2008 EDGE / WIDETRAK SNOWMOBILE SERVICE MANUAL FOREWORD This service manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator's perspective when seated in a normal riding position. Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper tools as specified. Comments or suggestions about this manual may be directed to: Service Publications Dept. @ Polaris Sales Inc. 2100 Hwy 55 Medina Minnesota 55340.
2008 EDGE / Widetrak Snowmobile Service Manual PN 9921481 Š Copyright 2007 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.
2008 EDGE / Widetrak Service Manual Chapters
Model Specifications........................... .... 1 General Information............................ .... 2 Maintenance....................................... .... 3 Fuel Systems...................................... .... 4 Engine Systems.................................. .... 5 Final Drive and Brake Systems.......... .... 6 PVT System........................................ .... 7 Front and Rear Suspensions.............. .... 8 Chassis............................................... .... 9 Electrical Systems.............................. .... 10 Wiring Schematics.............................. .... 11
Model Specifications
CHAPTER 1 Model Specifications
1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 2008 340 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 2008 340 TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 2008 SUPERSPORT / 550 LX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 2008 TRAIL TOURING DELUXE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 2008 TRAIL RMK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 2008 WIDETRAK LX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
1.1
Model Specifications SPECIFICATIONS
Carburetor Jetting Ambient Temperature
< -25°F/<-35°C
-30°F to -10°F/-34°C to -23°C
-15°F to +5°F/-26°C to -15°C
0°F to +20°F/-18°C to -7°C
+15°F to +35°F/-9°C to +2°C
+30°F to +50°F/-1°C to +10°C
+45°F to +65°F/+7°C to +18°C
>+60°F/>+16°C
2008 340
0-600 (0-2000)
185 #4
180 #3
170 #3
170 #3
165 #3
160 #3
155 #3
150 #3
Model Number: S08NB3AS Altitude Meters (feet)
Engine Fuji Fan-Cooled / Piston Port Induction
Engine Type Model Number
EC34-2PM074
Displacement / # Cylinders
339cc / 2
Bore (inches/mm)
2.45 / 62.23
Stroke (inches/mm)
2.19 / 55.6
600-1200 (2000-4000)
175 #3
170 #3
160 #3
160 #3
155 #3
150 #3
140 #2
140 #2
Piston to Cylinder Clearance (inches/mm)
.003 - .005 / .076 - .127
1200-1800 (4000-6000)
165 #3
160 #3
155 #3
150 #3
145 #3
140 #2
130 #2
130 #2
Installed Ring Gap (inches / mm)
.008 - .014 / .203 - .356
1800-2400 (6000-8000)
155 #3
150 #3
140 #3
135 #3
135 #2
130 #2
120 #1
120 #1
Operating RPM ±200
7000
2400-3000 (8000-10,000)
Idle RPM
1600
145 #3
140 #3
130 #2
130 #2
125 #2
120 #1
110 #1
110 #1
Engagement RPM ±200
4100
3000-3700 (10,000-12,000)
135 #3
130 #2
120 #2
115 #2
115 #1
110 #1
100 #1
100 #1
Carburetor Settings Type
Clutch Settings Mikuni VM30SS
Main Jet
170
Pilot Jet
35
Jet Needle/Clip position
5DP13 / 3
Needle Jet
O-6 (169)
Throttle Gap (Under Cutaway) (in/mm) Drill Bit Size Cutaway
.240 / 6.1 B - 15/64 2.5 AL
Valve Seat
1.5 Viton
Starter Jet
1.5
Pilot Air Jet
2.5
Air Screw (Turns Out)
1.5
Recommended Fuel Octane (R+M/2)
1.2
87 (Non-Oxygenated)
ALTITUDE meters (feet)
DRIVE CLUTCH Shift Weight
0-900 (0-3000)
10
900-1800 (3000-6000)
10M-B
1800-2700 (6000-9000)
10M-W
2700-3700 (9000-12,000)
10M-R
DRIVEN CLUTCH
Clutch Spring
Clutch Spring
Driven Helix
Gearing
110 / 290 (2287)
RED/BLK
S36 LW ER
16:41-72
Drive Clutch Bolt Torque: 50 lb.ft. (68Nm)
Model Specifications General
Front Suspension
Width (in/cm)
48 / 121.9
Suspension Type
Length (in/cm)
113 / 287
Shocks
Height (in/cm)
48 / 121.9
100 (1.79)
Estimated Dry Weight (lb/kg)
IFS Spring Rate lbs/in (N/mm)
450 / 204.5
.625 (15.9)
Fuel (Gallons / Liters)
11.8 / 44.7
Spring Pre-load Inches (cm)
Oil (Quarts / Liters)
3.25 / 3.1
Brake Fluid
DOT 4
Drive Belt Part Number Width (inches / cm) Side Angle Circumference (inches / cm) Center Distance (inches / cm)
3211078 1.438 / 3.65 28_ 46.625 / 118.4 11.5 / 29.2
Chaincase Center Distance (inches) Top Gear (Stock) Bottom Gear (Stock) Chain (Stock) Gear Lube Capacity (oz / ml) Reverse System
7.92 16 41 72 Polaris Synthetic 9 / 266.2 Perc
Alternator Output Operating Voltage Watts @ 13.5 Vdc (Total)
13.5 - 14.5 Vdc 240
Ignition Timing
Arvin Nitrex Gas Bag
Front Vertical Travel Inches (cm)
40.44 +/- .25 (102.71 +/- .63) Inches (cm) Camber Inches (cm)
.59 +/- .31 (1.5 +/- .8)
Toe Out Inches (cm) (Measured over 20 inches)
.12 - .25 (.30 - .63)
Rear Suspension Suspension Type Front Track Shock (FTS) FTS Spring Rate lbs/in (N/mm)
Torsion Springs
26.5_ @3000 RPM
Spark Plug Gap in.(mm)
.028 (.70)
Spark Plug
NGK BR8ES
CDI Marking
CU7245
Flywheel Marking
FP9313
10 (25.4)
Suspension Width
Rear Track Shock (RTS)
Electrical
1
EDGE 42.5
Rear Travel Inches (cm)
EDGE 121 Arvin Nitrex Gas Bag 200 - 240 (3.6 - 4.3) Ryde FX MPV Compression Adjustable .359 / 77_ (Stock) - PN 7041629-067 - PN 7041630 - 067 .375 / 77_ (Firm) - PN 7041942 - 067 - PN 7041943 - 067 13.9 (35.3)
Track Width - Inches (cm)
15 (38)
Length - Inches (cm)
121 (307)
Lug Height - Inches (cm)
.82 (2.08)
Track tension sag in/cm with 10 lbs/4.54kg placed 16 in/ 40cm ahead of rear idler shaft
3/8” - 1/2” (1 - 1.3cm)
1.3
Model Specifications 2008 340 Transport
Carburetor Jetting Ambient Temperature
< -25°F/<-35°C
-30°F to -10°F/-34°C to -23°C
-15°F to +5°F/-26°C to -15°C
0°F to +20°F/-18°C to -7°C
+15°F to +35°F/-9°C to +2°C
+30°F to +50°F/-1°C to +10°C
+45°F to +65°F/+7°C to +18°C
>+60°F/>+16°C
Model Number: S08NT3AS / S08NT3AE
Bore (inches/mm)
2.45 / 62.23
Stroke (inches/mm)
2.19 / 55.6
0-600 (0-2000)
185 #4
180 #3
170 #3
170 #3
165 #3
160 #3
155 #3
150 #3
Piston to Cylinder Clearance (inches/mm)
.003 - .005 / .076 - .127
600-1200 (2000-4000)
175 #3
170 #3
160 #3
160 #3
155 #3
150 #3
140 #2
140 #2
Installed Ring Gap (inches / mm)
.008 - .014 / .203 - .356
1200-1800 (4000-6000)
165 #3
160 #3
155 #3
150 #3
145 #3
140 #2
130 #2
130 #2
Operating RPM ±200
7000
1800-2400 (6000-8000)
Idle RPM
1600
155 #3
150 #3
140 #3
135 #3
135 #2
130 #2
120 #1
120 #1
Engagement RPM ±200
4100
2400-3000 (8000-10,000)
145 #3
140 #3
130 #2
130 #2
125 #2
120 #1
110 #1
110 #1
3000-3700 (10,000-12,000)
135 #3
130 #2
120 #2
115 #2
115 #1
110 #1
100 #1
100 #1
Engine Fuji Fan-Cooled / Piston Port Induction
Engine Type Model Number
Altitude Meters (feet)
EC34-2PM074
Displacement / # Cylinders
339cc / 2
Carburetor Settings Type
Mikuni VM30SS
Main Jet
170
Pilot Jet
35
Clutch Settings ALTITUDE meters (feet)
DRIVE CLUTCH Shift Weight
Jet Needle/Clip position
5DP13 / 3
Needle Jet
O-6 (169)
0-900 (0-3000)
10
Throttle Gap (Under Cutaway) (in/mm) Drill Bit Size
.240 / 6.1 B - 15/64
900-1800 (3000-6000)
10M-B
2.5 AL
1800-2700 (6000-9000)
10M-W
Valve Seat
1.5 Viton
2700-3700 (9000-12,000)
10M-R
Starter Jet
1.5
Pilot Air Jet
2.5
Air Screw (Turns Out)
1.5
Cutaway
Recommended Fuel Octane (R+M/2)
1.4
87 (Non-Oxygenated)
DRIVEN CLUTCH
Clutch Spring
Clutch Spring
Driven Helix
Gearing
110 / 290 (2287)
BLU/BLK
54/38 .25 LW ER
17:41-72
Drive Clutch Bolt Torque: 50 lb.ft. (68Nm)
Model Specifications General
Front Suspension
Width (in/cm)
48 / 121.9
Suspension Type
Length (in/cm)
128 / 325.1
Shocks
Height (in/cm)
49.5 / 125.7
100 (1.79)
Estimated Dry Weight (lb/kg)
IFS Spring Rate lbs/in (N/mm)
497 / 225.6
.625 (15.9)
Fuel (Gallons / Liters)
12.25 / 46.4
Spring Pre-load Inches (cm)
Oil (Quarts / Liters)
3.4 / 3.2 6.3 / 6
Suspension Width
Brake Fluid
DOT 4
Inches (cm)
Drive Belt Part Number Width (inches / cm) Side Angle Circumference (inches / cm) Center Distance (inches / cm)
3211078 1.438 / 3.65 28_ 46.625 / 118.4 11.5 / 29.2
Chaincase Center Distance (inches) Top Gear (Stock) Bottom Gear (Stock) Chain (Stock) Gear Lube Capacity (oz / ml) Reverse System
7.92 17 41 72 Polaris Synthetic 9 / 266.2 Perc
Arvin Nitrex Gas Bag
Front Vertical Travel Inches (cm)
Cooling System Capacity (Quarts / Liters)
Camber Inches (cm)
.59 +/- .31 (1.5 +/- .8)
Toe Out Inches (cm) (Measured over 20 inches)
.12 - .25 (.30 - .63)
Rear Suspension Suspension Type Front Track Shock (FTS) FTS Spring Rate lbs/in (N/mm) Rear Track Shock (RTS)
Torsion Springs 13.5 - 14.5 Vdc 240
Ignition Timing
26.5_ @ 3000 RPM
Spark Plug Gap in.(mm)
.028 (.70)
Spark Plug
10 (25.4)
40.44 +/- .25 (102.71 +/- .63)
Electrical Alternator Output Operating Voltage Watts @ 13.5 Vdc (Total)
1
EDGE 42.5
Rear Travel Inches (cm)
EDGE 136 Arvin Nitrex Gas Bag 200 - 240 (3.6 - 4.3) Ryde FX MPV Compression Adjustable .405 / 77_ (Stock) - PN 7041940 - 067 - PN 7041941 - 067 .375 / 77_ (Softer) - PN 7041942 - 067 - PN 7041943 - 067 13.9 (35.3)
NGK BR8ES
CDI Marking
CU7245
Flywheel Marking
FP9313 Track
Width - Inches (cm)
15 (38)
Length - Inches (cm)
136 (345)
Lug Height - Inches (cm) Track tension sag in/cm with 10 lbs/4.54kg placed 16 in/ 40cm ahead of rear idler shaft
1.25 (3.175) 1 1/8” - 1 3/8” (2.9 - 3.5cm)
1.5
Model Specifications 2008 Supersport / 550 LX
Carburetor Jetting Ambient Temperature
< -25°F/<-35°C
-30°F to -10°F/-34°C to -23°C
-15°F to +5°F/-26°C to -15°C
0°F to +20°F/-18°C to -7°C
+15°F to +35°F/-9°C to +2°C
+30°F to +50°F/-1°C to +10°C
+45°F to +65°F/+7°C to +18°C
>+60°F/>+16°C
Model Number:
0-600 (0-2000)
270 #4
260 #4
250 #4
240 #4
230 #3
220 #3
210 #2
200 #1
600-1200 (2000-4000)
260 #4
250 #4
240 #3
230 #3
220 #3
220 #2
210 #2
200 #1
1200-1800 (4000-6000)
250 #4
240 #3
230 #3
220 #3
210 #2
210 #2
200 #2
190 #1
1800-2400 (6000-8000)
230 #3
220 #3
220 #3
210 #2
210 #2
200 #2
190 #1
180 #1
2400-3000 (8000-10,000)
220 #3
210 #3
210 #2
200 #2
190 #2
190 #2
180 #1
170 #1
3000-3700 (10,000-12,000)
210 #3
200 #3
190 #2
190 #2
180 #2
180 #2
170 #1
160 #1
Supersport = S08NP5BS / S08NP5ES 550 LX = S08ND5BS Altitude Meters (feet)
Engine Fuji Fan-Cooled / Piston Port w/Reed Assist Induction
Engine Type Model Number
EC55PM101
Displacement / # Cylinders
544cc / 2
Bore (inches/mm)
2.87 / 73
Stroke (inches/mm)
2.56 / 65
Piston to Cylinder Clearance (inches/mm) Installed Ring Gap (inches / mm)
.0039 - .0053 (.10 - .135) .016 - .022 (.40 - .55)
Operating RPM ±200
7000
Idle RPM
1600
Engagement RPM ±200
3800 Clutch Settings
Carburetor Settings Type
Mikuni VM34
Main Jet
240
Pilot Jet
35
Jet Needle/Clip position
6BGY41 / 4
ALTITUDE meters (feet) 0-600 (0-2000)
DRIVE CLUTCH Shift Weight
Clutch Spring
DRIVEN CLUTCH Clutch Spring
Driven Helix
Gearing
10-62
600-1200 (2000-4000)
19:39-72 10-60
Needle Jet
Q-0 (480)
1200-1800 (4000-6000)
Throttle Gap (Under Cutaway) (in/mm) Drill Bit Size
.256 / 6.5 F
1800-2400 (6000-8000)
10-58
3.0
2400-3000 (8000-10000)
10-56
Valve Seat
1.5 Viton 1.5
3000-3600 (10000-12000)
10-56
Starter Jet Pilot Air Jet
2.5
Air Screw (Turns Out)
1.0
Cutaway
Recommended Fuel Octane (R+M/2)
1.6
87 (Non-Oxygenated)
Dk. BLU/ WHT
RED/BLU
56/42 - .36 LW ER
Drive Clutch Bolt Torque: 50 lb.ft. (68Nm)
18:39 72
Model Specifications General
Front Suspension
Width (in/cm)
48 / 121.9
Suspension Type
Length (in/cm)
113 / 287
Shocks
Height (in/cm)
48 / 121.9
IFS Spring Rate lbs/in (N/mm)
100 (1.79)
Spring Pre-load Inches (cm)
.625 (15.9)
Estimated Dry Weight (lb/kg)
Supersport = 470 (213.6) 550 LX = 489 (222)
Fuel (Gallons / Liters)
11.8 / 44.7
Oil (Quarts / Liters)
3.25 / 3.1
Brake Fluid
DOT 4
Drive Belt Part Number Width (inches / cm) Side Angle Circumference (inches / cm) Center Distance (inches / cm)
3211078 1.438 / 3.65 28_ 46.625 / 118.4 11.5 / 29.2
Chaincase Center Distance (inches) Top Gear (Stock) Bottom Gear (Stock) Chain (Stock) Gear Lube Capacity (oz / ml) Reverse System
7.92 19 39 72 Polaris Synthetic 9 / 266.2 Perc
Electrical Alternator Output Operating Voltage Watts @ 13.5 Vdc (Total)
Suspension Setup Width Inches (cm)
.028 (.70)
Spark Plug
Toe Out Inches (cm) (Measured over 20 inches)
.12 - .25 (.30 - .63)
Rear Suspension Suspension Type Front Track Shock (FTS)
Width - Inches (cm)
15 (38)
Length - Inches (cm)
121 (307)
Lug Height - Inches (cm)
.82 (2.08)
Track tension sag in/cm with 10 lbs/4.54kg placed 16 in/ 40cm ahead of rear idler shaft
Arvin Nitrex Gas Bag 200 - 240 (3.6 - 4.3)
Rear Track Shock (RTS)
Ryde FX MPV Compression Adjustable
Torsion Springs
FP6318 Track
EDGE 121
FTS Spring Rate lbs/in (N/mm)
EC55PM100 / 110
Flywheel Marking
40.44 +/- .25 (102.71 +/- .63) .59 +/- .31 (1.5 +/- .8)
NGK BR9ES
CDI Marking
10 (25.4)
Camber Inches (cm)
27_ @ 3000 RPM 14_ @ 6500 RPM
Spark Plug Gap in.(mm)
Arvin Nitrex Gas Bag
Front Vertical Travel Inches (cm)
13.5 - 14.5 Vdc 280
Ignition Timing
1
EDGE 42.5
Rear Travel Inches (cm)
.359 / 77_ (Stock: 550LX / Soft: Supersport) - PN 7041629 - 067 - PN 7041630 - 067 .375 / 77_ ( Firm: 550LX / Stock: Supersport) - PN 7041942 - 067 - PN 7041943 - 067 .405 / 77_ (Firm: Supersport) - PN 7041940 - 067 - PN 7041941 - 067 13.9 (35.3)
3/8” - 1/2” (1 - 1.3cm)
1.7
Model Specifications 2008 Trail Touring Deluxe
Carburetor Jetting Ambient Temperature
< -25°F/<-35°C
-30°F to -10°F/-34°C to -23°C
-15°F to +5°F/-26°C to -15°C
0°F to +20°F/-18°C to -7°C
+15°F to +35°F/-9°C to +2°C
+30°F to +50°F/-1°C to +10°C
+45°F to +65°F/+7°C to +18°C
>+60°F/>+16°C
Model Number: S08NT5BS / S08NT5BE
0-600 (0-2000)
270 #4
260 #4
250 #4
240 #4
230 #3
220 #3
210 #2
200 #1
600-1200 (2000-4000)
260 #4
250 #4
240 #3
230 #3
220 #3
220 #2
210 #2
200 #1
1200-1800 (4000-6000)
250 #4
240 #3
230 #3
220 #3
210 #2
210 #2
200 #2
190 #1
1800-2400 (6000-8000)
230 #3
220 #3
220 #3
210 #2
210 #2
200 #2
190 #1
180 #1
2400-3000 (8000-10,000)
220 #3
210 #3
210 #2
200 #2
190 #2
190 #2
180 #1
170 #1
3000-3700 (10,000-12,000)
210 #3
200 #3
190 #2
190 #2
180 #2
180 #2
170 #1
160 #1
Engine Fuji Fan-Cooled / Piston Port w/Reed Assist Induction
Engine Type Model Number
Altitude Meters (feet)
EC55PM101
Displacement / # Cylinders
544cc / 2
Bore (inches/mm)
2.87 / 73
Stroke (inches/mm)
2.56 / 65
Piston to Cylinder Clearance (inches/mm) Installed Ring Gap (inches / mm)
.0039 - .0053 (.10 - .135) .016 - .022 (.40 - .55)
Operating RPM ±200
7000
Idle RPM
1600
Engagement RPM ±200
3800
Carburetor Settings Type Main Jet Pilot Jet Jet Needle/Clip position
240 35 6BGY41 / 4
Needle Jet
Q-0 (480)
Throttle Gap (Under Cutaway) (in/mm) Drill Bit Size
.256 / 6.5 F
Cutaway
3.0
Valve Seat
1.5 Viton
Starter Jet
1.5
Pilot Air Jet
2.5
Air Screw (Turns Out)
1.0
Recommended Fuel Octane (R+M/2)
1.8
Clutch Settings
Mikuni VM34
87 (Non-Oxygenated)
ALTITUDE meters (feet) 0-600 (0-2000)
DRIVE CLUTCH Shift Weight
Clutch Spring
DRIVEN CLUTCH Clutch Spring
Driven Helix
Gearing
10-62
600-1200 (2000-4000)
21:41-74 10-60
1200-1800 (4000-6000)
BLU / WHT RED/BLU
1800-2400 (6000-8000)
56/42 - .36 LW ER
10-58
2400-3000 (8000-10000)
20:41-74 10-56
3000-3600 (10000-12000)
Dark Blue
Drive Clutch Bolt Torque: 50 lb.ft. (68Nm)
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Model Specifications General
Front Suspension
Width (in/cm)
48 / 121.9
Length (in/cm)
128 / 325.1
Height (in/cm)
49.5 / 125.7
Estimated Dry Weight (lb/kg)
570 / 258.8
IFS Spring Rate lbs/in (N/mm)
100 (1.79)
Fuel (Gallons / Liters)
12.25 / 146.4
Spring Pre-load Inches (cm)
.625 (15.9)
Oil (Quarts / Liters)
3.4 / 3.2
Brake Fluid
DOT 4
Drive Belt Part Number Width (inches / cm) Side Angle Circumference (inches / cm) Center Distance (inches / cm)
3211078 1.438 / 3.65 28_ 46.625 / 118.4 11.5 / 29.2
Chaincase Center Distance (inches) Top Gear (Stock) Bottom Gear (Stock) Chain (Stock) Gear Lube Capacity (oz / ml) Reverse System
7.96 21 41 74 Polaris Synthetic 9 / 266.2 Perc
Suspension Type
Arvin Nitrex Compression Adjustable
Shocks
Front Vertical Travel Inches (cm) Suspension Setup Width Inches (cm) Camber Inches (cm)
.59 +/- .31 (1.5 +/- .8)
Toe Out Inches (cm) (Measured over 20 inches)
.12 - .25 (.30 - .63)
Rear Suspension Suspension Type Front Track Shock (FTS) FTS Spring Rate lbs/in (N/mm) Rear Track Shock (RTS)
13.5 - 14.5 Vdc 280 27_ @ 3000 RPM 14_ @ 6500 RPM
Ignition Timing Spark Plug Gap in.(mm)
Torsion Springs
.028 (.70)
Spark Plug
NGK BR9ES
CDI Marking
10 (25.4)
40.44 +/- .25 (102.71 +/- .63)
Electrical Alternator Output Operating Voltage Watts @ 13.5 Vdc (Total)
1
EDGE 42.5
Rear Travel Inches (cm)
EDGE 136 Arvin Nitrex Gas Bag 200 - 240 (3.6 - 4.3) Ryde FX MPV Compression Adjustable .405 / 77_ (Stock) - PN 7041940 - 067 - PN 7041941 - 067 .375 / 77_ (Soft) - PN 7041942 - 067 - PN 7041943 - 067 13.9 (35.3)
EC55PM100 / 110
Flywheel Marking
FP6318 Track
Width - Inches (cm)
15 (38)
Length - Inches (cm)
136 (345.4)
Lug Height - Inches (cm) Track tension sag in/cm with 10 lbs/4.54kg placed 16 in/ 40cm ahead of rear idler shaft
1.0 / (2.5)
7/8” - 1 1/8” (2.2 - 2.9cm)
1.9
Model Specifications 2008 Trail RMK
Carburetor Jetting Ambient Temperature
< -25°F/<-35°C
-30°F to -10°F/-34°C to -23°C
-15°F to +5°F/-26°C to -15°C
0°F to +20°F/-18°C to -7°C
+15°F to +35°F/-9°C to +2°C
+30°F to +50°F/-1°C to +10°C
+45°F to +65°F/+7°C to +18°C
>+60°F/>+16°C
Model Number: S08NJ5BS / S08NJ5BE
0-600 (0-2000)
270 #4
260 #4
250 #4
240 #4
230 #3
220 #3
210 #2
200 #1
600-1200 (2000-4000)
260 #4
250 #4
240 #3
230 #3
220 #3
220 #2
210 #2
200 #1
1200-1800 (4000-6000)
250 #4
240 #3
230 #3
220 #3
210 #2
210 #2
200 #2
190 #1
1800-2400 (6000-8000)
230 #3
220 #3
220 #3
210 #2
210 #2
200 #2
190 #1
180 #1
2400-3000 (8000-10,000)
220 #3
210 #3
210 #2
200 #2
190 #2
190 #2
180 #1
170 #1
3000-3700 (10,000-12,000)
210 #3
200 #3
190 #2
190 #2
180 #2
180 #2
170 #1
160 #1
Engine Fuji Fan-Cooled / Piston Port w/Reed Assist Induction
Engine Type Model Number
Altitude Meters (feet)
EC55PM101
Displacement / # Cylinders
544cc / 2
Bore (inches/mm)
2.87 / 73
Stroke (inches/mm)
2.56 / 65
Piston to Cylinder Clearance (inches/mm) Installed Ring Gap (inches / mm)
.0039 - .0053 (.10 - .135) .016 - .022 (.40 - .55)
Operating RPM ±200
7000
Idle RPM
1600
Engagement RPM ±200
3800
Carburetor Settings Type Main Jet Pilot Jet Jet Needle/Clip position
210 35 6BGY41 / 2
Needle Jet
Q-0 (480)
Throttle Gap (Under Cutaway) (in/mm) Drill Bit Size
.264 / 6.71 G - 17/64
Cutaway
3.0
Valve Seat
1.5 Viton
Starter Jet
1.5
Pilot Air Jet
2.5
Air Screw (Turns Out)
.75
Recommended Fuel Octane (R+M/2)
1.10
Clutch Settings
Mikuni VM34
87 (Non-Oxygenated)
DRIVE CLUTCH
ALTITUDE meters (feet)
Shift Weight
0-600 (0-2000)
10-64
600-1200 (2000-4000)
10-62
DRIVEN CLUTCH
Clutch Spring
Clutch Spring
Driven Helix
Gearing
BLU/WHT
RED/BLU
56/42 .36 LW ER
19:43 - 74
1200-1800 (4000-6000) 10-60 1800-2400 (6000-8000) 2400-3000 (8000-10000)
10-58
3000-3600 (10000-12000)
10-56
Drive Clutch Bolt Torque: 50 lb.ft. (68Nm)
Model Specifications General
Front Suspension
Width (in/cm)
45.5 / 115.6
Length (in/cm)
124 / 315
Shocks
Height (in/cm)
48 / 121.9
100 (1.79)
Estimated Dry Weight (lb/kg)
IFS Spring Rate lbs/in (N/mm)
475 / 215.7
.625 (15.9)
Fuel (Gallons / Liters)
11.8 / 44.7
Spring Pre-load Inches (cm) Front Vertical Travel Inches (cm)
7.6 (19.3)
Oil (Quarts / Liters)
3.4 / 3.2
Brake Fluid
DOT 4
Drive Belt Part Number Width (inches / cm) Side Angle Circumference (inches / cm) Center Distance (inches / cm)
3211078 1.438 / 3.65 28_ 46.625 / 118.4 11.5 / 29.2
Chaincase Center Distance (inches) Top Gear (Stock) Bottom Gear (Stock) Chain (Stock) Gear Lube Capacity (oz / ml) Reverse System
7.92 19 43 74 Polaris Synthetic 9 / 266.2 Perc
Arvin Nitrex Gas Bag
Suspension Width 40.90 +/- .25 (103.88 +/- .63) Inches (cm) Camber Inches (cm)
.735 +/- .31 (1.5 +/- .8)
Toe Out Inches (cm) (Measured over 20 inches)
0 - .12 (0 - .30)
Rear Suspension Suspension Type Front Track Shock (FTS) FTS Spring Rate lbs/in (N/mm)
13.5 - 14.5 Vdc 280 27_ @ 3000 RPM 14_ @ 6500 RPM
Ignition Timing Spark Plug Gap in.(mm)
.028 (.70)
Spark Plug
Torsion Springs
NGK BR9ES
CDI Marking
EC55PM100 / 110
Flywheel Marking
FP6318 Track
Rear Travel Inches (cm)
Width - Inches (cm)
15 (38)
Length - Inches (cm)
136 (345)
Lug Height - Inches (cm) Track tension sag in/cm with 10 lbs/4.54kg placed 16 in/ 40cm ahead of rear idler shaft
1
EDGE RMK 41
Rear Track Shock (RTS)
Electrical Alternator Output Operating Voltage Watts @ 13.5 Vdc (Total)
Suspension Type
EDGE RMK 136 Arvin Nitrex Gas Bag 200 - 240 (3.6 - 4.3) Arvin Nitrex Compression Adjustable .347 / 77_ (Stock) - PN 7041627 - 067 - PN 7041628 - 067 .347 / 47 (Soft) - PN 7042081 - 067 - PN 7042082 - 067 .375 / 77 (Firm) - PN 7041631 - 067 - PN 7041632 - 067 .405 / 77_ (Most Firm) - PN 7041940 - 067 - PN 7041941 - 067 13.8 (35.1)
1.25 (3.175)
3/8” - 1/2” (1 - 1.3cm)
1.11