Page 1

2003 DEEP SNOW SERVICE MANUAL PN 9918051

PN 9918051 Printed in USA

T h e Wa y O u t .

2003 DEEP SNOW SERVICE MANUAL PN 9918051

TRAIL RMK 700 SKS 800 SKS 600 RMK 700 RMK 800 RMK


DEEP SNOW SERVICE MANUAL Foreword This manual is designed primarily for use by Polaris snowmobile service technicians in a properly equipped shop. Persons using this manual should have a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. The technician 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. Cleanliness of parts and tools as well as the work area is of primary importance. All references to left and right side of the vehicle are from the operator’s perspective when seated in a normal riding position. This manual includes procedures for maintenance operations, component identification and unit repair, along with service specifications for the Polaris Trail RMK, 600 RMK, 700 SKS, 700 RMK, 800 SKS, 800 RMK model snowmobiles. A table of contents is placed at the beginning of each chapter, and an alphabetic index is provided at the end of the manual for location of specific page numbers and service information. Keep this manual available for reference in the shop area. At the time of publication all information contained in this manual was technically correct. However, all materials and specifications are subject to change without notice. Comments or suggestions about this manual may be directed to: Polaris Sales Inc., Service Publications Department, 2100 Hwy 55 Medina, Minnesota 55340.

Deep Snow Snowmobile Service Manual (PN 9918051) Copyright 2001 Polaris Sales Inc.

Printed in U.S.A.


UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS Throughout these instructions, important information is brought to your attention by the following symbols: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

DANGER

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

Failure to follow WARNING instructions could result in severe injury or death to the operator, bystander or person inspecting or servicing the snowmobile. CAUTION: A CAUTION indicates special precautions that must be taken to avoid personal injury, or snowmobile or property damage. NOTE: A NOTE provides key information to clarify instructions.

Trademarks Polaris acknowledges the following products mentioned in this manual: FLEXLOC, Registered Trademark of SPS Technologies Loctite, Registered Trademark of the Loctite Corporation STA-BIL, Registered Trademark of Gold Eagle FOX, Registered Trademark of Fox Shox Nyogel, Trademark of Wm. F. Nye Co. Fluke, Registered Trademark of John Fluke Mfg. Co. Mity Vac, Registered Trademark of Neward Enterprises, Inc. Ammco, Registered Trademark of Ammco Tools, Inc. Torx, Registered Trademark of Textron Hilliard, Trademark of the Hilliard Corporation


GENERAL

MAINTENANCE

ENGINE

CARBURETION

DRIVE/DRIVEN CLUTCHES

BODY AND STEERING

SUSPENSIONS

BRAKES AND FINAL DRIVE

ELECTRICAL

WIRING DIAGRAMS


Publication Part Numbers / Service Manuals . . . . . . . . . . . . . Model Number Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . Vehicle Identification Number (VIN) . . . . . . . . . . . . . . . . . . . . . Standard Bolt Torque Specifications . . . . . . . . . . . . . . . . . . . . Decimal Equivalents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tap Drill Size Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Units of Measure Conversion Chart . . . . . . . . . . . . . . . . . . . . . Recommended Shop Supplies . . . . . . . . . . . . . . . . . . . . . . . . . Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Notes Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trail RMK Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600 RMK Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700 SKS Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700 EDGE RMK Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 800 SKS Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 EDGE RMK Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 800 EDGE VERTICAL ESCAPE RMK Specifications . . . . . .

1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 - 1.11 1.12 1.13 1.14 - 1.15 1.16 - 1.17 1.18 - 1.19 1.20 -- 1.21 1.22 -- 1.23 1.24 -- 1.25 1.26 -- 1.27


GENERAL INFORMATION Publication Numbers

Trail RMK

S03SR5BS

Owner’s Manual Supplement 9917613

600 RMK

S03NK6ES

9917598

9917801

9917802

700 RMK

S03NK7CS S03NK7CSA S03NL7CS S03NL7CSA

9917599 9917599 9917602 9917602

9917803

9917804

S03NK8CS S03NK7CSA S03NL8CS S03NL8CSA S03NM8CS S03NN8CS S03NS7CS S03NS7CSA S03NS8CS S03NS8CSA

9917601 9917601 9917603 9917603 9917610 9917610

9917803 9917803 9917803 9917803 9917807 9917807

9917804 9917804 9917804 9917804 9917808 9917808

9917606

9917605

9917806

9917607

9917805

9917806

Model(s)

800 RMK

700 SKS 800 SKS

Model No.

Parts Manual 9917805

Parts Microfiche 9917806

2003 Snowmobile Owner’s Manual (All) - PN 9917436 2003 Snowmobile Assembly Manual - PN 9916508

2003 Service Manuals 2000--2003 120 XC SP Trail Sport Super Sport, 340 EDGE, 500 EDGE, 440 PRO X FAN

9918046 9918048

Touring Wide Trak LX, 340 Touring, Sport Touring, Trail Touring, 500 Classic Touring, 600 Classic Touring, 700 Classic Touring, 800 Classic Touring

Frontier Frontier Classic, Frontier Touring

Trail Luxury 340 Classic EDGE, 500 Classic, 550 Classic, 600 Classic, 700 Classic

Deep Snow Trail RMK, 600/700/800 RMK, 700/800 SKS

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

High Performance 440 PRO X FAN, 440, 600, 700, 800 PRO X

9918047 9918050 9918049 9918051 9918052 9918053

Wallcharts

9918054

TRACK POSTER

9918459

1.1


GENERAL INFORMATION MODEL NUMBER IDENTIFICATION 2002 MODEL DESIGNATION YEAR DESIGNATION

ENGINE DESIGNATION S=Snow

S 0 2 S D 5

B S

MODEL / CHASSIS DESIGNATION S= North American Model U= European Model MODEL LINE (4TH DIGIT) S=Gen II L= Lite N= EDGE W=Mini Indy

MODEL TYPE (5TH DIGIT) A= Feature Option B= Basic C= Feature Option D= Deluxe E= Feature Option M--10 F= Feature Option J= 136 RMK (Edge) K= 144 RMK (Edge) L= 151 RMK (Edge) M= 156 RMK (Edge) P= Performance R= RMK (Gen II) S= SKS T= Touring U= Utility X= Racer

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

TUNNEL DECAL MODEL NO.

MADE IN U.S.A.

V.I.N. NO. THIS VEHICLE CONFORMS TO ALL APPLICABLE U.S. FEDERAL AND STATE REQUIREMENTS AND CANADA MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE. MFD. DATE:

PATENT NOTICE Mfd. by Polaris Industries Inc.. in Roseau, MN under one or more of the following patents: Patented Canada U.S. Patents 882,491/71 3,605,511 3,613,810 5,050,559 883,694/71 3,580,647 3,867,991 5,048,503 864,394/71 3,483,766 4,793,950 5,056,482 Canadian Rd. 3,533,662 5,038,881 5,099,813 34,573/71 3,545,821 5,172,675 5,074,271 34,572/71 3,605,510 5,090,386 5,191,531 1,227,823/87 3,525,412 5,050,564 3,613,811 7072133

These numbers should be referred to in any correspondence regarding warranty, service or replacement parts. The machine model and serial number identification decal is located on the right front side of the tunnel. The serial number is permanently stamped into the tunnel. The model number is embossed on the decal. Whenever corresponding about an engine it is important that the engine model and serial numbers be called out. Laser engraved model and serial numbers are located on the crankcase (intake side).

1.2


GENERAL INFORMATION Vehicle Identification Number Current snowmobiles have a 17 digit Vehicle Identification Number (VIN). The VIN is organized as follows: Digits 1-3: World Manufacturer Identifier. For Polaris, this is 4XA. Digits 4-9: Vehicle Descriptor Section. Digits 10-17: Vehicle Indicator Section. Digits 4-8 of the VIN identify the body style, type, engine type, and series. The VIN and the model number must be used with any correspondence regarding service or repair. World Mfg. ID

Example of Current VIN Number

1 S

2 N

3 1

Vehicle Descriptor

4 S

5 B

6 5

7 B

8 S

Vehicle Identifier

9 10 11 12 0 2 2 0

13 14 15 16 17 0 0 0 0 0

Model Series Engine Year Individual Serial No. Size Engine Check Manufacturing. Modifier Digit Type Location Code

Body Style

Vehicle Identification Number / Model Number Key Body Style

Type

Engine Size

Engine Modifier

Series

L=Lite

B=Base Model

1=100-199 cc

A=Fan

S=Domestic

N=Edge

D=Deluxe

2=200-299 cc

B=Liquid Twin

U=Europe

S=Gen II

P=Performance

3=300-399 cc

C=Case Reed Twin

W=Mini

R=RMK

4=400-499 cc

D=Liquid Triple

S=SKS

5=500-599 cc

E=Case Reed Triple

T=Touring

6=600-699 cc

U=Utility

7=700-799 cc

X=Racer

8=800-899 cc

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

1 = 2001 2 = 2002 3 = 2003

1.3


GENERAL INFORMATION Standard Torque Specifications The following torque specifications are to be used as a general guideline when torque value is not specified. There are exceptions in the steering, suspension, and engine areas. Always consult the torque chart and the specific manual section for torque values of fasteners.

Bolt Size

Threads/In (MM/Thread)

Grade 2

Torque in. lbs. (Nm) 24 . . . . . . . . . . . . . . 27 (3.1) . . . . . . . . . . . . . . . . 32 . . . . . . . . . . . . . . 31 (3.6) . . . . . . . . . . . . . . . . Torque ft. lbs. (Nm)* 1/4 20 . . . . . . . . . . . . . . 5 (7) . . . . . . . . . . . . . . . . . . 1/4 28 . . . . . . . . . . . . . . 6 (8) . . . . . . . . . . . . . . . . . . 5/16 18 . . . . . . . . . . . . . . 11 (15) . . . . . . . . . . . . . . . . 5/16 24 . . . . . . . . . . . . . . 12 (16) . . . . . . . . . . . . . . . . 3/8 16 . . . . . . . . . . . . . . 20 (27) . . . . . . . . . . . . . . . . 3/8 24 . . . . . . . . . . . . . . 23 (32) . . . . . . . . . . . . . . . . 7/16 14 . . . . . . . . . . . . . . 30 (40) . . . . . . . . . . . . . . . . 7/16 20 . . . . . . . . . . . . . . 35 (48) . . . . . . . . . . . . . . . . 1/2 13 . . . . . . . . . . . . . . 50 (69) . . . . . . . . . . . . . . . . 1/2 20 . . . . . . . . . . . . . . 55 (76) . . . . . . . . . . . . . . . . *To convert ft. lbs. to Nm multiply foot pounds by 1.356. *To convert Nm to ft. lbs. multply Nm by .7376. #10 #10

-

1.4

Grade 5

Grade 8

43 (5) . . . . . . . . . . . . . . . 60 (6.9) 49 (5.6) . . . . . . . . . . . . . . 68 (7.8) 8 (11) . . . . . . . . . . . . . . . . 10 (14) . . . . . . . . . . . . . . 17 (23) . . . . . . . . . . . . . . 19 (26) . . . . . . . . . . . . . . 30 (40) . . . . . . . . . . . . . . 35 (48) . . . . . . . . . . . . . . 50 (69) . . . . . . . . . . . . . . 55 (76) . . . . . . . . . . . . . . 75 (104) . . . . . . . . . . . . . 90 (124) . . . . . . . . . . . . .

12 (16) 14 (19) 25 (35) 29 (40) 45 (62) 50 (69) 70 (97) 80 (110) 110 (152) 120 (166)


GENERAL INFORMATION 1/64 . . . . . . . . . . . . . . . . . . . . . . . . . 1/32 . . . . . . . . . . . . . . . . . . . 3/64 . . . . . . . . . . . . . . . . . . . . . . . . . 1/16 . . . . . . . . . . . . . . 5/64 . . . . . . . . . . . . . . . . . . . . . . . . . 3/32 . . . . . . . . . . . . . . . . . . . 7/64 . . . . . . . . . . . . . . . . . . . . . . . 1/8 . . . . . . . . . 9/64 . . . . . . . . . . . . . . . . . . . . . . . . . 5/32 . . . . . . . . . . . . . . . . . . . 11/64 . . . . . . . . . . . . . . . . . . . . . . . . 3/16 . . . . . . . . . . . . . . 13/64 . . . . . . . . . . . . . . . . . . . . . . . . 7/32 . . . . . . . . . . . . . . . . . . . 15/64 . . . . . . . . . . . . . . . . . . . . . . . . 1/4 . . . . . . . . . . 17/64 . . . . . . . . . . . . . . . . . . . . . . . . 9/32 . . . . . . . . . . . . . . . . . . . 19/64 . . . . . . . . . . . . . . . . . . . . . . . . 5/16 . . . . . . . . . . . . . . 21/64 . . . . . . . . . . . . . . . . . . . . . . . . 11/32 . . . . . . . . . . . . . . . . . . 23/64 . . . . . . . . . . . . . . . . . . . . . . . . 3/8 . . . . . . . . . . 25/64 . . . . . . . . . . . . . . . . . . . . . . . . 13/32 . . . . . . . . . . . . . . . . . . 27/64 . . . . . . . . . . . . . . . . . . . . . . . . 7/16 . . . . . . . . . . . . . . 29/64 . . . . . . . . . . . . . . . . . . . . . . . . 15/32 . . . . . . . . . . . . . . . . . . 31/64 . . . . . . . . . . . . . . . . . . . . . . . . 1/2 . . . . . . . . . . 33/64 . . . . . . . . . . . . . . . . . . . . . . . . 17/32 . . . . . . . . . . . . . . . . . . 35/64 . . . . . . . . . . . . . . . . . . . . . . . . 9/16 . . . . . . . . . . . . . . 37/64 . . . . . . . . . . . . . . . . . . . . . . . . 19/32 . . . . . . . . . . . . . . . . . . 39/64 . . . . . . . . . . . . . . . . . . . . . . . . 5/8 . . . . . . . . . . 41/64 . . . . . . . . . . . . . . . . . . . . . . . . 21/32 . . . . . . . . . . . . . . . . . . 43/64 . . . . . . . . . . . . . . . . . . . . . . . 11/16 . . . . . . . . . . . . . 45/64 . . . . . . . . . . . . . . . . . . . . . . . . 23/32 . . . . . . . . . . . . . . . . . . 47/64 . . . . . . . . . . . . . . . . . . . . . . . . 3/4 . . . . . . . . . . 49/64 . . . . . . . . . . . . . . . . . . . . . . . . 25/32 . . . . . . . . . . . . . . . . . . 51/64 . . . . . . . . . . . . . . . . . . . . . . . . 13/16 . . . . . . . . . . . . . 53/64 . . . . . . . . . . . . . . . . . . . . . . . . 27/32 . . . . . . . . . . . . . . . . . . 55/64 . . . . . . . . . . . . . . . . . . . . . . . . 7/8 . . . . . . . . . . 57/64 . . . . . . . . . . . . . . . . . . . . . . . . 29/32 . . . . . . . . . . . . . . . . . . 59/64 . . . . . . . . . . . . . . . . . . . . . . . 15/16 . . . . . . . . . . . . . 61/64 . . . . . . . . . . . . . . . . . . . . . . . . 31/32 . . . . . . . . . . . . . . . . . . 63/64 . . . . . . . . . . . . . . . . . . . . . . . .

.0156 .0312 . . . . . . . . . . . . . . . . .0469 .0625 .0781 . . . . . . . . . . . . . . . . .0938 .1094 . . . . . . . . . . . . . . . . .1250 .1406 .1563 . . . . . . . . . . . . . . . . .1719 .1875 . . . . . . . . . . . . . . . . .2031 .2188 .2344 . . . . . . . . . . . . . . . . .25 .2656 . . . . . . . . . . . . . . . . .2813 .2969 .3125 . . . . . . . . . . . . . . . . .3281 .3438 . . . . . . . . . . . . . . . . .3594 .375 .3906 . . . . . . . . . . . . . . . . .4063 .4219 . . . . . . . . . . . . . . . . .4375 .4531 .4688 . . . . . . . . . . . . . . . . .4844 .5 . . . . . . . . . . . . . . . . . . . .5156 .5313 .5469 . . . . . . . . . . . . . . . . .5625 .5781 . . . . . . . . . . . . . . . . .5938 .6094 .625 . . . . . . . . . . . . . . . . . .6406 .6563 . . . . . . . . . . . . . . . . .6719 .6875 .7031 . . . . . . . . . . . . . . . . .7188 .7344 . . . . . . . . . . . . . . . . .75 .7656 .7813 . . . . . . . . . . . . . . . . .7969 .8125 . . . . . . . . . . . . . . . . .8281 .8438 .8594 . . . . . . . . . . . . . . . . .875 .8906 . . . . . . . . . . . . . . . . .9063 .9219 .9375 . . . . . . . . . . . . . . . . .9531 .9688 . . . . . . . . . . . . . . . . .9844

1 mm = .0394s 2 mm = .0787s 3 mm = .1181s 4 mm = .1575s 5 mm = .1969s 6 mm = .2362s 7 mm = .2756s 8 mm = .3150s 9 mm = .3543s 10 mm = .3937s 11 mm = .4331s 12 mm = .4724s 13 mm = .5118 14 mm = .5512s 15 mm = .5906s 16 mm = .6299s 17 mm = .6693s 18 mm = .7087s 19 mm = .7480s 20 mm = .7874s 21 mm = .8268s 22 mm = .8661s 23 mm = .9055s 24 mm = .9449s 25 mm = .9843

1.5


GENERAL INFORMATION SAE Tap Drill Sizes Thread Size

Drill Size

Thread Size

Drill Size

#0-80 #1-64 #1-72 #2-56 #2-64 #3-48 #3-56 #4-40 #4-48 #5-40 #5-44 #6-32 #6-40 #8-32 #8-36 #10-24 #10-32 #12-24 #12-28 1/4-20 1/4-28 5/16-18 5/16-24 3/8-16 3/8-24 7/16-14 7/16-20

3/64 53 53 51 50 5/64 45 43 42 38 37 36 33 29 29 24 21 17 4.6mm 7 3 F I O Q U 25/64

1/2-13 1/2-20 9/16-12 9/16-18 5/8-11 5/8-18 3/4-10 3/4-16 7/8-9 7/8-14 1-8 1-12 1 1/8-7 1 1/8-12 1 1/4-7 1 1/4-12 1 1/2-6 1 1/2-12 1 3/4-5 1 3/4-12 2-4 1/2 2-12 2 1/4-4 1/2 2 1/2-4 2 3/4-4 3-4

27/64 29/64 31/64 33/64 17/32 37/64 21/32 11/16 49/64 13/16 7/8 59/64 63/64 1 3/64 1 7/64 1 11/64 1 11/32 1 27/64 1 9/16 1 43/64 1 25/32 1 59/64 2 1/32 2 1/4 2 1/2 2 3/4

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

1.6

Drill Size #39 3/32 #30 1/8 #19 #20 #9 16/64 J 17/64 5/16 5/16 11/32 R 3/8 13/32 13/32

Decimal Equivalent 0.0995 0.0937 0.1285 0.125 0.166 0.161 0.196 0.234 0.277 0.265 0.3125 0.3125 0.3437 0.339 0.375 0.406 0.406

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


GENERAL INFORMATION Conversion Chart Unit of Measure

Multiplied by

Converts to

ft. lbs.

x 12

= in. lbs.

in. lbs.

x .0833

= ft. lbs.

ft. lbs.

x 1.356

= Nm

in. lbs.

x .0115

= kg-m

Nm

x .7376

= ft. lbs.

kg-m

x 7.233

= ft. lbs.

kg-m

x 86.796

= in. lbs.

kg-m

x 10

= Nm

in.

x 25.4

=mm

mm

x .03937

= in.

in.

x 2.54

= cm

mile (mi.)

x 1.6

= km

km

x .6214

= mile (mi.)

Ounces (oz)

x 28.35

= Grams (g)

Grams (g)

x 0.035

= Ounces (oz)

cc

x .03381

= Fluid Ounces (oz)

lb.

x .454

= kg

kg

x 2.2046

= lb.

Cubic inches (cu in)

x 16.387

= Cubic centimeters (cc)

Cubic centimeters (cc)

x 0.061

= Cubic inches (cu in)

Imperial pints (Imp pt)

x 0.568

= Liters (l)

Liters (l)

x 1.76

= Imperial pints (Imp pt)

Imperial quarts (Imp qt)

x 1.137

= Liters (l)

Liters (l)

x 0.88

= Imperial quarts (Imp qt)

Imperial quarts (Imp qt)

x 1.201

= US quarts (US qt)

US quarts (US qt)

x 0.833

= Imperial quarts (Imp qt)

US quarts (US qt)

x 0.946

= Liters (l)

Liters (l)

x 1.057

= US quarts (US qt)

US gallons (US gal)

x 3.785

=Liters (l)

Liters (l)

x 0.264

= US gallons (US gal)

Pounds - force per square inch (psi)

x 6.895

= Kilopascals (kPa)

Kilopascals (kPa)

x 0.145

= Pounds - force per square inch (psi)

Kilopascals (kPa)

x 0.01

= Kilograms - force per square cm

Kilograms - force per square cm

x 98.1

= Kilopascals (kPa)

qC to qF: 9 (qC + 40) y 5 -- 40 = qF qF to qC: 5 (qF + 40) y 9 -- 40 = qC

1.7


GENERAL INFORMATION Recommended Shop Supplies Description Chaincase Lubricant - Quart . . . . . . . . . . . . . . . . . . . . . . . Chaincase Lubricant - Gallon . . . . . . . . . . . . . . . . . . . . . . Chaincase Lubricant - 2.5 Gallon . . . . . . . . . . . . . . . . . . . Fuel System Deicer (Isopropyl) . . . . . . . . . . . . . . . . . . . . . Loctite Primer T - 6 Oz. Aerosol . . . . . . . . . . . . . . . . . . . . Loctite RC 680 - 10cc Retaining Compound . . . . . . . . . . Loctite/Chisel -- Gasket Remover - 18 Oz. . . . . . . . . . . . Metal Polish - 8 Oz. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DOT 3 Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fogging Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nyogelt Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fox Shock Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Premium All Season Grease (14 oz) . . . . . . . . . . . . . . . . Premium All Season Grease (3 oz) . . . . . . . . . . . . . . . . . Premium 60/40 Anti-Freeze/Coolant . . . . . . . . . . . . . . . . Premium Carbon Clean Fuel System Additive . . . . . . . . Polaris Battery Tender . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carbon Clean Fuel System Additive . . . . . . . . . . . . . . . . . T-9 Metal Protectant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankcase Sealant 3 Bond 1215 . . . . . . . . . . . . . . . . . . .

1.8

Part Number 2871280 2870464 2872281 2870505 2870585 2870584 2870601 2870632 2870990 2870791 2871329 2870995 2871423 2871322 2871323 2871326 2871076 2871326 2871064 2871557


GENERAL INFORMATION Service Glossary ACS: Alternator control switch. ACV: Alternating current voltage. Air Gap Spark Test: A good check for ignition voltage and general ignition system condition. Spark should arc 3/8” (1 cm) minimum from end of high tension lead to ground. Several testers are available commercially. Alternator: Electrical generator producing alternating current voltage. Bore: Diameter of cylinder. BTDC: Before Top Dead Center. Bump Steer: When skis toe in and toe out through suspension travel. CDI: Capacitor Discharge Ignition. Ignition system which stores voltage generated by the stator plate exciter coil in a capacitor or condenser (in CDI box). At the proper moment a voltage generated by the stator plate pulser coil closes an electronic switch (thyristor) in the CDI box and allows the voltage in the capacitor to discharge into the primary windings of the ignition coil. Center Cylinder: On three cylinder engines, the cylinder between Mag and PTO ends. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8” or 1 cm). Polaris measures chain length in number of pitches. Clutch Buttons: Plastic bushings which transmit rotation of the clutch to the movable sheave in the drive and driven clutch. Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face as the engine torques back. Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to close. Coil: A winding of wire around an iron core which has the ability to generate an electrical current when a magnetic field passes through it. Combustion Chamber: Space between cylinder head and piston dome at TDC. Compression: Reduction in volume or squeezing of a gas. Condenser/Capacitor: A storage reservoir for electricity, used in both E.T. and CDI systems. Crankshaft Run-Out: Run-out or “bend” of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in lower half of crankcase. Measure at various points especially at PTO. Maximum allowable run-out is .006” (.02 cm). DCV: Direct current voltage. Detonation: The spontaneous ignition of the unburned fuel/air mixture after normal spark ignition. Piston looks “hammered” through, rough appearance around hole. Possible causes: 1) lean fuel/air mixture; 2) low octane fuel; 3) over-advanced ignition timing; 4)compression ratio too high for the fuel octane. Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and out-of-round in the cylinder bore. Displacement: The volume of the cylinder displaced by Bore2 x Stroke x 3.1416 the piston as it travels from BDC to TDC. The formula is: = Displacement in 4 CCs Effective Compression Ratio: Compression ratio measured from after the piston closes the exhaust port. Electrical Open: Open circuit. An electrical circuit which isn’t complete. (i.e. poor connections or broken wire at hi-lo beam switch resulting in loss of headlights. Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended component. (i.e. a bare wire touching the snowmobile chassis under the seat resulting in loss of taillights and brake lights). End Seals: Rubber seals at each end of the crankshaft. Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt. Flat Head Bolt: To be used where finished surfaces require a flush fastening unit. Countersunk. Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction. g: Gram. Unit of weight in the metric system.

1.9


GENERAL INFORMATION Service Glossary Cont., Head Volume: Cylinder head capacity in cc, head removed from engine with spark plug installed. Heat Exchanger: A device used to transfer heat. They dissipate engine heat to the atmosphere. Hex Head Bolt: Standard type of wrench-applied hexagon head, characterized by clean, sharp corners trimmed to close tolerances. Recommended for general commercial applications. Hi-Fax: Trademark of Himont Advanced Materials. The special slide material which fits onto the bottom of the suspension rails. High Side: Sled pushes or tips up toward outside of turn. High Tension Wire: The heavy insulated wire which carries the high secondary voltage from the coil to the spark plug. Hole Shot: A term used when machine starts a race from a dead stop. Holed Piston: Piston in which a hole has formed on the dome. Possible causes: 1) detonation; 2) pre-ignition. Ignition Coil: A type of transformer which increases voltage in the primary windings (approx. 200V) to a higher voltage in the secondary windings (approx. 14KV - 32KV) through inductions. Secondary voltage is high enough to arc the air gap at the spark plug. Ignition Generating Coil: Exciter coil or primary charge coil. Stator plate coil which generates primary ignition voltage. CDI system uses one ignition generating coil. Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb. Kg/cm2: Kilograms per square centimeter. Metric equivalent of PSI. Keystone Ring: A piston ring with bevel on upper surface. Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction. Metric equivalent of ft. lbs. L Ring: A wide face piston ring with an ”L” shaped cross section. Leg of ”L” goes up when installing on piston. Labyrinth Seal: A pressure type center seal identified by series of grooves and lands. Polaris engines us this type of seal to separate the cylinders in the crankcase halves. Left Side: Always referred to based on normal operating position of the driver. Lighting Coil: Generates voltage for lights, battery charging, etc by electromagnetic induction. Loose: When the rear of the vehicle slides outward in a turn. The track does not grab sufficiently. mm: Millimeter. Unit of length in the metric system. 1mm = .040”. Mag End: Flywheel side of engine. Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the windings. This is how mechanical energy in our engines is converted to electrical energy in the lighting coil, ignition generating coils and trigger coil. Ohm: The measurement of electrical resistance opposing current flow. Oval Head Screw: Fully specified as ”oval countersunk”, this head is identical to the standard flat head, but possesses a rounded upper surface for attractiveness of design. PTO End: Power Take Off drive (clutch side). Pan Head Screw: Provides a low, large diameter head, but with characteristically high outer edges along the outer edge of the head where driving action is most effective. Slightly different head contour when supplied with Phillips Recess. See dotted line. Piston Clearance: Total distance between piston and cylinder wall. Piston Erosion: Piston dome melts. Usually occurs at the exhaust port area. Possible causes: 1) lean fuel/air mixture; 2) improper spark plug heat range; 3) Poor fuel. Pre-Ignition: A problem in combustion where the fuel/air mixture is ignited before normal spark ignition. Piston looks melted at area of damage. Possible causes: 1)incorrect spark plug heat range; 2) spark plug not properly torqued; 3) “glowing” piece of head gasket, metal burr or carbon in the combustion chamber; 4) lean fuel/air mixture; 5) Incorrect ignition timing. Primary Circuit: This circuit is responsible for the voltage build up in the primary windings of the coil. In the CDI system the parts include the exciter coil, the trigger coil, the wires from stator plate to CDI box and to the low resistance primary windings in the ignition coil.

1.10


GENERAL INFORMATION Service Glossary Cont., Primary Clutch: Drive clutch on engine. Primary Compression: Pressure built up in the crankcase of a two stroke engine. psi.: Pounds per square inch. Pushing: When the front of the vehicle does not steer as much as the driver desires. The skis do not grab sufficiently. R & R: Remove and replace. RFI: Radio Frequency Interference. Caused by high voltage from the ignition system. There are special plug caps and spark plugs to help eliminate this problem. Mandated in Canada. RPM: Revolutions Per Minute. Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms. Both result in energy conversion to heat. Right Side: Always referred to based on normal operating position of the driver. Round Head Screw:The familiar head most universally used for general application. Good slot depth, ample underhead bearing surface and finished appearance are characteristic of this head. Running Time: Ignition timing at specified RPM. Secondary Circuit: This circuit consists of the large secondary coil windings, high tension wire and ground through the spark plug air gap. Secondary Clutch: Driven clutch on chaincase or jackshaft. Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall. Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings. Self Steer: Pulling the machine to the inside of the track. Spark Plug Reach: Length of threaded portion of spark plug. Polaris uses 3/4� (2 cm) reach plugs. Static Timing: Ignition timing when engine is at zero RPM. Stator Plate: The plate mounted under the flywheel supporting the primary ignition components and lighting coils. Stroke: The maximum movement of the piston from bottom dead center to top dead center. It is characterized by 180q of crankshaft rotation. Surge Tank: The fill tank in the liquid cooling system. TDC: Top Dead Center. Piston’s most outward travel from crankshaft. Transfer: The movement of fuel/air from the crankcase to the combustion chamber in a two stroke engine. Trigger Coil: Pulser coil. Generates the voltage for triggering (closing) the thyristor and timing the spark in CDI systems. Small coil mounted at the top of the stator plate next to the ignition generating coil, or on the outside of the flywheel. V Regulator: Voltage regulator. Maintains maximum lighting coil output at approx. 14.5 ACV as engine RPM increases. Venturi: An area of air constriction. A venturi is used in carburetors to speed up air flow which lowers pressure in venturi to below atmospheric pressure, causing fuel to be pushed through jets, etc., and into the venturi to be mixed with air and form a combustible air/fuel mixture. Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit. Watt: Unit of electrical power. Watts = amperes x volts.

1.11


GENERAL INFORMATION General Service Precautions In order to perform service work efficiently and to prevent costly errors, the technician should read the text in this manual, thoroughly familiarizing him/herself with procedures before beginning. Photographs and illustrations have been included with the text as an aid. Notes, cautions and warnings have also been included for clarification of text and safety concerns. However, a knowledge of mechanical theory, tool use and shop procedures is necessary to perform the service work safely and satisfactorily. Use only genuine Polaris service parts. Cleanliness of parts and tools as well as the work area is of primary importance. Dirt and foreign matter will act as an abrasive and cause damage to precision parts. Clean the snowmobile before beginning service. Clean new parts before installing. Watch for sharp edges which can cause personal injury, particularly in the area of the tunnel. Protect hands with gloves when working with sharp components. If difficulty is encountered in removing or installing a component, look to see if a cause for the difficulty can be found. If it is necessary to tap the part into place, use a soft face hammer and tap lightly. Some of the fasteners in the snowmobile were installed with locking agents. Use of impact drivers or wrenches will help avoid damage to fasteners. 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). If a torquing sequence is indicated for nuts, bolts or screws, start all fasteners in their holes and hand tighten. Then, following the method and sequence indicated in this manual, tighten evenly to the specified torque value. When removing nuts, bolts or screws from a part with several fasteners, loosen them all about 1/4 turn before removing them. If the condition of any gasket or O-Ring is in question, replace it with a new one. Be sure the mating surfaces around the gasket are clean and smooth in order to avoid leaks. Some procedures will require removal of retaining rings or clips. Because removal weakens and deforms these parts, they should always be replaced with new parts. When installing new retaining rings and clips use care not to expand or compress them beyond what is required for installation. Because removal damages seals, replace any oil or grease seals removed with new parts. Polaris recommends the use of Polaris lubricants and greases, which have been specially formulated for the top performance and best protection of our machines. In some applications, such as the engine, warranty coverage may become void if other brands are substituted. Grease should be cleaned from parts and fresh grease applied before reassembly of components. Deteriorating grease loses lubricity and may contain abrasive foreign matter. Whenever removing or reinstalling batteries, care should be taken to avoid the possibility of explosion resulting in serious burns. Always disconnect the negative (black) cable first and reconnect it last. Battery electrolyte contains sulphuric acid and is poisonous! Serious burns can result from contact with the skin, eyes or clothing. ANTIDOTE: External - Flush with water. Internal - Drink large quantities or water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately. Eyes - Flush with water for 15 minutes and get prompt medical attention.

1.12


GENERAL INFORMATION Notes

1.13


GENERAL INFORMATION MODEL: . . . . . . . . . . TRAIL RMK MODEL NUMBER: . S03SR5BS ENGINE MODEL: . . EC55PM025 JETTING CHART AMBIENT TEMPERATURE

CARBURETION Type . . . . . . . . . . . . . . . . VM34SS Mikuni w/ACCS Main Jet . . . . . . . . . . . . 270 Pilot Jet . . . . . . . . . . . . . 35 Jet Needle . . . . . . . . . . . 6DEH11-3 Needle Jet . . . . . . . . . . . Q-0 (480) Cutaway . . . . . . . . . . . . 3.0 Air Screw . . . . . . . . . . . 1.5 Turns Valve Seat . . . . . . . . . . . 1.5 Viton Fuel Octane (R+M/2) . 87 Non-Oxygenated Throttle Gap 89 Oxygenated Under Cutaway . . . . . . .218s (5.54mm)

Below -30qF Below -34qC 34 C

-30_ to --10_F -34 to -23 C -34_to -23_C

--10_to +10_F -23 C -23_ to --12 -12_C

+10_to +30_F -12 to --1 C -12_to -1_C

+30_to +50_F -1 to +10_C +10 C -1_to

Above +50_F +10 C Above +10_C

0--600 (0--2000)

300 #3

290 #3

280 #3

270 #3

260 #3

250 #3

600--1200 (2000--4000)

300 #3

290 #3

280 #3

270 #3

260 #3

250 #3

1200--1800 1200 1800 ((4000000 -6000) 6000)

300 #3

290 #3

280 #3

270 #3

260 #3

250 #3

1800--2400 (6000--8000) (6000 8000)

300 #3

290 90 #3

280 80 #3

270 0 #3

260 60 #3

250 50 #3

2400--3000 (8000--10000) (8000 10000)

300 #3

290 90 #3

280 80 #3

270 0 #3

260 60 #3

250 50 #3

3000--3700 (10000--12000) (10000 12000)

300 #3

290 90 #3

280 80 #3

270 0 #3

260 60 #3

250 50 #3

Altitude

Meters ((Feet))

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

CLUTCH Type . . . . . . . . . . . . . . . . Belt . . . . . . . . . . . . . . . . . Belt Width (Projected) . Side Angle (Overall) . . Outside Circumference Center Distance . . . . . . Shift Weights . . . . . . . . Primary Spring . . . . . . . Secondary Spring . . . . Driven Helix . . . . . . . . .

P-85 3211070 1.375s (34.93) 28q 47.250s (120cm.) 12.00s 10-56 Bushed Dark Blue / White Silver / Blue R-32 #2

CLUTCH CHART DRIVE

Altitude Meters (Feet)

DRIVEN

Shift Weight

Clutch Spring

Clutch Spring

Driven Helix

Chaincase Gearing

0-900 (0-3000)

10-62 Bushed

Dark Blue / White

Silver/ Blue

R-32 #2

18-41-68P HYVO

900-1800 (3000-6000)

10-58 Bushed

Dark Blue / White

Silver/ Blue

R-32 #2

18-41-68P HYVO

1800-2700 (6000-9000)

10-56 Bushed

Dark Blue / White

Silver/ Blue

R-32 #2

18-41-68P HYVO

2700-3700 (9000-12000)

10-54 Bushed

Dark Blue / White

Silver/ Blue

R-32 #2

18-41-68H YVO

- Production Setting

ENGINE Type . . . . . . . . . . . . . . . . . . . . . . . Displacement . . . . . . . . . . . . . . . Bore . . . . . . . . . . . . . . . . . . . . . . . Stroke . . . . . . . . . . . . . . . . . . . . . Piston / Cylinder Clearance . . . Service Limit . . . . . . . . . . . . . . . . Piston Marking . . . . . . . . . . . . . . Piston Ring Marking . . . . . . . . . Piston Ring End Gap . . . . . . . . Head ccs (Uninstalled) . . . . . . . Head ccs (Installed) . . . . . . . . . Operating RPMr200 . . . . . . . . . Idle RPMr200 . . . . . . . . . . . . . . Engagement RPMr300 . . . . . . Cylinder Head Torque . . . . . . . . Cylinder Base Nut Torque . . . . Crankcase Torque (8mm) . . . . . Crankcase Torque (10mm) . . . Flywheel Torque . . . . . . . . . . . . .

1.14

Fan Cooled Reed Assist Twin 544cc 2.874s (73mm) 2.559s (65mm) 0.0035s - 0.0049s (0.09 - 0.125mm) 0.0078s (0.20mm) 5MB N 0.016s - 0.022s (0.40 - 0.55mm) 33.8r0.4cc 27.7cc 6800 RPM 1600 RPM 3800 RPM 18-19.5 ft.lbs. (25-27 Nm) 24-28 ft.lbs. (33-39 Nm) 16.6-18 ft.lbs. (23-35 Nm) N/A 60-65 ft.lbs. (83-90 Nm)

Fuel Pump Manuf. . . . . . Fuel Pump Mark . . . . . . . Oil Pump Manuf. . . . . . . . Oil Pump Mark . . . . . . . . Cylinder Head Mark . . . .

Taiyo FJP-3-100 Mikuni 55MB EC55PM


GENERAL INFORMATION MODEL: . . . . . . . . . . TRAIL RMK MODEL NUMBER: . S03SR5BS ENGINE MODEL: . . EC55PM025

ELECTRICAL

CAPACITIES

Flywheel I.D. . . . . . . CDI Marking . . . . . . . Alternator Output . . . Ignition Timing . . . . .

Mitsubishi 17620111 240 Watts 27q BTDC@3500RPMr1.5q 0.175s BTDC (r0.157s - 0.195s) 4.45mm BTDC (r3.97 - 4.93mm) Spark Plug / Gap . . . NGK BR9ES / 0.028s (0.7mm) Voltage Regulator . . LR7 Electric Start . . . . . . . Option LR7= Full wave voltage regulator Magneto Pulses . . . . 6

Fuel Tank . . . . . . . . . . Oil Tank . . . . . . . . . . . . Coolant . . . . . . . . . . . . Chaincase Oil . . . . . . .

SUSPENSION / CHASSIS

CHAINCASE

11.8 gallons (44.7 liters) 3 quarts (2.8 liters) N/A 9 fl. oz.(266cc)

Body Style . . . . . . . . Front Suspension . . Front Shocks . . . . . . IFS Spring Rate . . . . Front Spring Preload Front Vertical Travel Rear Suspension . . . Rear Axle Travel . . . Front Track Shock . . Spring Rate . . . . . . . . Rear Track Shock . . Rear Springs . . . . . . Track Type . . . . . . . . Track Tension . . . . . .

Gen II Sprockets / Chain . . . 18-41, 68P HYVO Indy XTRA 38s Reverse . . . . . . . . . . . . Option Nitrogen Cell Brake Pads . . . . . . . . . Type 341, Small 80#/in. Chaincase Center Dist.7.05s (17.9cm.) 5/16s Thread Adjust Driveshaft Sprockets . 2 Drivers 8.25s (21cm.) Brake Type . . . . . . . . . Polaris HPB XTRA-Lite 136s 12s (30.5cm.) Nitrogen Cell 181#/in. Indy Select .347s (sq.) / 77q 15sx136sx.1.25s (38.1x345.44x3.175cm.) 3/8s - 1/2s (1-1.3 cm.) slack with 10# (4.54kg) weight 16s (40.64cm.) ahead of rear idler shaft. Overall Snowmobile Length . . . . . . . . . . . . . . . . . 116s (295cm.) Overall Snowmobile Height . . . . . . . . . . . . . . . . . 45s (114cm.) Maximum Snowmobile Width . . . . . . . . . . . . . . . 43.5s (110.5cm.)

OPTIONAL REAR TORSION SPRINGS SOFT(STD)

MEDIUM

.347s(Sq.) Diameter x 77q .359 (Sq.) Diameter x 77q

FIRM .375�(Sq.) Diameter x 77q

L.H .7041627--067

L.H. 7041629--067

L.H. 7041631--067

R.H. 7041628--067

R.H. 7041630--067

R.H. 7041632--067

1.15


GENERAL INFORMATION MODEL: . . . . . . . . . . 600 EDGE RMK MODEL NUMBER: . S03NK6ES ENGINE MODEL: . . S2212--6044--PA6E JETTING CHART AMBIENT TEMPERATURE

CARBURETION Type . . . . . . . . . . . . . . . . Main Jet . . . . . . . . . . . . Pilot Jet . . . . . . . . . . . . . Jet Needle . . . . . . . . . . . Needle Jet . . . . . . . . . . . Cutaway . . . . . . . . . . . . Fuel Screw . . . . . . . . . . Air Scew . . . . . . . . . . . . Valve Seat . . . . . . . . . . . Fuel Octane (R+M/2) . Throttle Gap Under Cutaway . . . . . . Starter Jet . . . . . . . . . . . Pilot Air Jet . . . . . . . . . . Exhaust Spring

Below -30qF Below -34qC 34 C

-30_ to --10_F -34 to -23 C -34_to -23_C

--10_to +10_F -23 -12 C -23_ to --12_C

+10_to +30_F -12 to --1 C -12_to -1_C

+30_to +50_F -1 to +10_C +10 C -1_to

Above +50_F C Above +10 +10_C

0--600 (0--2000)

450 #4

430 #4

420 #3

400 #3

380 #3

370 #3

600--1200 (2000--4000)

410 #4

390 #3

380 #3

360 #3

340 #3

330 #2

1200--1800 1200 1800 ((4000000 -6000) 6000)

380 #3

360 #3

350 #3

330 #3

320 #2

300 #2

1800--2400 (6000--8000) (6000 8000)

360 #3 3

430 #3 3

320 #3 3

310 #2 2

290 #2 2

280 #2 2

2400--3000 (8000--10000) (8000 10000)

3 0 340 #3 3

3 0 320 #3 3

300 #2 2

290 90 #2 2

270 0 #2 2

260 60 #2 2

3000--3700 (10000--12000) (10000 12000)

330 #2 2

3 0 310 #2 2

290 90 #2 2

280 80 #2 2

260 60 #2 2

240 0 #2 2

Altitude ltitude

TM 38 w/TPS Mikuni 310 45 9DGI1--60--2 P-8 (825) 1.5 Notched 1.0 Turns .75 Turns 1.5 Key Switch Adj. Premium 91 Regular 87 Non-Oxy. 0.106s (2.7mm) 140 N/A Green/White

Meters ((Feet))

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

CLUTCH CHART

CLUTCH Type . . . . . . . . . . . . . . . . Belt . . . . . . . . . . . . . . . . . Belt Width (Projected) . Side Angle (Overall) . . Outside Circumference Center Distance . . . . . . Shift Weights . . . . . . . . Primary Spring . . . . . . . Driven Clutch . . . . . . . . Secondary Spring . . . . Driven Helix . . . . . . . . .

DRIVE

P-85 3211080 1.438s (36.53mm) 28q 46.625s (118.43cm.) 11.5s 10-54 Bushed Black/Green Roller Reverse Black/Yellow R-32

Altitude ltitude

DRIVEN

Shift Weight

Clutch Spring

Clutch Spring

Driven Helix

Chaincase Gearing

0-900 (0-3000)

10-60 Bushed

Black/ Green

Black / Yellow

R-32 Rev. Roller

19-39 72P HYVO

900-1500 (3000-5000)

10-58 Bushed

Black/ Green

Black / Yellow

R-32 Rev. Roller

19-39 72P HYVO

1500-2100 (5000-7000)

10-56 Bushed

Black/ Green

Black / Yellow

R-32 Rev. Roller

19-39 72P HYVO

2100-2700 (7000-9000)

10 54 Bushed

Black/ Green

Black / Yellow

R-32 Rev. Roller

19-39 72P HYVO

2700-3350 (9000-11000)

10AL Bushed

Black/ Green

Black / Yellow

R-32 Rev. Roller

19-39 72P HYVO

3350--4000 (11000-13000)

10 Bushed

Black/ Green

Black / Yellow

R-32 Rev. Roller

19-39 72P HYVO

Fuel Pump Manuf. . . . . . Fuel Pump Mark . . . . . . . Oil Pump Manuf. . . . . . . . Oil Pump Mark . . . . . . . . Cylinder Head Mark . . . .

Walbro N/A Mikuni 2540097 3022057

Meters (Feet)

- Production Setting

ENGINE Type . . . . . . . . . . . . . . . . . . . . . . . Displacement . . . . . . . . . . . . . . . Bore . . . . . . . . . . . . . . . . . . . . . . . Stroke . . . . . . . . . . . . . . . . . . . . . Piston / Cylinder Clearance . . . Service Limit . . . . . . . . . . . . . . . . Piston Marking . . . . . . . . . . . . . . Piston Ring Marking . . . . . . . . . Piston Ring End Gap . . . . . . . . Head ccs (Uninstalled) . . . . . . . Head ccs (Installed) . . . . . . . . . Operating RPMr200 . . . . . . . . . Idle RPMr200 . . . . . . . . . . . . . . Engagement RPMr300 . . . . . . Cylinder Head Torque . . . . . . . . Cylinder Base Nut Torque . . . . Crankcase Torque (8mm) . . . . . Crankcase Torque (10mm) . . .

1.16

Liquid Cooled Case Reed w/TPS 593cc 2.9930s 3.041s (77.25mm) 2.520 (64mm) 0.0044s - 0.0058s (0.11 - 0.15mm) .0059� (0.15mm) 3021088 N/A 0.012s - 0.018s (0.30 - 0.46mm) 36.0cc 29.0cc 8000 RPM 1500 RPM N/A RPM 18-22 ft.lbs. (25-30 Nm) 30-34 ft.lbs. (41-47 Nm) 20-24 ft.lbs. (28-33 Nm) 26-30 ft.lbs. (36-41 Nm)


GENERAL INFORMATION MODEL: . . . . . . . . . . 600 EDGE RMK MODEL NUMBER: . S03NK6ES ENGINE MODEL: . . S2212--6044--PA6E

ELECTRICAL Flywheel I.D. . . . . . . CDI Marking . . . . . . . Alternator Output . . . Ignition Timing . . . . .

Spark Plug / Gap . . . Voltage Regulator . . Electric Start . . . . . . . Magneto Pulses . . . .

CAPACITIES 4010677 Fuel Tank . . . . . . . . . . 4010682 Oil Tank . . . . . . . . . . . . 280 Watts Coolant . . . . . . . . . . . . 24_@3500RPMr500q Chaincase Oil . . . . . . . With TPS Unplugged. .1350s BTDC 3.43mm BTDC Champion RN57YCC / 0.025s (0.64mm) T1 Option 6

SUSPENSION / CHASSIS

11.8 gallons (44.7 liters) 3.25 quarts (3.1 liters) 4.78 quarts (4.5L) 11 fl. oz.(325mL)

CHAINCASE

Body Style . . . . . . . . Front Suspension . . IFS Shocks . . . . . . . . IFS Spring Rate . . . . Front Spring Preload Front Vertical Travel Rear Suspension . . . Rear Axle Travel . . . Front Track Shock . . Spring Rate . . . . . . . . Rear Track Shock . . Rear Springs . . . . . . Track Type . . . . . . . . Track Tension . . . . . .

EDGE RMK Sprockets / Chain . . . 19-39 72P HYVO EDGE RMK Reverse . . . . . . . . . . . . Electric Reverse Nitrex Brake Pads . . . . . . . . . Type 81, Large 100#/in. Chaincase Center Dist.7.92s (20.12cm.) 3/4s Thread Adjust Driveshaft Sprockets . 2 Drivers Wide, XHS 7.2s - 7.6s (18.3 - 19.3cm.) Brake Type . . . . . . . . . Polaris HPB Liquid Cooled EDGE RMK 17s (43cm.) Nitrex 170#/in. Indy Select .359s (sq.) / 47q 15sx144sx2.0s (38x366x5cm.) 3/8s - 1/2s (1-1.3 cm.) slack with 10# (4.54kg) weight 16s (40.64cm.) ahead of rear idler shaft. Overall Snowmobile Length . . . . . . . . . . . . . . . . . 120s (305cm.) Overall Snowmobile Height . . . . . . . . . . . . . . . . . 48s (122cm.) Maximum Snowmobile Width . . . . . . . . . . . . . . . 45.5s (115.5cm.)

OPTIONAL REAR TORSION SPRINGS SOFT .347s(Sq.) Diameter x 47q

(STD)

FIRM

.359(Sq.) Diameter x 47q .375s(Sq.) Diameter x 47q

(144”/151”) 7042081--067 (144”/151”) 7042068--067 (144”/151”) 7042079--067 (144”/151”) 7042082--067 (144”/151”) 7042069--067 (144”/151”) 7042080--067

1.17


GENERAL INFORMATION MODEL: . . . . . . . . . . 700 SKS MODEL NUMBER: . S03NS7CS ENGINE MODEL: . . S2316--7070--PA7C

JETTING CHART AMBIENT TEMPERATURE

CARBURETION Type . . . . . . . . . . . . . . . . Main Jet . . . . . . . . . . . . Pilot Jet . . . . . . . . . . . . . Jet Needle . . . . . . . . . . . Needle Jet . . . . . . . . . . . Cutaway . . . . . . . . . . . . Air Screw . . . . . . . . . . . Valve Seat . . . . . . . . . . . Fuel Octane (R+M/2) . Throttle Gap Under Cutaway . . . . . . Starter Jet . . . . . . . . . . . Pilot Air Jet . . . . . . . . . . Exhaust Valve Spring .

TM40 Mikuni 440 45 J8--9DGN5--57/3 P--8 1.5 1.25 1.8 Key Switch Adj. Premium 91 Regular 87 Non-Oxy (2.0mm) 145 N/A Green/Yellow

CLUTCH Type . . . . . . . . . . . . . . . . Belt . . . . . . . . . . . . . . . . . Belt Width (Projected) . Side Angle (Overall) . . Outside Circumference Center Distance . . . . . . Shift Weights . . . . . . . . Primary Spring . . . . . . . Secondary Spring . . . . Driven Helix . . . . . . . . .

Below -30qF Below -34qC 34 C

-30_ to --10_F -34 to -23 C -34_to -23_C

--10_to +10_F -23 -12 C -23_ to --12_C

+10_to +30_F -12 to --1 C -12_to -1_C

+30_to +50_F -1 to +10_C +10 C -1_to

Above +50_F C Above +10 +10_C

0--600 (0--2000)

480 #4

460 #3

440 #3

420 #3

400 #3

390 #2

600--1200 (2000--4000)

450 #3

430 #3

410 #3

400 #3

380 #2

360 #2

1200--1800 1200 1800 ((4000000 -6000) 6000)

420 #3

400 #3

390 #3

370 #2

350 #2

330 #2

1800--2400 (6000--8000) (6000 8000)

400 00 #3 3

380 #3 3

360 #2 2

3 0 340 #2 2

330 #2 2

3 0 310 #2 2

2400--3000 (8000--10000) (8000 10000)

3 0 370 #3 3

350 #2 2

330 #2 2

3 0 320 #2 2

300 #2 2

280 80 #2 2

3000--3700 (10000--12000) (10000 12000)

3 0 340 #2 2

330 #2 2

3 0 310 #1 1

290 90 #2 2

270 0 #2 2

260 60 #2 2

Altitude ltitude

Meters ((Feet))

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

CLUTCH CHART P-85 3211080 1.438s (3.63cm.) 28q 46.625s (118.42cm.) 11.50s 10-62 Black/Green Silver / Blue R11#2

DRIVE

Altitude ltitude Meters (Feet)

DRIVEN Chaincase Gearing/Pitch e ri g/Pitch

Shift Weight

Clutch Spring

Clutch Spring

Driven Helix

0-900 (0-3000)

10 -62 1062

Black / Green

Silver / Blue

R11 #2

23--39 74P HYVO

900-1800 (3000-6000)

10 -60 1060

Black / Green

Silver / Blue

R11 #2

23--39 74P HYVO

1800-2700 (6000-9000)

10 -58 1058

Black / Green

Silver / Blue

R11 #3

23--40 74P HYVO

Black / Green

Silver / Blue

R11 #3

23--40 74P HYVO

2700-3700 (9000-12000)

10 -56 1056

- Production Setting

ENGINE Type . . . . . . . . . . . . . . . . . . . . . . . Displacement . . . . . . . . . . . . . . . Bore . . . . . . . . . . . . . . . . . . . . . . . Stroke . . . . . . . . . . . . . . . . . . . . . Piston / Cylinder Clearance . . . Service Limit . . . . . . . . . . . . . . . . Piston Marking . . . . . . . . . . . . . . Piston Ring Marking . . . . . . . . . Piston Ring End Gap . . . . . . . . Head ccs (Uninstalled) . . . . . . . Head ccs (Installed) . . . . . . . . . Operating RPMr200 . . . . . . . . . Idle RPMr200 . . . . . . . . . . . . . . Engagement RPMr300 . . . . . . Cylinder Head Torque . . . . . . . . Cylinder Base Nut Torque . . . . Crankcase Torque (8mm) . . . . . Crankcase Torque (10mm) . . . Flywheel Torque . . . . . . . . . . . . .

1.18

Liquid Cooled Case Reed Twin 701cc 3.1889s (81mm) 2.6772s (68mm) 0.0044s - 0.0058s (0.11 - 0.15mm) 0.0060� 3021041 N/A 0.014s - 0.020s (.36 - .51mm) 38.15r.50cc 29.5--30.5cc 8000 RPM 1400 RPM 3500 RPM 18-22 ft.lbs. (25-30 Nm) 30-34 ft.lbs. (41-47 Nm) 20-24 ft.lbs. (28-33 Nm) 26-30 ft.lbs. (36-42 Nm) 90 ft.lbs. (124 Nm)

Fuel Pump Manuf. . . . . . Fuel Pump Mark . . . . . . . Oil Pump Manuf. . . . . . . . Oil Pump Mark . . . . . . . . Cylinder Head Mark . . . .

Walbro FPA-4 Mikuni 03A 3021022


GENERAL INFORMATION MODEL: . . . . . . . . . . 700 SKS MODEL NUMBER: . S03NS7CS ENGINE MODEL: . . S2316--7070--PA7C

ELECTRICAL Flywheel I.D. . . . . . . CDI Marking . . . . . . . Alternator Output . . . Ignition Timing . . . . .

Spark Plug / Gap . . . Voltage Regulator . . Electric Start . . . . . . . Magneto Pulses . . . .

CAPACITIES 4010677 Fuel Tank . . . . . . . . . . 4010717 Oil Tank . . . . . . . . . . . . 280 Watts Coolant . . . . . . . . . . . . 20q @2000RPMr500 Chaincase Oil . . . . . . . 0.1003s BTDC 2.5485mm BTDC Champion RN57YCC / 0.025s (0.64mm) T1 Option 6

SUSPENSION / CHASSIS

11.8 gallons (44.7 liters) 3.25 quarts (3.08 liters) 4.9 quarts(4.6L) 11 fl. oz.(325cc)

CHAINCASE

Body Style . . . . . . . . Front Suspension . . Front Shocks . . . . . . IFS Spring Rate . . . . Front Spring Preload Front Vertical Travel Rear Suspension . . . Rear Axle Travel . . . Front Track Shock . . Spring Rate . . . . . . . . Rear Track Shock . . Rear Springs . . . . . . Track Type . . . . . . . . Track Tension . . . . . .

EDGE Sprockets / Chain . . . 23-39-70P HYVO EDGE RMK Reverse . . . . . . . . . . . . Option Alum IFP Brake Pads . . . . . . . . . Type 81, Large 100#/in. Chaincase Center Dist.7.92s (20.12cm.) 4.59s(11.66cm.)Thread Adjust Driveshaft Sprockets . 2 Drivers Wide 7.2s - 7.6s (18.3 - 19.3cm.) Brake Type . . . . . . . . . Polaris HPB, Liquid Cooled EDGE RMK 17 s(43 cm.) Arvin IFP 170#/in. Arvin IFP C/A .359s (sq.) / 77q 15sx144sx1.25s (38.1x365.76x3.175cm.) 3/8s - 1/2s (1-1.3 cm.) slack with 10# (4.54kg) weight 16s (40.64cm.) ahead of rear idler shaft. Overall Snowmobile Length . . . . . . . . . . . . . . . . . 120s (305cm.) Overall Snowmobile Height . . . . . . . . . . . . . . . . . 48s (122cm.) Maximum Snowmobile Width . . . . . . . . . . . . . . . 47s (119cm.)

OPTIONAL REAR TORSION SPRINGS (700 SKS) SOFT

MEDIUM(STD)

FIRM

.347”(Sq.) Diameter x 77_

.359s(Sq.) Diameter x 77_

.405”(Sq.) Diameter x 77_

L.H. 7041627--067

L.H. 7041629--067

L.H. 7041655--067

R.H. 7041628--067

R.H. 7041630--067

R.H. 7041656--067

1.19


GENERAL INFORMATION MODEL: . . . . . . . . . . 700 EDGE RMK 144”, 151” MODEL NUMBER: . S03NK7CSA ENGINE MODEL: . . S2313--7070--PA7C JETTING CHART AMBIENT TEMPERATURE

Throttle Gap Under Cutaway . . . . . . Starter Jet . . . . . . . . . . . Pilot Air Jet . . . . . . . . . . Fuel Screw . . . . . . . . . . Exhaust Valve Spring

-30_ to --10_F -34 to -23 C -34_to -23_C

--10_to +10_F -23 -12 C -23_ to --12_C

+10_to +30_F -12 to --1 C -12_to -1_C

+30_to +50_F -1 to +10_C +10 C -1_to

Above +50_F C Above +10 +10_C

0--600 (0--2000)

500 #4

490 #4

470 #3

450 #3

430 #3

410 #3

600--1200 (2000--4000)

470 #4

450 #3

430 #3

410 #3

390 #3

380 #2

1200--1800 1200 1800 ((4000000 -6000) 6000)

440 #3

420 #3

400 #3

380 #3

370 #2

350 #2

1800--2400 (6000--8000) (6000 8000)

400 00 #3 3

380 #3 3

360 #3 3

3 0 340 #2 2

330 #2 2

3 0 310 #2 2

2400--3000 (8000--10000) (8000 10000)

360 #3 3

3 0 340 #3 3

3 0 320 #2 2

300 #2 2

290 90 #2 2

270 0 #2 2

3000--3700 (10000--12000) (10000 12000)

3 0 320 #3 3

300 #2 2

290 90 #2 2

270 0 #2 2

250 50 #2 2

230 30 #2 2

Altitude ltitude

CARBURETION Type . . . . . . . . . . . . . . . . Main Jet . . . . . . . . . . . . Pilot Jet . . . . . . . . . . . . . Jet Needle . . . . . . . . . . . Needle Jet . . . . . . . . . . . Cutaway . . . . . . . . . . . . Air Screw . . . . . . . . . . . Valve Seat . . . . . . . . . . . Fuel Octane (R+M/2) .

Below -30qF Below -34qC 34 C

TM 40 w/TPS Mikuni 340 45 9DGN5--57--2 P-8 (825) Meters ((Feet)) 2.0 1.0 Turns 1.8 Key Switch Adjustable . . Premium 91 Regular 87 Non-Oxy 0.984s (2.5mm) 145 N/A 1.75 Turns out Orange

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

CLUTCH CHART DRIVE

CLUTCH Type . . . . . . . . . . . . . . . . Belt . . . . . . . . . . . . . . . . . Belt Width (Projected) . Side Angle (Overall) . . Outside Circumference Center Distance . . . . . . Shift Weights . . . . . . . . Primary Spring . . . . . . . Secondary Spring . . . . Driven Helix . . . . . . . . .

Shift Weight

Clutch Spring

Clutch Spring

Driven Helix

Chaincase Ge ring Gearing (144”,151”)

0-900 (0-3000)

10--62 Bushed

Black / Green

Silver / Blue

R-8 #3

19 39 72P 19-39 HYVO

900-1500 (3000-5000)

10--60 Bushed

Black / Green

Silver / Blue

R-8 #3

19 39 72P 19-39 HYVO

1500-2100 (5000-7000)

10-58 Bushed

Black / Green

Silver / Blue

R-8 #3

19 39 72P 19-39 HYVO

2100-2700 (7000-9000)

10-56 Bushed

Black / Green

Silver / Blue

R-8 #3

19 39 72P 19-39 HYVO

2700--3350 (9000--11000)

10--54 Bushed

Black / Green

Silver / Blue

R-8 #3

19-39 72P HYVO

3350--4000 (11000--13000)

10--AL Bushed

Black / Green

Silver / Blue

R-8 #3

19-39 72P HYVO

Altitude ltitude

P-85 3211080 1.438s (36.53mm) 28q 46.625s 11.5s 10-56 Bushed Black/Green Silver / Blue R-8 #3

Meters ((Feet))

DRIVEN

- Production Setting

ENGINE Type . . . . . . . . . . . . . . . . . . . . . . . Displacement . . . . . . . . . . . . . . . Bore . . . . . . . . . . . . . . . . . . . . . . . Stroke . . . . . . . . . . . . . . . . . . . . . Piston / Cylinder Clearance . . . Service Limit . . . . . . . . . . . . . . . . Piston Marking . . . . . . . . . . . . . . Piston Ring Marking . . . . . . . . . Piston Ring End Gap . . . . . . . . Head ccs (Uninstalled) . . . . . . . Head ccs (Installed) . . . . . . . . . Operating RPMr200 . . . . . . . . . Idle RPMr200 . . . . . . . . . . . . . . Engagement RPMr300 . . . . . . Cylinder Head Torque . . . . . . . . Cylinder Base Nut Torque . . . . Crankcase Torque (8mm) . . . . .

1.20

Liquid Cooled Case Reed w/TPS 701cc 3.1889s (81mm) 2.6772s (68mm) 0.0043s - 0.0057s (0.11 -- 0.14mm) .0058” 3021307 N/A 0.014s - 0.020s (0.36 - 0.51mm) N/A N/A 8100 RPM 1500 RPM N/A 18-22 ft.lbs. (25-30 Nm) 30-34 ft.lbs. (41-47 Nm) 20-24 ft.lbs. (28-33 Nm)

Fuel Pump Manuf. . . . . . Fuel Pump Mark . . . . . . . Oil Pump Manuf. . . . . . . . Oil Pump Mark . . . . . . . . Cylinder Head Mark . . . .

N/A N/A Mikuni 2540102 N/A

Flywheel Torque90 ft.lbs. (124 Nm)


GENERAL INFORMATION MODEL: . . . . . . . . . . 700 EDGE RMK 144”, 151” MODEL NUMBER: . S03NK7CSA ENGINE MODEL: . . S2313--7070--PA7C

ELECTRICAL Flywheel I.D. . . . . . . CDI Marking . . . . . . . Alternator Output . . . Ignition Timing . . . . .

Spark Plug / Gap . . . Voltage Regulator . . Electric Start . . . . . . . Magneto Pulses . . . .

CAPACITIES 4010677 Fuel Tank . . . . . . . . . . 4010718 Oil Tank . . . . . . . . . . . . 280 Watts Coolant . . . . . . . . . . . . 18q BTDC@3250RPMr500 Chaincase Oil . . . . . . . With TPS Unplugged. 0.0815s BTDC 2.0705mm BTDC Champion RN57YCC / 0.025s (0.64mm) T1 Option 6

SUSPENSION / CHASSIS

11.8 gallons (44.7 liters) 3.25 quarts (3.1 liters) 4.9 quarts (4.6L) 11 fl. oz.(325cc)

CHAINCASE

Body Style . . . . . . . . EDGE Sprockets / Chain . . . 21--41 74P HYVO(136) Front Suspension . . EDGE RMK 19--39 72P HYVO (144, 151) Front Shocks . . . . . . Nitrex or Ryde FX IFP Reverse . . . . . . . . . . . . Option IFS Spring Rate . . . . 100#/in Brake Pads . . . . . . . . . Type 81, Large Front Spring Preload Nitrex 3/8s / Ryde FX IFP 4.25” Chaincase Center Dist.7.92s (20.12cm.) Front Vertical Travel 7.2s - 7.6s (18.3 - 19.3cm.) Driveshaft Sprockets . 2 Drivers Wide, XHS Rear Suspension . . . EDGE RMK 136”, 144s or 151” Brake Type . . . . . . . . . Polaris HPB Liquid Cooled Rear Axle Travel . . . 17”(43cm.) 144”--17.5” (45cm.) 151” Front Track Shock . . Nitrex or Ryde FX IFP Spring Rate . . . . . . . . 170#/in. Rear Track Shock . . Indy Select or Ryde FX R/R Rear Springs . . . . . . .359”sq./47q Track Type . . . . . . . . 15sx144s/151sx2.00s (38.1x366/384x5cm.) Track Tension . . . . . . 3/8s - 1/2s (1-1.3 cm.) slack with 10# (4.54kg) weight 16s (40.64cm.) ahead of rear idler ....... shaft. Overall Snowmobile Length . . . . . . . . . . . . . . . . . 144s=120s(305cm.) / 151s=129s(328cm.) Overall Snowmobile Height . . . . . . . . . . . . . . . . . 45s (114cm.) Maximum Snowmobile Width . . . . . . . . . . . . . . . 45.5s (116cm.)

OPTIONAL REAR TORSION SPRINGS SOFT

(STD)

FIRM

.347s(Sq.) Diameter x 47q .359s(Sq.) Diameter x 47q .375s(Sq.) Diameter x 47q (144”/151”) 7042081--067 (144”/151”) 7042068--067 (144”/151”) 7042079--067 (144”/151”) 7042082--067 (144”/151”) 7042069--067 (144”/151”) 7042080--067

1.21


GENERAL INFORMATION MODEL: . . . . . . . . . . 800 SKS MODEL NUMBER: . S03NS8CS ENGINE MODEL: . . S2315--8070--PA8C JETTING CHART AMBIENT TEMPERATURE

CARBURETION Type . . . . . . . . . . . . . . . . Main Jet . . . . . . . . . . . . Pilot Jet . . . . . . . . . . . . . Jet Needle . . . . . . . . . . . Needle Jet . . . . . . . . . . . Cutaway . . . . . . . . . . . . Fuel Screw . . . . . . . . . . Valve Seat . . . . . . . . . . . Fuel Octane (R+M/2) . Throttle Gap Under Cutaway . . . . . . Starter Jet . . . . . . . . . . . Pilot Air Jet . . . . . . . . . . Air Screw Exhaust Valve Spring

Altitude ltitude

TM 40 Mikuni 480 PTO/470 MAG 40 J8--9DGN5--57/3 P-8 1.5 2.5 Turns Out 1.8 Key Switch Adj. Premium 91 Regular 87 Non-Oxy 0.0787s (2.0mm) 135 N/A 1.5 Turns Out Pink/Yellow

-30_ to --10_F -34_to -23_C

--10_to +10_F -23_ to --12_C

+10_to +30_F -12_to --1_C

0--600 (0--2000)

520N/510N #4

500/490 #3

480/470 #3

460/450 #3

440/430 #3

420/410 #3

600--1200 (2000--4000)

490/480 #3

470/460 #3

450/440 #3

430/420 #3

410/400 #2

400/390 #2

1200--1800 1200 1800 (4000--6000) (4000 6000)

460/450 #3

440/430 #3

420/410 #3

400/390 #2

390/380 #2

370/360 #2

1800--2400 (6000--8000) (6000 8000)

430/420 #3

410/400 #3

400/390 #2

380/370 #2

360/350 #2

340/330 #2

2400--3000 (8000--10000) (8000 10000)

400/390 #3

390/380 #2

370/360 #2

350/340 #2

330/320 #2

310/300 #2

3000--3700 (10000--12000) (10000 12000)

380/370 #3

260/350 #2

340/330 #2

320/310 #2

300/290 #2

280/270 #2

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

CLUTCH CHART Altitude ltitude

P-85 3211080 1.438s (36.52mm) 28q 46.625s 11.50s 10-64 Black/Green Blue R-11 #2

DRIVEN

Shift Weight

Clutch Spring

Clutch Spring

Driven Helix

Chaincase Gearing

0-900 (0-3000)

10 64 10-64

Bl ck/ ree Black/Green

Blue

R-11 #2

23--39 74P HYVO

900-1800 (3000-6000)

10 62 10-62

Bl ck/ ree Black/Green

Blue

R-11 #2

23--39 74P HYVO

1800-2700 (6000-9000)

10 60 10-60

Bl ck/ ree Black/Green

Blue

R-11 #3

21--40 74P HYVO

2700-3700 (9000-12000)

10 58 10-58

Bl ck/ ree Black/Green

Blue

R-11 #3

21--40 74P HYVO

Meters (Feet)

- Production Setting

ENGINE Type . . . . . . . . . . . . . . . . . . . . . . . Displacement . . . . . . . . . . . . . . . Bore . . . . . . . . . . . . . . . . . . . . . . . Stroke . . . . . . . . . . . . . . . . . . . . . Piston / Cylinder Clearance . . . Service Limit . . . . . . . . . . . . . . . . Piston Marking . . . . . . . . . . . . . . Piston Ring Marking . . . . . . . . . Piston Ring End Gap . . . . . . . . Head ccs (Uninstalled) . . . . . . . Head ccs (Installed) . . . . . . . . . Operating RPMr200 . . . . . . . . . Idle RPMr200 . . . . . . . . . . . . . . Engagement RPMr200 . . . . . . Cylinder Head Torque . . . . . . . . Cylinder Base Nut Torque . . . . Crankcase Torque (10mm) . . . Flywheel Torque . . . . . . . . . . . . .

1.22

Above +50_F Above +10_C

XXX

DRIVE

CLUTCH Type . . . . . . . . . . . . . . . . Belt . . . . . . . . . . . . . . . . . Belt Width (Projected) . Side Angle (Overall) . . Outside Circumference Center Distance . . . . . . Shift Weights . . . . . . . . Primary Spring . . . . . . . Secondary Spring Driven Helix . . . . . . . . .

Meters (Feet)

+30 to +50_F +30_to +50 F -1_to 1_t +10_C 10_C

Below -30qF Below -34qC

Liquid Cooled Case Reed Twin 794cc 3.3464s (85mm) 2.7559s (70mm) 0.006s - 0.0074s (0.15 - 0.188mm) 0.0074� (0.188mm) 3021315 N/A 0.016s - 0.022s (0.41 - 0.56mm) 45.7r0.5cc 32.2r0.5cc 7900 RPM 1300 RPM 3800 RPM 18-22 ft.lbs. (25-30 Nm) 30-34 ft.lbs. (41-47 Nm) 26-30 ft.lbs. (36-41 Nm) 90 ft.lbs. (124 Nm)

Fuel Pump Manuf. . . . . . Fuel Pump Mark . . . . . . . Oil Pump Manuf. . . . . . . . Oil Pump Mark . . . . . . . . Cylinder Head Mark . . . .

Walbro N/A Mikuni 2540053 3021294


GENERAL INFORMATION MODEL: . . . . . . . . . . 800 SKS MODEL NUMBER: . S03NS8CS ENGINE MODEL: . . S2315--8070--PA8C

ELECTRICAL Flywheel I.D. . . . . . . CDI Marking . . . . . . . Alternator Output . . . Ignition Timing . . . . .

Spark Plug / Gap . . . Voltage Regulator . . Electric Start . . . . . . . Magneto Pulses . . . .

CAPACITIES 4010677 Fuel Tank . . . . . . . . . . 4010719 Oil Tank . . . . . . . . . . . . 280 Watts Coolant . . . . . . . . . . . . 28q BTDC@2000RPM Chaincase Oil . . . . . . . with TPS unplugged 0.2005in. 5.0913mm Champion RN57YCC / 0.025s (0.64mm) T1 Option 6

SUSPENSION / CHASSIS

11.8 gallons (44.7 liters) 4 quarts (3.8 liters) 4.9 quarts (4.6L) 11 fl. oz.(325cc)

CHAINCASE

Body Style . . . . . . . . Front Suspension . . Front Shocks . . . . . . IFS Spring Rate . . . . Front Spring Preload Front Vertical Travel Rear Suspension . . . Rear Axle Travel . . . Front Track Shock . . Spring Rate . . . . . . . . Rear Track Shock . . Rear Springs . . . . . . Track Type . . . . . . . . Track Tension . . . . . .

EDGE Sprockets / Chain . . . 23--39-74P HYVO EDGE SKS, CRC Reverse . . . . . . . . . . . . Option Ryde FX IFP Brake Pads . . . . . . . . . Type 81, Large 100#/in. Chaincase Center Dist.7.92s (20.12cm.) 4.59s Thread Adjust Driveshaft Sprockets . 4 Drivers Wide 7.2s - 7.6s (18.3 - 19.3cm.) Brake Type . . . . . . . . . Polaris HPB, Liquid Cooled EDGE SKS 17s (43cm.) Ryde FX IFP 170#/in. Rappid Adjust Ryde FX .359s (sq.) / 47q 15sx144sx1.25s (38.1x365.76x3.175cm.) 3/8s - 1/2s (1-1.3 cm.) slack with 10# (4.54kg) weight 16s (40.64cm.) ahead of rear idler shaft. Overall Snowmobile Length . . . . . . . . . . . . . . . . . 120s (305cm.) Overall Snowmobile Height . . . . . . . . . . . . . . . . . 48s (122cm.) Maximum Snowmobile Width . . . . . . . . . . . . . . . 47s (119cm.)

OPTIONAL REAR TORSION SPRINGS SOFT

MEDIUM(STD)

FIRM

.347s(Sq.) Diameter x 47q .359s(Sq.) Diameter x 47q .375s(Sq.) Diameter x 47q 7042081--067

7042068--067

7042079--067

7042082--067

7042069--067

7042080--067

1.23


GENERAL INFORMATION MODEL: . . . . . . . . . . 800 EDGE RMK 144”, 151”, 159” MODEL NUMBER: . S03NK8CSA, S03NL8CSA, S03NK8CS, S03NL8CS, S03NM8CS ENGINE MODEL: . . S2314--8070--PA8C JETTING CHART AMBIENT TEMPERATURE

Throttle Gap Under Cutaway . . . . . . Starter Jet . . . . . . . . . . . Pilot Air Jet . . . . . . . . . . Exhaust Valve Spring .

TM 40 w/ TPS 350 45 9DGN6--57 / 2 P-8 (825) 2.0 1.5 Turn .0 75Turn 1.8 Key Switch Adj. Premium 91 Regular 87 Non-Oxy 0.102s (2.6mm) 145 N/A Pink

CLUTCH Type . . . . . . . . . . . . . . . . Belt . . . . . . . . . . . . . . . . . Belt Width (Projected) . Side Angle (Overall) . . Outside Circumference Center Distance . . . . . . Shift Weights . . . . . . . . Primary Spring . . . . . . . Secondary Spring . . . . Driven Helix . . . . . . . . .

-30_ to --10_F -34 to -23 C -34_to -23_C

--10_to +10_F -23 -12 C -23_ to --12_C

+10_to +30_F -12 to --1 C -12_to -1_C

+30_to +50_F -1 to +10_C +10 C -1_to

Above +50_F C Above +10 +10_C

0--600 (0--2000)

510N #5

490 #4

470 #4

450 #4

430 #3

410 #3

600--1200 (2000--4000)

480 #4

470 #4

450 #4

430 #3

410 #3

390 #2

1200--1800 1200 1800 ((4000000 -6000) 6000)

450 #4

430 #4

410 #3

390 #3

370 #2

350 #2

1800--2400 (6000--8000) (6000 8000)

410 #4

390 #3 3

370 #3 3

350 #2 2

330 #2 2

310 #2 2

2400--3000 (8000--10000) (8000 10000)

3 0 370 #3 3

350 #3 3

330 #2 2

3 0 310 #2 2

290 90 #2 2

270 0 #2 2

3000--3700 (10000--12000) (10000 12000)

3 0 340 #3 3

3 0 320 #2 2

300 #2 2

280 80 #2 2

260 60 #2 2

240 0 #1 1

Altitude ltitude

CARBURETION Type . . . . . . . . . . . . . . . . Main Jet . . . . . . . . . . . . Pilot Jet . . . . . . . . . . . . . Jet Needle . . . . . . . . . . . Needle Jet . . . . . . . . . . . Cutaway . . . . . . . . . . . . Fuel Screw . . . . . . . . . . Air Screw . . . . . . . . . . . Valve Seat . . . . . . . . . . . Fuel Octane (R+M/2) .

Below -30qF Below -34qC 34 C

Meters ((Feet))

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

CLUTCH CHART DRIVE

Altitude

Clutch Spring

Clutch Spring

Driven Helix

Chaincase Gearing e ri g (144, 151)

Chaincase Gearing e ri g (159)

0-600 (0-2000)

10 64 10-64

Black Green

Silver / Blue

R-8 #2

21--41 74P HYVO

19--39 72P HYVO

600-1200 (2000-4000)

10 64 10-64

Black Green

Silver / Blue

R--8 #3

21--41 74P HYVO

19--39 72P HYVO

1200-1800 (4000-6000)

10 62 10-62

Black Green

Silver / Blue

R-8 #3

21--41 74P HYVO

19--39 72P HYVO

1800-2400 (6000-8000)

10 60 10-60

Black Green

Silver / Blue

R-8 #3

Black Green Black Green

Silver / Blue Silver / Blue

R-8 #3 R-8 #3

21--41 74P HYVO 21--41 74P HYVO 21--41 74P HYVO

19--39 72P HYVO 19--39 72P HYVO 19--39 72P HYVO

Altitude

P-85 3211080 1.438s 28q 46.625s 11.50s 10-60 Bushed Black/Green Silver / Blue R-8 #3

Meters ((Feet))

DRIVEN

Shift Weight

2400-3000 (8000-10000)

10-58

3000-3600 (10000-12000)

10-56

- Production Setting

ENGINE Type . . . . . . . . . . . . . . . . . . . . . . . Displacement . . . . . . . . . . . . . . . Bore . . . . . . . . . . . . . . . . . . . . . . . Stroke . . . . . . . . . . . . . . . . . . . . . Piston / Cylinder Clearance . . . Service Limit . . . . . . . . . . . . . . . . Piston Marking . . . . . . . . . . . . . . Piston Ring Marking . . . . . . . . . Piston Ring End Gap . . . . . . . . Head ccs (Uninstalled) . . . . . . . Head ccs (Installed) . . . . . . . . . Operating RPMr200 . . . . . . . . . Idle RPMr200 . . . . . . . . . . . . . . Engagement RPMr300 . . . . . . Cylinder Head Torque . . . . . . . . Cylinder Base Nut Torque . . . . Crankcase Torque (8mm) . . . . . Crankcase Torque (10mm) . . . Flywheel Torque . . . . . . . . . . . . .

1.24

Liquid Cooled Case Reed w/TPS 794cc 3.3464s (85mm) 2.7559s (70mm) 0.006s - 0.0074s (0.15 - 0.188mm) N/A 3021184 N/A 0.016s - 0.022s (0.41 - 0.56mm) 46 - 47cc 33 - 33cc 8000RPM 1500 RPM 4000 RPM 18-22 ft.lbs. (25-30 Nm) 30-34 ft.lbs. (41-47 Nm) 29-24 ft.lbs. (28-33 Nm) 26-30 ft.lbs. (36-41 Nm) 90 ft.lbs. (124 nm)

Fuel Pump Manuf. . . . . . Fuel Pump Mark . . . . . . . Oil Pump Manuf. . . . . . . . Oil Pump Mark . . . . . . . . Cylinder Head Mark . . . .

Walbro N/A Mikuni 2540053 3021294


GENERAL INFORMATION MODEL: . . . . . . . . . . 800 EDGE RMK 144”, 151”, 159” MODEL NUMBER: . S03NK8CSA, S03NL8CSA, S03NK8CS, S03NL8CS, S03NM8CS ENGINE MODEL: . . S2314--8070--PA8C

ELECTRICAL Flywheel I.D. . . . . . . CDI Marking . . . . . . . Alternator Output . . . Ignition Timing . . . . .

Spark Plug / Gap . . . Voltage Regulator . . Electric Start . . . . . . . Magneto Pulses . . . .

CAPACITIES 4010677 Fuel Tank . . . . . . . . . . 4010720 Oil Tank . . . . . . . . . . . . 280 Watts Coolant . . . . . . . . . . . . 29q BTDC@3250RPMr500 Chaincase Oil . . . . . . . with TPS unplugged 0.2146s BTDC 5.4510mm BTDC Champion RN57YCC / 0.025s (0.64mm) T1 Option 6

SUSPENSION / CHASSIS

11.8 gallons (44.7 liters) 3.25 quarts (3.1 liters) 4.9(4.63L) 11 fl. oz.(325mL)

CHAINCASE

Body Style . . . . . . . . Front Suspension . . IFS Shocks . . . . . . . . IFS Spring Rate . . . . Front Spring Preload

EDGE RMK Sprockets / Chain . . . . 21--41 74P EDGE RMK Reverse . . . . . . . . . . . . Option Nitrex or Ryde FX IFP Brake Pads . . . . . . . . . . Type 81, Large 100#/in. Chaincase Center Dist. 7.92s (20.12cm.) Nitrex 3/8s (1cm) Driveshaft Sprockets . 2 Drivers Wide Ryde FX IFP 4 1/4”(10.8cm) Brake Type . . . . . . . . . . HPB Liquid Cooled Front Vertical Travel 7.2s - 7.6s (18.3 - 19.3cm.) Rear Suspension . . . EDGE RMK Rear Axle Travel . . . 144” -- 17”(43cm.) 151” -- 17.5”(44.5cm.) Front Track Shock . . Nitrex Spring Rate . . . . . . . . 170#/in. All Models. Rear Track Shock . . Select Rear Springs . . . . . . .359s (sq.) / 47q Track Type . . . . . . . . 15sx144sx2.0s (38.1x365.76x5.08cm.) 15sx151sx2.0s (38.1x383.40x5.08cm.) Track Tension . . . . . . 3/8s - 1/2s (1-1.3 cm.) slack with 10# (4.54kg) weight 16s (40.64cm.) ahead of rear idler shaft. Overall Snowmobile Length . . . . . . . . . . . . . . . . . 144s Track 119.75s (304.2cm.) 151s / 159” Track=129s (328cm.) Overall Snowmobile Height . . . . . . . . . . . . . . . . . 48s (122cm.) Maximum Snowmobile Width . . . . . . . . . . . . . . . 47.25s (120cm.)

OPTIONAL REAR TORSION SPRINGS SOFT

MEDIUM(STD)

FIRM

.347s(Sq.) Diameter x 47q .359s(Sq.) Diameter x 47q .375s(Sq.) Diameter x 47q 7042081--067

7042068--067

7042079--067

7042082--067

7042069--067

7042080--067

1.25


GENERAL INFORMATION MODEL: . . . . . . . . . . 800 VERTICAL ESCAPE RMK 159� MODEL NUMBER: . S03NN8CS ENGINE MODEL: . . S2314--8070--PA8C JETTING CHART

CARBURETION Type . . . . . . . . . . . . . . . . Main Jet . . . . . . . . . . . . Pilot Jet . . . . . . . . . . . . . Jet Needle . . . . . . . . . . . Needle Jet . . . . . . . . . . . Cutaway . . . . . . . . . . . . Fuel Screw . . . . . . . . . . Air Screw . . . . . . . . . . . Valve Seat . . . . . . . . . . . Fuel Octane (R+M/2) . Throttle Gap Under Cutaway . . . . . . Starter Jet . . . . . . . . . . . Pilot Air Jet . . . . . . . . . . Exhaust Valve Spring .

AMBIENT TEMPERATURE

TM 40 w/ TPS 350 45 9DGN6--57 / 2 P-8 2.0 1.5 Turn .75Turn 1.8 Key Switch Adj. Premium 91 Regular 87 Non-Oxy

Below -30qF Below -34qC 34 C

-30_ to --10_F -34 to -23 C -34_to -23_C

--10_to +10_F -23 -12 C -23_ to --12_C

+10_to +30_F -12 to --1 C -12_to -1_C

+30_to +50_F -1 to +10_C +10 C -1_to

Above +50_F C Above +10 +10_C

0--600 (0--2000)

510N #5

490 #4

470 #4

450 #4

430 #3

410 #3

600--1200 (2000--4000)

480 #4

470 #4

450 #4

430 #3

410 #3

390 #2

1200--1800 1200 1800 ((4000000 -6000) 6000)

450 #4

430 #4

410 #3

390 #3

370 #2

350 #2

1800--2400 (6000--8000) (6000 8000)

410 0 #4

390 #3 3

3 0 370 #3 3

350 #2 2

330 #2 2

3 0 310 #2 2

2400--3000 (8000--10000) (8000 10000)

3 0 370 #3 3

350 #3 3

330 #2 2

3 0 310 #2 2

290 90 #2 2

270 0 #2 2

3000--3700 (10000--12000) (10000 12000)

3 0 340 #3 3

3 0 320 #2 2

300 #2 2

280 80 #2 2

260 60 #2 2

240 0 #1 1

Altitude ltitude

Meters ((Feet))

0.102s (2.6mm) 145 N/A Pink

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

CLUTCH CHART DRIVE

CLUTCH Type . . . . . . . . . . . . . . . . Belt . . . . . . . . . . . . . . . . . Belt Width (Projected) . Side Angle (Overall) . . Outside Circumference Center Distance . . . . . . Shift Weights . . . . . . . . Primary Spring . . . . . . . Secondary Spring . . . . Driven Helix . . . . . . . . .

P-85 3211080 1.438s 28q 46.625s 11.50s 10--64 Black/Green Black/Red 58/44--.46

Meters ((Feet))

DRIVEN

DRIVEN

Shift Weight

Clutch Spring

Clutch Spring

Driven Helix

Chaincase Gearing e ri g (159)

0-600 (0-2000)

10 64 10-64

Black/ Green

Bl ck / Red Black

(58/44 -.46 (58/4446 Rev)

19--39 72P HYVO

19--39 72P HYVO

600-1200 (2000-4000)

10 64 10-64

Black/ Green

Bl ck / Red Black

(58/44 -.46 (58/4446 Rev)

19--39 72P HYVO

19--39 72P HYVO

1200-1800 (4000-6000)

10 62 10-62

Black/ Green

Bl ck / Red Black

(58/44 -.46 (58/4446 Rev)

19--39 72P HYVO

19--39 72P HYVO

1800-2400 (6000-8000)

10 60 10-60

Black/ Green

Bl ck / Red Black

(58/44 -.46 (58/4446 Rev)

2400-3000 (6000-10000)

10-58

Black / Red

(58/44--.46 Rev)

3000-3600 (10000-12000)

10-56

Black / Red

(58/44--.46 Rev)

19--39 72P HYVO 19--39 72P HYVO 19--39 72P HYVO

19--39 72P HYVO 19--39 72P HYVO 19--39 72P HYVO

Altitude ltitude

Black/ Green Black/ Green - Production Setting

ENGINE Type . . . . . . . . . . . . . . . . . . . . . . . Displacement . . . . . . . . . . . . . . . Bore . . . . . . . . . . . . . . . . . . . . . . . Stroke . . . . . . . . . . . . . . . . . . . . . Piston / Cylinder Clearance . . . Service Limit . . . . . . . . . . . . . . . . Piston Marking . . . . . . . . . . . . . . Piston Ring Marking . . . . . . . . . Piston Ring End Gap . . . . . . . . Head ccs (Uninstalled) . . . . . . . Head ccs (Installed) . . . . . . . . . Operating RPMr200 . . . . . . . . . Idle RPMr200 . . . . . . . . . . . . . . Engagement RPMr300 . . . . . . Flywheel Torque . . . . . . . . . . . . .

1.26

Liquid Cooled Case Reed w/TPS 794cc 3.3464s (85mm) 2.7559s (70mm) 0.006s - 0.0074s (0.15 - 0.188mm) N/A 3021184 N/A 0.016s - 0.022s (0.41 - 0.56mm) 46 - 47cc 33 - 33cc 8000RPM 1500 RPM 4000 RPM 90 ft.lbs. (124 nm)

Fuel Pump Manuf. . . . . . Fuel Pump Mark . . . . . . . Oil Pump Manuf. . . . . . . . Oil Pump Mark . . . . . . . . Cylinder Head Mark . . . .

Walbro N/A Mikuni 2540053 3021294

Chaincase Gearing e ri g (159VE)


GENERAL INFORMATION MODEL: . . . . . . . . . . 800 VERTICAL ESCAPE RMK 159” MODEL NUMBER: . S03NM8CS ENGINE MODEL: . . S2314--8070--PA8C

ELECTRICAL Flywheel I.D. . . . . . . CDI Marking . . . . . . . Alternator Output . . . Ignition Timing . . . . .

Spark Plug / Gap . . . Voltage Regulator . . Electric Start . . . . . . . Magneto Pulses . . . .

CAPACITIES 4010677 Fuel Tank . . . . . . . . . . 4010720 Oil Tank . . . . . . . . . . . . 280 Watts Coolant . . . . . . . . . . . . 29q BTDC@3250RPMr500 Chaincase Oil . . . . . . . with TPS unplugged 0.2146s BTDC 5.4510mm BTDC Champion RN57YCC / 0.025s (0.64mm) T1 Option 6

SUSPENSION / CHASSIS

11.8 gallons (44.7 liters) 3.25 quarts (3.1 liters) 4.9 Qts (4.6L) 11 fl. oz.(325mL)

CHAINCASE

Body Style . . . . . . . . Front Suspension . . IFS Shocks . . . . . . . . IFS Spring Rate . . . . Front Spring Preload Front Vertical Travel Rear Suspension . . . Rear Axle Travel . . . Front Track Shock . . Spring Rate . . . . . . . . Rear Track Shock . . Rear Springs . . . . . . Track Type . . . . . . . . Track Tension . . . . . .

EDGE RMK Sprockets / Chain . . . . 19--39--72P EDGE RMK Reverse . . . . . . . . . . . . Option Ryde FX IFP/Comp Adjustable Brake Pads . . . . . . . . . . Type 81, Large 100#/in. Chaincase Center Dist. 7.92s (20.12cm.) Ryde FX IFP 4 1/4”(10.8cm) Driveshaft Sprockets . 2 Drivers Wide 7.2s - 7.6s (18.3 - 19.3cm.) Brake Type . . . . . . . . . . HPB Liquid Cooled EDGE RMK 18.5” (47cm.) Ryde FX IFP 170#/in. Ryde FX IFP Compression and Rebound Adjustable .359s (sq.) / 47q 15sx159sx2.0s (38.1x 404 x5.08cm.) 3/8s - 1/2s (1-1.3 cm.) slack with 10# (4.54kg) weight 16s (40.64cm.) ahead of rear idler shaft. Overall Snowmobile Length . . . . . . . . . . . . . . . . . 129” (328cm.) Overall Snowmobile Height . . . . . . . . . . . . . . . . . 48s (122cm.) Maximum Snowmobile Width . . . . . . . . . . . . . . . 45.5s (115.5cm.)

OPTIONAL REAR TORSION SPRINGS SOFT

MEDIUM(STD)

FIRM

.347s(Sq.) Diameter x 47q .359s(Sq.) Diameter x 47q .375s(Sq.) Diameter x 47q 7042081--067

7042068--067

7042079--067

7042082--067

7042069--067

7042080--067

1.27


General Maintenance Inspection Sheet . . . . . . . . . . . . . . . . . Recommended Maintenance Products . . . . . . . . . . . . . . . . . . Air Filter Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sediment Trap, Oil / Fuel Filter Maintenance . . . . . . . . . . . . . General Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chaincase Oil / Drive Chain Maintenance . . . . . . . . . . . . . . . Water Pump Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling System Inspection and Maintenance . . . . . . . . . . . . Suspension Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Track Inspection and Maintenance . . . . . . . . . . . . . . Spark Plug Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PVT Drive Belt Inspection and Maintenance . . . . . . . . . . . . . Headlight Inspection and Replacement . . . . . . . . . . . . . . . . . Handlebar Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Systems Inspection and Adjustment . . . . . . . . . . . . . . Throttle Lever Freeplay Adjustment . . . . . . . . . . . . . . . . . . . . . General Cleaning and Lubrication Recommendations . . . . . Exhaust System/VES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 - 2.11 2.12 2.13 2.14 2.15 2.16 2.17 2.18 -- 2.19 2.20 -- 2.22


MAINTENANCE 500 Mile (805 km) Initial Maintenance Inspection

__1.

Re-torque cylinder head(s) (cold) & cylinder base nuts

__2.

Check ignition timing

__17a. Brakes-Hydraulic A. Check brake fluid level. Should be 1/4� from top on large style reservoir, 1/8� from top on older small style

______ observed BTDC

reservoir.

______ corrected BTDC __3.

Check clutch offset (belt removed)

B. Check for proper hose security and routing

__4.

Check belt condition

C. Check for system fluid leaks

__5.

Check and adjust belt tension

D. Visually inspect pads for wear damage or looseness

__6.

Inspect rubber engine mounts

__7.

Torque engine mounting plate to chassis fasteners

__8.

Adjust engine torque stop (if equipped)

__9.

Carburetor Inspections

__10.

E. Check security and surface condition of brake disc. __17b. Brake-Mechanical A. Lubricate brake cable. NOTE: Must use Polaris clutch and cable lube. B. Check brake pad and brake disc condition and mounting

A.

Adjust choke plungers

B.

Adjust pilot air screw

C.

Synchronize carburetor at idle and off idle

__18. Check auxiliary shut-off switch

D.

Adjust engine idle RPM

__19. Perform throttle safety switch tests

E.

Adjust throttle lever free play

__20. Check brake light for proper operation

F.

Synchronize oil pump lever

__21. Check tail lights

G.

Inspect choke/throttle cables

__22. Check Headlamp security and high-low beam operation.

H.

Inspect vent lines for wear or kinking

__23. Liquid cooled models:

C. Adjust brake to proper specifications

Electronic Fuel Injection System Inspections-if applicable

A. Check coolant level and specific gravity

A.

Check and adjust throttle position sensor

B. Check water pump drive belt condition & deflection

B.

Check and adjust MR screw

C.

Check battery state of charge

C. Check coolant hose, routing and clamps

D.

Adjust idle RPM

D. Inspect heat exchangers condition and fasteners

E.

Check charging system

F.

Adjust throttle lever free play

G.

Synchronize oil pump lever

__11.

Check ski toe alignment

__12.

Torque and inspect all steering fasteners

__13.

Torque suspension to tunnel mounting bolts

__14.

Check rear suspension fasteners for tightness

__15.

Adjust track tension and align track

__16.

Remove chaincase cover, flush chaincase, inspect

(where applicable)

E. Check cooling system for proper coolant circulation. __24. V.E.S. (Variable Exhaust System) - if applicable A. Disassemble and clean components __

ACCS A. Inspect vent lines

Recommendations _______________________________________________________

and adjust chain, refill with new chaincase oil. _______________________________________________________

Polaris Service Technician ________________________________

Base Inspection Price ________________

Authorized Dealer ______________________________________

Parts ________________________________

Date ______________________________

Labor _______________________________

2.1


MAINTENANCE Recommended Maintenance Products ENGINE OIL Part #

Description

RETAINING/SEALING PRODUCTS Packaging (size / quantity)

Part #

Description

Packaging (size/quantity)

2871721

Synthetic 2-Cycle Premium Gold

Quarts/ 6

2870652

Fuel Stabilizer

16 oz / 12

2871722

Synthetic 2-Cycle Premium Gold

Gallon / 4

2872280

Fuel Stabilizer

2.5 Gallon / 2

2871723

Synthetic 2-Cycle Premium Gold

16 Gallon Drum

2871329

Nyogelt Grease

2 oz

2871884

Synthetic 2 Cycle Premium Gold

55 Gallon Drum

2871064

T-9 Metal Protectant

each

2871098

Premium 2-Cycle Oil (TC-W3)

Quart Cans / 12

2870632

Metal Polish

10 oz / each

2871097

Premium 2-Cycle Oil (TC-W3)

Gallon / 6

2871076

Battery Tendert

each

2871240

Premium 2-Cycle Oil (TC-W3)

2.5 Gallon / 2

2870585

Primer N, Aerosol

25 gr / 1

2871566

Premium 2-Cycle Oil (TC-W3)

16 Gallon Drum

2870584

680 Retaining Compound

10cc / each

2871385

Premium 2-Cycle Oil (TC-W3)

30 Gallon Drum

2871949

Threadlock 242

50cc / 10

2871096

Premium 2-Cycle Oil (TC-W3)

55 Gallon Drum

2871950

Threadlock 242

6cc / 12

2872927

VES 2 Cycle Synthetic Oil

Quart

2871951

Threadlock 262

50cc / 10

2872925

VES 2 Cycle Synthetic Oil

Gallon

2871952

Threadlock 262

6cc / 12

2872924

VES 2 Cycle Synthetic Oil

55 Gallon Drum

2871953

Threadlock 271

6cc / 12

2872607

Nature Oil (TC-W3)

Gallon

2871954

Threadlock 271

36cc / 6

2872926

Nature Oil (TC-W3)

55 Gallon Drum

2871955

Instant Adhesive: Prism 401

3cc / 30

2871956

Pipe Sealant 565

50cc / 6

2872435

Cross Shaft Break-in Lube

8 oz / 12

2871957

Silicone, Black RTV

3 oz tube / 12

2872436

Cross Shaft Break-in Lube

2.5 Gal / 2

2871958

Silicone, Black RTV

11 oz Cartridge/12

2871326

Carbon Clean Plus

12 oz / 12

2871959

Ultra Blue RTV

3.35 oz / 12

2871280

Premium Chaincase Lubricant

Quart / 12

2871960

Ultra Blue RTV

13 oz Cartridge/12

2870464

Premium Chaincase Lubricant

Gallon / 4

2871961

518 Flange Sealant

50cc / 10

2872281

Premium Chaincase Lubricant

2.5 Gallon / 2

2872951

Synthetic Chaincase Lubricant

12 oz.

2873105

Synthetic Chaincase Lubricant

Quart

2873106

Synthetic Chaincase Lubricant

2872952 2871323

MAINTENANCE PRODUCTS

CRANKCASE SEALANTS 2871557

3 Bond 1215

Gallon

2871967

Synthetic Lube Value Pack

4 / Value pack

Synthetic Chaincase Lubricant

2.5 Gallon

2871593

TC-W3 Lube Value Pack

4 / Value pack

Premium Antifreeze 60/40 Premix

Gallon / 6

2871534

Premium Antifreeze 60/40 Premix

Quart / 12

2871589

2870995

Premium Gas Shock Oil

Quart / 6

2871966

Restore polish/scuff remover

12 / 12 oz.

2872279

Premium Gas Shock Oil

2.5 Gallon / 2

2871965

Reflect Wax Final Finish

12 / 12 oz.

2870990

Premium Brake Fluid DOT-3

12oz / 12

2871964

Renew vinyl rubber protector

12 / 12 oz.

2870791

Premium Fogging Oil (spray)

12/12 oz

2871517

Premium Fogging Oil (liquid with spout)

Quart / 12

2873019

100 Octane

5 Gallon

2871518

Premium Fogging Oil (liquid)

Gallon / 6

2872980

100 Octane

16 Gallon Drum

2871312

Grease Gun Kit (All Season)

3 oz / 4

2872981

100 Octane

55 Gallon Drum

2871322

Premium All Season Grease

24oz / 10

2873019

110 Octane

5 Gallon

2871423

Premium All Season Grease

14 3 oz /

2872982

110 Octane

16 Gallon Drum

2871460

Premium Starter Grease

2 oz / 12

2872983

110 Octane

55 Gallon Drum

2871592

Barrel Pump (for 16/30/55 gal. drums)

Each

2871285

Flex Spout (fits gal. and 2.5 gal. jugs)

25

2870505

Isopropyl

10 oz / 24

2.2

5oz

VALUE PACKS

WAX AND POLISH Revival/Detailing Kit

6 / Kit

RACING FUELS


MAINTENANCE Air Filter Maintenance The intake foam filter limits snow ingestion into the intake system. When operating in loose powder snow, check top of foam filter periodically to remove any accumulation of snow. CAUTION: Do not operate machine with the intake filters removed. This can cause carburetor icing resulting in poor fuel economy or carburetor malfunction. A A

B B

Key Components A

Intake Foam Filter

B

Air Intake Box

A

A

ACCS (Altitude Compensating Carburetor System) The Trail RMK is equipped with Polaris ACCS. The ACCS is designed to compensate automatically for changes in altitude without having to change carburetor jets.

A

ACCS does not require periodic maintenance.

C

NOTE: Tampering or adjustments to the ACCS may cause severe engine damage. A.

Airbox

B.

Vent Line Attachment

C.

ACCS Valve

B

2.3


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

Cleaning Procedure - Plug 1. Turn the fuel tank supply valve off. 2. Position a container or shop towels to catch the contaminated gasoline. 3. Slide the clamp (1) away from the drain plug (2) and remove the drain plug from the sediment tube. 4. Wipe off residue from plug and reinstall with clamps. Continue until all the traps have been emptied.

1

2

When draining the traps, fuel spillage will occur. Be sure to work in a well ventilated area away from anything which may cause the fuel to ignite such as open flames, sparks, heaters, trouble lights, cigarettes, etc. 1

Oil Filter / Fuel Filter Maintenance Most models use an oil filter (2) which is of a special design and must not be substituted. This filter should be changed annually or every 1200 miles (1920 km). Inspect oil line condition at 2000 miles (3200 km).

2

NOTE: The direction of the arrows indicates the direction of the flow through the filters. Edge models utilize a special oil filter (3) that is built into the oil sending unit located in the bottom of the oil tank. It should be replaced every other season. NOTE: After changing the oil filter, the oil injection system must be bled of all trapped air. See your dealer for instructions or have your dealer perform the filter change and bleeding operation for you.

Fuel Filter 1

2

The in tank fuel filter (1) and fuel lines should be inspected regularly. Special attention should be given to the system’s fuel line condition after periods of storage. Normal deterioration from weather and fuel compounds can occur. Do not use pliers or a similar tool to remove fuel lines. Damage could occur. Do not kink the fuel line. Damage could occur. If a fuel has been damaged or kinked, replace it.

2.4

Oil Filters

3


MAINTENANCE Lubrication Points Lubricate the following fittings with Polaris Premium All Season grease annually or approximately every 1000 miles (1600 km). Remove weight from the component being greased to permit better penetration and flushing of the joint. S Spindles, left and right. Polaris Premium All Season Grease 14 oz. PN 2871423

S Rear suspension pivot shafts. S Lubricate both front ski pivots at fitting as shown using Polaris All Season grease. S Grease jackshaft and driveshaft (clutch side) bearings.

Grease Gun Kit PN 2871312

S Use an aerosol lubricant on the steering post support bracket.

Grease Gun (Point Type) Adapter: PN 2871174

S Grease steering post lower pivot. S Grease center steering arm (bell crank), pitman arm, and idler arm (where applicable). NOTE: A grease gun kit complete with grease and adaptors is available to lubricate all fittings on Polaris snowmobiles.

+

+

+ +

+ +

+

+ Aerosol

Jackshaft + +

+

Jackshaft Bearing Greasing Loosen driven clutch retaining bolt and pull clutch outward to expose bearing. Use a point type grease gun fitting to inject grease through hole in flangette into bearing until grease purges out inside or outside bearing seal. Push clutch back onto shaft and replace clutch retaining bolt.

Driveshaft

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

2.5


MAINTENANCE Chaincase Oil Level The drive chain is continuously immersed in oil. Proper oil level is determined by checking the level on the dipstick with machine placed on a level surface. The oil level should be between the “safe� marks on the dipstick. Add oil through dipstick opening to maintain proper level. Use Polaris chaincase oil. Do not overfill. A Polaris Chaincase Lubricant Quart PN 2871280 Gallon PN 2870464 2.5 Gallon PN 2872281

Synthetic Chaincase Lubricant (80W) 12 oz. PN 2872951 Qt. PN 2873105 Gallon PN 2873106 2.5 Gallon PN 2872952

B

CAUTION: Do not mix or use other types of lubricant. Excessive wear to chain, sprockets and bearings may result.

C D

Drive Chain Tension - Chaincase cover installed F

To obtain correct chain tension: 1. Elevate rear of machine so track is off floor.

E Ill. 1

Magnetic Plug

2. Rotate driven clutch counterclockwise to move all chain slack to the tensioner side. Lock the brake lever. 3. Loosen adjuster bolt jam nut. 4. Finger tighten adjuster bolt until it can no longer be adjusted by hand. 5. Back off adjuster bolt 1/4 turn. 6. Tighten jam nut while holding adjuster bolt. 7. The chain is now tensioned. Release brake lever lock.

Drive Chain Tension - Chaincase cover removed To obtain correct chain tension: 1. Remove drain plug (F) and drain oil into a suitable container. Dispose of properly. 2. Remove the chaincase cover. 3. While putting a slight reverse tension on the chain by turning brake disc as indicated by the arrow (A), there should be approximately 1/4-3/8s (.6-1 cm.) deflection on the chain at point (B). Refer to illustration 1. 4. The chain is adjusted by loosening the adjusting bolt locknut (C) and turning adjusting bolt (D) until correct chain deflection is obtained. 5. Lock the adjusting bolt locknut (C) while holding a wrench on the adjusting bolt (D) to prevent it from turning. 6. Reinstall the chaincase cover and drain plug. Add Polaris synthetic chaincase lubricant (PN 2871478) through the dipstick opening to the level described above. NOTE: Clean the magnetic plug (E) every 500 miles (800 km) and whenever checking or changing lubricant.

2.6


MAINTENANCE Water Pump Belt Tension 700 and 800 Domestic big block Twins. The water pump belt on 600 RMK, 700 RMK and 800 RMK domestic big block twin snowmobile engines should be inspected every 1500 miles. Belts should be inspected by measuring the width at several locations around the belt. Belt width at any location should not be thinner than .250s (6.35mm). Replace the belt if you notice any loose cords, broken cracked or missing cogs, and variations in width. If the water pump belt fails, serious engine damage could result. Nominal thickness of a new belt should be approximately .345s (8.75mm).

Replace if width is less than .25s (6.35mm). Nominal new width is .345s (8.75mm).

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

1.

A weight is needed to test belt deflection. Construct a weight out of wire and weights such as thick washers. Use the illustration to assist you . The finished weight should weigh 2 lbs.

Weight Construction

2. Measure the belt deflection using the following procedure: .062s to .090s Wire Suggested

a. Hang weight midway between pulleys. Weight must hang free and not rest on any part of machine. b. Lay a straight edge or straight piece of stiff material (steel is suggested) across the top of both pulleys. The straight edge should measure approximately 1/8s x 8s x 1s. c.

Measure the gap between the belt and the straight edge at the point where the weight is hanging.

d.

Measured distance must be between .1s and .25s. If the measured distance is more than the specification, try another waterpump belt.

Wide Enough to Span Belt

Weight should equal 2 lbs.

Hang Weight Here

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

Oil Pump Adjustment Refer to Chapter 3 for oil pump adjustment procedures.

2.7


MAINTENANCE Cooling System Overview WARNING

Never remove the pressure cap when the engine is warm or hot. If the pressure cap is to be removed, the engine must be cool. Severe personal injury could result from steam or hot liquid. Use of a non-standard pressure cap will not allow the recovery system to function properly. If the cap should need replacement, install the correct Polaris cap with the same pressure rating. Refer to the appropriate parts manual.

Coolant Level Coolant level in the coolant bottle must be maintained between the minimum and maximum levels to prevent overheating and serious engine damage.

Recommended Coolant Use a 60/40 mixture of antifreeze and distilled water depending on the freeze protection required for your area. Do not use tap water in the system or reduced cooling or filter contamination may result. Replace coolant every 2 years or if contaminated.

Bleeding the Cooling System - Pressure Caps If the cooling system should become low in the tank, the system should be bled of any trapped air using the following procedure: 1. Allow the system to cool completely. Loosen the bleed screw and full the reservoir to the indicated Full Cold Mark. Once Full, tighten the bleed screw. 2. Apply parking brake and run the engine at specified idle RPM until the thermostat opens (approximately 5 to 8 minutes). NOTE: It is important that the thermostat stays open! When the thermostat opens it will draw in cold coolant from the heat exchangers and the cold coolant may close the thermostat again. Make sure the thermostat opens and stays open! Once the thermostat is open tip the snowmobile slightly on its right side. Cycle the RPM from idle to enough RPM (4000) to get coolant to flow but not enough RPM to engage the clutch. This allows air to bleed from the rear crossover tube. Then tilt the machine slightly on its left side so that the coolant bottle is the highest point in the cooling system. Cycle the RPM from idle to enough RPM (4000) to get coolant to flow but not enough RPM to engage the clutch. It is important to get enough coolant flow to purge the air from the front close-off cooler and observe this air reaching the bottle. 3. Place the snowmobile in its normal position and loosen the bleed screw at the top of the water outlet manifold until trapped air has been purged. Tighten the bleed screw. Turn off the machine and release parking brake. Allow the system to cool completely. Re-check the coolant level after the cap has been removed and add coolant to fill line if necessary. Our testing has shown that after the machine has cooled down, 3 ounces or more of coolant may have to be added. This procedure should take approximately 15 minutes. NOTE: It is important to get enough coolant flow to purge the air from the crossover hose or rear cooler and observe this air reaching the bottle. WARNING

S S

2.8

When performing the following checks and adjustments, stay clear of all moving parts to avoid serious personal injury. Never remove the pressure cap when the engine is warm or hot. If the pressure cap is to be removed, the engine must be cool. Severe personal injury could result from stream or hot liquid.


MAINTENANCE Suspension Lubrication To maintain rider comfort and to retard wear of the pivot shafts, the suspension pivot shafts should be lubricated with Polaris Premium All Season Grease, PN 2871423, at 500 miles (800 km) initially; 1000 miles (1600 km) and before summer storage each year. The riding characteristics of the snowmobile will be affected by lack of lubrication of these shafts. NOTE: A grease gun kit complete with grease and adaptors is available to lubricate all fittings on Polaris snowmobiles. Order PN 2871312.

Suspension Lubrication

Refer to the following examples for suspension lubrication points.

EDGE RMK Style

L

L

L

L

L

Forward

L

2.9


MAINTENANCE

WARNING

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

Track Maintenance WARNING

Never make this maintenance check with the engine running as serious personal injury can result. Using a hoist, safely lift and support the rear of the snowmobile off the ground. Rotate the track by hand to check for any possible damage. To inspect track rods, carefully examine the track along the entire length of each rod, bending the track and inspecting for breakage. The three most common places where breakage occurs are shown in the illustration. If any rod damage is found, the track should be replaced.

2 1

3

1 2

WARNING

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

Lug

Track window

Track Alignment Track alignment affects track tension. Misalignment will cause excessive wear to the track, hifax, and slide rail. A periodic check should be made to see that the track is centered and running evenly on the slide rails. NOTE: If excessive hi-fax wear occurs due to poor snow conditions, additional wheel kits are available. 1. Safely support the rear of the machine with the track off the ground. 2. Start the engine and apply a small amount of throttle until the track turns slowly at least five complete revolutions. Stop the engine. 3. Inspect track alignment by looking through the track window to make sure the rails are evenly spaced on each side. If the track runs to the left, loosen left locknut and tighten the left adjusting bolt. If the track runs to the right, loosen right locknut and tighten the right adjusting bolt. 4. After adjustments are complete, be sure to tighten locknuts and idler shaft bolts. Torque to specification.

Rail

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

Hi-fax

Lock Nut

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

2.10


MAINTENANCE Track Tension Data Suspension

Weight

Measurement Location

Measurement

XTRA Lite 136s

10 lbs (4.54 kg)

16s ahead of rear idler shaft

3/8 - 1/2s (1 - 1.3 cm)

EDGE RMK 136”

10 lbs (4.54 kg)

16s ahead of rear idler shaft

3/8 - 1/2s (1 - 1.3 cm)

EDGE RMK/SKS 144”

10 lbs (4.54 kg)

16s ahead of rear idler shaft

3/8 - 1/2s (1 - 1.3 cm)

EDGE 151”/159”

10 lbs (4.54 kg)

16s ahead of rear idler shaft

3/8 - 1/2s (1 - 1.3 cm)

WARNING

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

Track Tension 1. Turn the machine off. 2. Lift the rear of the machine and safely support it off the ground. 3. Place a 10 lb. (4.5 kg) weight on the track at a point approximately 16s (40.6 cm.) ahead of the center of the rear idler wheel. 4. Check for proper slack between the track clip wear surface and the hi-fax (C). NOTE: Measure at the point where the weight is hanging. If the track needs adjustment: 5. Loosen rear idler shaft bolts (D) on both sides of the machine. 6. Loosen track adjusting bolt locknuts (A). 7. Tighten or loosen the track adjusting bolts (B) evenly as necessary to obtain proper track tension. 8. Tighten idler shaft bolts and adjuster bolt locknuts. NOTE: Track alignment affects track tension. Misalignment will cause excessive wear to the track and slide rail. Excessive Hi Fax wear will appear on units with track tension set too tight.

Rear Idler Shaft Bolt

C Adjuster Screw

Track

Locknut

10 lb. Weight (4.5 kg) Hi-fax

2.11


MAINTENANCE Spark Plug Selection Original equipment parts or their equivalent should always be used. However, the heat range of spark plugs is of utmost importance. A spark plug with a heat range which is too high will cause engine damage. A spark plug with a heat range which is too low will cause excessive fouling. In selecting a spark plug heat range for production, a manufacturer is forced to assume that the engine is going to be operated under extreme heavy duty conditions. This protects the engine from internal damage in the event that the purchaser actually does operate the engine in this manner. This selection however, could cause the customer who normally operates the engine under medium or light duty to experience spark plug failure. CAUTION: A plug with a heat range which is too high may cause engine damage if the engine is operated in conditions more severe than that for which the spark plug was intended. A new engine can cause temporary spark plug fouling even though the heat range is correct, due to the preservative which has been added during assembly of the engine to combat rust and corrosion. Avoid prolonged idle speeds, as plug fouling and carbonization will result. Always use resistor type spark plugs. NOTE: Incorrect fuel mixture can often cause a spark plug to appear to be too dark or too light in color. Before changing spark plug heat ranges, be sure the correct jetting is installed in the carburetors and proper carburetor function is verified. The spark plug and its condition is indicative of engine operation. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds. Immediately check the spark plug for correct color.

Normal The insulator tip is gray, tan, or light brown. There will be a few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetion adjustments.

Wet Fouled The insulator tip is black. A damp oily film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. General causes are excessive oil, use of non-recommended injection oil, excessive idling, idle too low or too rich, or weak ignition output. 1. Inspect electrodes for wear and carbon buildup. Look for a sharp outer edge with no rounding or erosion of the electrodes. 2. Clean with electrical contact cleaner or a glass bead spark plug cleaner only. CAUTION: A wire brush or coated abrasive should not be used. 3. Measure gap with a wire gauge and adjust to specifications by bending ground electrode carefully. 4. Coat spark plug threads with a small amount of anti-seize compound. 5. Install spark plug and torque to specification.

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

2.12


MAINTENANCE Drive Belt WARNING

Inspect the condition of the drive belt. Inspect clutch sheaves for damage, wear, or belt residue. Clean with non-oil base cleaner such as isopropyl alcohol. To ensure belt life, install belts so they operate in the same direction of rotation. Position the identification numbers so that you can read them standing on left side of machine. This will keep the belt rotating in the same direction. If belt has been operated with numbers readable from right side of machine, re-install belt in this direction.

Belt Removal 1. Be sure key switch is off and engine has come to a complete stop. Remove the retaining pin and open the clutch guard. 2. Apply brake (or lock parking brake if so equipped). 3. Grasp belt firmly midway between clutches and pull upward and rearward to open the driven clutch sheaves. Remove the belt from the driven clutch and then from the drive clutch.

Removal

Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. 2. Turn the driven clutch moveable sheave clockwise while at the same time pushing inward and forcing the belt down between the sheaves. 3. Hold the belt down between the sheaves and roll the bottom portion over the outer clutch sheave. Once installed, be sure to work the belt to the outer edge of the sheave. Be sure to release parking brake if applied. 4. Close the clutch guard and reinstall the retaining knob or pin.

3. Installation

1.

Drive Belt Polaris Electric Reverse / TEAM Clutches 1. Be sure key switch is off and engine has come to a complete stop. Remove the retaining pin and open the clutch guard. 2. Apply brake (or lock parking brake if so equipped). 3. PERC equipped models: Remove one of the three belt tensioner adjuster bolts. Locate the 1 1/2” long bolt from the tool kit and thread it into the open hole. Tighten the bolt until the sheaves open far enough to remove the belt. TEAM equipped models: Locate the “L” wrench in the tool kit and insert into the threaded hole. Screw in wrench until the sheaves open far enough to remove the belt.

Polaris Electric Reverse

3.

TEAM Clutch

2.13


MAINTENANCE Headlight Adjustment

25’ (7.6 m)

The headlight can be adjusted for vertical aim using the following procedure: 1. Place the snowmobile on a level surface with the headlight approximately 25’ (7.6 m) from a wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall.

Lamp Center Height 2s (5.1 cm)

3. Start the engine and turn the headlight switch to high beam. 4. Observe the headlight aim. The most intense part of the headlight beam should be aimed 2s (5.1 cm) below the mark placed on the wall in Step 2. NOTE: Rider weight must be included on the seat. 5. If necessary, the headlight aim can be adjusted by turning the adjustment knob located inside the hood just below the headlamp opening. Turn knob in or out as needed for proper aim.

Removing Halogen Bulbs - Low Beam NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot which will shortend the life of the lamp. 1. PInch ends of spring together and lift until it releases from spring retainer. 2. Lift spring carefully around wire harness and flip to outside of housing. 3. With wire harness attached to bulb, withdraw bulb from housing. 4. Grasp bulb by metal base and carefully separate bulb from harness.

Installing Low Beam Bulb 1. Hold bulb by metal base only and install into wire harness. 2. Insert bulb into housing. 3. Carefully flip spring back into housing placing it around wire harness. 4. Squeeze spring together until it is over spring retainer and release. 5. Verify headlight aim.

Removing and Installing Halogen Bulbs - High Beam 1. 2. 3. 4.

Remove wire harness. Grasp bulb firmly and twist it 1/2 turn counterclockwise. Remove bulb from housing and replace with new bulb. Place bulb and housing back inside hole and turn housing 1/2 turn clockwise to lock into place. 5. Reinstall wire harness to housing.

2.14

Headlight Adjustment Knob

Wire Harness Bulb Spring


MAINTENANCE Taillight Bulb Replacement Lens

1. Remove (5) Phillips screws from taillight lens. 2. Working from front to back, carefully pry lens away from housing and remove. 3. Pull bulb straight out from socket and insert new bulb. 4. Reinstall lens.

Handlebar Adjustment

Bulbs

1. Remove handlebar cover. 2. Using a 7/16s (11 mm) wrench, loosen four nuts on bottom of adjuster block. NOTE: Turn handlebar to left or right for access to back nuts. 3. Adjust handlebar to the desired height. Be sure that handlebars, brake lever and throttle lever operate smoothly and do not hit the gas tank, windshield or any other part of the machine when turned fully to the left or right. 4. Torque the handlebar adjuster block bolts to specification. Maintain an equal gap at front and rear of block.

Socket Screws 2

1

5. Replace handlebar cover. 3

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

4

WARNING

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

Brake Inspection The brake lever reserve should be inspected frequently. Measure the clearance between the lever and handlebar grip. Inspection should be made with the lever firmly depressed. Lever reserve (A) should be no less than 1/2s (1.3 cm.).

Hydraulic Brake Caliper Backing

Replacement of brake pads will be necessary when the brake pad material is thinner than the backing plate (approximately 1/16s (1.6mm).

Chaincase

Excessive Lever Travel The snowmobile’s hydraulic brakes are self-adjusting. If excessive brake pad clearance should develop, the caliper must be disassembled, cleaned, and repaired. See chapter 8 for brake service information.

Pad Disc

2.15


MAINTENANCE Replenishing Brake Fluid Remove brake fluid master cylinder reservoir cover. Add Polaris brake fluid as required to bring the level up to the top of the fluid level mark on the inside of the reservoir (B). The proper fluid level is 1/4-5/16s (.6-.8 cm) below the lip of the reservoir opening. NOTE: On some models, the brake fluid level can be seen through the plastic reservoir. The fluid should be maintained between the minimum and maximum marks on the reservoir for those models.

1/4-5/16s (.6-.8 cm)

B

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

Polaris DOT 3 High Temp Brake Fluid

1/4 - 5/16s (.6 - .8 cm) below lip of reservoir opening

PN 2870990

WARNING

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

Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause a springy or spongy brake lever action. Bleeding is necessary to remove air from the system. 1. Remove brake fluid master cylinder reservoir cover and gasket. CAUTION:Brake fluid is a hazardous material. Contact with decals, paint, and many plastics will cause damage. Use proper precautions when handling brake fluid. 2. Fill the master cylinder reservoir and replace gasket and cover. Keep the fluid level 1/4-5/16s (.6-.8 cm) below lip of reservoir opening. 3. Slip a rubber tube over the ball of the bleeder valve and direct the flow of fluid into a container. WARNING

Never re-use brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. This causes the boiling temperature of the brake fluid to drop, leading to early brake fade and the possibility of serious injury. 4. Squeeze brake lever a full stroke. Then unscrew bleeder valve (A) 3/4 of a turn to release air. 5. Close bleeder valve first and then release brake lever. Repeat steps 4 and 5 until fluid flows from bleeder valve in a solid stream free of air bubbles. Do not allow reservoir to run dry or air will be drawn into system. 6. Re-fill reservoir to proper level after bleeding operation. Do not overfill the master cylinder. 7. Replace gasket and cover. During the bleeding procedure make sure to keep the reservoir as level as possible to minimize the possibility of air entering the system.

2.16

Bleeder Tube A


MAINTENANCE Throttle Lever Free Play Throttle lever free play must always provide a specified clearance between throttle lever and throttle block. This clearance is controlled by the throttle cable sleeve(s) and the idle speed screw(s). Throttle Lever Freeplay .010 - .030s (.25 - .8 mm) .010-.030s (.25-.8 mm)

If the idle speed screw(s) is adjusted inward and the cable sleeve(s) is not adjusted to take up the throttle lever to throttle block clearance, the engine may misfire or kill upon initial throttle opening. CAUTION: After any idle speed adjustments are made, the throttle lever to throttle block clearance and oil pump adjustment must be checked and adjusted. NOTE: When adjustments are made on models which have more than one carburetor, refer to Section 6, Carburetion, for proper carburetor synchronization adjustments.

Mechanical Reverse Adjustment Due to break-in or replacement of components, the reverse shift mechanism may require adjustment. 1. Loosen jam nuts on linkage rod (A). 2. Turn the threaded linkage rod (B) to lengthen or shorten the throw until reverse engages fully. 3. Tighten jam nuts and re-check adjustment.

B A

2.17


MAINTENANCE Cleaning And Preservation Of Hood, Chassis And Trim Proper storage starts by cleaning, washing and waxing the hood, chassis, upholstery and plastic parts. Clean and touch up with paint any rusted or bare metal surfaces. Ensure that all corrosive salt and acids are removed from surfaces before beginning preservation with waxes and rust inhibitors (grease, oil, or paint). If the machine is equipped with a battery, disconnect the battery cables and clean the cables and battery posts. Fill battery to proper level with distilled water and charge to full capacity. Remove and store the battery in a cool dry place. The machine should be stored in a dry garage or shed out of the sunlight and covered with a fabric snowmobile cover. Do not use plastic to cover the machine; moisture will be trapped inside causing rust and corrosion problems.

Controls And Linkage All bushings, spindle shafts and tie rod ends should be coated with a light coat of oil or grease. Throttle controls and cables should be lubricated. Force a small amount of lubricant down cables.

Electrical Connections Separate electrical connector blocks and clean corrosive build-up from connectors. Lubricate or pack connector blocks with Nyogelt grease and reconnect. Replace worn or frayed electrical wire and connectors.

Nyogelt Grease PN 2871329

Clutch And Drive System Remove drive belt and store in a cool dry location. Lubricate sheave faces and ramps of drive and driven clutches with light oil or rust inhibitor. All lubrication applied as a rust preventative measure must be cleaned off before installing belt for service and operating machine.

Chaincase Lubricant Change chaincase lubricant as outlined in this section. Remove the outer cover and clean the chaincase thoroughly.

Lubrication Refer Chapter 2 for complete lubrication information. To prevent corrosion, always grease jackshaft and drive shaft (clutch side) bearings with premium all season grease. Loosen driven clutch retaining bolt and pull clutch outward to expose bearing. Use a point type grease gun fitting to inject grease through hole in flangette into bearing until grease purges out inside or outside bearing seal. Push clutch back on shaft and replace clutch retaining bolt. Inject grease into fitting on speedometer drive adaptor until grease purges out inside or outside bearing seal. Lubricate both front ski pivots at bushings and spindles. See Ill.1 and 2.

Ski Spindle and Bushings q

Ill. 1

2.18


MAINTENANCE

Grease Gun Adapter Point Type: PN 2871174

Grease

Polaris Premium All Season Grease PN 2871423 14 oz. T-9 Metal Protectant PN 2871064

Grease

Jackshaft Bearing

Use T-9 Metal Protectant (or equivalent) on shock absorber shafts to help prevent corrosion.

Grease

Under normal conditions moderate track tension should be maintained during summer storage. Rubber track tension should be maintained at the prescribed normal operating tension specified in this manual. The rear of the machine should be supported off the ground to allow free hanging of track.

Engine and Carburetor

Ill. 2

Driveshaft Bearing

Fog engine with Polaris Fogging Oil (aerosol type) according to directions on can. Polaris Fogging Oil PN 2870791 Carbon Clean PN 2871326 Treat the fuel system with Polaris Carbon Clean. If Polaris Carbon Clean is not used, fuel tank, fuel lines, and carburetor should be completely drained of gasoline.

Battery Disconnect and remove battery. Fill with distilled water. Clean terminals and cables. Apply dielectric grease. Charge until specific gravity is at least 1.270 (each cell). If machine is to be stored for one month or longer, fill and charge battery monthly using Polaris Battery Tender, or a 1 amp trickle charger to maintain at 1.270 specific gravity. Polaris Battery Tender PN 2871076

Exhaust System At approximately 2000 miles, or in preparation of off season storage, it is a good idea to check the exhaust system for wear or damage. To inspect, allow the engine and exhaust system to cool completely. Open the hood and inspect the muffler and pipes for cracks or damage. Check for weak or missing retaining springs or damper/support grommets. WARNING

Exhaust system temperatures can exceed 900q F (500q C). Serious burns may occur if this inspection is performed without allowing adequate time for the exhaust system to cool. Never perform this procedure with the engine running.

2.19


MAINTENANCE Exhaust System At approximately 1000 to 2000 miles, or in preparation of off season storage, it is a good idea to check the exhaust system for wear or damage. To inspect, allow the engine and exhaust system to cool completely. Open the hood and inspect the muffler and pipes for cracks or damage. Check for weak or missing retaining springs or damper/ support grommets. WARNING

Exhaust system temperatures can exceed 932q F (500q C). Serious burns may occur if this inspection is performed without allowing adequate time for the exhaust system to cool. Never perform this procedure with the engine running.

Variable Exhaust System (V.E.S.) Some snowmobiles are equipped with the Polaris Variable Exhaust System (V.E.S.) This unique exhaust valve management system changes the effective exhaust port height in the cylinder to provide maximum horsepower at high RPM without sacrificing fuel economy and engine torque at low to midrange throttle settings. Spring Cover

Piston

Bellows

Housing Exhaust Valve

In order to understand the operation and function of the V.E.S. we must first consider the characteristics of a two stroke engine. The height of the exhaust port in a two stroke engine cylinder has an affect 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 pipe to match) produce more horsepower at high RPM, but only at the expense of low to midrange fuel economy and torque. On the other hand, “low” port engines provide good fuel economy in the midrange and make their power at relatively lower RPM, but will not produce as much peak horsepower for a given displacement range. In general, an engine designed for a racing or high performance snowmobile will have a relatively high exhaust port compared to an engine of the same displacement range designed for touring. Although the V.E.S. does not in itself increase horsepower, it does allow an engine to be designed for maximum horsepower without the inherent disadvantages of a high exhaust port. The main components of the V.E.S. are the exhaust valve, valve housing, bellows, piston, return spring, and cover. A guillotine style exhaust valve is connected to a moveable piston. This piston is attached to a flexible bellows, forming two chambers. The lower chamber is connected to the cylinder by a drilled passageway located just above the exhaust port. The upper chamber is vented to atmospheric pressure. A valve return spring is located in the upper chamber between the piston and cover.

2.20


MAINTENANCE At idle and low speeds, the exhaust valve is held in the “low port” position by the return spring. When throttle is applied (and RPM begins to increase) rising cylinder pressure is applied to the under side of the bellows via the actuation port. This forces the exhaust valve upward against spring pressure. The valve continues to move upward toward the “High Port” position as cylinder pressure, horsepower, and RPM increase.

V.E.S. Maintenance Due to the simplicity of V.E.S. design, maintenance is limited to a periodic inspection and cleaning of system components. The V.E.S. should be disassembled, inspected, and cleaned (remove carbon deposits) every 1000 to 2000 miles, depending on operating conditions. To ensure maximum performance and minimize required maintenance, Polaris recommends the use of VES Synthetic 2 Cycle lubricant. The use of other lubricants may cause improper function of the valve mechanism, and increase the frequency of required cleaning due to excessive buildup of carbon deposits.

Bolt Valve cover Spring Valve cap Bellows Washer

Valve housing

V.E.S. Removal and Cleaning For more information V.E.S. removal and cleaning, refer to Engines, Chapter 3.

Gasket Valve

V.E.S. Troubleshooting Symptom Engine will not reach designed operating RPM

Possible Cause Valve not opening or not opening completely: 1. Exhaust valve sticking 2. Cylinder pressure feed port restricted 3. Bellows damaged or not sealing correctly 4. Incorrect spring 5. Problem in clutch setup, drive line, engine, etc.

Poor acceleration; hesitation; High RPM performance is normal or near normal

Remedy

1. Remove carbon deposits, burrs etc. 2. Clean port 3. Inspect bellows, fastener straps, and gasket and repair as required 4. Inspect 5. Inspect

Valve opening too early: 1. Valve sticking open or partially open

1. Clean, Inspect

2. Broken, damaged, or incorrect, spring

2. Inspect, Replace

2.21


MAINTENANCE Polaris Variable Exhaust System Springs Spring PN

COLOR

Load @ 1.0 In. (LBS.) r 0.4

Load @ .630 In. (LBS.) r 0.5

Free Length

Wire Dia. (In.)

7041786--01

RED/WHITE

3.0

4.3

1.854

.041

7041786--02

BLUE/WHITE

4.0

6.0

1.740

.045

7041786--03

GREEN/WHITE

5.0

7.0

1.930

.045

7041786--04

YELLOW/WHITE

5.0

8.0

1.620

.045

7041786--05

ORANGE/WHITE

7.0

9.0

2.300

.046

7041786--06

PINK/WHITE

6.0

8.0

2.110

.046

7041786--07

PURPLE/WHITE

9.0

11.0

2.670

.049

7041786--08

GREEN/YELLOW

8.0

10.0

2.400

.049

7041786--09

RED/YELLOW

3.0

3.7

2.586

.037

7041786--11

PINK/YELLOW

9.0

11.5

2.323

.051

7041704--01

BLUE

4.0

6.0

1.752

.0475

7041704--02

ORANGE

5.5

8.3

1.729

.0475

7041704--03

PINK

4.7

7.1

1.734

.046

7041704--04

PURPLE

3.1

4.7

1.726

.040

7041704--05

YELLOW

2.4

3.6

1.734

.037

7041705--06

WHITE

1.6

2.8

1.537

.036

These springs will change the timing characteristics of the exhaust valve opening. A heavier spring will keep the valve in the closed position longer, while a lighter spring will allow the valve to open sooner. NOTE: If making any changes to the valve springs make sure to change all springs so that each valve spring is the same.

2.22


MAINTENANCE Notes

2.23


Engine Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Torque Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550 Engine Disassembly and Inspection . . . . . . . . . . . . . . . . . 550 Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500/600 Libertyt Engine Disassembly and Inspection . . . . . 500/600 Libertyt Engine Assembly . . . . . . . . . . . . . . . . . . . . . 700/800 Libertyt Disassembly and Inspection . . . . . . . . . . . 700/800 Libertyt Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . EV Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optional EV springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Honing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankcase Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Truing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Indexing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump Operation / Adjustment . . . . . . . . . . . . . . . . . . . . . . . . Cooling System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 3.2 -- 3.4 3.5 -- 3.8 3.9 -- 3.12 3.13 -- 3.19 3.20 -- 3.25 3.26 -- 3.29 3.30 -- 3.34 3.35 -- 3.40 3.40 -- 3.44 3.45 -- 3.47 3.48 3.49 -- 3.50 3.51 3.52 3.53 3.54 -- 3.55 3.56 -- 3.57 3.58 3.59 3.60 -- 3.63 3.64 6.65 -- 3.66 3.67 -- 3.69


ENGINES Engine Torque Specifications When tightening bolts, nuts, or screws, a torque pattern should be followed to ensure uniform equal tension is applied to all fasteners. Proper torque application prevents fasteners from loosening or breaking in critical service. It also minimizes wear and eliminates premature or needless repair costs. Following uniform torque application sequence patterns ensures optimum performance from precision machined, close tolerance assemblies. The most common units of torque in the English system are ft. lb. and in. lb. In the Metric system, torque is commonly expressed in units of kg-m or Nm (Newton Meters). Multiply foot pounds by .1383 to obtain kg-m. Move decimal point one place to the right to obtain Nm from kg-m.

Engine 550 Fan Cooled Twin Cylinder EC55 SN50**

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

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

Crankcase Crankcase 8 mm 10 mm 16.6-18 ft.lbs. N/A (22-25 Nm)

60-65 ft.lbs. (83-90 Nm)

20-24 ft.lbs. (29 - 33 Nm) 18-22 ft. lbs. (25 - 30 Nm)

30-34 ft.lbs (41-47 Nm) 30-34 ft.lbs (42-47 Nm)

20-24 ft.lbs. (28 - 33 Nm) 20-24 ft.lbs. (28 - 33 Nm)

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

N/A

SN60-70** 26-30 Ft lbs SN70** (36-41 Nm) SN80** ** Torque head bolts prior to torquing cylinder base nuts.. Apply Loctitet 242.

Flywheel

All 6mm Crankcase Bolts . . . . . 108 in. lbs. (12.4 Nm) All 7/16-14 Engine Mount Strap Bolts . . . . . 44-48 ft. lbs. (60-66.3 Nm)

3.1


ENGINES Torque Sequences - EC55 Engines

2 5

4

3

6 1 CYLINDER HEAD

1

4 MAG SIDE

PTO SIDE 3

2

CYLINDER BASE

7

5 9

1

3

11

12

4

2

10

8

6

CRANKCASE - TWIN CYLINDER - Fuji

3.2


ENGINES Torque Sequence / Domestic 500 8

5 9

1

4

2

3

10

12

11 7

6

CYLINDER HEAD Domestic 500

3

5

6

7

1

2

4

8

CYLINDER BASE Domestic 500

5

8 1

9

11

3

12

4

2

7

10

14

13

6

15 CRANKCASE Domestic 500

3.3


ENGINES Torque Sequence / Domestic 600 / 700 / 800

10

12

3

1

6

8

4

5

9

7

2

11

CYLINDER HEAD Domestic Twins 600 / 700 / 800

5

1

6

3

2

4

CRANKCASE Domestic Twins 600 / 700 / 800

3

5

7

1

6

2

CYLINDER BASE Domestic Twins 600 / 700 / 800

3.4

4

8


ENGINES Engine Removal, Typical 1. On some models, it may be necessary to remove the hood for easier access to engine components or to prevent damage.

2. Disconnect battery ground (--) from battery (if applicable). Shut off fuel.

Ground Cable

3. Remove fuel pump or CDI from airbox if applicable.

4. Remove airbox.

3.5


ENGINES Engine Removal, Typical-Cont. 5. Free recoil rope from chassis. NOTE:Be sure to tie a knot in recoil rope upon removal so rope doesn’t wind up into recoil housing.

6. Loosen clamps at carburetor mounting flange. Pull carbs from adaptors and secure out of the way. Note routing of all cables and hoses for reassembly.

7. Disconnect oil pump control cable.

8. Disconnect and plug oil supply line. TIP: A bolt or spare water trap plug can be used to plug the oil line from the oil reservoir.

3.6


ENGINES Engine Removal, Typical-Cont. 9. Remove drive belt. NOTE:If drive clutch removal is necessary, it may be done at this time. Refer to Chapter 5, clutches.

10. Remove exhaust system.

11. Disconnect coolant supply hoses as necessary at the most convenient location on liquid cooled models. Drain coolant into suitable container.

3.7


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2003 Polaris 700 RMK 151 F0 SNOWMOBILE Service Repair Manual  
2003 Polaris 700 RMK 151 F0 SNOWMOBILE Service Repair Manual  
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