjust ride comfort Turn a clicker counter clockwise to decrea...

Page 524: ...ance Compression damping can be adjusted at the front suspension and at the front and rear track shock Make adjustments in increments then test ride When adjusting the front suspension always adjust both clickers equally To stop bottoming of the front or rear suspension stiffer ride rotate the clicker s clockwise two clicks as viewed from the top of the clicker then test ride Repeat the adjustment...

Page 525: ...NOTICE Adding 1 1 seat or additional cargo may affect handling and require a spring rate change TORSION SPRING SETTING RECOMMENDED USAGE Low Rider s and gear 140 180lb If less than 140 use the optional spring chart for softer springs Medium Rider s and gear 180 220lb High Rider s and gear 220 260lb If above 260 use the optional spring chart for heaver springs OPTIONAL SPRINGS If the correct balanc...

Page 526: ...FULL HARD Switchback Assault 6 REAR SUSPENSION FRONT TRACK SHOCK FACTORY SPRING SETTINGS IMPORTANT When making spring setting adjustments always remove the weight of the snowmobile from the spring being adjusted Always verify the spring collars retainers are tight and holding the spring s in position NOTICE Never adjust spring preload to an installed length longer than the factory length or shorte...

Page 527: ...obile Service Manual Copyright Polaris Inc 8 73 FRONT TRACK SHOCK FACTORY CLICKER SETTINGS MODEL CLICKER SETTING FROM FULL HARD Switchback Assault 6 REAR TRACK SHOCK FACTORY CLICKER SETTINGS MODEL CLICKER SETTING FROM FULL HARD Switchback Assault 6 STEERING SUSPENSIONS ...

Page 528: ...ock Recharging Kit 2200421 Gas Fill Tool PS 45259 Gas Shock Fill PU 51039 Gas Fill Tool Replacement Needles 20 Pack PS 45259 1 Shock Body Holding Tool 1 3 4 PS 45629 Shock Body Holding Tool 1 5 8 2871071 Shock Body Holding Tool 2 1 8 PS 45281 Shock Rod Holding Tool 1 2 Diameter Rod 2871352 Shock Rod Holding Tool 5 8 Diameter Rod 2872429 STEERING SUSPENSIONS ...

Page 529: ... Protector 5 8 Diameter 2201640 Shock Absorber Spring Compression Tool 2870623 Shock Spring Pre Load Adjustment Tool 2870803 Walker Evans T Handle Tool PS 45908 IFP Depth Tool Fox Walker Evans 2871351 FOX Air Assist Bearing Wrench Commercially Available FOX P N 398 00 644 Bosch Automotive Service Solutions 1 800 345 2233 or http polaris service solutions com STEERING SUSPENSIONS ...

Page 530: ...7045432 7045462 Model Walker Evans 1 75 Piggyback Indy XC 129 137 Walker Evans 1 75 Velocity Piggyback Indy VR1 129 137 Walker Evans 2 Velocity Piggyback Switchback Assault 146 Extended Length inches 17 30 17 30 17 30 Collapsed Length inches 11 45 11 45 11 45 Stroke inches 5 85 5 85 5 85 Shock Rod inches 500 625 625 IFP Depth inches 2 00 Bottom of reservoir to bottom of floating piston 2 00 Bottom...

Page 531: ... 700 x 006 800 x 006 900 x 006 1 00 x 006 1 20 x 006 1 30 x 010 875 x 090 625 x 065 700 x 006 800 x 006 900 x 006 1 00 x 006 1 20 x 008 1 30 x 010 1 50 x 120 600 x 015 900 x 006 1 00 x 008 1 20 x 008 1 30 x 008 1 45 x 008 1 20 x 006 1 55 x 010 Adjuster N A 6 ID x 25 x 19 6 ID x 25 x 19 6 ID x 25 x 19 6 ID x 25 x 18 6 ID x 25 x 18 6 ID x 25 x 15 6 ID x 25 x 15 6 ID x 25 x 15 6 ID x 25 x 12 6 ID x 2...

Page 532: ...ns 2 Piggyback Indy VR1 129 137 Walker Evans 2 Piggyback Switchback Assault 146 Extended Length inches 12 95 12 95 12 95 Collapsed Length inches 8 95 8 95 8 95 Stroke inches 4 125 4 125 4 125 Shock Rod inches 500 625 625 IFP Depth inches 1 5 Top of reservoir to top of floating piston 1 75 Top of reservoir to top of floating piston 1 75 Top of reservoir to top of floating piston Oil Volume Full Ful...

Page 533: ...900 x 010 1 00 x 010 1 10 x 010 1 20 x 010 800 x 010 1 30 x 010 1 00 x 075 KAR Round Up 600 x 015 800 x 008 900 x 008 1 00 x 008 1 30 x 008 1 45 x 008 1 55 x 008 1 55 x 008 1 55 x 010 1 00 x 075 KAR Round Up 600 x 015 800 x 008 1 10 x 008 1 55 x 010 1 55 x 010 1 55 x 010 1 55 x 010 1 30 x 008 1 55 x 012 Ring 1 55 x 008 Adjuster N A 6 ID x 25 x 19 6 ID x 25 x 19 6 ID x 25 x 19 6 ID x 30 x 18 6 ID x...

Page 534: ...elocity Piggyback Indy VR1 129 137 Walker Evans 1 75 Velocity Piggyback Switchback Assault 146 Extended Length inches 19 28 19 28 19 28 Collapsed Length inches 13 48 13 48 13 48 Stroke inches 5 80 5 80 5 80 Shock Rod inches 500 625 625 IFP Depth inches 2 25 Top of reservoir to top of floating piston 2 25 Top of reservoir to top of floating piston 2 25 Top of reservoir to top of floating piston Oil...

Page 535: ...ton Bleed 082 052 0 Shaft Bleed 0 086 120 x 4 Compression 875 x 090 KAR Round Side Up 750 x 060 KAR Round Side Up 700 x 010 900 x 008 1 10 x 008 1 20 x 008 900 x 008 1 25 x 008 1 30 x 006 1 30 x 008 1 30 x 010 1 30 x 010 1 30 x 010 1 10 x 025 800 x 010 900 x 012 1 00 x 012 1 10 x 010 1 25 x 010 1 30 x 012 1 30 x 012 1 30 x 025 700 x 006 800 x 015 800 x 015 900 x 008 1 00 x 008 1 10 x 010 1 20 x 01...

Page 536: ... unit Refer to the instructions for the proper procedure of discharging the gas pressure from a shock Protective eye wear should be worn to avoid risk of injury while servicing gas charged shocks When removing the spring from a shock that utilizes a fixed lower retainer the use of a proper spring compressor should be used to avoid risk of bodily injury It is important that the gas shock be retaine...

Page 537: ...0 008 1800082 800 1800083 900 1800084 1 000 1800085 1 100 1800086 1 200 1800087 1 250 1800088 1 300 1800052 700 010 1800053 800 1800054 900 1800055 1 000 1800056 1 100 1800057 1 200 1800379 1 250 1800058 1 300 1800059 700 012 1800060 800 1800061 900 1800062 1 000 1800063 1 100 1800064 1 200 1800089 1 250 1800072 1 300 1800066 700 015 1800067 800 1800068 900 1800069 1 000 1800070 1 100 1800380 1 20...

Page 538: ...1801105 1 100 1801128 800 006 1801127 900 1801126 1 000 1801125 1 100 1801124 1 200 1801123 1 300 1801122 1 450 1801121 1 500 1800588 700 008 1801116 800 1801106 900 1801107 1 000 1801108 1 100 1801109 1 200 1800584 1 300 1801110 1 450 1801111 1 500 1801112 1 550 1801113 700 010 1801117 800 1800244 900 1800245 1 000 1800246 1 100 1800247 1 200 1800248 1 300 1800249 1 450 1800250 1 500 1800251 1 55...

Page 539: ... SIZE THICKNESS 1800255 1 200 1800256 1 300 1800257 1 450 1800258 1 500 1800259 1 550 1801120 600 015 1801115 700 1801119 800 1800260 900 1800261 1 000 1800262 1 100 1800263 1 200 1800264 1 300 1800265 1 450 1800266 1 500 1800267 1 550 1800268 1 000 090 WASHERS 1800269 1 100 1800270 1 250 1800271 1 300 025 STEERING SUSPENSIONS ...

Page 540: ... Stack 2 Piston Valve 3 Compression Valve Stack 4 Shock Shaft NOTICE The rebound and compression valve stacks will always be positioned as shown in the illustration regardless of how the shock assembly is installed on the snowmobile WALKER EVANS PISTON VALVE ORIENTATION The face of the piston with the greater number of relief ports q will always face the rebound valve stack REBOUND SIDE COMPRESSIO...

Page 541: ...YBACK SHOCK IFP DEPTH When measuring IFP depth A on Walker Evans Piggyback shocks measure from the top of the reservoir to the Internal Floating Piston IFP using a Vernier Caliper Reference the shock specification tables in this chapter for measurement A NOTICE The flat side of the IFP faces the clicker assembly STEERING SUSPENSIONS ...

Page 542: ...88 9850064 R03 2021 650 850 Matryx Trail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc WALKER EVANS FORCE PIGGYBACK WALKER EVANS PIGGYBACK SHOCK ASSEMBLY VIEW STEERING SUSPENSIONS ...

Page 543: ...ith new when removed i Seal Head Assembly 45 ft lbs 61 N m Replace seal head assembly if shaft bushing is damaged worn o Shock Body a Jounce Bumper s Spring Retainer d Body Cap 45 ft lbs 61 N m f Adjuster Assembly 25 ft lbs 34 N m Adjuster Assembly Nut 45 in lbs 5 N m g Sticker h Piston Seal Spacer j End Cap Service Port Replace service port assembly after fifth charging k Snap Ring l Sleeve 1 Bus...

Page 544: ... Perform work in clean environment Always discard used O rings and wear bands discard used shock oil into appropriate container Gas shock oil replacement does not require shock reservoir body removal or clicker disassembly Service these components only if required Shock shaft bearing cap service is always recommended when changing shock oil 1 Remove the shock from the vehicle Clean the shock to re...

Page 545: ... the shock body CAUTION Residual nitrogen gas may exist inside shock Wear eye protection and use caution when removing shock rod bearing cap 9 Remove the shock from the vise and pour shock oil into an approved container Place shock back into vise 10 Push the reservoir cap down and remove the snap ring 11 Remove the reservoir cap from the reservoir 12 Remove the bleed screw and O ring from the inte...

Page 546: ...ve the rebound valve stack piston valve and compression valve stack from the shock rod 17 Remove the bearing cap 18 To service the bearing cap remove and discard the bearing cap O ring Use a pick to remove the wiper seal U cup seal inner O ring and shaft bushing if required IMPORTANT Do not to scratch or gouge the O ring seal grooves when removing the bearing cap O rings and seals NOTICE The beari...

Page 547: ...y from the body cap NOTICE Servicing the clicker assembly is difficult without the proper tools 22 Optional service Remove the spacer and O ring from the clicker assembly 23 Optional service Disassemble the clicker assembly as shown Discard all O rings and replace with new NOTICE Clicker compression washers may differ from shock to shock See specification tables for washer settings 24 Optional ser...

Page 548: ...ent damage or marks to the shock the use of soft jaws on a vise is recommended Perform work in clean environment Always discard used O rings and wear bands discard used shock oil into appropriate container 1 Obtain new shock oil and new O rings wear bands for the components removed from the shock 2 Optional service If removed reinstall the shock body tube Torque the body cap tube to specification ...

Page 549: ... the shock reservoir tube Torque to specification TORQUE Clicker Assembly 25 ft lbs 34 N m 6 Reinstall the clicker knob and screw 7 Obtain a new reservoir tube O ring Coat the O ring with new shock oil Reinstall reservoir tube and O ring Torque to specification TORQUE Reservoir Body 10 ft lbs 14 N m 8 Assemble the bearing cap Coat a new bearing cap O ring q with new shock oil Install into bearing ...

Page 550: ... seal e should be orientated as shown Bushing r shown for reference 12 Coat the shock shaft and bearing assembly with shock oil Install the bearing assembly onto the shock shaft with the wrench flats facing the rod end eyelet Install a new O ring onto the bearing cap 13 Install the compression valve stack onto the shock rod Coat a new piston valve wear band with shock oil and install onto valve In...

Page 551: ...y onto the IFP Verify the bleed screw and O ring are removed from the IFP Coat the IFP with shock oil 17 Slowly Insert the IFP into the reservoir using the T handle tool Allow as much air as possible to escape as the IFP is installed 18 Slowly stroke the IFP up and down to bleed air from the shock be sure to bottom out the IFP in the reservoir Allow sufficient time for all air bubbles to dissipate...

Page 552: ...he air is removed push the assembly down until the threads engage the tube Torque bearing cap to specification TORQUE Seal Head Bearing Cap 45 ft lbs 61 N m 26 Verify there is shock oil above the IFP in the reservoir 27 Slowly pull the shock rod out till the shock is fully extended 28 Remove the bleed screw and O ring from the IFP 29 Set the IFP depth to specification Reinstall the O ring and blee...

Page 553: ...021 650 850 Matryx Trail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc 8 99 33 Install the service port button screw and O ring 34 Reinstall the shock bushings and spacers STEERING SUSPENSIONS ...

Page 554: ...0 9850064 R03 2021 650 850 Matryx Trail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc WALKER EVANS VELOCITY PIGGYBACK WALKER EVANS PIGGYBACK SHOCK ASSEMBLY VIEW STEERING SUSPENSIONS ...

Page 555: ...lbs 14 N m d End Cap Service Port Replace service port assembly after fifth charging f IFP Piston Assembly g Adjuster Assembly 25 ft lbs 34 N m Adjuster Assembly Nut 45 in lbs 5 N m h Seal Head Assembly 45 ft lbs 61 N m Replace seal head assembly if shaft bushing is damaged worn j Snap Ring k O Ring Replace with new when removed l Spring Retainer 1 Piston Assembly 2 Lock Nut 15 ft lbs 20 N m 2 Jam...

Page 556: ...mmended Perform work in clean environment Always discard used O rings and wear bands discard used shock oil into appropriate container Gas shock oil replacement does not require shock reservoir body removal or clicker disassembly Service these components only if required Shock shaft bearing cap service is always recommended when changing shock oil 1 Remove the shock from the vehicle Clean the shoc...

Page 557: ...m the shock body CAUTION Residual nitrogen gas may exist inside shock Wear eye protection and use caution when removing shock rod bearing cap 9 Remove the shock from the vise and pour shock oil into an approved container Place shock back into vise 10 Push the reservoir cap down and remove the snap ring 11 Remove the reservoir cap from the reservoir 12 Remove the bleed screw and O ring from the int...

Page 558: ...ove the rebound valve stack piston valve and compression valve stack from the shock rod 17 Remove the bearing cap 18 To service the bearing cap remove and discard the bearing cap O ring Use a pick to remove the wiper seal U cup seal inner O ring and shaft bushing if required IMPORTANT Do not to scratch or gouge the O ring seal grooves when removing the bearing cap O rings and seals NOTICE The bear...

Page 559: ...Remove the clicker assembly from the shock bridge NOTICE Servicing the clicker assembly is difficult without the proper tools 22 Optional service Disassemble the clicker assembly as shown Discard all O rings and replace with new NOTICE Clicker compression washers may differ from shock to shock See specification tables for washer settings 23 Discard all O rings and wear bands from removed component...

Page 560: ...commended Perform work in clean environment Always discard used O rings and wear bands discard used shock oil into appropriate container 1 Obtain new shock oil and new O rings wear bands for the components removed from the shock 2 Optional service If the clicker assembly was removed from the body cap reassemble the clicker components Tighten nut to specification TORQUE Clicker Assembly Nut 45 in l...

Page 561: ...e the bearing cap Coat a new bearing cap O ring q with new shock oil Install into bearing cap 7 Apply shock oil to a new U cup seal w Install the seal as shown The flat side of the seal faces out NOTICE Use the rounded end of a ball point pen or marker to push the U cup seal into position 8 Apply shock oil to a new wiper seal e Install the wiper seal as shown 9 When assembled the O ring q U cup se...

Page 562: ...to valve Install the assembly onto the shock shaft Install the rebound valve stack onto the shock rod NOTICE The side of valve with the greater number of relief ports is the rebound side Install with rebound side facing up 12 Install a new lock nut and torque to specification TORQUE Shock Rod Lock Nut 15 ft lbs 20 N m 13 Remount the shock body assembly in the vise Set the clicker to full soft Fill...

Page 563: ...tion from the valve stack on the shock rod 20 Fill the shock body with oil Dip the piston valve stack into the oil Fill the shock body with oil to the bottom of the cap threads 21 Slightly oscillate the piston rod to allow the piston to enter shock body bore as it purges the air out 22 With the piston completely submerged in oil cycle the rod in and out to remove any remaining trapped air undernea...

Page 564: ...oir cap and install cap Install the snap ring NOTICE The service port should be inspected and replaced if the rubber pellet u is worn or the shock has been re charged more than five times 30 Charge the shock with nitrogen to the specified pressure The shock rod should extend during charging 31 Install the service port button screw and O ring 32 Reinstall the shock bushings and spacer STEERING SUSP...

Page 565: ...IGHT SIDE PANEL ASSEMBLY VIEW 9 15 LEFT SIDE PANEL ASSEMBLY VIEW 9 16 CONSOLE ASSEMBLY VIEW 9 17 SEAT ASSEMBLY VIEW 9 18 BUMPER ASSEMBY VIEWS 9 19 FRONT BUMPER ASSEMBLY VIEW 9 19 REAR BUMPER CLOSEOFF ASSEMBLY VIEW 9 20 BODY SERVICE 9 21 SIDE PANEL REMOVAL 9 21 SIDE PANEL INSTALLATION 9 21 HOOD REMOVAL 9 22 HOOD INSTALLATION 9 22 CONSOLE REMOVAL 9 23 CONSOLE INSTALLATION 9 25 BONDED COMPONENT SERVI...

Page 566: ... Snowmobile Service Manual Copyright Polaris Inc LEFT BULKHEAD CLIP REMOVAL 9 38 LEFT BULKHEAD CLIP INSTALLATION 9 39 RIGHT BULKHEAD CLIP REMOVAL 9 40 RIGHT BULKHEAD CLIP INSTALLATION 9 41 LEFT SUPPORT BRACE REMOVAL 9 42 LEFT SUPPORT BRACE INSTALLATION 9 42 CHASSIS ...

Page 567: ...ir is completed in accordance with local rules and regulations Wear gloves face mask and protective eye wear when removing original adhesive from chassis components Never apply excessive heat or flame to bonded components when not intending to remove them from the chassis The engine overstructure steering support assembly and floor board support tubes are bonded components THESE COMPONENTS ARE NOT...

Page 568: ...h new when removed a Inner Chaincase to Bulkhead Cooler Fastener 26 ft lbs 35 N m Replace with new when removed e Crossover Tube Fastener 22 ft lbs 30 N m s Stud Plate r Dart Clip d Rivet t Clip Idler Bracket Fastener 9 ft lbs 12 N m f Washer y Clip Mounting Fasteners g Nut 9 ft lbs 12 N m u Lower Steering Mount Fasteners 22 ft lbs 30 N m h Chaincase Housing i Idler Bracket j Chaincase Side Suppor...

Page 569: ...Nut 26 ft lbs 35 N m a Jackshaft Bearing Mount e Clip Idler Bracket Fastener 9 ft lbs 12 N m s Rivet r Side Support Fasteners 26 ft lbs 35 N m Replace with new when removed d Jackshaft Nut Plate t Crossover Tube Fastener 22 ft lbs 30 N m f Idler Bracket y Left Support Brace g Crossover Tube u Nut h Lower Steering Mount i Jackshaft Bearing Mount to Bulkhead Fasteners j Lower Steering Mount Fastener...

Page 570: ...ce Fasteners 22 ft lbs 30 N m j Washer r Right Tube Brace k Stud Plate t Front Lower Over Structure Fasteners 22 ft lbs 30 N m l Nut 9 ft lbs 12 N m y Rivets 1 Cable Tie u Load Center Bracket 2 Cable Clap i Load Center Mount 2 Rivet o Tube Brace Fasteners 22 ft lbs 30 N m 2 Rear Frame Over Structure a Left Tube Brace 2 Tube Spacers s Nut 2 Tube Shims d Foam Pads 2 Upper Over Structure Fasteners 12...

Page 571: ... Crossover Snowmobile Service Manual Copyright Polaris Inc 9 7 CLUTCH GUARD FOOTRESTS ASSEMBLY VIEW q Console Support t Clutch Guard Support w U Nut y Left Footrest Closeoff e Rivets u Clutch Guard r Right Footrest Closeoff i Nut 8 ft lbs 10 N m CHASSIS ...

Page 572: ...Y VIEW NOTICE Image for reference only as models may vary slightly q Tunnel Assembly u Rear Running Board Spacer w Right Footrest Support i Washer e Rivets o Nut 9 ft lbs 12 N m r Footrest Support Fasteners 7 ft lbs 9 N m a Left Running Board t Right Running Board s Left Footrest Support y Running Board Mount Fastener CHASSIS ...

Page 573: ...Inc 9 9 BODY ASSEMBLY VIEWS HOOD ASSEMBLY VIEW q Hood i RH Hood Trim w LH Hood Trim o Hood Cap Assembly e LH Hood Plug a Hood Cap Fasteners 18 in lbs 2 N m r 1 4 Turn Retainer s Middle Hood Screen t 1 4 Turn Stud d Retainer y Hood Trim Fasteners 11 in lbs 1 25 N m f Lower Hood Screen u RH Hood Plug CHASSIS ...

Page 574: ...rmance Crossover Snowmobile Service Manual Copyright Polaris Inc HOOD FOAM ASSEMBLY VIEW NOTICE Inside view of hood q LH Rear Hood Foam r RH Middle Hood Foam w RH Rear Hood Foam t Front Hood Foam e LH Middle Hood Foam Kit All Pieces Included CHASSIS ...

Page 575: ...uge 7S gauge shown u Display Wire Cover w Display Door i Latch Spring e Display Door Seal o Latch Bottom r Hood Cap a Display Door Latch Fastener 15 in lbs 1 7 N m Latch may stick if overtightened t Grommet s Friction Hinge Friction hinge to be pressed in flush with edge of the hood cap y Top Latch d Display Fasteners 53 in lbs 6 N m CHASSIS ...

Page 576: ...2 9850064 R03 2021 650 850 Matryx Trail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc NOSEPAN ASSEMBLY VIEW q Nosepan r Fiber Pad w RH Nosepan Foam t LH Nosepan Foam e Rivet CHASSIS ...

Page 577: ...nce Crossover Snowmobile Service Manual Copyright Polaris Inc 9 13 RIGHT FENDER ASSEMBLY VIEW q Right Fender t Snow Exhaust Deflector w Plastic Rivet y Fender Fasteners 36 in lbs 4 N m e RH IFS Hole Plug u Washer r Rivet i Exhaust Outlet Boot CHASSIS ...

Page 578: ... R03 2021 650 850 Matryx Trail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc LEFT FENDER ASSEMBLY VIEW q Left Fender r Rivet w Plastic Rivet t LH Upper Fender Foam e LH IFS Hole Plug CHASSIS ...

Page 579: ...ce Manual Copyright Polaris Inc 9 15 RIGHT SIDE PANEL ASSEMBLY VIEW q RH Side Panel Trim y Retainers w RH Side Panel u Brake Duct e 1 4 Turn Latch i Side Panel Trim Fasteners 10 in lbs 1 1 N m r Washer o RH Upper Side Panel Foam t Latch Grommet a RH Lower Side Panel Foam CHASSIS ...

Page 580: ...anual Copyright Polaris Inc LEFT SIDE PANEL ASSEMBLY VIEW q LH Side Panel Trim y Side Panel Trim Fasteners 10 in lbs 1 1 N m w LH Side Panel u LH Front Upper Side Panel Foam e 1 4 Turn Latch i LH Rear Lower Side Panel Foam r Washer o LH Rear Upper Side Panel Foam t Latch Grommet CHASSIS ...

Page 581: ...le Fasteners 71 in lbs 8 N m f Retainer e Belt Removal Tool g RH Console Trim r LH Lower Console Foam h Console Vent t Seal j Recoil Handle y LH Console Trim k Recoil Pocket u LH Upper Console Foam l Recoil Roller Nut 71 in lbs 8 N m i Filler Neck Nut 1 Roller Bushing o 1 4 Turn Clip 2 Recoil Roller a Plastic Rivets 2 Recoil Roller Fastener s Console Switch Panel CHASSIS ...

Page 582: ... 850 Matryx Trail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc SEAT ASSEMBLY VIEW q Seat Assembly r Washer w Rear Tank Trim t 1 4 Turn Latch e Latch Grommet y Rear Tank Trim Nuts 44 in lbs 5 N m CHASSIS ...

Page 583: ...ight Polaris Inc 9 19 BUMPER ASSEMBY VIEWS FRONT BUMPER ASSEMBLY VIEW q Front Bumper y Bumper Mounting Nuts 7 ft lbs 10 N m w RH 1 4 Turn Mount u LH 1 4 Turn Mount e Rivet i Front Lower Bumper r Bumper Mounting Fasteners o Bumper Nosepan Fasteners 7 ft lbs 10 N m t Pipe Chassis Bracket CHASSIS ...

Page 584: ...p Plate t Rear Bumper f Snow Flap Plate Fastener 42 in lbs 4 7 N m Ensure the screw is seated against the aluminum plate and snowflap is tight against the bumper y Bumper Fasteners 75 in lbs 8 5 N m g Tunnel Protector Fastener Only applicable if stud protection accessory kit is installed u Rivet h Tunnel Protector Only applicable if stud protection accessory kit is installed i Tube Plug j Nut 7 ft...

Page 585: ...ly latched before starting the engine unless instructed to do so for servicing reasons 1 Rotate the three 1 4 turn fasteners q at the front and rear of the panel 2 Open the side panel then pull the panel outward to release the tabs at the bottom SIDE PANEL INSTALLATION 1 Align the tabs on the side panel with the slots q in the fender and console Left side shown right side similar 2 Carefully inser...

Page 586: ... Remove the left and right side panels 2 Rotate the 1 4 turn fasteners q at the rear corners of the hood 3 Pull hood over 1 4 turn mounts before lifting on hood 4 Disconnect the hood wire harness connector w 5 Remove the hood assembly from the vehicle HOOD INSTALLATION 1 Install the hood q by inserting the front of the hood into the nosepan 2 Lay the hood down onto the overstructure 3 Reconnect th...

Page 587: ...abs at the bottom Repeat this step to remove the side panel from opposite side of the snowmobile 2 Rotate the 1 4 turn fasteners e at the rear corners of the hood 3 Disconnect the hood harness connector r from the main harness 4 Remove the hood assembly t 5 Turn the 1 4 turn latch at the rear of the seat and lift up to remove the seat 6 Remove the two fasteners y that secure the console and lower ...

Page 588: ...lutch tool a that secure the lower portion of the console 9 Remove fuel cap s and plastic fuel filler neck nut d 10 Lift up the center of the console and disconnect the key switch connector f from the key switch NOTICE If needed the switch panel may be removed to disconnect the key switch connector and any accessory connections 11 Carefully remove console g and set to the side with the starter rop...

Page 589: ...nnections Reinstall the switch panel once all connections are made 2 Remove the fuel cap and install the console into position Install the plastic fuel filler neck nut d and fuel cap s NOTICE When installing the console make sure the o ring on the fuel tank neck is in place and not damaged 3 Install the two fasteners i push pin rivet o and clutch tool a that secure the lower portion of the console...

Page 590: ...8 N m 6 Install the seat and secure with 1 4 turn latch 7 Install the hood t by inserting the front of the hood into the nosepan 8 Connect the hood harness connector r to the main harness NOTICE Verify the harness connectors are clean and dry prior to assembly 9 Rotate the 1 4 turn fasteners e at the rear corners of the hood to secure the rear of the hood to the console 10 Align the tabs at the bo...

Page 591: ... Performance Crossover Snowmobile Service Manual Copyright Polaris Inc 9 27 11 Close the side panel w and secure by rotating the three 1 4 turn latches q Repeat this step to install the side panel onto opposite side of the snowmobile CHASSIS ...

Page 592: ...rapidly losing consciousness unconscious or convulsing BONDED COMPONENT OVERVIEW The following serviceable components are bonded with structural adhesive Left right bulkhead clips are bonded to the left support brace and chaincase Chaincase Left support bonded to tunnel Bulkhead floor plate Top of tunnel bulkhead cooler NOTICE The left and right bulkhead clips are not bonded to each other Please r...

Page 593: ...NOTICE New bonded parts should be washed with warm soapy water and allowed to dry completely before the adhesive is applied ADHESIVE APPLICATOR KITS Polaris offers a repair kit individual adhesive cartridges and replacement needle packs It is recommended to leave the product unopened until needed When performing multiple repairs at one time leave the mixer needle attached to the cartridge when not...

Page 594: ...re ready to apply the adhesive remove the cartridge end caps Level the plunger by slowing squeezing the trigger and expelling the adhesive from the plug onto a scrap piece of material 2 Attach a new mixer needle to the cartridge 3 While holding the mixer needle over a piece of scrap material slowly compress the caulk gun trigger to fill the mixer needle The needle will automatically mix and dispen...

Page 595: ...ance Crossover Snowmobile Service Manual Copyright Polaris Inc 9 31 ADHESIVE APPLICATION PATTERNS IMPORTANT Reference the following illustrations showing the exact patterns for each bonded component when applying the adhesive BULKHEAD FLOOR CHASSIS ...

Page 596: ...9 32 9850064 R03 2021 650 850 Matryx Trail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc CHAINCASE REAR TABS RIGHT BULKHEAD CLIP CHAINCASE SUPPORT SPAR MATING SURFACE CHASSIS ...

Page 597: ...9 9850064 R03 2021 650 850 Matryx Trail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc 9 33 RIGHT BULKHEAD CLIP FRONT CORNER LEFT SUPPORT MATING SURFACE CHASSIS ...

Page 598: ...9 34 9850064 R03 2021 650 850 Matryx Trail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc LEFT BULKHEAD CLIP SUPPORT SPAR MATING SURFACE LEFT BULKHEAD CLIP FRONT CORNER CHASSIS ...

Page 599: ...rs Pry the plate away from the chassis 5 Continue working the screwdriver along the edge of the plate until the plate can be grasped with a Vise Grip pliers 6 Using the Vise Grip pliers pull peel the plate away from the chassis Discard the plate 7 Thoroughly clean the chassis mating surfaces where the plate attaches to the chassis Reference the Bonded Component Surface Preparation section BULKHEAD...

Page 600: ...embly See Engine Removal page 3 31 Fuel tank assembly See Fuel Tank Removal page 5 26 Bulkhead floor plate See Bulkhead Floor Plate Removal page 9 35 2 Drill out the rivets q securing the cooler to the top of the tunnel 3 Remove the fasteners w securing the cooler to the sides of the tunnel Drill out the rivet e securing the cooler to the chaincase housing 4 Remove the cooler from the chassis 5 Re...

Page 601: ...o the sides of the tunnel Install new rivet e securing the cooler to the chaincase housing Torque fasteners to specification TORQUE Chaincase Side Support Fasteners 26 ft lbs 35 N m Tube Brace Fastener 22 ft lbs 30 N m 4 Reinstall the following components Bulkhead floor plate See Bulkhead Floor Plate Installation page 9 35 NOTICE Allow the adhesive to cure for 24 hours at 68 F 20 C before placing ...

Page 602: ...er Tube Fastener 4 Remove the fasteners t securing the bulkhead clips 5 Remove the fasteners y securing the bulkhead clip to the steering idler bracket 6 Remove the tie rod boot and tie rod if not already removed 7 Wearing heat resistant gloves use a propane gas torch to heat the adhesive u between where the bulkhead clip mates with the engine side support brace 8 Apply torch until adhesive begins...

Page 603: ...bulkhead clip Loosely install the fasteners q y that attach the bulkhead clip q Lower Steering Mount Fasteners r Idler Bracket Fastener w Clip Mounting Fasteners t Side Support Fasteners e Front Lower Over Structure Fasteners y Crossover Tube Fastener 5 Torque fasteners to specification TORQUE Lower Steering Mount Fastenersq 22 ft lbs 30 N m Clip Mounting Fasteners w 26 ft lbs 35 N m Front Lower O...

Page 604: ...astener r Lower Steering Mount Fasteners 4 Remove the fasteners t securing the bulkhead clips 5 Remove the fasteners y securing the bulkhead clip to the steering idler bracket 6 Remove the tie rod boot and tie rod if not already removed 7 Wearing heat resistant gloves use a propane gas torch to heat the adhesive u between the two components 8 Apply torch until adhesive begins to crackle During thi...

Page 605: ... Loosely install the fasteners q y that attach the bulkhead clip q Side Support Fasteners r Lower Steering Mount Fasteners w Crossover Tube Fastener t Idler Bracket Fastener e Clip Mounting Fasteners y Front Lower Over Structure Fasteners 5 Torque fasteners to specification TORQUE Side Support Fasteners q 26 ft lbs 35 N m Crossover Tube Fastener w 22 ft lbs 30 N m Clip Mounting Fasteners e 26 ft l...

Page 606: ...part removing adhesive and then re applying new adhesive 6 Note the residual adhesive on the brace bulkhead clip and tunnel If the component is to be re used the adhesive must be completely removed See Bonded Component Surface Preparation section LEFT SUPPORT BRACE INSTALLATION NOTICE Read and understand the following steps to ensure the adhesive is applied correctly 1 Verify the bulkhead clip sid...

Page 607: ...ISPLAY 10 15 HOOD HARNESS ROUTING RETENTION 7S DISPLAY 10 16 HANDLEBAR HARNESS 10 17 HANDLEBAR HARNESS COMPONENT LOCATIONS 10 17 HANDLEBAR HARNESS ROUTING RETENTION 10 18 HANDLEBAR CONNECTIONS PINOUT 10 19 HANDLEBAR HARNESS CONNECTOR TERMINAL INSPECTION 10 19 HANDLEBAR HARNESS CONNECTOR TERMINAL DE PINNING 10 20 LEFT HAND CONTROL OVERVIEW 10 23 LEFT HAND CONTROL PINOUT 10 23 DIAGNOSTIC TROUBLE COD...

Page 608: ...FIC GRAVITY TEST 10 51 BATTERY TENDER PORT 10 52 BATTERY OFF SEASON STORAGE 10 52 STANDARD INSTRUMENT CLUSTER 10 53 STANDARD INSTRUMENT CLUSTER OVERVIEW 10 53 STANDARD INSTRUMENT CLUSTER REMOVAL 10 53 STANDARD INSTRUMENT CLUSTER INSTALLATION 10 53 STANDARD INSTRUMENT CLUSTER PINOUT 10 54 7S DISPLAY WITH INTEGRATED RIDE COMMAND 10 55 7S DISPLAY OVERVIEW 10 55 7S DISPLAY REMOVAL 10 55 7S DISPLAY INS...

Page 609: ...GAUGE POWER RELAY 10 81 CAPACITORS 10 82 GROUND SPEED SENSOR CAPACITOR OVERVIEW 10 82 MEASURING CAPACITANCE 10 82 ELECTRIC START BATTERY BRACKET 10 83 BATTERY BRACKET ASSEMBLY VIEW 10 83 ELECTRIC START HARNESS ROUTING 10 84 BATTERY HARNESS ROUTING 10 86 STARTER MOTOR FLEX DRIVE ASSEMBLY VIEW 10 90 STARTER MOTOR FLEX DRIVE REMOVAL 10 91 STARTER MOTOR FLEX DRIVE INSTALLATION 10 92 STARTER SOLENOID B...

Page 610: ...10 4 9850064 R03 2021 650 850 Matryx Trail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc 12V ACCESSORY RCA ADAPTER 10 100 BATTERY ELECTRICAL ...

Page 611: ...ian immediately EYES flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases keep sparks flame cigarettes etc away ventilate when charging or using in a closed space and always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN WARNING SHOCK HAZARD Always disconnect the battery prior to servicing engine and electrical system Electrical ...

Page 612: ...hassis components including hand warmers and thumb warmer RD WH BRN Circuits Gauge PWR Connect 12 VDC battery voltage to power instrument cluster lights and to supply power to EV actuator when viewing data list items and the engine is off RD BK BRN Circuits Critical PWR Connect 12 VDC battery voltage to this connector to power fuel pump and oil pump Also provides the power to the EV Learn Relay RD...

Page 613: ...mper 3 Tether Switch t EGT 2 Sensor 1 Diagnostic Power Connector 3 VCM y PBR DC Power 2 Front Work Light 3 Driver Seat Heater Switch u Chassis Hood 2 Digital Wrench 3 Fuel Pump i Stator Signals 2 CAN2 Data Enable 3 Rear Harness o Ferrite Suppressor 2 Logger Switch 3 Ignition Switch a Ignition Coil MAG 2 Oil Level 3 Handlebar Connection s Ignition Coil PTO 2 Ground Speed Capacitor 3 Left Hand Contr...

Page 614: ...0 Matryx Trail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc CHASSIS HARNESS RETENTION LOCATIONS q Cable Tie Retention Locations The white tape on the harness signifies a retention point BATTERY ELECTRICAL ...

Page 615: ...Matryx Trail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc 10 9 CHASSIS HARNESS ROUTING NOTICE If harness replacement is required note the routing of the harness for installation purposes BATTERY ELECTRICAL ...

Page 616: ...03 2021 650 850 Matryx Trail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc REAR HARNESS COMPONENT LOCATIONS q Main Harness e Passenger Power w Driver Seat Heater r Tail Light BATTERY ELECTRICAL ...

Page 617: ...rail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc 10 11 REAR HARNESS ROUTING RETENTION ROUTING NOTICE If harness replacement is required note the routing of the harness for installation purposes BATTERY ELECTRICAL ...

Page 618: ...0 Matryx Trail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc RETENTION The white tape on the harness signifies a retention point q Cable Tie Retention Location w P clamp Retention Location BATTERY ELECTRICAL ...

Page 619: ...mance Crossover Snowmobile Service Manual Copyright Polaris Inc 10 13 HOOD HARNESS COMPONENT LOCATIONS STANDARD INSTRUMENT CLUSTER q Display Connector e 12V Accessory Power Connector w Main Harness Connector r Headlight Connector BATTERY ELECTRICAL ...

Page 620: ...ail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc HOOD HARNESS ROUTING RETENTION STANDARD INSTRUMENT CLUSTER q Edge Clip Retention Locations The white tape on the harness signifies a retention point BATTERY ELECTRICAL ...

Page 621: ...ssover Snowmobile Service Manual Copyright Polaris Inc 10 15 HOOD HARNESS COMPONENT LOCATIONS 7S DISPLAY q Display Connector r 12V Accessory Power Connector w USB Port t Headlight Connector e Main Harness Connector y Display USB Connector BATTERY ELECTRICAL ...

Page 622: ...ervice Manual Copyright Polaris Inc HOOD HARNESS ROUTING RETENTION 7S DISPLAY q Edge Clip Retention Locations w Cable Tie Retention Location The cable tie retains the V2V and GPS antenna wiring together The white tape on the harness signifies a retention point BATTERY ELECTRICAL ...

Page 623: ...formance Crossover Snowmobile Service Manual Copyright Polaris Inc 10 17 HANDLEBAR HARNESS HANDLEBAR HARNESS COMPONENT LOCATIONS q Handlebar Connections Connector 12 pin connector w Left Hand Control Connector 16 pin connector BATTERY ELECTRICAL ...

Page 624: ...yright Polaris Inc HANDLEBAR HARNESS ROUTING RETENTION q Reusable Rubber Clamps Secures harness to the handlebar e Connector Clip The connector clips secure the connectors to the air box w Handlebar Wire Clamp The wire clamp has a clip that hooks onto the handlebar riser block BATTERY ELECTRICAL ...

Page 625: ...rminal removal tool to pry the white connector lock it will damage the terminal removal tool 1 Remove the side panels and hood 2 Remove the resonator 3 Disconnect the handlebar connections connector and or the LH controls connector 4 Carefully raise the white terminal lock in the chassis connector into service mode by using a small flat bladed screwdriver to pry upward gently through the access wi...

Page 626: ...of the terminal lock will stand 0 15 in 3 8 mm above the connector body in this position You will hear and feel a click once this position is reached 8 Connect the handlebar connections connector and or the LH controls connector 9 Install the resonator 10 Install the hood and side panels HANDLEBAR HARNESS CONNECTOR TER MINAL DE PINNING NOTICE The following components must use the terminal de pinni...

Page 627: ...to relieve tension on the terminal retainers 9 Insert the terminal release tool into the round release slot of the associated terminal s until it releases the terminal retainer and then gently pull the wire out of the connector Terminal Release Tool PF 52576 10 Remove the affected component from the handlebar INSTALLATION 1 Install the new component onto the handlebar 2 Carefully install the wires...

Page 628: ...ith the Christmas tree clips on the connectors 6 Place console switch panel w near its installed position and connect the main harness key switch connector to the key switch e 7 Install the two push rivets securing the console switch panel IMPORTANT If a heater is replaced it must be calibrated with Digital Wrench otherwise the control will not be accurate If more than one heater is replaced the C...

Page 629: ...r s manual for user information q Back Button t High Beam Button w Up Button y Down Button e Heated Grips Button u Reverse Button r Select Button DIAGNOSTICS Digital wrench must be used troubleshooting issues with the left hand control LEFT HAND CONTROL PINOUT PIN FUNCTION 1 Critical Power 2 Chassis Power 3 Ground 4 High Beam 5 Reverse 6 RH Warmer 7 LH Warmer 8 Throttle Warmer 9 CAN High 10 CAN Lo...

Page 630: ...cuit near console Right grip heater current falls below current limit hystersis 5 C110B Right Grip Heater Driver Under Current Right grip heater measured current below current limit value Continue normal operation Check right grip heater for damage or an open circuit Check right grip heater wiring for broken wire near console Right grip heater current rises above current limit hystersis 6 C110C Ri...

Page 631: ...ully start removing console switch panel w and disconnect the key switch connector from the key switch e before completely removing the console switch panel 5 Disconnect the handlebar connections connector r and left hand controls connector t from the main harness Remove the connectors from the Christmas tree clips on the connectors 6 Carefully retrieve the connectors through the console switch pa...

Page 632: ...ver from the left hand control assembly and remove INSTALLATION 1 Install the left hand control and left hand control cover onto the handle bar 2 Install the four left hand control mounting fasteners Torque control block screws to specification in the sequence shown in the image TORQUE Left Hand Control Screws 20 in lbs 2 3 N m Do not over torque 3 Return the brake master cylinder to its specified...

Page 633: ...ain harness Make sure the connectors get secured to the air box with the Christmas tree clips on the connectors 7 Place console switch panel w near its installed position and connect the main harness key switch connector to the key switch e 8 Install the two push rivets securing the console switch panel IMPORTANT If the left hand control was replaced the CALIBRATE ALL option in DW is needed BATTER...

Page 634: ...TINGS EGT SENSOR ROUTING PIPE EGT SENSOR 1 The EGTsensor q is connected into the pipe Route the EGTsensor wire toward the load center 2 Take up some slack in the EGTsensor wire harness and secure to the load center bracket with a routing clip w 3 Connect the EGTsensor connector e to the main harness connector BATTERY ELECTRICAL ...

Page 635: ...the resonator Route the EGTsensor wire harness up to the plenum 2 Route the EGTsensor wire harness rearward and connect the EGTsensor connector e to the main harness connector 3 Take up the EGTsensor wire harness slack and secure the slack EGTsensor connector and main harness with a panduit strap r NOTICE Orientation of panduit strap should point outward like shown BATTERY ELECTRICAL ...

Page 636: ... under the coolant hose and secure in the hose electrical support with a panduit w 2 Continue to route the speed sensor harness upward toward the connector placement bracket and secure with an edge clip panduit strap e 3 Complete routing by connecting speed sensor connector r to the main harness connector Secure the speed sensor connector to the connector placement bracket using the Christmas tree...

Page 637: ...de over structure tube and pass harness in between over structure tube and main harness 2 Secure knock DET sensor harness and main harness to the over structure tube with a panduit w 3 Continue to route the knock DET sensor harness toward the PTO side of vehicle and connect the knock DET sensor connector e to the main harness connector 4 Secure the knock DET sensor connector and harness slack to t...

Page 638: ...sor q is secured to the cylinder head 2 The ECTsensor jumper harness should route upward Connect the ECT jumper harness connector e to the main harness connector NOTICE Ensure the ECTsensor jumper harness slack is secured with a panduit strap w as shown IMPORTANT ECT IS GLUED TO JUMPER HARNESS CONNECTOR DO NOT ATTEMPT TO SEPARATE THE ECT FROM THE JUMPER HARNESS BATTERY ELECTRICAL ...

Page 639: ... air box 1 Route the MAG coil harness down to the spark plug support and secure the harness with a panduit strap q 2 Install spark plug cap w on MAG side spark plug The PTO coil pack is mounted to the MAG side of the air box 3 Route the PTO coil harness down to the spark plug support and secure the harness with a panduit strap e 4 Install spark plug cap r on PTO side spark plug BATTERY ELECTRICAL ...

Page 640: ...wmobile Service Manual Copyright Polaris Inc IGNITION COIL PACK CONNECTORS 1 Connect the MAG coil connector white connector q from the main harness to the coil pack Connect the PTO coil connector blue connector w from the main harness to the coil pack BATTERY ELECTRICAL ...

Page 641: ...rottle body using two 90 Christmas tree routing clips q and panduit strap w 2 Route the fuel injector harness along the coolant hose toward the right side of the vehicle Secure fuel injector harness in stator wire support with a panduit strap e 3 Route the fuel injector upward toward the coolant bottle and secure on the outside of the hose electrical support with a panduit r BATTERY ELECTRICAL ...

Page 642: ...l injector upward toward the coolant bottle and secure in the hose electrical support with a panduit t 5 Complete routing by connecting fuel injector harness connector y to the main harness connector Secure the fuel injector harness connector to the connector placement bracket using the Christmas tree clip on the connector BATTERY ELECTRICAL ...

Page 643: ...s up to the stator wire retainer and secure jumper harness with a panduit strap e 3 Route the oil pump jumper harness upward toward the coolant bottle and secure on the outside of the hose electrical support with a panduit r Continue to route the oil pump jumper harness upward and secure in the hose electrical support with a panduit t 4 Complete routing by connecting oil pump jumper harness connec...

Page 644: ...ON Spare 10A Fuse A1 B1 Spare 15A Fuse C1 D1 10A Fuse Rear Acc A2 Power In A3 Power Out 10A Fuse Accessory A4 Power In A5 Power Out 15A Fuse LHC Chassis PWR A6 Power In A7 Power Out Spare 10A Fuse A8 A9 15A Fuse ECM Power B2 Power In B3 Power Out 10A Fuse Headlight B4 Power In B5 Power Out OPEN B6 B7 2A Fuse Brake Light B8 Power In B9 Power Out BATTERY ELECTRICAL ...

Page 645: ...1 Spare 15A Fuse C1 D1 10A Fuse Rear Acc A2 RD BU Load Center Rear Harness Fused Passenger Power A3 RD WH Splice Chassis Power 1 Load Center Chassis Power 10A Fuse Accessory A4 RD WH Load Center Splice Accessory Power Accessory Fused Power A5 BUS Load Center Load Center Chassis Load Center Bus 15A Fuse LHC Chassis PWR A6 RD WH Load Center Left Hand Controls Fused Drive Chassis Power A7 BUS Load Ce...

Page 646: ...oad Center ECU CNA Battery Voltage PK BK Electric Start Load Center Fused Battery Power Relay Battery Charge D4 RD Load Center Load Center Critical Power C4 RD WH Splice Chassis Power 1 Load Center Chassis Power D5 RD YE Load Center Battery Charge Splice Chassis Power C5 OG DG ECU CNA Load Center Battery Charge Relay Control 15A Fuse Fuel Pump GND D6 BN YE Fuel Pump Ground Load Center Fuel Pump Gr...

Page 647: ...ormance Crossover Snowmobile Service Manual Copyright Polaris Inc 10 41 LOAD CENTER LOCATION The load center q is located on a bracket secured to the front cross tube NOTICE To access the fuse box remove the side panels and hood BATTERY ELECTRICAL ...

Page 648: ...N Hot exhaust system parts can cause burns Allow adequate time for the exhaust system to cool Never perform this procedure with the engine running 1 Remove the right side panel 2 Remove the plastic rivet q and fastener w securing the console panel to the chassis 3 Remove the plastic rivet e securing the fender to the chassis 4 Disconnect the black negative battery cable r first 5 Disconnect the re...

Page 649: ...rged prior to its initial use Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance 1 Ensure that the battery is fully charged 2 Carefully place the battery in the battery bracket 3 Place the battery shield q on the battery bracket 4 Install the battery hold down strap w 5 Connect and tighten the RED positive ...

Page 650: ...er the rubber strap If the ground wires cable are routed down the side of the battery they may interfere with the rear side panel tab Note the routing of the RED positive battery cable t and that the right fender is pulled away from the chassis Item y is the battery power fuse and item u is the battery tender fuse TORQUE Battery Cable Connector 36 in lbs 4 N m 7 Verify that cables are properly rou...

Page 651: ...life The types of batteries are Dry Shipped Absorbed Glass Mat AGM AGM Low Maintenance To identify which type of battery the vehicle has refer to the examples below and follow the correct service procedures that follow in the manual DRY SHIPPED AGM BATTERY Battery NOTactivated when packaged Removable cap plugs strip on top of battery Distilled water added as required Lead Acid only Vent tube on si...

Page 652: ... top of the battery IMPORTANT Do not remove the sealing strip until ready to activate the battery 2 Remove the top strip of caps on the electrolyte package NOTICE Retain this strip of caps for battery sealing after it has been filled WARNING DO NOT pierce or otherwise open the foil seals on the electrolyte container or attempt to separate the individual electrolyte containers 3 Place the electroly...

Page 653: ...o the top of the battery NOTICE Only install caps by hand DO NOT use a hammer or excessive force IMPORTANT Ensure the sealing caps are flush with the battery NOTICE Maximum battery performance and longevity depends on following the rest and charging activation steps 7 Allow battery to stand for 1 2 hours This allows the electrolyte to permeate the plates for optimal performance 8 Charge the batter...

Page 654: ...ernal damage may occur if a non AGM compliant battery charger is used or if too much current is applied during charging NOTICE Battery voltage may reach more than 16 volts during initial charging session 2 Allow battery to stand for 1 2 hours before checking voltage 3 Check open circuit voltage Continue charging as needed Battery Open Circuit Voltage 12 6 Volts Test the battery using the PU 50296 ...

Page 655: ...res should be charged daily If possible these vehicles should be connected to the recommended battery charger continuously IMPORTANT Always use the recommended automatic battery charger and wait for the charger to complete the charge cycle before disconnecting it AGM BATTERY CHARGING DEEPLY DIS CHARGED BELOW 3 VOLTS AGM batteries discharged to a voltage of 3 volts or less may not be recognized by ...

Page 656: ... battery If the test results show that battery failed proceed with battery replacement AGM LOW MAINTENANCE BATTERY MAINTENANCE IMPORTANT NEVER add electrolyte or distilled water to the battery Doing so will damage the case and shorten the life of the battery If you do not drive the vehicle for more than TWO weeks maintain the Absorbent Glass Mat AGM battery with the BatteryMINDer 2012 AGM 2 AMP ch...

Page 657: ...itester to the battery in the same manner as was done in the OCV test The reading should be 12 6 volts or greater Engage the starter and observe the battery voltage while cranking the engine Continue the test for 15 seconds During cranking the observed voltage should not drop below 9 5 volts If the beginning voltage is 12 6 volts or higher and the cranking voltage drops below 9 5 volts during the ...

Page 658: ...ver the vehicle is not used for a period of two months or more remove the battery from the vehicle ensure that it is fully charged and store it out of the sun in a cool dry place Check battery voltage each month during storage and or recharge as needed to maintain a full charge NOTICE Battery charge can be maintained by using a Polaris battery tender charger or by charging once a month to make up ...

Page 659: ...r software display setting and user information STANDARD INSTRUMENT CLUSTER REMOVAL 1 Carefully remove the instrument cluster q from the display door 2 As the instrument cluster is removed disconnect the instrument cluster connector w STANDARD INSTRUMENT CLUSTER INSTALLATION 1 Carefully position the instrument cluster near its installed position and connect the instrument cluster connector w 2 Ins...

Page 660: ...anual Copyright Polaris Inc STANDARD INSTRUMENT CLUSTER PINOUT PIN COLOR FUNCTION 1 YE CAN2 HI 2 DG CAN2 LOW 3 RD BK CRITICAL PWR 4 RD BK CRITICAL PWR 5 BN CHASSIS GND 6 7 8 YE RD HIGH BEAM HEADLIGHT PWR 9 10 11 VT WH FUEL LEVEL 12 13 14 15 16 WH RD ACCENT LED CONTROL BATTERY ELECTRICAL ...

Page 661: ...VAL 1 Remove the side panels and hood 2 With the hood removed flip the hood over and cut remove the edge clip q from the tab on the display wire cover 3 Flip the hood back over Slide the top latch w and open the display door e 4 Remove the USB port r from the display cover wire clamp 5 Remove the bottom two display cover fasteners t and remove the display wire cover y 6 Disconnect the USB connecto...

Page 662: ...isplay fasteners w Torque fasteners to specification TORQUE Display Fasteners 53 in lbs 6 N m 2 Connect the USB connector e display connector r V2V antenna connector t and GPS antenna connector y into the display 3 Position the display wire cover near the display door Route USB cable and secure the USB port u in the display wire cover clamp NOTICE Make sure the USB cable in not pinched between the...

Page 663: ...asteners o Torque fasteners to specification NOTICE Make sure the tab of the display wire cover is installed into the holder on the back of the display door TORQUE Display Fasteners 53 in lbs 6 N m 5 Close the display door a and flip the hood over 6 Install edge clip or new cable tie s to secure the hood harness to the tab on the display wire cover 7 Reinstall the hood and side panels BATTERY ELEC...

Page 664: ...anual Copyright Polaris Inc 7S DISPLAY PINOUT PIN COLOR FUNCTION 1 YE CAN HI 2 DG CAN LOW 3 RD DG SWITCHED DISPLAY POWER 4 RD YE CONSTANT DISPLAY POWER 5 BN CHASSIS GND 6 7 8 YE RD HIGH BEAM HEADLIGHT PWR 9 10 11 VT WH FUEL LEVEL 12 13 14 15 16 WH RD ACCENT LED CONTROL BATTERY ELECTRICAL ...

Page 665: ...ce Crossover Snowmobile Service Manual Copyright Polaris Inc 10 59 LED HEADLIGHT TAIL LIGHT HEADLIGHT ASSEMBLY VIEW q Headlight e Headlight Fasteners 22 in lbs 2 5 N m w Headlight Adjuster Hardware Includes adjuster knob and retainer BATTERY ELECTRICAL ...

Page 666: ...hassis circuit and are always on When the driver pushes the high beam button on the left hand control the high beam LEDs in the headlight will illuminate The RD DG circuit power for the high beam signal comes from the key switch and is connected to the YE RD high beam circuit The high beam output will only turn on when the engine is running NOTICE The high beam LEDs and instrument cluster indicato...

Page 667: ...nc 10 61 LED HEADLIGHT INSTALLATION 1 Install the headlight e and the three fasteners w that secure the headlight Torque fasteners to specification TORQUE Headlight Fasteners 22 in lbs 2 5 N m 2 Connect the headlight connector q to the headlight 3 Install the hood 4 Install the side panels BATTERY ELECTRICAL ...

Page 668: ...4 R03 2021 650 850 Matryx Trail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc TAILLIGHT ASSEMBLY VIEW q Taillight w Taillight Fasteners 16 in lbs 1 8 N m w Taillight Cover BATTERY ELECTRICAL ...

Page 669: ...uminated when the engine is running The brake light circuit is protected by a 2 AMP fuse This circuit is closed when the brake lever is pulled If the fuse is blown there is a short in this circuit LED TAILLIGHT REMOVAL 1 Remove the two fasteners q securing the taillight assembly 2 Carefully pull the taillight assembly forward and disconnect the taillight connector w Remove the taillight assembly e...

Page 670: ...x Trail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc 2 Install the two fasteners q securing the taillight assembly Torque fasteners to specification TORQUE Taillight Fasteners 16 in lbs 1 8 N m BATTERY ELECTRICAL ...

Page 671: ... and system sensors The 14 volt engine circuit also sometimes referred to as the critical circuit powers the fuel pump electronic oil pump and EVES Learn Relay The EVES Learn Relay powers the EVES Actuator instrumentation headlights and tail light The 14 4 volt chassis circuit powers the hand warmers thumb warmer and accessory DC power The battery charge relay powers the battery charge circuit The...

Page 672: ... Splice Chassis Ground P4 Brown PBR Ground 1 Splice Chassis Ground P5 Dark Green CAN Low Splice CAN Low P6 Orange Load Center ECU Power STATOR CHARGING LEAD PIN WIRE COLORS TO OR FROM COMPONENT FUNCTION Y1 Yellow PBR Alternating Current AC Y2 Yellow PBR Alternating Current AC Y3 Yellow PBR Alternating Current AC PBR DC POWER PIN WIRE COLORS TO OR FROM COMPONENT FUNCTION P1 Red White Chassis Power ...

Page 673: ...10 9850064 R03 2021 650 850 Matryx Trail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc 10 67 PBR CIRCUIT BATTERY ELECTRICAL ...

Page 674: ...ine Replace regulator Engine stop P1618 Chassis Voltage Disabled 520376 31 Internal degradation or internal component failure Chassis output disabled Replace regulator Engine stop P1619 Low ECU Voltage 520377 31 Internal component failure Reduced ECU injector voltage increased Critical fuel pump voltage Replace regulator Engine stop P161A Reduced Performance 520378 31 Internal component failure Re...

Page 675: ... harness Test headlight with battery Condition no longer exists P160B Critical open circuit 520368 5 Critical wire open None Inspect harness Check fuel pump Condition no longer exists P160F Critical overload 520368 6 Non standard loads on Critical power line Reduced Critical fuel pump voltage Check engagement of PBR connectors Check sled for electrical modifications Condition no longer exists P160...

Page 676: ... Power Up harness leads to the ECU PWR diagnostic test connector on the Next Gen Service Power Harness 6 Connect the power up harness to the battery NOTICE If the snowmobile is equipped with a fully charged battery it can be used to supply power to the test connectors If using a stand alone service battery do not place the battery in the tunnel footwells Place the battery on the floor next to the ...

Page 677: ...The software part number will be shown Click Continue 14 Request an Authorization Key from the Dealer Web Site and click Continue 15 Digital Wrench will reprogram the PBR software Once complete click Finish 16 Click Return 17 Once the PBR software update is successful Digital Wrench can be disconnected BATTERY ELECTRICAL ...

Page 678: ...0 Matryx Trail Performance Crossover Snowmobile Service Manual Copyright Polaris Inc STATOR STATOR CIRCUIT ARCHITECTURE q 3 Phase AC Coils w Crankshaft Position Sensor 2 Tooth e Crankshaft Position Sensor 5 Tooth BATTERY ELECTRICAL ...

Page 679: ...OF EACH STATOR LEG AT CHARGING RPM 1 Set the selector dial to measure AC Voltage 2 Start the engine and let it idle 3 While holding the engine at a specified RPM separately measure the voltage across each leg of the stator by connecting the meter leads to the wires leading from the alternator Y1 to Y2 Y1 to Y3 Y2 to Y3 4 Refer to the following table for approximate AC Voltage readings according to...

Page 680: ...s to the stator wire support on the coolant hose and secure stator harness and fuel injector harness with a panduit strap w 3 Continue routing the stator harness to the throttle cable hose support on the coolant hose and secure stator harness and fuel injector harness with a panduit strap e 4 Route the stator harness upward along the air box and secure to the routing clip r on the air box Connect ...

Page 681: ...nowmobile Service Manual Copyright Polaris Inc 10 75 FERRITE SUPPRESSOR The Ferrite Suppressor q attaches around the stator signal wires behind the connector on the main harness This suppressor reduces high frequency noise on ECU CPS input circuit BATTERY ELECTRICAL ...

Page 682: ... the connector onto the actuator A click should be heard Then push the lock into the connector When the lock is pushed in a second click should be heard NOTICE The position of the connector lock mechanism should be checked if you are experiencing diagnostic trouble codes related to the E VES system or if the EV Learn Procedure fails due to insufficient battery voltage and the battery is supplying ...

Page 683: ...RE HARNESS LEAD ROUTING 1 From the load center route the EV actuator wire harness lead along the shock tower cross tube and secure to the routing clip q 2 Continue routing the EV actuator wire harness down to the EV actuator and secure to the routing clip w 3 Connect the EV actuator connector e to the EV actuator BATTERY ELECTRICAL ...

Page 684: ...t by mating it with an existing key If both of the original keys are lost the ignition switch assembly must be replaced OIL LEVEL SENDER To test the oil level sender position the sender as it would be in the oil tank Allow the float to drop in the direction it would if the oil tank were empty Continuity should be present when using a multimeter to test the sender with the float in the empty positi...

Page 685: ...790Ω 185 Run Flipper Released 2148Ω 185 Shutdown Above Idle BRAKE SWITCH The brake switch is integrated into the brake lever assembly When the brake lever is pulled the switch closes The closed switch completes the brake signal to the ECU and rear brake LEDs The ECU signals the instrument cluster to illuminate the brake icon PIN CONTINUITY SWITCH POSITION CONTINUITY BETWEEN Pushed Red and ORG BLK ...

Page 686: ...s battery voltage to the display and GPS puck when the ignition key is in the ON position BATTERY TENDER FUSE NOTICE Applies only to models equipped with a battery electric start wire harness The battery electric start wire harness features a 10 amp battery tender fuse CIRCUIT BREAKER NOTICE Applies only to models equipped with a battery electric start wire harness A 20 amp circuit breaker is conn...

Page 687: ...G Battery Charge Relay Control NOTICE If relay is removed for service re install with a drop of NyoGel on each connector blade GAUGE POWER RELAY The Gauge Power Relay is located in the load center This relay provides the following Gauge PWR test connector Instrument cluster IDD power EV actuator PWM converter power Brake Taillight power PIN WIRE COLOR FUNCTION D8 RD Critical Power C8 RD Critical P...

Page 688: ...he following test was validated using a Fluke 115 Digital Multimeter Different meters can be used but may provide slightly different resistance readings Testing LOW μF Capacitors 1 Remove the capacitor from the circuit 2 Set the multimeter to measure capacitance 3 Connect the red test probe to the terminal and the black test probe to the terminal NOTICE Multimeters with capacitance testing typical...

Page 689: ...ove BLACK battery cable first and then RED cable Reverse order during battery installation q Cable Tie a Stud Plate w Black Battery Ground Cable s Stud Plate e Red Battery Cable d Starter Solenoid r Seal Bulb f Routing Clip t Battery Bracket g Red Battery Solenoid Cable y Battery Bracket Fastener 22 ft lbs 30 N m h Battery u Routing Clip j Terminal Hardware 36 in lbs 4 N m i D ring Rubber Strap k ...

Page 690: ...reference only 1 The electric start harness connector q should be connected to the chassis harness in location shown below 2 Secure the electric start harness with a panduit w to the rear over structure tube NOTICE The panduit head should point away from the fuel tank 3 Secure the battery tender port e to the console support with two fasteners BATTERY ELECTRICAL ...

Page 691: ...85 4 The electric start harness should route down the right footrest support and be secured with tape on clip r in location shown 5 Connect the start solenoid connector t to the start solenoid 6 Finish routing by securing the battery tender fuse to the right footrest with an edge clip y as shown BATTERY ELECTRICAL ...

Page 692: ...2 Connect the negative battery cable to the negative battery terminal e and route the cable downward toward edge clip on the right footrest 3 Connect the solenoid end of the positive battery cable to the right solenoid post r and route the cable downward toward edge clip on the right footrest 4 Secure the positive and negative battery cables together with the edge clip panduit in location shown t ...

Page 693: ...r Snowmobile Service Manual Copyright Polaris Inc 10 87 5 Route the positive and negative battery cables under the battery tray and secure together with the edge clip panduit in location shown y NOTICE The white tape signifies a retention point BATTERY ELECTRICAL ...

Page 694: ...ry cables toward the starter Connect the starter end of the positive battery cable to the positive starter terminal u 7 Connect the negative battery cable to the negative starter terminal i 8 Secure the positive and negative battery cables together with the panduit in location shown o NOTICE The white tape signifies a retention point BATTERY ELECTRICAL ...

Page 695: ... start harness battery power bullet connector should be connected to the female bullet connector as shown q 2 Connect the electric start harness battery negative bullet connector to the female bullet connector as shown w 3 Make sure the electric start harness is routed along the right footrest and secured in the edge clip panduit in the location shown e BATTERY ELECTRICAL ...

Page 696: ...hen RED cable Reverse order during battery installation q Nut 8 ft lbs 11 N m i Pinion Assembly w Nut 8 ft lbs 11 N m o Pinion Bracket Fasteners 7 ft lbs 10 N m Replace with new when removed e Lock Washer a Rubber Pad r Electric Start Clip Bracket s Electric Start Bracket Fasteners 7 ft lbs 10 N m t Starter Motor d Electric Start Lower Tube Bracket y Gear Clamp Do not over tighten strip teeth f El...

Page 697: ... serviced with the engine in the snowmobile 1 Remove the side panels and hood 2 Disconnect the battery Remove the black cable first 3 Remove the exhaust pipe and silencer 4 When servicing the pinion gear remove the following components Oil tank clutch guard Drive belt Drive clutch Y pipe 5 Remove the fasteners q attaching the pinion assembly to the engine 6 Carefully remove the pinion assembly w f...

Page 698: ...t Fasteners 7 ft lbs 10 N m 2 Loosely fit the gear clamp e around the starter motor and place the starter motor back into the snowmobile 3 Next install the flex drive on to the starter motor shaft 4 Assemble the starter motor back onto the bracket as shown in the image Attach the black battery ground cable e to the post and install washer r and lock nut t 5 Attach the red starter motor power cable...

Page 699: ...meter Test coil resistance across the connector terminals q and w at room temperature 77 F 25 C and compare to specification Starter Solenoid Coil Resistance 2 5 Ω Test the start solenoid by applying battery voltage to the connector terminals q and w for a maximum of 5 seconds With the solenoid energized at room temperature 77 F 25 C verify there is continuity between the two red cable posts e and...

Page 700: ...ease switch The software stop system is activated when the throttle release switch is closed closed throttle but the TPS Throttle Plate Position is still above idle When this occurs the ECU will determine the throttle cable is stuck and disable the ignition system To test the throttle lever measure the resistance with the lever pushed closed and compare results to those listed for the throttle rel...

Page 701: ...o the LHC The LHC will then supply power to each heating element until the set temperature is met The LHC recognizes when each heating element meets the set temperature by determining its resistance value which changes dependent on surface temperature 7S Display Display communicates user defined temperature based on mode selected via CAN to left hand control LHC Left Hand Control Sends power to he...

Page 702: ... degrees NOTICE The engine needs to be running for the heating elements to function If the temperature readings do not match this could indicate faulty SmartWarmers calibration heating elements LHC or infrared thermometer If the elements feel warm but do not reach the preset temperatures the SmartWarmers calibration procedure in Digital Wrench should be performed and the surface temperature can be...

Page 703: ... CIRCUIT WIRE COLOR NOMINAL RESISTANCE ROOM TEMP 68 F 20 C Yellow to Grey LH Heater 3 3 ohms 10 Blue to Brown RH Heater FULL LENGTH HAND WARMERS Full length hand warmers differ from standard length warmers in that they are cut to match the bend of the integrated handlebar hooks Because of this there are separate warming elements for the left and right side of the handlebar assembly To install note...

Page 704: ...er Up harness leads to the ECU PWR and Chassis PWR diagnostic test connectors on the Next Gen Service Power Harness and have the key turned on For non electric start models connect the Chassis Power Up harness leads to the ECU PWR Chassis PWR and Gauge PWR diagnostic test connectors on the Next Gen Service Power Harness The Tri Power Up Adapter can be used to power all three connections Tri Power ...

Page 705: ...nents that have been replaced and then click Continue to proceed 14 Select the temperature method to calibrate the grips in either case the hand warmers should not have been turned on in the last 30 minutes If the engine has not been run in the last 8 hours the intake air temperature maybe used If the engine has been run but the hand warmers have not Ambient Air Temperature may be used 15 Enter th...

Page 706: ...otected by the 10A accessory fuse located in the load center Because this circuit is fuse protected it is recommended that the 12V receptacle be used for power sensitive devices RCA POWER PLUG W COVER The accessory kit part number for the RCA Power Plug w cover is 2883824 The RCA Power Plug w Cover e mounts to the console switch panel and is plugged into the main vehicle wire harness RCA accessory...

Page 707: ...ing Diagnosis 1 74 Belt Deflection Adjustment 2 26 7 29 Inspection 2 26 7 29 Belt Inspection 7 9 Belt To Sheave Clearance Adjustment 7 23 Bottom End General Information 3 84 Brake Caliper Piston Seal Replacement 6 43 Brake Disc Inspection 6 45 Replacement 6 45 Brake Lever Master Cylinder Service 6 38 Brake Line Brake Line Routing 6 46 Brake System Assembly View 6 32 Brake Bleeding 2 38 6 36 Pad In...

Page 708: ...Detonation DET Troubleshooting 4 5 Diagnostic Diagnostic Power Connector 4 2 10 6 Diagnostic Trouble Codes DTCs Left Hand Control 1 32 10 24 Digital Wrench Communication Errors 1 38 Data List Display 1 42 Data Trigger Freeze Frame 1 43 Diagnostic Trouble Codes DTCs 1 41 ECU Injector Oil Pump Replacement Menu 1 47 ECU Replacement 1 47 ECU Reprogramming Reflash 1 66 Electronic Oil Pump Flow Offset 1...

Page 709: ...hort To Ground 1 78 Testing For A Short To Voltage 1 79 Testing for Intermittent Conditions 1 80 Testing Voltage Drop 1 81 Electrical System Charging Lighting System 10 5 Ignition Timing 10 5 Electrical Systems Auxiliary Stop Switch 10 78 Oil Level Sender 10 78 Stator Circuit Architecture 10 72 Electronic Oil Pump Flow Offset Identification 3 8 Manual Prime Procedure 3 24 Mounting 3 8 Prime Proced...

Page 710: ...ndard Gauge 2017 to Current 5 7 Fuse Battery Power 10 80 Battery Tender 10 80 G General Cautions and Notes 9 3 H Hand Guard Assembly View 8 7 Hand Warmers Full Length Hand Warmers 10 97 Resistance Check 10 97 Handlebar Assembly View 8 6 Component Fasteners 2 40 8 48 Component Locations 2 41 8 49 Left Hand Control Adjustment 2 43 8 51 Handlebar Angle Adjustment 2 42 8 50 Handlebar Connections Pinou...

Page 711: ... 2 22 Drive Belt 1 73 Drive Belt Break In 2 6 Drive Chain Adjustment 2 33 6 10 Drive Clutch 1 73 Driven Clutch 1 73 Emission Control Information 2 4 Emission Control Label 2 4 Emission Control Maintenance Requirements 2 4 Engine Break In Period 2 6 Exhaust System 2 32 Front Suspension Inspection Wide Fixed Camber 2 44 Fuel System 2 30 Intake Filters 2 31 Non Ionizing Radiation 2 4 Periodic Mainten...

Page 712: ...Strap Adjustment 8 63 Removal IGX 146 8 46 Removal PRO CC 8 43 Rear Track Shock Factory Clicker Settings 8 68 8 73 Rear Track Shock RTS Service IGX 8 42 Service PRO CC 8 39 Recoil Assembly View 3 102 Recoil Housing Assembly 3 104 Disassembly 3 103 Installation 3 106 Removal 3 103 Reed Petal Installation 3 73 Removal 3 72 Replacement Inspection 3 71 Reed Valve Assembly View 3 64 Inspection 3 70 Rel...

Page 713: ...Analysis 1 75 Suspension Quick Set Up Guide 8 70 Sway Bar Assembly View 8 14 Switch Ignition Switch 10 78 Switches Brake Switch 10 79 Tether Switch 10 79 T Taillight Assembly View 10 62 Team Driven Springs 7 8 Thermostat Installation 3 136 Location 3 138 Removal 3 135 Testing 3 138 Throttle Body Installation 5 14 Removal 5 9 Throttle Position Sensor TPS Testing 4 16 Wire Routing 4 18 Thumb Warmer ...

Page 714: ... RD WH PCH32 GY PCH32 GY PCH31 GY OG PCH31 GY OG LED03 VT YE LED03 VT YE PCH06 4 RD WH PCH06 4 RD WH GE04 BN WH GE04 BN WH GE01 BN GE01 BN EA01 1 BN YE EA01 1 BN YE EA01 2 BN YE EA01 2 BN YE EA01 3 BN YE EA01 3 BN YE 1 2 3 A B C D E F G H I 4 5 6 7 8 9 10 WIRE COLOR LEGEND BG BK BU DB BN GY GN DG OG PK RD VT WH YE BEIGE TAN BLACK LIGHT BLUE DARK BLUE BROWN GRAY LIGHT GREEN DARK GREEN ORANGE PINK R...

Page 715: ......

Page 716: ......

Page 717: ... HIGH BEAM HEADLIGHT PWR PCR20 1 TXL 0 5 YE RD HIGH BEAM CONTROL SPLICE 2 DISPLAY 8 HIGH BEAM HEADLIGHT PWR PCR20 2 TXL 0 5 YE RD HIGH BEAM CONTROL SPLICE 2 HEADLIGHT C HIGH BEAM HEADLIGHT PWR 07 31 20 GC07 BN GC07 BN PCR15 RD BK PCR15 RD BK PCR20 YE RD PCR20 YE RD CAN2H 3 YE CAN2H 3 YE CAN2L 1 DG CAN2L 1 DG GC07 3 BN GC07 3 BN GC07 2 BN GC07 2 BN PCR20 2 YE RD PCR20 2 YE RD PCR20 1 YE RD PCR20 1 ...

Page 718: ...BATTERY TENDER FUSE 10A A TBD 015 TXL 0 8 RD BATTERY TENDER FUSE 10A B BATT PWR SPLICE 2 TBD 016 TXL 1 0 BN GND SPLICE 2 BATTERY P1 TBD 07 31 20 004 WH 004 WH 001 BN 001 BN 002 BN 002 BN 003 BN 003 BN 006 RD YE 006 RD YE 007 RD YE 007 RD YE 005 RD YE 005 RD YE 008 PK BK 008 PK BK 013 RD 013 RD 011 RD YE 011 RD YE 009 BK 009 BK 014 RD 015 RD 015 RD 012 RD 012 RD 010 RD YE 010 RD YE 016 BN 016 BN 1 ...

Page 719: ...XL SBBC 0 8 DB MAIN HARNESS F DRIVER SEAT HEATER 2 DRIVER SEAT HEATER LOW 07 31 20 01 RD 01 RD 02 OG 02 OG 03 3 BN 03 3 BN 03 2 BN 03 2 BN 04 RD WH 04 RD WH 03 BN 03 BN 03 1 BN 03 1 BN 06 DB 06 DB 05 GY OG 05 GY OG 1 2 3 4 5 A B C D E WIRE COLOR LEGEND BG BK BU DB BN GY GN DG OG PK RD VT WH YE BEIGE TAN BLACK LIGHT BLUE DARK BLUE BROWN GRAY LIGHT GREEN DARK GREEN ORANGE PINK RED VIOLET PURPLE WHIT...

Page 720: ...XL SBBC 0 8 DB MAIN HARNESS F DRIVER SEAT HEATER 2 DRIVER SEAT HEATER LOW 07 31 20 01 RD 01 RD 02 OG 02 OG 03 3 BN 03 3 BN 03 2 BN 03 2 BN 04 RD WH 04 RD WH 03 BN 03 BN 03 1 BN 03 1 BN 06 DB 06 DB 05 GY OG 05 GY OG 1 2 3 4 5 A B C D E WIRE COLOR LEGEND BG BK BU DB BN GY GN DG OG PK RD VT WH YE BEIGE TAN BLACK LIGHT BLUE DARK BLUE BROWN GRAY LIGHT GREEN DARK GREEN ORANGE PINK RED VIOLET PURPLE WHIT...

Page 721: ...XL SBBC 0 8 DB MAIN HARNESS F DRIVER SEAT HEATER 2 DRIVER SEAT HEATER LOW 07 31 20 01 RD 01 RD 02 OG 02 OG 03 3 BN 03 3 BN 03 2 BN 03 2 BN 04 RD WH 04 RD WH 03 BN 03 BN 03 1 BN 03 1 BN 06 DB 06 DB 05 GY OG 05 GY OG 1 2 3 4 5 A B C D E WIRE COLOR LEGEND BG BK BU DB BN GY GN DG OG PK RD VT WH YE BEIGE TAN BLACK LIGHT BLUE DARK BLUE BROWN GRAY LIGHT GREEN DARK GREEN ORANGE PINK RED VIOLET PURPLE WHIT...

Page 722: ... REMOVED BK WH E BK WH E LEVEL SENDER OUTPUT F 6 1 1 2 E MEASURE PER PFA MOUNTING IN FUEL TANK DIAGRAM FUEL GAUGE READING REF FUEL HEIGHT H BOTTOM OF FLOAT RESISTANCE OHMS PIN FUNCTION 1 PWM OUT 2 PWM SET 3 POWER 4 GROUND DIGITAL WRENCH A B C D E F G H P1 P2 GROUND SPEED CAPACITOR 180 TERMINALS P1 P2 CHASSIS GND 1 DETONATION SENSOR BOSCH 1 928 403 698 1 2 IGNITION COIL MAG P1 P2 SPLICE CHASSIS POW...

Page 723: ...ER 2 ACC FUSED PWR 23 PCH06 1 TXL 0 8 RD WH SPLICE ACCESSORY POWER 1 DRIVER SEAT HEATER SWITCH A ACC FUSED PWR 24 PCH06 2 TXL 0 8 RD WH RCA ACCESSORY POWER A SPLICE ACCESSORY POWER 1 ACC FUSED PWR 25 PCH06 3 TXL 0 8 RD WH SPLICE ACCESSORY POWER 1 HOOD CHASSIS 9 ACC FUSED PWR 26 PCH06 4 TXL 0 8 RD WH SPLICE ACCESSORY POWER 2 FRONT WORK LIGHT SWITCH A ACC FUSED PWR 27 PCH06 5 TXL 0 8 RD WH SPLICE AC...

Page 724: ...FUNCTION 1 PWM OUT 2 PWM SET 3 POWER 4 GROUND DIGITAL WRENCH A B C D E F G H P1 P2 GROUND SPEED CAPACITOR 180 TERMINALS P1 P2 CHASSIS GND 1 DETONATION SENSOR BOSCH 1 928 403 698 1 2 IGNITION COIL MAG P1 P2 SPLICE CRITICAL POWER 2 1 2 OIL LEVEL SWITCH P N 4012624 PTO IGNITION COIL P N 4014009 MAG IGNITION COIL P N 4014010 TMAP SENSOR BOSCH 1 928 403 736 1 2 3 4 OIL PUMP P N 1204446 FUEL PUMP P N 25...

Page 725: ...2 CRITICAL PWR 17 PCR08 TXL 0 8 RD FUEL PUMP 1 SPLICE CRITICAL POWER 2 2 CRITICAL PWR 18 PCR10 TXL 0 8 RD BK LOAD CENTER D9 LOAD CENTER B9 BRAKE LIGHT PWR 19 PCR11 TXL 0 8 RD BK HANDLEBAR CONNECTION 3 LOAD CENTER B8 FUSED BRAKE LIGHT PWR 20 PCR14 TXL 0 8 RD BK LOAD CENTER C3 LOAD CENTER B4 FUSED GAUGE PWR 21 PCR15 TXL 0 8 RD BK SPLICE LIGHT POWER 1 LOAD CENTER B4 FUSED LIGHT PWR 22 PCR15 1 TXL 0 8...

Page 726: ...H A B C D E F G H P1 P2 GROUND SPEED CAPACITOR 180 TERMINALS P1 P2 CHASSIS GND 1 DETONATION SENSOR BOSCH 1 928 403 698 1 2 IGNITION COIL MAG P1 P2 SPLICE SENSOR POWER 1 1 2 OIL LEVEL SWITCH P N 4012624 PTO IGNITION COIL P N 4014009 MAG IGNITION COIL P N 4014010 TMAP SENSOR BOSCH 1 928 403 736 1 2 3 4 OIL PUMP P N 1204446 FUEL PUMP P N 2521342 PUMP 1 3 4 2 EV ACTUATOR P N 4014355 MAG FUEL INJECTOR ...

Page 727: ...EB10 2 TXL 1 0 RD DB LOAD CENTER B3 INJECTOR PWR SPLICE 1 INJECTOR PWR 14 EB10 3 TXL 2 0 RD DB INJECTOR PWR SPLICE 2 PBR DC POWER P2 INJECTOR PWR SENSE 15 EB10 4 TXL 0 5 RD DB DIGITAL WRENCH A INJECTOR PWR SPLICE 2 INJECTOR PWR 16 EB17 TXL 0 5 OG YE ECU_CNB 17 IGNITION COIL PTO P1 IGN PTO 17 EB30 TXL 0 5 RD WH ECU_CNB 30 SPLICE SENSOR POWER 1 1 SENSOR PWR 18 EB30 1 TXL 0 5 RD WH SPLICE SENSOR POWE...

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