Page 1

2001 HIGH PERFORMANCE 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 2001 Polaris 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.

2001 High Performance Snowmobile Service Manual (PN 9916690) Copyright 2000 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 Willwood, Trademark of the Willwood Corporation


Foreword Welcome to the 2001 Polaris racing season! Thank you for selecting Polaris as your racing machine. The enclosed technical information, which is based on our past experience, should be reviewed by your team for machine preparation. Do not feel that these suggestions are a must, but use them as a starting point. This information has been outlined with reference to the sections in our 2001 Snowmobile Service Manuals. You will want to refer to them regularly to ensure correct procedures are followed. The section index enables the user to quickly locate the component unit section desired. A table of contents is placed at the beginning of each chapter to aid the user in locating general areas of information. Keep this manual available for reference. In order to provide you with the best support possible, Polaris racing, engineering, and testing department personnel must have timely and accurate data from the field. The weekly racing report form is a valuable source of this data. As a part of the Polaris team, your input is highly valued and never ignored. A Race Report Form is included with this manual for your convenience. We request that you fill out the race forms and return them by mail or facsimile (715)355--8797 within 48 hours after every race. We want to read or hear all of your comments, so feel free to use the back of the form or attach another sheet if necessary. Even if you aren’t on the race program, please send us your comments. At Polaris, we are committed to your racing effort. We wish you the best of luck in the season ahead!


CHAPTER INDEX CHAPTER 1 . . . . . . . . . . . . . . . . General Information CHAPTER 2 . . . . . . . . . . . . . . . . Engines CHAPTER 3 . . . . . . . . . . . . . . . . Fuel / Carburetion CHAPTER 4 . . . . . . . . . . . . . . . . Drive / Driven Clutches CHAPTER 5 . . . . . . . . . . . . . . . . Chassis, Brakes and Final Drive CHAPTER 6 . . . . . . . . . . . . . . . . Front Suspensions CHAPTER 7 . . . . . . . . . . . . . . . . Rear Suspensions CHAPTER 8 . . . . . . . . . . . . . . . . Electrical/Wiring Diagrams


CHAPTER 1 GENERAL INFORMATION

High Performance parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Initial Break--In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Race Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Publication numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications, XCF SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications, 440 EDGE Pro X . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications, 600 EDGE Pro X . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications, 500 XC EDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications, 500 XC SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications, 600 XC SP, EDGE X . . . . . . . . . . . . . . . . . . . . . . . . . Specifications, 700 XC SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications, 800 XC SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications, 800 XCR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications, 500 RMK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications, 600 RMK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications, 700 RMK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications, 800 RMK, S.C. SP . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tap Drill Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Set Up Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

1.1--1.2 1.3 1.4 1.5--1.6 1.8--1.9 1.10--1.1 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 1.28--1.29 1.30--1.31 1.32--1.33 1.34 1.35 1.36 1.37 1.38--1.40 1.41 1.42--1.49


GENERAL INFORMATION

PART

DESCRIPTION

NUMBER

PART

DESCRIPTION

Fox Shocks NUMBER 2900153

REMOTE RESERVOIR REAR TRACK (RACE)

2900152

REMOTE RESERVOIR REAR TRACK (TRAIL)

2900049

XTRA LITE COMPETITION PACKAGE

2900068

TORSION BAR,9/16”, 2000--01 EDGE

2900069

TORSION BAR,5/8”, 2000--01 EDGE

2900071

Lightweight Sway Bar Kit Tubular (5/8 EDGE 00--01)

2900070

Lightweight Sway Bar Kit Tubular (5/8 RMK 00--01)

2900183

Lighweight Sway Bar Kit,5/8” Tubular, 01 EDGE Racer

2900184

Lightweight Sway Bar Kit Tubular, 9/16”, (01 EDGE Racer)

2900156

KIT--IDLER WHEEL,4TH

Clutch Components 2900178

ROLLER DRIVEN CLUTCH

Roller Clutch Components 2900169

HELIX,DRIVEN, 34--DEG,ROLLER

2900177

HELIX,DRIVEN, R3,ROLLER

2900172

HELIX,DRIVEN, R12, ROLLER

2900173

HELIX,DRIVEN, R11, ROLLER

2900176

HELIX,DRIVEN, R4, ROLLER

2900170

HELIX,DRIVEN, 36--DEG, ROLLER

2900174

HELIX,DRIVEN, R8, ROLLER

2900171

HELIX,DRIVEN, R32, ROLLER

2900175

HELIX,DRIVEN, R5, ROLLER

5521587--309

EDGE EXTRA WIDE RAIL SLIDERS (01 EDGE Racer)

Button Clutch Components 2900034

Ramp, driven, 40--36 Combo

2900035

Ramp, driven, R1, 40--32

2900036

Ramp, driven, 42--32

2900037

Ramp, driven, R3, 45--32

2900038

Ramp, driven, R4, 50--32

2900039

Ramp, driven, R5, 40--34

2900040

Ramp, driven, R6, 42--34

2900041

Ramp, driven, R7, 45--34

2900042

Ramp, driven, R8, 50--34

2900043

Ramp, driven, R9, 40--36

2900044

Ramp, driven, R10, 42--36

2900045

Ramp, driven, R11, 45--36

2900046

Ramp, driven, R32, 50--34

5521556--309

2900067

EDGE EXTRA WIDE RAIL SLIDERS (00--01 EDGE)

TIE DOWN KIT,HOOD Hood/Seat

2900047

Ramp, driven, R12, 50--36

2900048

Ramp, driven, 42 / 36 / 34

2900026

WEIGHT,SHIFT,MATCHED,10--60

2900027

WEIGHT,SHIFT,MATCHED,10--56

2900028

WEIGHT,SHIFT,MATCHED,10--54

2900029

WEIGHT,SHIFT,MATCHED,10--58

2900129--293

Lightweight Composite Hood EDGE Racing (Red)

2900128--070

Lightweight Composite Hood RMK (Black)

2900128--293

Lightweight Composite Hood RMK (Red)

2900128--246

Lightweight Composite Hood RMK (Rigel Blue)

2900124

Lightweight Seat RMK

2900181

Lightweight Seat EDGE

Torsion Spring Kits (90 Weights

Belts 3211086

Belt, Close Tolerance Standard Compound, EDGE

3211087

Belt, Close Tolerance CVT Compound, EDGE Engine Kits

2900151

HIGH ALTITUDE HEAD (2000 800 RMK)

2900127

Electric E.V. Kit (500 E.V. Engines)

2900126

Electric E.V. Kit (600 E.V. Engines)

2900063

TORSION SPRING KIT .347, 90 Deg. Square

2900064

TORSION SPRING KIT .359, 90 Deg. Square

2900065

TORSION SPRING KIT .375, 90 Deg. Square

2900066

TORSION SPRING KIT .405, 90 Deg. Square

2900095

TORSION SPRING KIT .347, 77 Deg. Square

2900096

TORSION SPRING KIT .359, 77 Deg. Square

2900097

TORSION SPRING KIT .375, 77 Deg. Square

2900098

TORSION SPRING KIT .405, 77 Deg. Square

1.1


GENERAL INFORMATION 2900002

18 Tooth HYVO, Cut Metal Gear

2900003

19 Tooth HYVO, Cut Metal Gear

2900004

20 Tooth HYVO, Cut Metal Gear

2900005

21 Tooth HYVO, Cut Metal Gear

2900006

22 Tooth HYVO, Cut Metal Gear

2900007

23 Tooth HYVO, Cut Metal Gear

2900008

24 Tooth HYVO, Cut Metal Gear

2900009

25 Tooth HYVO, Cut Metal Gear

2900010

37 Tooth HYVO, Cut Metal Gear

2900011

38 Tooth HYVO, Cut Metal Gear

2900012

39 Tooth HYVO, Cut Metal Gear

2900013

40 Tooth HYVO, Cut Metal Gear

2900014

41 Tooth HYVO, Cut Metal Gear

2900015

42 Tooth HYVO, Cut Metal Gear

2900016

43 Tooth HYVO, Cut Metal Gear

2900138

43 Tooth, Lightweight Cut Metal Gear, HYVO

2900139

42 Tooth, Lightweight Cut Metal Gear, HYVO

2900140

41 Tooth, Lightweight Cut Metal Gear, HYVO

2900141

40 Tooth, Lightweight Cut Metal Gear, HYVO

2900142

39 Tooth, Lightweight Cut Metal Gear, HYVO

2900143

38 Tooth, Lightweight Cut Metal Gear, HYVO

2900144

37 Tooth, Lightweight Cut Metal Gear, HYVO

2900025

Lightweight Jackshaft Kit

3221108

Chain HYVO, 76 PITCH

3221109

Chain HYVO, 74 PITCH

3221110

Chain HYVO, 72 PITCH

3221112

Chain HYVO, 68 PITCH

3221113

Chain HYVO, 66 PITCH

3221114

Chain HYVO, 64 PITCH

3221115

Chain HYVO, 70 PITCH

2900180

MOTOR--MOUNT,KIT,AGGR,TRAIL,65 EDGE

2900179

MOTOR--MOUNT,KIT, DRAG,65 EDGE

2900020

MOTOR--MOUNT,KIT,AGGR,TRAIL,70D

2900021

MOTOR--MOUNT,KIT,DRAG,90D

2900022

MOTOR--MOUNT,KIT,DRAG,90D

2900023

MOTOR--MOUNT,KIT,AGGR,TRAIL,70D

2900024

MOTOR--MOUNT,KIT,DRAG,90D

2900019

TRACK,121”X1.5 --NOTCHED

2900018

TRACK,121”X--1.75 --NOTCHED

HYVO Chain

Motor Mounts

Tracks

1.2

2900017

TRACK,121X2” NOTCHED

5411825

TRACK--121”X15”X1”MOD LIGHTNING

5411963

TRACK--121X1.25 SHOCKWAVE

5411994

TRACK--121X15X1,SHOCKWAVE

5411995

TRACK--144”X2” Series 3 (Hard Lug)


GENERAL INFORMATION Polaris’ new 440 Edge Pro X and XCF SP edge models have been designed and tested to endure the toughest of all races. Many hours of testing have gone into development, and engineering has decided to use a predetermined weight rider and snow cross racing for stock setup. After uncrating your machine, be sure to test ride so setup can be determined for your riding style and characteristics. The following are setup tips for your brand new 440 Edge Pro X or XCF SP.

1. Stock suspension setup for the 2001 440/600 Pro X and XCF SP is geared to a 170 lb (77.18 kg) pro rider. 2. Stock carburetion, clutching and gearing is for 0-3000 ft. (0-900 m). 3. In this manual, there are numerous optional springs, optional carburetor jets, optional clutch weights, and optional gears to suit your riding preference and location. When changing to optional parts, always test what you have done. Do not be afraid to experiment. 4. Be sure to use good quality studs and a pattern to maximize your traction and safety.

Break-in The new 440/600 Edge Pro X and XCF SP are high performance snowmobiles, and break-in is a vital step to ensure the performance of your machine will be at its peak. 1. 2. 3. 4. 5. 6.

Always break-in any new part for 50-75 miles before using it for racing. Clutch springs and belts need to be broken in to reach their peak in performance. On the 440 Edge Pro X, always use the correct type of fuel for the timing system you are using. Always use the recommended Polaris oil for your snowmobile. Always break-in a new or rebuilt engine to ensure durability. Maintain your exhaust valves frequently to ensure they are operating to their fullest capability.

440 Jetting for Temperature and Altitude

1.3


GENERAL GENERAL INFORMATION INFORMATION South Side Race Support: Contact: Bruce Gaspardi 546 Curran Hwy. North Adams, MA 01247 Phone: (413) 664-7111 Racing: Cross country, Snowcross Service Capabilities: OEM parts, Foxt shock rebuilding and valving, lubricants, Woody’s traction products, clutch disassembly tools mounted in trailer, Hot Seat clutch parts, OEM clutch parts, NGK spark plugs, miscellaneous hardware. Wahl Brothers Racing: Contact: Dave Hwy 11 West Greenbush, MN 56726 Phone: (218) 782-2295 Racing: All Service Capabilities: OEM parts, Foxt shock rebuilding and valving, lubricants, traction products, clutch disassembly, miscellaneous hardware. Karkoulas Racing: Contact: Troy Karkoulas S2225 Scugog Brock Town Line Sunderland ON Canada L0C 1H0 Phone: (705) 357--1226 Racing: All

Polaris Racing 10303 Calumet Ave. Suite # 3 Mosinee, WI 54455 Phone: (715) 355--5157 Fax: (715) 355--8797

1.4


GENERAL INFORMATION 2001 Publication Numbers Model

Model No.

Owner’s Manual Supplement

Parts Manual

Parts Microfiche

XCF

S01NX4FS

9916161

9916162

9916163

440 Edge Pro X

S01NX4CS

9916166

9916167

9916168

600 Edge Pro X

S01NX6ES

9916884

9916885

9916886

500 XC SP

S01NP5CS

9915889

9916040

9916041

600 XC SP / X

S01NP6ES

9915623

9916153

9916154

700 XC SP

S01NP7AS

9915929

9916090

9916091

800 XC SP

S01NP8BS

9915925

9916110

9916111

600 RMK 136

S01SR6DS

9916022

9916023

9916024

700 RMK 136

S01SR7AS

9916027

9916028

9916029

800 RMK 144, 151

S01SM8BS

9916143, 9916148

9916144

9916145

800 XCR

S01SB8AS

9916067

9916068

9916069

2000 Publication Numbers Model

Model No.

Owner’s Manual Supplement

Parts Manual

Parts Microfiche

XCF XC SP

S00NX4FS

9915615

9915616

9915617

440 XC SP

S00NX4CS

9915372

9915402

9915430

500 XC SP 45th Anniversary

S00SP5CS

9915373

9915403

9915431

600 XC SP

S00SP6ES

9915374

9915404

9915432

700 XC SP

S00SP7AS

9915377

9915407

9915435

600 RMK

S00SR6DS

9915382

9915412

9915440

700 RMK

S00SR7AS(A)

9915380

9915410

9915438

800 RMK

S00SR8BS

9915381

9915411

9915439

800 XCR

S00SB8AS

9915371

9915401

9915429

2001 Snowmobile Owner’s Manual (All) - 9915622 2000 Snowmobile Owner’s Manual (All) - 9915247 2000 High Performance Manual - 9915985

1.5


GENERAL GENERAL INFORMATION INFORMATION Service Manuals 120 XC SP

2001

9916684

Trail Sport 340 DLX, Indy 500 EDGE, SuperSport EDGE

2001

9916685

Two-Up / Touring Wide Trak LX, 340 Touring, Sport Touring, Sport Touring ES, 500 Classic Touring, 600 Classic Touring

2001

9916686

Trail Luxury 500 Classic, 600 Classic, 700 Classic, 800 LE

2001

9916687

Deep Snow 700 SKS, Trail RMK, 500/600/700/800 RMK, 800 RMK Snowcheck Special

2001

9916688

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

2001

9916689

High Performance (Race) 440 XCF SP, 440/600 Edge Pro X, 500/600/700/800 XC SP, 600/700/800 RMK, 800 XCR

2001

9916690

Wallcharts

2001

9916692

2000 Snow Complete Set w/wallcharts (all models except race)

2000

9915986

Fan Cooled Models

2000

9915980

Mid Range Liquid Cooled (500s, 600 triple)

2000

9915981

Performance Liquids (600 twins,700s, 800s)

2000

9915982

120 XCR

2000

9915983

High Performance (Race)

2000

9915985

Wall Chart Packet only

2000

9915984

1.6


GENERAL INFORMATION

2001 Specifications 440 XCF SP 440 Edge Pro X 600 Edge Pro X 500 XC Edge 500 XC SP Edge 600 XC SP, X Edge 700 XC SP Edge 800 XC SP Edge 500 RMK 600 RMK 700 RMK 800 RMK, S.C. Special

1.7


GENERAL GENERAL INFORMATION INFORMATION MODEL: . . . . . . . . . . XCF SP MODEL NUMBER: . S01NX4FS ENGINE MODEL: . . EC45PM022

JETTING CHART AMBIENT TEMPERATURE

Altitude

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

VM34AL Mikuni 340 PTO/330 MAG 45 6DHK06--03 Q-2(286) 3.0 1.0 Turns 1.5 Viton 87 Non-Oxygenated or 89 Oxygenated

Throttle Gap Under Cutaway . . . . . . .244〉 -(6.2mm) Idle Sync Gap Under Cutaway . . . . . . .218〉 - (5.54mm)

Meters (Feet)

Below -20 -20F F Below -29C

-20 to +10_F -20_ +10 F -29_to -12_C

+10 to +40_F +10_to +40 F -12_ to +5_C

Above +40 +40_F F Above 5_C

0-900 (0-3000)

PTO 360 MAG 350 #3

PTO 340 MAG 330 #3

PTO 320 MAG 310 #3

PTO 300 MAG 290 #3

900-1800 (3000-6000)

PTO 320 MAG 310 #3

PTO 310 MAG 300 #3

PTO 290 MAG 280 #3

PTO 270 MAG 260 #2

1800-2700 (6000-9000)

PTO 290 MAG 280 #3

PTO 270 MAG 260 #3

PTO 260 MAG 250 #2

PTO 240 MAG 230 #2

2700-3700 (9000-12000)

PTO 260 MAG 250 #3

PTO 250 MAG 240 #2

PTO 230 MAG 220 #2

PTO 220 MAG 210 #2

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

CLUTCH CHART DRIVE

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

Altitude

P-85 3211078 1 7/16〉 28 56 5/8〉 11.50〉 10-54 Almond Red Silver/Blue R5 #2

Meters (Feet)

Clutch Spring

Clutch Spring

Driven Helix

Chaincase Gearing

0-900 (0-3000)

10-54 Bushed

Almond/ Red

Silver Blue

R5 #-2

22--43 P HYVO

900-1800 (3000-6000)

10-54 Bushed

Almond/ Red

Silver Blue

R5 #-2

22--43 74 P HYVO

1800-2700 (6000-9000)

10

Almond/ Red

Silver Blue

R5 #-2

22--43 74 P HYVO

2700-3700 (9000-12000)

10

Almond/ Red

Silver Blue

R5 #-2

22--43 74 P HYVO

ENGINE Type . . . . . . . . . . . . . . . . . . . . . . . Fan Cooled Cylinder Reed Displacement . . . . . . . . . . . . . . . 438 cc Bore . . . . . . . . . . . . . . . . . . . . . . . 2.579〉 (65.5mm) Stroke . . . . . . . . . . . . . . . . . . . . . 2.559〉 (65mm) Piston / Cylinder Clearance . . . 0.0028〉 - 0.0041〉 (0.070 - 0.105 mm) Piston Marking . . . . . . . . . . . . . . 4RA Piston Ring Marking . . . . . . . . . 4N Piston Ring End Gap . . . . . . . . 0.012 - 0.018 (.3 - .45 mm) Head cc’s .4cc (Uninstalled) . . . . . . . . 24.2 cc Head cc’s.4cc (Installed) . . . . . . . . . . . 21.2 cc Operating RPM200 . . . . . . . . . 7750 RPM Idle RPM200 . . . . . . . . . . . . . . 1600 RPM Engagement RPM300 . . . . . . 4600 RPM Cylinder Head Torque . . . . . . . . 18-19 ft.lbs (2.5-2.8 kg-m) Cylinder Base Nut Torque . . . . 24-28 ft.lbs (3.3-3.9 kg-m) Crankcase Torque (8mm) . . . . . 17-18 ft.lbs (2.2-2.3 kg-m) Crankcase Torque (10mm) . . . 23-25 ft.lbs (3.2-3.5 kg-m) Flywheel Torque . . . . . . . . . . . . . 60-65 ft.lbs (8.3-9 kg-m)

1.8

DRIVEN

Shift Weight


GENERAL INFORMATION MODEL: . . . . . . . . . . XCF SP MODEL NUMBER: . S01NX4FS ENGINE MODEL: . . EC45PM022

ELECTRICAL

CAPACITIES

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

F004T32971 17620201 240 Watts @ 4000 RPM 27 BTDC@3000RPM1.5 0.175〉 BTDC (0.157〉-0.195〉) 4.45mm BTDC (3.97-4.93mm) Spark Plug / Gap . . . NGK BR9ES / 0.028” (0.7mm) Lights: Head . . . . . . 2 60 High/50 Low Tail . . . . . . . . 2@3 watts Brake . . . . . . 18 watts Voltage Regulator . . LR7 Electric Start . . . . . . . Option *LR9= Half wave voltage regulator

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

SUSPENSION / CHASSIS

CHAINCASE

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

11.8 Gal. (45.4 L) 3.5 Quarts (3.3 L) N/A 8 oz.

EDGE Pro X Sprockets / Chain . . . 22-43, 74 P 3/4HYVO EDGE Pro X Reverse . . . . . . . . . . . . Option Arvin Ryde FXt Brake Pads . . . . . . . . . Type 81 130#/in. Chaincase Center Dist.7.658 (19.45cm) 1.88〉 Thread Adjust Driveshaft Sprockets . 2 Drivers 9.36〉 (23.77 cm.) Brake Type . . . . . . . . . Polaris HPB EDGE Pro X 13.86〉 (35.20 cm.) Arvin Emulsiont 170#/in. Arvin Ryde FXt Clicker .359〉 / 77 15〉x121〉x.82〉 (38.1x307.34x2.08cm.) 1 1/2” (38mm) slack with 10# (4.54kg) weight 16” (40.64cm.) ahead of rear idler shaft

OPTIONAL REAR TORSION SPRINGS 2001 XCF SP/440 Edge Pro X Rear Torsion Springs SOFT

MEDIUM(STD)

FIRM

.347〉(sq.) diameter/77

.359〉(sq.) diameter/77

.375〉(sq.) diameter/77

L.H 7041627-067

L.H. 7041629-067

L.H. 7041631-067

R.H. 7041628-067

R.H 7041630-067

R.H. 7041632-067

1.9


GENERAL GENERAL INFORMATION INFORMATION MODEL: . . . . . . . . . . 440 Edge Pro X MODEL NUMBER: . S01NX4CS ENGINE MODEL: . . S44-44-PO 2093 JETTING CHART AMBIENT TEMPERATURE

Altitude

CARBURETION Type . . . . . . . . . . . . . . . . TMX-34 Mikuni Main Jet . . . . . . . . . . . . 350 Pilot Jet . . . . . . . . . . . . . 22.5 Jet Needle . . . . . . . . . . . 6GL64--61--3 Needle Jet . . . . . . . . . . . Q-8 (Fixed) Cutaway . . . . . . . . . . . . 2.5 Air Screw . . . . . . . . . . . 1.0 Turns Valve Seat . . . . . . . . . . . 1.5 Viton Fuel Octane w/o Ethanol (R+M/2) 92 Octane Prem. Unlead. Throttle Gap Under Cutaway . . . . . . .098〉(2.5 mm) (Engine side) Exhaust Valve Spring Red/White

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

P-85 3211080 1.438〉 (34.93mm) 28 46.625” (118.43cm.) 11.5〉 (305mm) S53H Almond/Red Blue/Orange R-49 #2

Meters (Feet)

Below -20 -20F F Below -29C

-20 to +10_F -20_ +10 F -29_to -12_C

+10 to +40_F +10_to +40 F -12_ to +5_C

Above +40 +40_F F Above 5_C

0-900 0 900 (0-3000) (0 3000)

390 #3

370 #3

340 #3

320 #3

900-1800 900 1800 (3000-6000) (3000 6000)

350 #3

330 #3

310 #3

290 #3

1800-2700 1800 2700 (6000-9000) (6000 9000)

320 #3

300 #3

280 #3

260 #3

2700-3700 2700 3700 (9000-12000) (9000 12000)

280 #3

270 #3

250 #3

230 #3

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

CLUTCH CHART DRIVE

Altitude Meters (Feet)

DRIVEN

Shift Weight

Clutch Spring

Clutch Spring

Driven Helix

Chaincase Gearing

0-900 (0-3000)

S53H

Almond Red

Blue/ Orange

R49 #2

22:43 74P

900-1800 (3000-6000)

S51H

Almond Red

Blue/ Orange

R49 #3

22:43 74P

1800-2700 (6000-9000)

S49H

Almond Red

Blue/ Orange

R49 #3

22:43 74P

2700-3700 (9000-12000)

S49H

Almond Red

Blue/ Orange

R49 #3

22:43 74P

Note: Production main jet is a 350 for 92 octane fuel. Do not run below 0_F at 0--1000 feet. Standard timing curve position = “D”.

Timing positions pg 2.12 Fine Tuning jetting chart p1.3 ENGINE Type . . . . . . . . . . . . . . . . . . . . . . . Displacement . . . . . . . . . . . . . . . Bore . . . . . . . . . . . . . . . . . . . . . . . Stroke . . . . . . . . . . . . . . . . . . . . . Piston / Cylinder Clearance . . . Service Limit . . . . . . . . . . . . . . . . Piston Marking . . . . . . . . . . . . . . Piston Ring Marking . . . . . . . . . Piston Ring End Gap . . . . . . . . Head cc’s (Uninstalled) . . . . . . . Head cc’s (Installed) . . . . . . . . . Operating RPM200 . . . . . . . . . Idle RPM200 . . . . . . . . . . . . . . Engagement RPM300 . . . . . . Cylinder Head Torque . . . . . . . . Cylinder Base Nut Torque . . . . Crankcase Torque (8mm) . . . . . Crankcase Torque (10mm) . . . Flywheel Torque . . . . . . . . . . . . .

1.10

Liquid Cooled Case Reed w/V.E.S. 438 cc 2.598〉 (66mm) 2.520〉 (64mm) 0.0023〉 - 0.0037〉(0.06 - 0.095mm) 0.0059〉 (0.15mm) EK2185/28 “o” faces upward .008〉-.020〉(.20-.51mm) TBA TBA 8750 RPM 1600 RPM 5000 RPM 20-24 ft.lbs(2.8-3.3 kgm) 30-34 ft.lbs(4.15-4.7 kgm) 20-24 ft.lbs(2.8-3.3 kgm) N/A 90 ft.lbs(12.4 kgm)


GENERAL INFORMATION MODEL: . . . . . . . . . . 440 Edge Pro X MODEL NUMBER: . S01X4CS ENGINE MODEL: . . S44-44-PO 2093

ELECTRICAL

CAPACITIES

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

4010523 Fuel Tank . . . . . . . . . . 4010469 Oil Tank . . . . . . . . . . . . 280 Watts Coolant . . . . . . . . . . . . 22 BTDC@4500RPM1.5 Chaincase Oil . . . . . . . .with pipe sensor unplugged Spark Plug / Gap . . . Champion RN-57YCC / 0.028” (0.7mm) PN 3070190 Lights: Head . . . . . . 2 60High/50Low Tail . . . . . . . . 2@2 watts Brake . . . . . . 1@17 watts Voltage Regulator . . LR7 Electric Start . . . . . . . N/A *LR7= Full wave voltage regulator

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

11.8 Gal. (45.4 L) 2.0 Quarts (3.3 L) 4 Quarts (3.78 L) 9 oz.

CHAINCASE

EDGE Sprockets / Chain . . . 21-41, 74 P 3/4 HYVO EDGE PRO -- X Reverse . . . . . . . . . . . . N/A Arvin IFP piggy back remote . . . Brake Pads . . . . . . . . . Wilwood reservoir w/ Externally adjustable Chaincase Center Dist.7.658”(19.54.) compression damping. . . . . . . . . . Driveshaft Sprockets . 2 Drivers-wide 120/220#/in. . . . . . . Brake Type . . . . . . . . . Willwood Dual Piston TBA〉 Thread Adjust 9.00〉 (26.46 cm..) EDGE PRO X 13.90〉 (35.31 cm..) Arvin IFP remote reservoir w/externally adjustable compression damping 170#/in. Arvin IFP remote reservoir w/externally adjustable compression damping .359〉 (sq.) / 77 15〉x121〉x1.25〉 (38.1x307.34x3.175cm.) 1 1/2〉 (38mm) slack with 10# (4.54kg) weight 16〉 (40.64cm.) ahead of rear idler shaft

OPTIONAL REAR TORSION SPRINGS 2000 XCF SP/440 Edge Pro X Rear Torsion Springs SOFT

MEDIUM(STD)

FIRM

.347〉(sq.) diameter/77

.359〉(sq.) diameter/77

.375〉(sq.) diameter/77

L.H 7041627-067

L.H. 7041629-067

L.H. 7041631-067

R.H. 7041628-067

R.H 7041630-067

R.H. 7041632-067

1.11


GENERAL GENERAL INFORMATION INFORMATION MODEL: . . . . . . . . . . 600 Edge Pro X MODEL NUMBER: . S01NX6ES ENGINE MODEL: . . S60--44--PO--6E--2234

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

JETTING CHART (2) TM 38 Mikuni w/TPS 420 45 J8--9DFH7-60-2 P-8 1.5 N/A 1.5 Viton Key Switch Adjustable .091”(2.3mm) 0.7 Long 140 1.5 Turns Green/Yellow

AMBIENT TEMPERATURE

Altitude Meters (F ) (Feet)

Below -20 -20F F Below -29C

-20 to +10_F -20_ +10 F -29_to -12_C

+10 to +40_F +10_to +40 F -12_ to +5_C

Above +40 +40_F F Above 5_C

0-900 (0-3000) (0 3000)

450 #3

420 #3

390 #3

370 #3

900-1800 900 1800 (3000-6000) (3000 6000)

410 #3

380 #3

360 #3

340 #2

1800-2700 1800 2700 (6000-9000) (6000 9000)

370 #3

340 #3

320 #2

300 #2

2700-3700 2700 3700 (9000-12000) (9000 12000)

320 #3

310 #2

290 #2

270 #2

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

CLUTCH CHART DRIVE

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

Altitude

P-85 3211080 1.438〉 (34.93mm) 28 46.625“(118.43) 11.5〉 (305mm) 10--58 Almond Red Silver/Blue R-11 #2

Meters (Feet)

DRIVEN

Shift Weight

Clutch Spring

Clutch Spring

Driven Helix

Chaincase Gearing

0-900 (0-3000)

10 -58 1058

Almond Red

Silver/ Blue

R11 #2

24--41 74 P HYVO

900-1800 (3000-6000)

10 -56 1056

Almond Red

Silver/ Blue

R11 #2

24-41 74 P HYVO

1800-2700 (6000-9000)

10 -54 1054

Almond Red

Silver/ Blue

R11 #2

24 41 74 P HYVO

2700-3700 (9000-12000)

10 -54 1054

Almond Red

Silver/ Blue

R11 #3

24-41 74 P HYVO

ENGINE Type . . . . . . . . . . . . . . . . . . . . . . . Displacement . . . . . . . . . . . . . . . Bore . . . . . . . . . . . . . . . . . . . . . . . Stroke . . . . . . . . . . . . . . . . . . . . . Piston / Cylinder Clearance . . . Piston Marking . . . . . . . . . . . . . . Piston Ring Marking . . . . . . . . . Piston Ring End Gap . . . . . . . . Head ccs (Uninstalled) . . . . . . . Head ccs (Installed) . . . . . . . . . Operating RPM200 . . . . . . . . . Idle RPM100 . . . . . . . . . . . . . . Engagement RPM200 . . . . . . Cylinder Head Torque . . . . . . . . Cylinder Base Nut Torque . . . . Crankcase Torque (8mm) . . . . . Crankcase Torque (10mm) . . . Flywheel Torque . . . . . . . . . . . . .

1.12

Liquid Cooled Case Reed w/VES 600cc 3.041〉 (77.25mm) 2.520 (64mm) .0045〉-.0059〉 (.11-.15mm) 2202a N/A .014〉-.020〉 (.38-.51mm) 36-37cc 29-30cc 8000 1500 4800 20-24 ft.lbs. (28-33 Nm) 30-34 ft.lbs. (41-47 Nm) 20-24 ft.lbs. (28-33 Nm) N/A 90 ft.lbs. (124 Nm)

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

120 psi Walbro E-806 Mikuni 02A 3022057


GENERAL INFORMATION MODEL: . . . . . . . . . . 600 Edge Pro X MODEL NUMBER: . S01NX6ES ENGINE MODEL: . . S60--44--PO--6E2234

ELECTRICAL

CAPACITIES

Flywheel I.D. . . . . . . 4060223 Fuel Tank . . . . . . . . . . CDI Marking . . . . . . . 4010458 Oil Tank . . . . . . . . . . . . Alternator Output . . . 280 Watts Coolant . . . . . . . . . . . . Ignition Timing . . . . . 24 BTDC@3300RPM1.5 Chaincase Oil . . . . . . . .Spark Plug / Gap . . Champion RN-57YCC / 0.025” (0.7mm) Lights: Head . . . . . . 2 60High/50 Low Tail . . . . . . . . 2@2 watts Brake . . . . . . 1@17 watts Voltage Regulator . . LR7 Electric Start . . . . . . . N/A *LR7= Full wave voltage regulator

SUSPENSION / CHASSIS

11.8 Gal. (45.4 L) 2.0 Quarts (3.3 L) 4 Quarts (3.78 L) 9 oz.

CHAINCASE

Body Style . . . . . . . . EDGE Sprockets / Chain . . . 24:41, 74 P 3/4 HYVO Front Suspension . . EDGE PRO -- X Reverse . . . . . . . . . . . . N/A Front Shocks . . . . . . Arvin IFP piggy back remote Brake Pads . . . . . . . . . Willwood Reservoir w/ Externally adjustable Chaincase Center Dist.7.658〉(19.45cm.) compression damping Driveshaft Sprockets . 2 Drivers-wide IFS Spring Rate . . . . 120/220#/in. Brake Type . . . . . . . . . Willwood Dual Piston Front Spring Preload TBA〉 Thread Adjust Front Vertical Travel 9.00〉 (26.46 cm.) Rear Suspension . . . EDGE Rear Travel . . . . . . . . 13.90〉 (35.31 cm.) Front Track Shock . . Arvin IFP remote reservoir w/externally adjustable compression damping Spring Rate . . . . . . . . 170#/in. Rear Track Shock . . Arvin IFP remote reservoir w/externally adjustable compression damping Rear Springs . . . . . . .359〉 (sq.) / 77 Track Type . . . . . . . . 15〉x121〉x1.25〉 (38.1x307.34x3.175cm.) Track Tension . . . . . . 1 1/2〉 (38mm) slack with 10# (4.54kg) weight 16〉 (40.64cm.) ahead of rear idler shaft

OPTIONAL REAR TORSION SPRINGS 2000 XCF SP/440 Edge Pro X Rear Torsion Springs SOFT

MEDIUM(STD)

FIRM

.347〉(sq.) diameter/77

.359〉(sq.) diameter/77

.375〉(sq.) diameter/77

L.H 7041627-067

L.H. 7041629-067

L.H. 7041631-067

R.H. 7041628-067

R.H 7041630-067

R.H. 7041632-067

1.13


GENERAL GENERAL INFORMATION INFORMATION MODEL: . . . . . . . . . . INDY 500 XC EDGE MODEL NUMBER: . S01NP5AS ENGINE MODEL: . . S5044POA1-1947

JETTING CHART AMBIENT TEMPERATURE

Altitude

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

(2) TM 38 Mikuni 390 40 9EFHI-60-2 P-6 1.5 1.5 Turns 1.5 Viton 87 Non-Oxygenated or 89 Oxygenated

Throttle Gap Under Cutaway . . . . . . 0.098〉 (2.5mm) Starter Jet . . . . . . . . . . . 145 Pilot Air Jet . . . . . . . . . . 0.7 Long

Meters (Feet)

Below -20 -20F F Below -29C

-20 to +10_F -20_ +10 F -29_to -12_C

+10 to +40_F +10_to +40 F -12_ to +5_C

Above +40 +40_F F Above 5_C

0-900 0 900 (0-3000) (0 3000)

410 #2

390 #2

370 #2

340 #2

900-1800 900 1800 (3000-6000) (3000 6000)

380 #2

350 #2

330 #2

310 #1

1800-2700 1800 2700 (6000-9000) (6000 9000)

340 #2

320 #2

300 #1

280 #1

2700-3700 2700 3700 (9000-12000) (9000 12000)

300 #2

280 #1

270 #1

250 #1

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

CLUTCH CHART DRIVE

Altitude

Clutch Spring

Clutch Spring

Driven Helix

Chaincase Gearing

0-900 (0-3000)

10 54 10-54

Dark Blue / White

Silver

R-32 #2

22-40-74P HYVO

900-1800 (3000-6000)

10 54 10-54

Dark Blue / White

Silver

R-32 #3

21-40-74P HYVO

1800-2700 (6000-9000)

10 AL

Dark Blue / White

Silver / Blue

R-32 #1

20-40-74P HYVO

2700-3700 (9000-12000)

10

Dark Blue / White

Silver / Blue

R-32 #1

20-40-74P HYVO

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

P-85 3211080 1.438〉 (36.52mm) 28 46.625〉 11.50 10-54 Dark Blue / White Silver R-32 #2

DRIVEN

Shift Weight

Meters (Feet)

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 RPM200 . . . . . . . . . Idle RPM200 . . . . . . . . . . . . . . Engagement RPM300 . . . . . . Cylinder Head Torque . . . . . . . . Cylinder Base Nut Torque . . . . Crankcase Torque (8mm) . . . . . Crankcase Torque (10mm) . . . Flywheel Torque . . . . . . . . . . . . .

1.14

Liquid Cooled Case Reed 500cc 2.776〉 (70.5mm) 2.520〉 (64mm) 0.0045〉 - 0.0063〉 (0.11 - 0.16mm) N/A EK 2205 N/A 0.012〉 - 0.018〉 (0.30 - 0.46mm) 27.50.5cc 24.4cc 8000 RPM 1500 RPM 3900 RPM 20-24 ft.lbs. (28-33 Nm) 30-34 ft.lbs. (41-47 Nm) 20-24 ft.lbs. (28-33 Nm) N/A 90 ft.lbs. (124 Nm)

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

125 psi Walbro FPA-3 Mikuni 01B 3021048


GENERAL INFORMATION MODEL: . . . . . . . . . . INDY 500 XC EDGE MODEL NUMBER: . S01NP5AS ENGINE MODEL: . . S5044POA1-1947

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

Spark Plug / Gap . . . Lights: Head . . . . . . Tail . . . . . . . . Brake . . . . . . Voltage Regulator . . Electric Start . . . . . . . Magneto Pulses . . . .

CAPACITIES Kokusan 4060223 Fuel Tank . . . . . . . . . . 4010438 Oil Tank . . . . . . . . . . . . 280 Watts Coolant . . . . . . . . . . . . 12 BTDC@3000RPM1.5 Chaincase Oil . . . . . . . 0.343〉 BTDC (0.008〉) 0.872mm BTDC (0.208mm) Champion RN57YCC / 0.025〉 (0.64mm) PN 2870448 (x2) PN 4030024 (x2) PN 4030045 (x1) T1 Option 6

SUSPENSION / CHASSIS

11.8 gallons (44.7 liters) 4 quarts (3.8 liters) 4 quarts (3.8 liters) 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 . . . 22-40, 74P HYVO EDGE Reverse . . . . . . . . . . . . Option Indy Select Brake Pads . . . . . . . . . Type 81, Large 100#/in. Chaincase Center Dist.7.92〉 (20.12cm.) 1/4〉 Thread Adjust Driveshaft Sprockets . 2 Drivers Wide 10〉 (25.4cm.) Brake Type . . . . . . . . . Polaris HPB, Liquid Cooled Improved Travel EDGE 13.9〉 (35.3cm.) FOX IFP 200#/in. variable Position Sensitive .375〉 (sq.) / 77 15〉x121〉x.82〉 (38.1x307.34x2.08cm.) 3/8〉 - 1/2〉 (1-1.3 cm.) slack with 10# (4.54kg) weight 16〉 (40.64cm.) ahead of rear idler shaft. Overall Snowmobile Length . . . . . . . . . . . . . . . . . 113〉 (287cm.) Overall Snowmobile Height . . . . . . . . . . . . . . . . . 45〉 (114cm.) Maximum Snowmobile Width . . . . . . . . . . . . . . . 48〉 (122cm.)

OPTIONAL REAR TORSION SPRINGS SOFT

MEDIUM(STD)

FIRM

.359〉(Sq.) Diameter x 77 .375〉(Sq.) Diameter x 77 .405〉(Sq.) Diameter x 77 L.H . 7041629-067

L.H. 7041942-067

L.H. 7041940-067

R.H. 7041630-067

R.H. 7041943-067

R.H. 7041941-067

1.15


GENERAL GENERAL INFORMATION INFORMATION MODEL: . . . . . . . . . . INDY 500 XC SP EDGE MODEL NUMBER: . S01NP5CS (A, B) ENGINE MODEL: . . S5044POA2-1948

JETTING CHART AMBIENT TEMPERATURE

Altitude

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 . . . . . . . . . . Exhaust Valve Spring .

(2) TM 38 w/TPS Mikuni 400 40 9EFH01-60-3 P-6 1.5 1.25 Turns 1.5 Viton Key Switch Adjustable 91 Premium 89 Regular 0.0787〉 (2.0mm) 145 0.7 Long Purple / White

-20 to +10_F -20_ +10 F -29_to -12_C

+10 to +40_F +10_to +40 F -12_ to +5_C

Above +40 +40_F F Above 5_C

0-900 0 900 (0-3000) (0 3000)

420 #3

400 #3

380 #3

350 #3

900-1800 900 1800 (3000-6000) (3000 6000)

390 #3

360 #3

340 #3

320 #2

1800-2700 1800 2700 (6000-9000) (6000 9000)

350 #3

330 #3

310 #2

290 #2

2700-3700 2700 3700 (9000-12000) (9000 12000)

310 #3

290 #2

270 #2

260 #2

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

CLUTCH CHART DRIVE

Altitude

P-85 3211080 1.438〉 (36.52mm) 28 46.625〉 11.50〉 10-54 Dark Blue / White Silver / Blue R-8 #3

DRIVEN

Shift Weight

Clutch Spring

Clutch Spring

Driven Helix

Chaincase Gearing

0-900 (0-3000)

10 54 10-54

Dark Blue / White

Silver / Blue

R-8 #2

22-40 74P HYVO

900-1800 (3000-6000)

10 AL

Dark Blue / White

Silver / Blue

R-8 #3

22-40 74P HYVO

1800-2700 (6000-9000)

10M

Dark Blue / White

Silver / Blue

R-8 #3

21-40 74P HYVO

2700-3700 (9000-12000)

10B

Dark Blue / White

Silver / Blue

R-8 #3

21-40 74P HYVO

Meters (Feet)

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

Meters (Feet)

Below -20 -20F F Below -29C

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 RPM200 . . . . . . . . . Idle RPM200 . . . . . . . . . . . . . . Engagement RPM300 . . . . . . Cylinder Head Torque . . . . . . . . Cylinder Base Nut Torque . . . . Crankcase Torque (8mm) . . . . . Crankcase Torque (10mm) . . . Flywheel Torque . . . . . . . . . . . . .

1.16

Liquid Cooled Case Reed w/VES 500cc 2.776〉 (70.5mm) 2.520〉 (64mm) 0.0045〉 - 0.0055〉 (0.11 - 0.14mm) N/A 2252c N/A 0.012〉 - 0.018〉 (0.30 - 0.46mm) 26.50.5cc 25.20.5cc 8400 RPM 1500 RPM 4100 RPM 20-24 ft.lbs. (28-33 Nm) 30-34 ft.lbs. (41-47 Nm) 20-24 ft.lbs. (28-33 Nm) N/A 90 ft.lbs. (124 Nm)

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

120 psi Walbro FPA-3 Mikuni 06 3021040


GENERAL INFORMATION MODEL: . . . . . . . . . . INDY 500 XC SP EDGE MODEL NUMBER: . S01NP5CS (A, B) ENGINE MODEL: . . S5044POA2-1948

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

Spark Plug / Gap . . . Lights: Head . . . . . . Tail . . . . . . . . Brake . . . . . . Voltage Regulator . . Electric Start . . . . . . . Magneto Pulses . . . .

CAPACITIES Kokusan 4060223 Fuel Tank . . . . . . . . . . 4010440 Oil Tank . . . . . . . . . . . . 280 Watts Coolant . . . . . . . . . . . . 20 BTDC@3000RPM1.5 Chaincase Oil . . . . . . . With TPS Unplugged. 0.0944〉 (0.0811 - 0.11) 2.3986mm (2.0584 - 2.7664) Champion RN57YCC / 0.028〉 (0.7mm) PN 2870448 (x2) PN 4030024 (x2) PN 4030045 (x1) T1 Option 6

SUSPENSION / CHASSIS

11.8 gallons (44.7 liters) 4 quarts (3.8 liters) 4 quarts (3.8 liters) 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 . . . 22-40-74P HYVO EDGE Reverse . . . . . . . . . . . . Option Fox IFP Brake Pads . . . . . . . . . Type 81, Large 68/160#/in. Chaincase Center Dist.7.92〉 (20.12cm.) 1 3/4〉 Thread Adjust Driveshaft Sprockets . 2 Drivers Wide 10.3〉 (26.2cm.) Brake Type . . . . . . . . . Polaris HPB, Liquid Cooled Improved Travel EDGE 13.9〉 (35.3cm.) Fox IFP 160#/in. variable Position Sensitive .375〉 (sq.) / 77 15〉x121〉x.91〉 (38.1x307.34x2.31cm.) 3/8〉 - 1/2〉 (1-1.3 cm.) slack with 10# (4.54kg) weight 16〉 (40.64cm.) ahead of rear idler shaft. Overall Snowmobile Length . . . . . . . . . . . . . . . . . 113〉 (287cm.) Overall Snowmobile Height . . . . . . . . . . . . . . . . . 45〉 (114cm.) Maximum Snowmobile Width . . . . . . . . . . . . . . . 48〉 (122cm.)

OPTIONAL REAR TORSION SPRINGS SOFT

MEDIUM(STD)

FIRM

.359〉(Sq.) Diameter x 77 .375〉(Sq.) Diameter x 77 .405〉(Sq.) Diameter x 77 L.H . 7041629-067

L.H. 7041942-067

L.H. 7041940-067

R.H. 7041630-067

R.H. 7041943-067

R.H. 7041941-067

1.17


GENERAL GENERAL INFORMATION INFORMATION MODEL: . . . . . . . . . . INDY 600 XC SP EDGE / 600 EDGE X MODEL NUMBER: . S01NP6ES (A, B, X) ENGINE MODEL: . . S6044POA2-1949

JETTING CHART AMBIENT TEMPERATURE

Altitude

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

(2) TM 38 Mikuni w/TPS 430 40 9DFH-60-3 P-8 2.5 N/A 1.5 Viton Key Switch Adjustable 0.0787〉 (2mm) 0.9 Long 140 1.5 Turns Pink

-20 to +10_F -20_ +10 F -29_to -12_C

+10 to +40_F +10_to +40 F -12_ to +5_C

Above +40 +40_F F Above 5_C

0-900 0 900 (0-3000) (0 3000)

460 #3

430 #3

400 #3

380 #3

900-1800 900 1800 (3000-6000) (3000 6000)

410 #3

390 #3

360 #3

340 #2

1800-2700 1800 2700 (6000-9000) (6000 9000)

370 #3

340 #3

310 #2

290 #2

2700-3700 2700 3700 (9000-12000) (9000 12000)

320 #3

290 #2

270 #2

260 #2

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

CLUTCH CHART DRIVE

Altitude

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

Meters (Feet)

Below -20 -20F F Below -29C

P-85 3211080 1.438〉 (36.52mm) 28 46.625〉 11.50〉 10-58 Dark Blue/White Silver/Blue R-11 #2

Meters (Feet)

DRIVEN

Shift Weight

Clutch Spring

Clutch Spring

Driven Helix

Chaincase Gearing

0-900 (0-3000)

10 58 10-58

Dark Blue / White

Silver / Blue

R-11 #2

23-39 74P HYVO

900-1800 (3000-6000)

10 56 10-56

Dark Blue / White

Silver / Blue

R-11 #2

23-39 74P HYVO

1800-2700 (6000-9000)

10 54 10-54

Dark Blue / White

Silver / Blue

R-11 #2

32-39 74P HYVO

2700-3700 (9000-12000)

10 54 10-54

Dark Blue / White

Silver / Blue

R-11 #3

23-39 74P HYVO

ENGINE Type . . . . . . . . . . . . . . . . . . . . . . . Displacement . . . . . . . . . . . . . . . Bore . . . . . . . . . . . . . . . . . . . . . . . Stroke . . . . . . . . . . . . . . . . . . . . . Piston / Cylinder Clearance . . . Piston Marking . . . . . . . . . . . . . . Piston Ring Marking . . . . . . . . . Piston Ring End Gap . . . . . . . . Head ccs (Uninstalled) . . . . . . . Head ccs (Installed) . . . . . . . . . Operating RPM200 . . . . . . . . . Idle RPM100 . . . . . . . . . . . . . . Engagement RPM200 . . . . . . Cylinder Head Torque . . . . . . . . Cylinder Base Nut Torque . . . . Crankcase Torque (8mm) . . . . . Crankcase Torque (10mm) . . . Flywheel Torque . . . . . . . . . . . . .

1.18

Liquid Cooled Case Reed w/VES 600cc 3.041〉 (77.25mm) 2.520 (64mm) .0045〉-.0059〉 (.11-.15mm) 2202a N/A .014〉-.020〉 (.38-.51mm) 36-37cc 29-30cc 8000 1400 4250 20-24 ft.lbs. (28-33 Nm) 30-34 ft.lbs. (41-47 Nm) 20-24 ft.lbs. (28-33 Nm) N/A 90 ft.lbs. (124 Nm)

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

120 psi Walbro E-806 Mikuni 02A 3022057


GENERAL INFORMATION MODEL: . . . . . . . . . . INDY 600 XC SP EDGE / 600 EDGE X MODEL NUMBER: . S01NP6ES (A, B, X) ENGINE MODEL: . . S6044POA2-1949

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

Spark Plug / Gap . . . Lights: Head . . . . . . Tail . . . . . . . . Brake . . . . . . Voltage Regulator . . Electric Start . . . . . . . Magneto Pulses . . . .

CAPACITIES Kokusan 4060223 Fuel Tank . . . . . . . . . . 4010439 Oil Tank . . . . . . . . . . . . 280 Watts Coolant . . . . . . . . . . . . 24 BTDC@3250RPM500 RPM Chaincase Oil . . . . . . . With TPS unplugged 0.1350〉 3.430mm Champion RN57YCC / 0.025〉 (0.64mm) PN 2870448 (x2) PN 4030024 (x2) PN 4030045 (x1) T1 Option 6

SUSPENSION / CHASSIS

11.8 gallons (44.7 liters) 4 quarts (3.8 liters) 4 quarts (3.8 liters) 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 Reverse . . . . . . . . . . . . Option Fox IFP Brake Pads . . . . . . . . . Type 81, Large 68/160#/in. Chaincase Center Dist.7.92〉 (20.12cm.) 1 3/4〉 Thread Adjust Driveshaft Sprockets . 2 Drivers Wide 10.3〉 (26.2cm.) Brake Type . . . . . . . . . Polaris HPB, Liquid Cooled Improved Travel EDGE 13.9〉 (35.3cm.) Fox IFP 160#/in. variable Position Sensitive .375〉 (sq.) / 77 15〉x121〉x.91〉 (38.1x307.34x2.31cm.) 3/8〉 - 1/2〉 (1-1.3 cm.) slack with 10# (4.54kg) weight 16〉 (40.64cm.) ahead of rear idler shaft. Overall Snowmobile Length . . . . . . . . . . . . . . . . . 113〉 (287cm.) Overall Snowmobile Height . . . . . . . . . . . . . . . . . 45〉 (114cm.) Maximum Snowmobile Width . . . . . . . . . . . . . . . 48〉 (122cm.)

OPTIONAL REAR TORSION SPRINGS SOFT

MEDIUM(STD)

FIRM

.359〉(Sq.) Diameter x 77 .375〉(Sq.) Diameter x 77 .405〉(Sq.) Diameter x 77 L.H . 7041629-067

L.H. 7041942-067

L.H. 7041940-067

R.H. 7041630-067

R.H. 7041943-067

R.H. 7041941-067

1.19


GENERAL GENERAL INFORMATION INFORMATION MODEL: . . . . . . . . . . INDY 700 XC SP EDGE MODEL NUMBER: . S01NP7AS (A, B) ENGINE MODEL: . . S7070POA1-1951

JETTING CHART AMBIENT TEMPERATURE

Altitude

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

(2) TM40 Mikuni 460 45 9DFH06-57-2 P-8 2.0 1.25 Turns 1.8 87 Non-Oxygenated or 89 Oxygenated

Throttle Gap Under Cutaway . . . . . . 0.0787〉 (2.0mm) Starter Jet . . . . . . . . . . . 145 Pilot Air Jet . . . . . . . . . . 0.8 Long

Meters (Feet)

Below -20 -20F F Below -29C

-20 to +10_F -20_ +10 F -29_to -12_C

+10 to +40_F +10_to +40 F -12_ to +5_C

Above +40 +40_F F Above 5_C

0-900 0 900 (0-3000) (0 3000)

490 #2

460 #2

430 #2

400 #2

900-1800 900 1800 (3000-6000) (3000 6000)

440 #2

410 #2

380 #2

360 #1

1800-2700 1800 2700 (6000-9000) (6000 9000)

390 #2

360 #2

330 #1

310 #1

2700-3700 2700 3700 (9000-12000) (9000 12000)

330 #2

310 #1

280 #1

260 #1

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

CLUTCH CHART DRIVE

Altitude

Clutch Spring

Clutch Spring

Driven Helix

Chaincase Gearing

0-900 (0-3000)

10-60 Bushed

Almond Round

Silver / Blue

R-11 #2

23-39 74P HYVO

900-1800 (3000-6000)

10-58 Bushed

Almond Round

Silver / Blue

R-11 #2

23-39 74P HYVO

1800-2700 (6000-9000)

10-56 Bushed

Almond Round

Silver / Blue

R-11 #3

22-39 74P HYVO

2700-3700 (9000-12000)

10-54 Bushed

Almond Round

Silver / Blue

R-11 #3

22-39 74P HYVO

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

P-85 3211080 1.438〉 (36.52mm) 28 46.625〉 11.50〉 10-60 Bushed Almond / Round Silver / Blue R-11 #2

DRIVEN

Shift Weight

Meters (Feet)

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 RPM200 . . . . . . . . . Idle RPM200 . . . . . . . . . . . . . . Engagement RPM200 . . . . . . Cylinder Head Torque . . . . . . . . Cylinder Base Nut Torque . . . . Crankcase Torque (8mm) . . . . . Crankcase Torque (10mm) . . . Flywheel Torque . . . . . . . . . . . . .

1.20

Liquid Cooled Case Reed Twin 700cc 3.1889〉 (81mm) 2.6772〉 (68mm) 0.0047〉 - 0.0060〉 (0.12 - 0.15mm) N/A 2108 N/A 0.014〉 - 0.020〉 (0.36 - 0.51mm) 40.2.50cc 31 - 32cc 8250 RPM 1500 RPM 4100 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)

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

125 psi Walbro FPA-4 Mikuni 03A 3021022


GENERAL INFORMATION MODEL: . . . . . . . . . . INDY 700 XC SP EDGE MODEL NUMBER: . S01NP7AS (A, B) ENGINE MODEL: . . S7070POA1-1951

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

Spark Plug / Gap . . . Lights: Head . . . . . . Tail . . . . . . . . Brake . . . . . . Voltage Regulator . . Electric Start . . . . . . . Magneto Pulses . . . .

CAPACITIES Kokusan 4060223 Fuel Tank . . . . . . . . . . 4010331 Oil Tank . . . . . . . . . . . . 280 Watts Coolant . . . . . . . . . . . . 19 BTDC@2500RPM1.5 Chaincase Oil . . . . . . . 0.0907〉 (0.077〉 - 0.11〉) 2.3036mm (2.0 - 2.7mm) Champion RN57YCC / 0.025〉 (0.64mm) PN 2870448 (x2) PN 4030024 (x2) PN 4030045 (x1) T1 Option 6

SUSPENSION / CHASSIS

11.8 gallons (44.7 liters) 4 quarts (3.8 liters) 4 quarts (3.8 liters) 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 Reverse . . . . . . . . . . . . Option Fox IFP Brake Pads . . . . . . . . . Type 81, Large 68/160#/in. Chaincase Center Dist 7.92〉 (20.12cm.) 1 3/4〉 Thread Adjust Driveshaft Sprockets . 2 Drivers Wide 10.3〉 (26.2cm.) Brake Type . . . . . . . . . Polaris HPB, Liquid Cooled Improved Travel EDGE 13.9〉 (35.3cm.) Fox IFP 160#/in. variable Position Sensitive .375〉 (sq.) / 77 15〉x121〉x.91〉 (38.1x307.34x2.31cm.) 3/8〉 - 1/2〉 (1-1.3 cm.) slack with 10# (4.54kg) weight 16〉 (40.64cm.) ahead of rear idler shaft. Overall Snowmobile Length . . . . . . . . . . . . . . . . . 113〉 (287cm.) Overall Snowmobile Height . . . . . . . . . . . . . . . . . 45〉 (114cm.) Maximum Snowmobile Width . . . . . . . . . . . . . . . 48〉 (122cm.)

OPTIONAL REAR TORSION SPRINGS SOFT

MEDIUM(STD)

FIRM

.359〉(Sq.) Diameter x 77 .375〉(Sq.) Diameter x 77 .405〉(Sq.) Diameter x 77 L.H . 7041629-067

L.H. 7041942-067

L.H. 7041940-067

R.H. 7041630-067

R.H. 7041943-067

R.H. 7041941-067

1.21


GENERAL GENERAL INFORMATION INFORMATION MODEL: . . . . . . . . . . INDY 800 XC SP EDGE MODEL NUMBER: . S01NP8BS (A, B) ENGINE MODEL: . . S8070POA1-1952

JETTING CHART AMBIENT TEMPERATURE

Altitude

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

(2) TM 40 Mikuni 460 45 9EFY2-61-3 P-8 2.0 1.75 Turns 1.8 Key Switch Adjustable 91 Premium 89 Regular

Throttle Gap Under Cutaway . . . . . . 0.0787〉 (2.0mm) Starter Jet . . . . . . . . . . . 145 Pilot Air Jet . . . . . . . . . . 0.7 Long

Meters (Feet)

Below -20 -20F F Below -29C

-20 to +10_F -20_ +10 F -29_to -12_C

+10 to +40_F +10_to +40 F -12_ to +5_C

Above +40 +40_F F Above 5_C

0-900 0 900 (0-3000) (0 3000)

490 #3

460 #3

430 #3

400 #3

900-1800 900 1800 (3000-6000) (3000 6000)

440 #3

420 #3

390 #3

370 #2

1800-2700 1800 2700 (6000-9000) (6000 9000)

400 #3

380 #3

350 #2

330 #2

2700-3700 2700 3700 (9000-12000) (9000 12000)

360 #3

340 #2

320 #2

300 #2

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

CLUTCH CHART DRIVE

Altitude

Clutch Spring

Clutch Spring

Driven Helix

Chaincase Gearing

0-900 (0-3000)

10 64 10-64

Almond Round

Silver

R-12 #2

25-41 76P HYVO

900-1800 (3000-6000)

10 62 10-62

Almond Round

Silver

R-12 #2

25-41 76P HYVO

1800-2700 (6000-9000)

10 60 10-60

Almond Round

Silver /Blue

R-12 #2

25-41 76P HYVO

2700-3700 (9000-12000)

10 58 10-58

Almond Round

Silver /Blue

R-12 #2

25-41 76P HYVO

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

P-85 Roller 3211080 1.438〉 (36.52mm) 28 46.625〉 11.50〉 10-64 Almond / Round Silver R-12 #2

DRIVEN

Shift Weight

Meters (Feet)

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 RPM200 . . . . . . . . . Idle RPM200 . . . . . . . . . . . . . . Engagement RPM200 . . . . . . Cylinder Head Torque . . . . . . . . Cylinder Base Nut Torque . . . . Crankcase Torque (8mm) . . . . . Crankcase Torque (10mm) . . . Flywheel Torque . . . . . . . . . . . . .

1.22

Liquid Cooled Case Reed Twin 794cc 3.3464〉 (85mm) 2.7559〉 (70mm) 0.006〉 - 0.0074〉 (0.15 - 0.188mm) N/A 2261 N/A 0.016〉 - 0.022〉 (0.41 - 0.56mm) 50.00.5cc 36.0 - 37.0cc 8000 RPM 1300 RPM 4100 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) 90 ft.lbs. (124 Nm)

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

140 psi Walbro FPA-4 Mikuni 03A 3021066


GENERAL INFORMATION MODEL: . . . . . . . . . . INDY 800 XC SP EDGE MODEL NUMBER: . S01NP8BS (A, B) ENGINE MODEL: . . S8070POA1-1952

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

Spark Plug / Gap . . . Lights: Head . . . . . . Tail . . . . . . . . Brake . . . . . . Voltage Regulator . . Electric Start . . . . . . . Magneto Pulses . . . .

CAPACITIES Kokusan 4060223 Fuel Tank . . . . . . . . . . 4010405 Oil Tank . . . . . . . . . . . . 280 Watts Coolant . . . . . . . . . . . . 13 BTDC@3000500RPM Chaincase Oil . . . . . . . 0.0443〉 1.1251mm Champion RN57YCC / 0.028〉 (0.7mm) PN 2870448 (x2) PN 4030024 (x2) PN 4030045 (x1) T1 Option 6

SUSPENSION / CHASSIS

11.8 gallons (44.7 liters) 4 quarts (3.8 liters) 4 quarts (3.8 liters) 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 . . . 25-41-76P HYVO EDGE Reverse . . . . . . . . . . . . Option Fox IFP Brake Pads . . . . . . . . . Type 81, Large 68/160#/in. Chaincase Center Dist.7.92〉 (20.12cm.) 1 3/4〉 Thread Adjust Driveshaft Sprockets . 4 Drivers Wide 10.3〉 (26.2cm.) Brake Type . . . . . . . . . Polaris HPB, Liquid Cooled Improved Travel EDGE 13.9〉 (35.3cm.) Fox IFP 160#/in. variable Position Sensitive .375〉 (sq.) / 77 15〉x121〉x.91〉 (38.1x307.34x2.31cm.) 3/8〉 - 1/2〉 (1-1.3 cm.) slack with 10# (4.54kg) weight 16〉 (40.64cm.) ahead of rear idler shaft. Overall Snowmobile Length . . . . . . . . . . . . . . . . . 113〉 (287cm.) Overall Snowmobile Height . . . . . . . . . . . . . . . . . 45〉 (114cm.) Maximum Snowmobile Width . . . . . . . . . . . . . . . 48〉 (122cm.)

OPTIONAL REAR TORSION SPRINGS SOFT

MEDIUM(STD)

FIRM

.359〉(Sq.) Diameter x 77 .375〉(Sq.) Diameter x 77 .405〉(Sq.) Diameter x 77 L.H . 7041629-067

L.H. 7041942-067

L.H. 7041940-067

R.H. 7041630-067

R.H. 7041943-067

R.H. 7041941-067

1.23


GENERAL INFORMATION MODEL: . . . . . . . . . . INDY 800 XCR MODEL NUMBER: . S01SB8AS ENGINE MODEL: . . EC79-PL013

JETTING CHART AMBIENT TEMPERATURE

Altitude

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

(3) TM 38Mikuni 440 50 9DH6-54-3 P-4 Fixed 2.0 0.75 Turns 1.5 Viton Key Switch Adjustable 91 Premium 89 Regular 0.059〉 (1.5mm) 145 0.9 Blue

P-85 3211075 1.438〉 (36.52mm) 28 47.625〉 12.00〉 10-60 Bushed Almond Silver / Blue R-12 #2

-20 to +10_F -20_ +10 F -29_to -12_C

+10 to +40_F +10_to +40 F -12_ to +5_C

Above +40 +40_F F Above 5_C

0-900 0 900 (0-3000) (0 3000)

460 #3

440 #3

420 #2

390 #2

900-1800 900 1800 (3000-6000) (3000 6000)

420 #3

400 #3

380 #2

350 #2

1800-2700 1800 2700 (6000-9000) (6000 9000)

380 #3

360 #2

340 #2

320 #2

2700-3700 2700 3700 (9000-12000) (9000 12000)

340 #2

320 #2

300 #2

280 #2

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

CLUTCH CHART DRIVE

Altitude Meters (Feet)

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

Meters (Feet)

Below -20 -20F F Below -29C

DRIVEN

Shift Weight

Clutch Spring

Clutch Spring

Driven Helix

Chaincase Gearing

0-900 (0-3000)

10-60 Bushed

Almond

Silver / Blue

R-12 #2

24-39 70P HYVO

900-1800 (3000-6000)

10-58 Bushed

Almond

Silver / Blue

R-12 #2

24-39 70P HYVO

1800-2700 (6000-9000)

10-58 Bushed

Almond

Silver / Blue

R-12 #2

23-41 70P HYVO

2700-3700 (9000-12000)

10-56 Bushed

Almond

Silver / Blue

R-12 #2

23-41 70P HYVO

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 RPM200 . . . . . . . . . Idle RPM200 . . . . . . . . . . . . . . Engagement RPM300 . . . . . . Cylinder Head Torque . . . . . . . . Cylinder Base Nut Torque . . . . Crankcase Torque (8mm) . . . . . Crankcase Torque (10mm) . . . Flywheel Torque . . . . . . . . . . . . .

1.24

L/C Case Reed Triple w/VES 794cc 2.8346〉 (72mm) 2.5591〉 (65mm) 0.0028〉 - 0.0041〉 (0.07 - 0.105mm) 0.0078〉 (0.20mm) 79B 79A 0.012〉 - 0.018〉 (0.30 - 0.45mm) 28.1cc 23.9cc 8500 RPM 1500 RPM 4000 RPM 18-19.5 ft.lbs. (25-27 Nm) 23-25 ft.lbs. (32-35 Nm) 20-22 ft.lbs. (28-30 Nm) 23-35 ft.lbs. (32-35 Nm) 60-65 ft.lbs. (83-90 Nm)

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

140 psi Mikuni DF62 Mikuni 79A N / 79


GENERAL INFORMATION MODEL: . . . . . . . . . . INDY 800 XCR MODEL NUMBER: . S01SB8AS ENGINE MODEL: . . EC79-PL013

ELECTRICAL

CAPACITIES

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

FP9103 Fuel Tank . . . . . . . . . . CU7312 Oil Tank . . . . . . . . . . . . 280 Watts Coolant . . . . . . . . . . . . 26 BTDC@3500RPM1.5 Chaincase Oil . . . . . . . 0.163〉 BTDC (0.008〉) 4.138mm BTDC (0.021mm) Spark Plug / Gap . . . Champion RN2C / 0.028〉 (0.7mm) Lights: Head . . . . . . Low: PN 2870448 (x1), High: PN 4010253 (x2) Tail . . . . . . . . PN 4032084 (x2) Brake . . . . . . PN 4030045 (x2) Voltage Regulator . . LR7 Electric Start . . . . . . . Option *LR7= Full wave voltage regulator Magneto Pulses . . . . 6

SUSPENSION / CHASSIS

11.8 gallons (44.7 liters) 2.4 quarts (2.3 liters) 7 quarts (6.6 liters) 9 fl. oz.(266cc)

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 . . . . . .

Gen II Sprockets / Chain . . . 24-39-70P HYVO Indy XC-10 Reverse . . . . . . . . . . . . Option Fox IFP Brake Pads . . . . . . . . . Type 81, Large 120#/in. Chaincase Center Dist.7.05〉 (17.91cm.) 1 7/8〉 Thread Adjust Driveshaft Sprockets . 4 Drivers 10〉 (25.4cm.) Brake Type . . . . . . . . . Polaris HPB, Liquid Cooled XTRA-10 121〉 10.2〉 (25.9cm.) Fox IFP 200#/in. variable Electronic Adjustable Shock .359〉 (sq.) / 77 15〉x121〉x.91〉 (38.1x307.34x2.31cm.) 3/8〉 - 1/2〉 (1-1.3 cm.) slack with 10# (4.54kg) weight 16〉 (40.64cm.) ahead of rear idler shaft. Overall Snowmobile Length . . . . . . . . . . . . . . . . . 109〉 (277cm.) Overall Snowmobile Height . . . . . . . . . . . . . . . . . 44〉 (112cm.) Maximum Snowmobile Width . . . . . . . . . . . . . . . 48〉 (122cm.)

OPTIONAL REAR TORSION SPRINGS SOFT

MEDIUM(STD)

FIRM

.359〉(Sq.) Diameter x 85 .359〉(Sq.) Diameter x 77 .375〉(Sq.) Diameter x 77 L.H. 7041763-067

L.H. 7041629-067

L.H. 7041631-067

R.H. 7041764-067

R.H. 7041630-067

R.H. 7041632-067

1.25


GENERAL INFORMATION MODEL: . . . . . . . . . . INDY 500 RMK MODEL NUMBER: . S01SR5AS ENGINE MODEL: . . S5044POB2-1985

JETTING CHART AMBIENT TEMPERATURE

Altitude

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

(2) TM38 Mikuni 270 45 9FH4-57-2 P-6 1.5 Notched 0.5 Turns 1.5 Viton 87 Non-Oxygenated or 89 Oxygenated

Throttle Gap Under Cutaway . . . . . . 0.098〉 (2.5mm) Starter Jet . . . . . . . . . . . 155 Pilot Air Jet . . . . . . . . . . 0.7 Long

Meters (Feet)

Below -20 -20F F Below -29C

-20 to +10_F -20_ +10 F -29_to -12_C

+10 to +40_F +10_to +40 F -12_ to +5_C

Above +40 +40_F F Above 5_C

0-900 0 900 (0-3000) (0 3000)

430 #3

410 #3

390 #3

370 #3

900-1800 900 1800 (3000-6000) (3000 6000)

370 #3

350 #3

330 #2

310 #2

1800-2700 1800 2700 (6000-9000) (6000 9000)

310 #2

290 #2

270 #2

250 #2

2700-3700 2700 3700 (9000-12000) (9000 12000)

280 #2

260 #2

240 #2

220 #2

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

CLUTCH CHART DRIVE

Altitude

Clutch Spring

Clutch Spring

Driven Helix

Chaincase Gearing

0-900 (0-3000)

10 56 10-56

Almond

Silver / Blue

R-32 #3

18-41-68P HYVO

900-1800 (3000-6000)

10 AL 10-AL

Almond

Silver / Blue

R-32 #3

18-41-68P HYVO

1800-2700 (6000-9000)

10

Almond

Silver / Blue

R-32 #3

18-41-68P HYVO

2700-3700 (9000-12000)

10M

Almond

Silver / Blue

R-32 #3

18-41-68P HYVO

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

P-85 3211074 1.438〉 (36.52mm) 28 47.625〉 (121cm) 12.00〉 10 Almond Silver / Blue R-32 #3

DRIVEN

Shift Weight

Meters (Feet)

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 RPM200 . . . . . . . . . Idle RPM200 . . . . . . . . . . . . . . Engagement RPM300 . . . . . . Cylinder Head Torque . . . . . . . . Cylinder Base Nut Torque . . . . Crankcase Torque (8mm) . . . . . Crankcase Torque (10mm) . . . Flywheel Torque . . . . . . . . . . . . .

1.26

Liquid Cooled Case Reed Twin 500cc 2.776〉 (70.5mm) 2.520〉 (64mm) 0.0045〉 - 0.0063〉 (0.11 - 0.16mm) N/A EK2205 N/A 0.012〉 - 0.018〉 (0.30 - 0.46mm) 27.50.5cc 25.0cc 8000 RPM 1500 RPM 4000 RPM 20-24 ft.lbs. (28-33 Nm) 30-34 ft.lbs. (41-47 Nm) 20-24 ft.lbs. (28-33 Nm) N/A 90 ft.lbs. (124 Nm)

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

125 psi Walbro FPA-3 Mikuni 01B 3021048


GENERAL INFORMATION MODEL: . . . . . . . . . . INDY 500 RMK MODEL NUMBER: . S01SR5AS ENGINE MODEL: . . S5044POB2-1985

ELECTRICAL

CAPACITIES

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

Kokusan 4060223 Fuel Tank . . . . . . . . . . 4010259 Oil Tank . . . . . . . . . . . . 280 Watts Coolant . . . . . . . . . . . . 12 BTDC@2250RPM1.5 Chaincase Oil . . . . . . . 0.034〉 BTDC (0.008〉) 0.872mm BTDC (0.208mm) Spark Plug / Gap . . . Champion RN2C / 0.025〉 (0.64mm) Lights: Head . . . . . . Low: PN 2870448 (x1), High: PN 4010253 (x2) Tail . . . . . . . . PN 4030024 (x2) Brake . . . . . . PN 4030045 (x1) Voltage Regulator . . LR7 Electric Start . . . . . . . Option *LR7= Full wave voltage regulator Magneto Pulses . . . . 6

SUSPENSION / CHASSIS

11.8 gallons (44.7 liters) 3 quarts (2.8 liters) 5 quarts (4.7 liters) 9 fl. oz.(266cc)

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 . . . . . .

Gen II Sprockets / Chain . . . 18-41, 68P HYVO Indy X-10 38〉 CRC Reverse . . . . . . . . . . . . Option Nitrogen Cell Brake Pads . . . . . . . . . Type 81, Large 80#/in. Chaincase Center Dist.7.05〉 (17.91cm) 5/8〉 Thread Adjust Driveshaft Sprockets . 2 Drivers Wide, XHS 8.25 in.(21cm) Brake Type . . . . . . . . . Polaris HPB XTRA-Lite 136〉 12〉 (30.5cm) Nitrogen Cell 200#/in. variable Indy Select .347〉 (sq.) / 77 15〉x136〉x1.5〉 (38.1x345.44x3.81cm) 3/8〉 - 1/2〉 (1-1.3 cm) slack with 10# (4.54kg) weight 16〉 (40.64cm) ahead of rear idler shaft. Overall Snowmobile Length . . . . . . . . . . . . . . . . . 116〉 (295cm) Overall Snowmobile Height . . . . . . . . . . . . . . . . . 45〉 (114cm) Maximum Snowmobile Width . . . . . . . . . . . . . . . 43.5〉 (110.4cm)

OPTIONAL REAR TORSION SPRINGS SOFT

MEDIUM(STD)

FIRM

.347〉(Sq.) Diameter x 90 .347〉(Sq.) Diameter x 77 .359〉(Sq.) Diameter x 77 L.H .7041911-067

L.H. 7041627-067

L.H. 7041629-067

R.H. 7041912-067

R.H. 7041628-067

R.H. 7041630-067

1.27


GENERAL INFORMATION MODEL: . . . . . . . . . . INDY 600 RMK MODEL NUMBER: . S01SR6DS ENGINE MODEL: . . S6070POA2-1988

JETTING CHART AMBIENT TEMPERATURE

Altitude

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

(2) TM 40 w/TPS Mikuni 310 40 8BEYI-57-2 P-8 (825) 2.0 2.0 Turns 1.8 Key Switch Adjustable Premium 91 Regular 87 Non-Oxygen ated

Throttle Gap Under Cutaway . . . . . . 0.137〉 (3.5mm) Starter Jet . . . . . . . . . . . 145 Pilot Air Jet . . . . . . . . . . 0.6 Long

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

Meters (Feet)

Below -20 -20F F Below -29C

-20 to +10_F -20_ +10 F -29_to -12_C

+10 to +40_F +10_to +40 F -12_ to +5_C

Above +40 +40_F F Above 5_C

0-900 0 900 (0-3000) (0 3000)

460 #4

430 #4

400 #3

380 #3

900-1800 900 1800 (3000-6000) (3000 6000)

400 #3

370 #3

350 #2

330 #2

1800-2700 1800 2700 (6000-9000) (6000 9000)

350 #3

330 #2

310 #2

290 #2

2700-3700 2700 3700 (9000-12000) (9000 12000)

320 #2

310 #2

290 #2

270 #2

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

CLUTCH CHART DRIVE

Altitude

Clutch Spring

Clutch Spring

Driven Helix

Chaincase Gearing

0-900 (0-3000)

10-58 Bushed

Almond Round

Silver / Blue

R-8 #2

19-40 68P HYVO

900-1800 (3000-6000)

10-56 Bushed

Almond Round

Silver / Blue

R-8 #2

19-40 68P HYVO

1800-2700 (6000-9000)

10-54 Bushed

Almond Round

Silver / Blue

R-8 #2

19-40 68P HYVO

2700-3700 (9000-12000)

10 Bushed

Almond Round

Silver / Blue

R-8 #3

19-40 68P HYVO

Meters (Feet)

P-85 3211065 1.438〉 (36.53mm) 28 48.375〉 (122.87cm) 12.5〉 10-54 Almond Round Silver / Blue R-8 #2

DRIVEN

Shift Weight

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 RPM200 . . . . . . . . . Idle RPM200 . . . . . . . . . . . . . . Engagement RPM300 . . . . . . Cylinder Head Torque . . . . . . . . Cylinder Base Nut Torque . . . . Crankcase Torque (8mm) . . . . . Crankcase Torque (10mm) . . . Flywheel Torque . . . . . . . . . . . . .

1.28

Liquid Cooled Case Reed w/TPS 593cc 2.9930〉 (74.5mm) 2.6772〉 (68mm) 0.0044〉 - 0.0058〉 (0.11 - 0.15mm) N/A 2171 N/A 0.012〉 - 0.018〉 (0.30 - 0.46mm) 34.0cc 26.0cc 8000 RPM 1400 RPM 4100 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) 90 ft.lbs. (124 Nm)

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

125 psi Walbro FPA Mikuni 03A 3021021


GENERAL INFORMATION MODEL: . . . . . . . . . . INDY 600 RMK MODEL NUMBER: . S01SR6DS ENGINE MODEL: . . S6070POA2-1988

ELECTRICAL

CAPACITIES

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

Kokusan 4060223 Fuel Tank . . . . . . . . . . 4010334 Oil Tank . . . . . . . . . . . . 280 Watts Coolant . . . . . . . . . . . . 20 BTDC@3000RPM1.5 Chaincase Oil . . . . . . . With TPS Unplugged. 0.1003〉 BTDC (0.0861〉 - 0.1157〉) 2.5485mm BTDC (2.188 - 2.939mm) Spark Plug / Gap . . . Champion RN57YCC / 0.025〉 (0.64mm) Lights: Head . . . . . . Low: PN 2870448 (x1), High: PN 4010253 (x2) Tail / Brake . PN 4030043 (x1) Voltage Regulator . . LR7 Electric Start . . . . . . . Option *LR7= Full wave voltage regulator Magneto Pulses . . . . 6

SUSPENSION / CHASSIS

11.8 gallons (44.7 liters) 3 quarts (2.8 liters) 5.5 quarts (5.2 liters) 9 fl. oz.(266cc)

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 . . . . . .

Gen II Sprockets / Chain . . . 19-40-68P HYVO Indy XC-10 38” CRC Reverse . . . . . . . . . . . . Option Nitrogen Cell Brake Pads . . . . . . . . . Type 81, Large 100#/in. Chaincase Center Dist.7.05〉 (17.91cm) 1/2〉 Thread Adjust Driveshaft Sprockets . 2 Drivers Wide, XHS 7.4〉 - 7.8〉 (18.8 - 19.8cm) Brake Type . . . . . . . . . Polaris HPB Liquid Cooled XTRA-Lite 136〉 11.5〉 (29.2cm) Ryde FX 200#/in. variable Indy Select .359〉 (sq.) / 85 15〉x136〉x 1.75〉 (38.1x307.34x2.08cm) 3/8〉 - 1/2〉 (1-1.3 cm) slack with 10# (4.54kg) weight 16〉 (40.64cm) ahead of rear idler shaft. Overall Snowmobile Length . . . . . . . . . . . . . . . . . 116〉 (295cm) Overall Snowmobile Height . . . . . . . . . . . . . . . . . 45〉 (114cm) Maximum Snowmobile Width . . . . . . . . . . . . . . . 44.25〉 (112.4cm)

OPTIONAL REAR TORSION SPRINGS SOFT

MEDIUM(STD)

FIRM

.347〉(Sq.) Diameter x 90 .359〉(Sq.) Diameter x 85 .359〉(Sq.) Diameter x 77 L.H .7041911-067

L.H. 7041763-067

L.H. 7041629-067

R.H. 7041912-067

R.H. 7041764-067

R.H. 7041630-067

1.29


GENERAL INFORMATION MODEL: . . . . . . . . . . INDY 700 RMK MODEL NUMBER: . S01SR7AS (S01SM7AS) ENGINE MODEL: . . S7070POB2-1992

JETTING CHART AMBIENT TEMPERATURE

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

Altitude

(2) TM 40 w/TPS Mikuni MAG 340 / PTO 320 45 8DGY1-57-2 P-8 (825) 2.0 2.5 Turns 1.8 Key Switch Adjustable

Below -20 -20F F Below -29C

-20 to +10_F -20_ +10 F -29_to -12_C

+10 to +40_F +10_to +40 F -12_ to +5_C

Above +40 +40_F F Above 5_C

0-900 (0-3000)

MAG 490 PTO 470 #4

MAG 460 PTO 440 #4

MAG 430 PTO 410 #4

MAG 400 PTO 380 #4

900-1800 (3000-6000)

MAG 440 PTO 420 #3

MAG 420 PTO 400 #3

MAG 390 PTO 370 #3

MAG 370 PTO 350 #2

1800-2700 (6000-9000)

MAG 390 PTO 370 #3

MAG 370 PTO 350 #3

MAG 340 PTO 320 #2

MAG 320 PTO 300 #2

2700-3700 (9000-12000)

MAG 360 PTO 340 #2

MAG 340 PTO 320 #2

MAG 320 PTO 300 #2

MAG 300 PTO 280 #1

Meters (Feet)

0.118〉 (3.0mm) 145 0.9 Long

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

- Production Setting

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

P-85 3211065 1.438〉 (36.53mm) 28 48.375〉 12.5〉 10-56 Bushed Almond Round Silver / Blue R-11 #2

CLUTCH CHART DRIVE Shift Weight

Clutch Spring

Clutch Spring

Driven Helix

Chaincase Gearing (136”)

Chaincase Gearing (144”)

0-900 (0-3000)

10-60 Bushed

Almond Round

Silver / Blue

R-11 #2

20-39 68P HYVO

19 40 68P 19-40-68P HYVO

900-1800 (3000-6000)

10-58 Bushed

Almond Round

Silver / Blue

R-11 #2

20-39 68P HYVO

19 40 68P 19-40-68P HYVO

1800-2700 (6000-9000)

10-56 Bushed

Almond Round

Silver / Blue

R-11 #2

20-39 68P HYVO

19 40 68P 19-40-68P HYVO

2700-3700 (9000-12000)

10-54 Bushed

Almond Round

Silver / Blue

R-11 #3

20-39 68P HYVO

19 40 68P 19-40-68P HYVO

Altitude Meters (Feet)

DRIVEN

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 RPM200 . . . . . . . . . Idle RPM200 . . . . . . . . . . . . . . Engagement RPM300 . . . . . . Cylinder Head Torque . . . . . . . . Cylinder Base Nut Torque . . . . Crankcase Torque (8mm) . . . . . Crankcase Torque (10mm) . . . Flywheel Torque . . . . . . . . . . . . .

1.30

Liquid Cooled Case Reed w/TPS 700cc 3.1889〉 (81mm) 2.6772〉 (68mm) 0.0047〉 - 0.0060〉 (0.12 - 0.15mm) N/A 2108 N/A 0.014〉 - 0.020〉 (0.36 - 0.51mm) 40.2.50cc 32.0 - 33.0cc 8000 RPM 1500 RP”M 4300 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) 90 ft.lbs. (124 Nm)

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

125 psi Walbro FPA-4 Mikuni 03A 3021022


GENERAL INFORMATION MODEL: . . . . . . . . . . INDY 700 RMK MODEL NUMBER: . S01SR7AS (S01SM7AS) ENGINE MODEL: . . S7070POB2-1992

ELECTRICAL

CAPACITIES

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

Kokusan 4060223 Fuel Tank . . . . . . . . . . 4010333 Oil Tank . . . . . . . . . . . . 280 Watts Coolant . . . . . . . . . . . . 20 BTDC@3000RPM1.5 Chaincase Oil . . . . . . . With TPS Unplugged. 0.1003〉 BTDC (0.0861〉 - 0.1157〉) 2.5485mm BTDC (2.188 - 2.939mm) Spark Plug / Gap . . . Champion RN57YCC / 0.025〉 (0.64mm) Lights: Head . . . . . . Low: PN 2870448 (x1), High: PN 4010253 (x2) Tail / Brake . PN 4030043 (x1) Voltage Regulator . . LR7 Electric Start . . . . . . . Option *LR7= Full wave voltage regulator Magneto Pulses . . . . 6

SUSPENSION / CHASSIS

11.8 gallons (44.7 liters) 3 quarts (2.8 liters) 5.5 quarts (5.2 liters) 9 fl. oz.(266cc)

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 . . . . . .

Gen II Sprockets / Chain . . . 19-40 68P HYVO Indy XC-10 38〉 CRC Reverse . . . . . . . . . . . . Option Nitrogen Cell Brake Pads . . . . . . . . . Type 81, Large 100#/in. Chaincase Center Dist.7.05〉 (17.91cm) 1/2〉 Thread Adjust Driveshaft Sprockets . 2 Drivers Wide, XHS 7.4〉 - 7.8〉 (18.8 - 19.8cm) Brake Type . . . . . . . . . Polaris HPB Liquid Cooled XTRA-Lite 136” or 144〉 11.5〉 - 12〉 (29.2 - 30.5cm) Nitrogen Cell 190#/in. Indy Select .359〉 (sq.) / 85 15〉x136〉x1.75〉 (38.1x345.44x4.44cm) or 15〉x144〉x2.0〉 (38.1x365.76x5.08cm) 3/8〉 - 1/2〉 (1-1.3 cm) slack with 10# (4.54kg) weight 16〉 (40.64cm) ahead of rear idler shaft. Overall Snowmobile Length . . . . . . . . . . . . . . . . . 136〉 Track= 116〉 (295cm) 144〉 Track= 119.75〉 (304.2cm) Overall Snowmobile Height . . . . . . . . . . . . . . . . . 45〉 (114cm) Maximum Snowmobile Width . . . . . . . . . . . . . . . 44.25〉 (122cm)

OPTIONAL REAR TORSION SPRINGS SOFT

MEDIUM(STD)

FIRM

.347〉(Sq.) Diameter x 90 .359〉(Sq.) Diameter x 85 .359〉(Sq.) Diameter x 77 L.H .7041911-067

L.H. 7041763-067

L.H. 7041629-067

R.H. 7041912-067

R.H. 7041764-067

R.H. 7041630-067

1.31


GENERAL GENERAL INFORMATION INFORMATION MODEL: . . . . . . . . . . INDY 800 RMK / 800 RMK S.C. SPECIAL MODEL NUMBER: . S01SM8BS (A, B) ENGINE MODEL: . . S8070POA2-2022 JETTING CHART AMBIENT TEMPERATURE

Altitude

Below -20 -20F F Below -29C

-20 to +10_F -20_ +10 F -29_to -12_C

+10 to +40_F +10_to +40 F -12_ to +5_C

Above +40 +40_F F Above 5_C

0-900 (0-3000)

MAG 450 PTO 430 #4

MAG 420 PTO 400 #4

MAG 390 PTO 370 #4

MAG 370 PTO 350 #3

900-1800 (3000-6000)

MAG 420 PTO 410 #3

MAG 390 PTO 370 #3

MAG 360 PTO 340 #3

MAG 340 PTO 310 #2

1800-2700 (6000-9000)

MAG 390 PTO 370 #3

MAG 360 PTO 340 #3

MAG 330 PTO 310 #2

MAG 310 PTO 290 #2

2700-3700 (9000-12000)

MAG 350 PTO 330 #2

MAG 320 PTO 300 #2

MAG 290 PTO 370 #2

MAG 270 PTO 250 #1

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

(2) TM 40 w/ TPS Mikuni MAG 330 / PTO 310 55 9EFY8-61-2 P-8 (825) 2.0 Notched 1.0 Turn 1.8 Key Switch Adjustable 91 Premium 89 Regular

Meters (Feet)

XXX #X

Throttle Gap Under Cutaway . . . . . . 0.098〉 (2.5mm) Starter Jet . . . . . . . . . . . 145 Pilot Air Jet . . . . . . . . . . 0.7 Long

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

CLUTCH CHART

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

DRIVE

P-85 3211065 1.438〉 28 48.375〉 12.50〉 10-60 Almond / Round Silver / Blue R-8 #2

Altitude Meters (Feet)

DRIVEN

Shift Weight

Clutch Spring

Clutch Spring

Driven Helix

Chaincase Gearing

0-900 (0-3000)

10 64 10-64

Almond Round

Silver / Blue

R-8 #2

20-39 68P HYVO

900-1500 (3000-5000)

10 62 10-62

Almond Round

Silver / Blue

R-8 #2

20-39 68P HYVO

1500-2100 (5000-7000)

10 60 10-60

Almond Round

Silver / Blue

R-8 #2

20-39 68P HYVO

2100-2700 (7000-9000)

10 58 10-58

Almond Round

Silver / Blue

R-8 #2

20-39 68P HYVO

2700-3300 (9000-11000)

10-56

Almond Round

Silver / Blue

R-8 #2

20-39 68P HYVO

3300-3900 (11000-13000)

10-54

Almond Round

Silver / Blue

R-8 #2

20-39 68P HYVO

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 RPM200 . . . . . . . . . Idle RPM200 . . . . . . . . . . . . . . Engagement RPM300 . . . . . . Cylinder Head Torque . . . . . . . . Cylinder Base Nut Torque . . . . Crankcase Torque (8mm) . . . . . Crankcase Torque (10mm) . . . Flywheel Torque . . . . . . . . . . . . .

1.32

Liquid Cooled Case Reed w/TPS 794cc 3.3464〉 (85mm) 2.7559〉 (70mm) 0.006〉 - 0.0074〉 (0.15 - 0.188mm) N/A 2261 N/A 0.016〉 - 0.022〉 (0.41 - 0.56mm) 46 - 47cc 33 - 33cc 8000RPM 1400 RPM 3800 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)

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

140 psi Walbro FPA-4 Mikuni 03A 3021066


GENERAL INFORMATION MODEL: . . . . . . . . . . INDY 800 RMK / 800 RMK S.C. SPECIAL MODEL NUMBER: . S01SM8BS (A, B, C) ENGINE MODEL: . . S8070POA2-2022

ELECTRICAL

CAPACITIES

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

Kokusan 4060223 Fuel Tank . . . . . . . . . . 4010446 Oil Tank . . . . . . . . . . . . 280 Watts Coolant . . . . . . . . . . . . 25 BTDC@3500RPM1.5 Chaincase Oil . . . . . . . 0.1609〉 BTDC (0.1429〉 - 0.1803〉) 4.0860mm BTDC (3.6223 - 4.578mm) Spark Plug / Gap . . . Champion RN57YCC / 0.025〉 (0.64mm) Lights: Head . . . . . . Low: PN 2870448 (x1), High: PN 4010253 (x2) Tail / Brake . PN 4030043 (x1) Voltage Regulator . . LR7 Electric Start . . . . . . . Option *LR7= Full wave voltage regulator Magneto Pulses . . . . 6

SUSPENSION / CHASSIS

11.8 gallons (44.7 liters) 3 quarts (2.8 liters) 5.5 quarts (5.2 liters) 9 fl. oz.(266cc)

CHAINCASE

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

Gen II Sprockets / Chain . . . 20-39-68P HYVO Indy XC-10 38〉 CRC Reverse . . . . . . . . . . . . Option Nitrogen Cell Brake Pads . . . . . . . . . Type 81, Large 100#/in. Chaincase Center Dist.7.05〉 (17.91cm) 1/2〉 Thread Adjust Driveshaft Sprockets . 2 Drivers Wide, XHS 7.4〉 - 7.8〉 (18.8 - 19.8cm) Brake Type . . . . . . . . . Polaris HPB Liquid Cooled XTRA-Lite 144〉 / (XTRA-Lite 151〉) 12〉 - 12.5〉 (30.5 - 31.8cm) S01SM8BS: Nitrogen Cell Rear Track Shock . . . Indy Select S01SM8BSA: Nitrogen Cell Indy Select S01SM8BSB: Fox IFP Fox IFP S01SM8BSC: Fox IFP Fox IFP Spring Rate . . . . . . . . 190#/in. All Models. Rear Springs . . . . . . .359〉 (sq.) / 85 All Models. Track Type . . . . . . . . 15〉x144〉x2.0〉 (38.1x365.76x5.08cm) or 15〉x151〉x2.0〉 (38.1x383.40x5.08cm) Track Tension . . . . . . 3/8〉 - 1/2〉 (1-1.3 cm) slack with 10# (4.54kg) weight 16〉 (40.64cm) ahead of rear idler shaft. Overall Snowmobile Length . . . . . . . . . . . . . . . . . 144〉 Track 119.75〉 (304.2cm) / 151〉 Track= 123.5〉 (314cm) Overall Snowmobile Height . . . . . . . . . . . . . . . . . 45〉 (114cm) Maximum Snowmobile Width . . . . . . . . . . . . . . . 44.25〉 (112.4cm)

OPTIONAL REAR TORSION SPRINGS SOFT

MEDIUM(STD)

FIRM

.347〉(Sq.) Diameter x 90 .359〉(Sq.) Diameter x 85 .359〉(Sq.) Diameter x 77 L.H .7041911-067

L.H. 7041763-067

L.H. 7041629-067

R.H. 7041912-067

R.H. 7041764-067

R.H. 7041630-067

1.33


GENERAL GENERAL INFORMATION INFORMATION

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 1.382. *To convert Nm to ft.lbs. multiply Nm by .7376. #10 #10

1.34

-

Grade 5

Grade 8

43 (5.0) . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . 1 ............

.0156 .0312 . . . . . . . . . . . . . . . . . . 1 mm = .0394〉 .0469 .0625 .0781 . . . . . . . . . . . . . . . . . . 2 mm = .0787〉 .0938 .1094 . . . . . . . . . . . . . . . . . . 3 mm = .1181〉 .1250 .1406 .1563 . . . . . . . . . . . . . . . . . . 4 mm = .1575〉 .1719 .1875 . . . . . . . . . . . . . . . . . . 5 mm = .1969〉 .2031 .2188 .2344 . . . . . . . . . . . . . . . . . . 6 mm = .2362〉 .25 .2656 . . . . . . . . . . . . . . . . . . 7 mm = .2756〉 .2813 .2969 .3125 . . . . . . . . . . . . . . . . . . 8 mm = .3150〉 .3281 .3438 . . . . . . . . . . . . . . . . . . 9 mm = .3543〉 .3594 .375 .3906 . . . . . . . . . . . . . . . . . . 10 mm = .3937〉 .4063 .4219 . . . . . . . . . . . . . . . . . . 11 mm = .4331〉 .4375 .4531 .4688 . . . . . . . . . . . . . . . . . . 12 mm = .4724〉 .4844 .5 . . . . . . . . . . . . . . . . . . . . . 13 mm = .5118 .5156 .5313 .5469 . . . . . . . . . . . . . . . . . . 14 mm = .5512〉 .5625 .5781 . . . . . . . . . . . . . . . . . . 15 mm = .5906〉 .5938 .6094 .625 . . . . . . . . . . . . . . . . . . . 16 mm = .6299〉 .6406 .6563 . . . . . . . . . . . . . . . . . . 17 mm = .6693〉 .6719 .6875 .7031 . . . . . . . . . . . . . . . . . . 18 mm = .7087〉 .7188 .7344 . . . . . . . . . . . . . . . . . . 19 mm = .7480〉 .75 .7656 .7813 . . . . . . . . . . . . . . . . . . 20 mm = .7874〉 .7969 .8125 . . . . . . . . . . . . . . . . . . 21 mm = .8268〉 .8281 .8438 .8594 . . . . . . . . . . . . . . . . . . 22 mm = .8661〉 .875 .8906 . . . . . . . . . . . . . . . . . . 23 mm = .9055〉 .9063 .9219 .9375 . . . . . . . . . . . . . . . . . . 24 mm = .9449〉 .9531 .9688 . . . . . . . . . . . . . . . . . . 25 mm = .9843 .9844 1.0

1.35


GENERAL GENERAL INFORMATION INFORMATION Unit of Measure

Multiplied by

Converts to

ft. lbs.

x 12

= in. lbs.

in. lbs.

x .0833

= ft. lbs.

ft. lbs.

x 1.382

= 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)

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)

C to F: 9 (C + 40)  5 -- 40 = F F to C: 5 (F + 40)  9 -- 40 = C

1.36


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

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

1.37


GENERAL GENERAL INFORMATION INFORMATION 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. 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) too high a compression ratio for the fuel octane; 2) low octane fuel; 3) over-advanced ignition timing; 4) lean fuel/air mixture. 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. E.T. Ignition: Energy Transfer ignition. Generates primary ignition voltage through electro magnetic induction.

1.38


GENERAL INFORMATION

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. Head Volume: Cylinder head capacity in cc, head removed from engine with spark plug installed. Heat Exchanger: A device used to transfer heat. Mounted under running boards, 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. 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, primary charge coil. Stator plate coil which generates primary ignition voltage. CDI system uses one ignition generating coil. Twin cylinder E.T. ignition systems use two ignition generating coils. Coil is mounted at the top of the stator plate. Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb. Kg/cm.2: Kilograms per square centimeter. Metric equivalent of PSI. Keystone Ring: A piston ring with bevel on upper inside 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 unit 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.

1.39


GENERAL GENERAL INFORMATION INFORMATION 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) too hot a spark plug; 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. Parts of this circuit include the exciter coil, points and condenser, wires from the stator plate to the small primary winding in the ignition 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. 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. Required in Canada. RPM: Revolutions Per Minute. Relay Coils: Electromagnetic device in an EFI system which controls circuit connection with input from another circuit. 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 when fully advanced or 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 180 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. 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.

1.40


GENERAL INFORMATION Handling Problems Handling problems usually require several changes in setup to correct. Most problems can be traced to improper suspension adjustment. If the problem is encountered when entering a corner, adjust the front end. If the problem is encountered when exiting a corner, adjust the rear suspension.

Service 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. Pictures 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.

1.41


GENERAL GENERAL INFORMATION INFORMATION The following information is provided as a general guide for starting set ups for various machines and race types. Much of it is gathered from the race reports turned in after each race. Don’t forget to turn in your race report! NOTE: All setups are initial starting points or recommendations only, and should be adjusted according to driver preference and style. Your preferred set up may vary to suit track conditions, riding style, and weight. Ice racing is a team sport requiring a quality pit crew. Select a crew that not only has the knowlegde to support the team effort, but also has the ability to be there for every race. The following pages list a few things that may help your team operate more efficiently and professionally. Each team member of the pit crew has his or her duties that are critical to the teams efficiency. Although an ice race may last for hours it is often won by saving seconds. Here are a few tips that may help you save a few.

Team Members and Their Duties 1. Pit crew members and their responsibilities These individuals should know the racing machine and its setups inside and out. On race day they should also keep track of what heat, semi’s, and finals you are in. They should also keep track of staging. This can be simplified if only one member is in control of knowing when and where the driver should be. This person should also be a motivated coach. 2. Track crew members break down and responsibilities: A. One track spotter This individual will be placed in the areas where the most incidences have happened in the past, and communicates information to the driver so he may avoid any unnecessary pit stops for repair. In shorter ice races, the spotter gives the driver information on other drivers lines in the corners and also helps the driver find smooth spots on the track. B. One “Team Manager” This is probably your most important team member. Not only should he/she be able to plan, schedule, order, request, push papers, and be a politician, this person has to know the set up of the support trailer and where everything is stored. He or she must anticipate and organize the tools that will most likely be needed. The driver listens to other crew members opinions, but the manager is the one who makes the final decisions. 3. Optional Crew Equipment SNascar style wireless communicator SLap top computer SClip board with counter SStop watch

1.42


GENERAL INFORMATION Front Suspension Camber Banked race tracks require more camber than flat race tracks because the rear end of the sled seems to get more of a bite due to the banking of the race track, keeping it from washing out. Also keep in mind the length of the race track, sharpness of the corners, and ice conditions. All of these factors will come into play in order to properly align the skis for your style of driving. Don’t be afraid to experiment and always test your setup. Camber measurement should be taken when machine is supporting its own weight; i.e. with jack stands under the rear bumper and under each trailing arm, for the most accurate measurement. Degree Wheel

Parallel Bar

S S

2 = about 1/8〉 4 = about 1/4〉

Camber (flat track) - right 2, left 0 Camber (banked track) - right 4, left 2

When setting camber with a degree wheel, find zero camber and set your dial to zero. Mount your dial to spindle housing and adjust upper and lower radius rods until degree wheel reads desired camber.

Degree Wheel

When setting camber with a parallel bar, make yourself two identical 3 1/2〉 x 1〉 square blocks to fit on top of the ski saddle. Insert the blocks just in front of the spindle and line up your parallel bar. Adjust your radius rods until you achieve your desired camber measurements Do not take the measurement off of the ski plastic. When skis are molded, there are variences in depth and thickness of the plastic.

Adjust radius rods

3 1/2〉 1〉 Block

Block

Saddle (Ski on)

Measure here

Saddle (Ski on)

1.43


GENERAL GENERAL INFORMATION INFORMATION Toe In/Toe Out Never toe the machine in. Try to run 1/16〉 to 1/8〉 toe out, depending on the amount of bump steer. This measurement should be taken off of the ski’s carbide when the machine is supporting its own weight (i.e. with jack stands under the rear bumper and under each trailing arm) for the most accurate measurement. When setting toe out, in ice racing only, use the inside ski for adjustment. This will help your sled corner by pulling to the inside of the race track (self steer).

Support Sled

Measure at front and rear of carbide

Caster Stock caster can be changed if building new trailing arms. Tip the spindle angle back 2 to give more camber change throughout the turning radius. This creates quicker, heavier, more aggressive steering and will help the machine track better in rough portions of the race track. It is important to note that when caster is altered the stock suspension geometry is changed, resulting in bump steer. To correct this, shim tie rods and change steering arm lengths.

Reinforcement Reinforcement is a very important part of ice racing. Be sure to use good quality material, don’t just double lower quality material. This will help keep weight down as well as give your machine a quality appearance.

Sway Bar - Adjustable When setting up the sway bar, pre-load neutral by positioning the sway bar parallel with the trailing arms when possible. Take out play in Heim joints by shortening the left Heim until the joints are tight (Ice oval only). Sway Bar Options:

Reinforcement Reinforcing is a very important part of ice racing. Try to strengthen by using good grades of mat, not by doubling up poor quality grades of parts. This will keep the weight of the machine down and give a professional appearance. Listed are just a few ways of strengthening your machine. S S S S S S S S S S

7/8〉 O.D. radius rods 7/16〉 fine thread grade 5 ski bolts Good grade aluminum ski reinforced with 1〉 O.D. metal or nylon hoop. (Cover hoop with padding) Check all stock welds throughout. Re-weld if necessary Use loctitet on bolts where needed, or safety wire 1/2〉 fine thread grade 5 rear trailing arm bolts 7/16〉 fine thread grade 5 front trailing arm, front radius rod bolts Chrome moly steering post with wood dowel in center Hardened spindles Aluminum throttle housing control

1.44


GENERAL INFORMATION Shocks Why gas shocks? Because one race is equal to one season of trail riding. Gas shocks such as FOX are a must because the valving can be changed and they can be rebuilt. This is important because conditions vary from track to track. Also, because of the length of an ice race, it’s important to have a shock you can rebuild and maintain from race to race. Quality shocks are as important as having a fresh engine. Remember, a lot of horse power won’t help if you can’t keep the machine on the ground.

Valving Stock front shock valving does not allow the front suspension to follow the contour of the track and doesn’t react quickly enough at high race speeds. Track conditions, driver weight and driving style have a great deal to do with the shock valving combination you choose. Smooth, high speed tracks require heavier valving than slower, rougher tracks. If you notice your skis are not maintaining contact with the ice, you may want to lighten valving to make the machine react more quickly. Remember to take advantage of travel. The reason you have four to five inches of travel is to provide a smooth ride.

Spring Rate Spring rate also changes with track conditions, driver weight, and driving style. A good place to start for a 470 lb. machine with a 180 lb. driver is a 146 lb., 7 1/2〉 long spring. Remember that preload doesn’t affect spring rate unless you are using progressive rate springs. Also, straight rate springs are easier to work with than progressive rate springs. Following are a few helpful hints: S S S S

S S

S S

Always use a quality Polaris spring Length of spring changes rate. Don’t use a spring that is too heavy - springs should allow at least 1〉 of ride in Hard ice requires softer springs. Soft ice requires harder springs. The same is true for sway bars. Less wall thickness (.065 to .058) might be needed if ice is hard and the machine tends to push when entering the corner. Too light a wall thickness tends to tip machine up at the start of the apex, causing a loose condition off the corner. Going to a lighter spring or swaybar allows the machine to roll into the corner causing the inside of track studs to be pulled out of the ice, making the machine loose. Be carefuel not to go too soft. This will cause highsiding and very aggressive handling. Springs can lose their rate even after one weekend of racing. Always keep notes on spring length and rates. Racing and qualifying set ups should differ. A softer suspension with more travel is a must as track conditions change and the track deteriorates. Sometimes a medium set up for both qualifying and race day is best. Most tracks require different springs, so have a good selection of springs on hand. See Suspension Section for optional springs and spring kits.

1.45


GENERAL GENERAL INFORMATION INFORMATION Rear Suspension Shocks You will need a good quality gas shock, such as Fox or Arvin âŒŞ , Stock rear shock valving usually works well.

Rear Suspension Springs The front (center shock) suspension spring should be changed from stock to a lighter rate depending on conditions. If not changed, it will place too much pressure on the front of the rail, causing the sled to push, or tip up (high side). If the spring is too light, the sled could become loose. Stock rear springs work well. Polaris does offer different rates if you choose to change them. See Suspension Section for optional springs.

Front Torque Arm Height Front torque arm height controls ski pressure when entering the corner to apex area of the turn. Install a 3/8âŒŞ eye bolt for quick adjustment. For safety reasons, retain the stock limiter strap.

Rear Torque Arm Height Rear torque arm springs control ski pressure when exiting the corner or when getting back on the power. Measure from the rail rubber to the bottom of the suspension torque arm. Use the stock limiter strap for adjustment.

Lubrication Mount two lube lines on each rail, for a total of four lube lines. Remove and disassemble the engine. Drill and tap another impulse hole in crankcase in line with rod pin. Install another fuel pump into this hole to pressurize the system lube lines. Be aware that the lube runs dry by the time the track is snowy enough for the lube system to be turned off. For this reason, a minimum of idler wheels are a must.

1.46


GENERAL INFORMATION Track and Traction CAUTION: Avoid placing studs too close to the edge of the track or track damage and/or failure may occur. Be sure to use a good grade of Loctite (for example high strength red), and allow a curing time of at least 24 hours. When possible, burn holes in the track with a 1/4〉 awl. This helps seal the holes and keep moisture out. If you do not burn the holes, use a hole cutter. Never use a drill bit. The cords will rip and make studding very difficult.

Carbides The first thing to look at when your machine doesn’t corner is carbides. Woody’s 10〉 comp bars are a good choice. Using the old style 464 stud pattern with this style seems to keep bars straighter. Always keep carbides sharp. Make sure when resharpening to keep a 60 angle. Less of an angle will prevent carbides from penetrating ice. Never exceed 60. Using more carbide on the right ski is not recommended for ice racing since the machine will not track straight.

1.47


GENERAL GENERAL INFORMATION INFORMATION Clutching There are unlimited combinations in clutching. The best way to find the ideal set up for you is to test and experiment. Remember that no two machines are alike. To clutch your machine properly you need to know at what RPM your engine puts out its peak performance. The best way to find this out is to put your engine on a Dyno. If this is not possible, you can get the information from your manufacturer or dealer. Assume your engine reaches peak power at 9000 RPM. You want to clutch your machine so the engine goes from clutch engagement RPM to 9000 RPM as quickly as possible without exceeding 9000 RPM, and staying at 9000 RPM until the clutches reach a 1:1 ratio. The difference between OEM clutching and race clutching would look something like the example shown below. When clutching do not be afraid to experiment.

10

10

9

9

8

8

7

7

6

6

5

5

4

4

3

3

2

2

1

1 1

2

3

4

TIME IN SECONDS OEM CLUTCHING

5

6

1

2

3

4

5

6

TIME IN SECONDS RACE CLUTCHING

Gearing Gearing will vary from track to track. Ideally you want your clutches to reach a 1:1 ratio at the end of the longest straightaway on the track. A good way to find proper gearing is find top speed on the track with a radar gun and then refer to the Polaris gearing chart in the Chassis/Brake/Final Drive chapter.

1.48


GENERAL INFORMATION Race Strategy Know the track and conditions. Monitor track conditions as the day goes on. Make sure you know where good ice is on the starting line before you pull up to the line. Know where the good and bad lines are in the corners. Every time the track is plowed you should check track conditions. This is the best way to find a good line or an edge over the competition. Keep a journal of race set ups and notes for each race track. This will save you a lot of time when you come back to a track in following years. Get to know how the flagman starts a race. Watch him closely when you’re not racing. Some flagmen tip off when they’re going to throw the flag. This can give you a good jump on the starting line. Get in shape. You can’t go fast around the race track if you’re too tired to hang onto the machine. If you want to win races, you have to be as fast at the end of the race as you are at the beginning. This requires strength and conditioning. Some good strength exercises for racing are pull ups, biceps curls, wrist curls, rowing, bench press, leg curls, and squats. Good conditioning exercises include running, racquetball, running stairs, biking, motocross riding, etc.

Details Make sure the tachometer is in a location which allows clear visibility so you can read it at a glance.Check handlebar bends and length. It is very important to you as the driver to have a comfortable grip at all times to avoid fatigue. Make sure the tether cord is mounted out of the way so that it won’t be knocked off while you are racing. Racing style, track length, sharpness of corners, and ice conditions all come into play when setting up your machine. Experimentation is the only way to achieve the best set up. Following are some tips for ice racing: S S S S S S

Recommended chaincase oil - Polaris Synthetic Chaincase Lubricant (PN 2871478 - 12 oz. bottle). 7/16〉 ID spring, approximately 1 1/2〉 long, loose fit, over 3/8〉 chain tightener bolt to keep tension on chain after stretch Check overflow bottle at every other pit stop for correct fluid level; also replace return lines from engine to bottle with high pressure line Check track tension at every other pit stop NOTE: Alternate maintenance checks at stops to save time Drill ski bushing out to 7/16〉 for larger Grade 5 ski bolt to prevent thread damage when quick changing skis with 1/2〉 impact wrench Install quick change fuel system and use a Nascar style can

1.49


CHAPTER 2 ENGINE

2 Improvements and Specifications . . . . . . . . . . . Torque Patterend and Specifications . . . . . . . . General Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full Stroke Compression Ratio Chart . . . . . . . . Compression Ratio Example . . . . . . . . . . . . . . . Head CC Removal Example . . . . . . . . . . . . . . . Port Opening Duration Example . . . . . . . . . . . . VES System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440 Edge Pro X Pipe Temp Sensor . . . . . . . . . 440 Edge Pro X Timing . . . . . . . . . . . . . . . . . . . . Engine Repair - 440/500/600 XC SP . . . . . . . . VES Maintenance - 440/500/600 XC SP . . . . . Engine Repair - 600 RMK/700/800 Twins . . . . Engine Repair - 800 XCR . . . . . . . . . . . . . . . . . . VES Maintenance - 800 XCR . . . . . . . . . . . . . . General Inspection Procedures . . . . . . . . . . . . . Cooling System Bleeding Procedures . . . . . . . Cooling System Exploded Views . . . . . . . . . . . Water Pump Belt - 600 RMK/700/800 Twins . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 2.2--2.3 2.4 2.5 2.6 2.7 2.7 2.8-2.10 2.11 2.12 2.13-2.22 2.23-2.26 2.27-2.38 2.39-2.45 2.46-2.49 2.50-2.61 2.62 2.63-2.67 2.68 2.69


ENGINE Improvements for 2001 440 / 600 Edge Pro X 1. 2. 3. 4. 5. 6. 7. 8.

New Cylinders 6mm shorter Rod New head Profile Different crankcase to accommodate the shorter rod All new manifold and pipe new CDI options with pipe sensor New exhaust valve guillotine Octane switches 92 oct is for 92 non--oxygenated pump fuel. 110 oct is for Polaris Fuel 110 octane 9. Koyo upper rod bearings

Ignition Switch Positions

OFF ON 110 OCT. ON 92 OCT.

2001 Model Specifications Machine Model

Engine Model

Cyl. Disp. CC’s

Bore MM

Bore Inches

Stroke MM

Stroke Inches

No. of Type of Cyl. Cooling

Fuel Octane (Min)

XCF

EC45PM021

438

65.5

2.579

65

2.559

2

Fan

87*

440 Edge Pro X

S44-44-00A1

438

66

2.598

64

2.520

2

Liquid

92**

500 XC SP

SN50-44-00A1AEV

500

70.5

2.776

64.0

2.520

2

Liquid

87*

600 Edge Pro X

SN60-44-PO6E2234

600

77.25

3.041

64.0

2.520

2

Liquid

87*

600 XC SP

SN60-44-00A1EV

600

77.25

3.041

64.0

2.520

2

Liquid

87*

700 XC SP

SN70-70-00A1

700

81.0

3.189

68.0

2.677

2

Liquid

87*

800 XC SP

S8070POA1--1952

800

85.0

3.3464

70

2.7559

2

Liquid

89*

600 RMK

SN60-70-00A2

593

74.5

2.993

68.0

2.677

2

Liquid

87*

700 RMK

SN70-70-00A2

700

81.0

3.189

68.0

2.677

2

Liquid

87*

800 RMK

SN80-70-00A2

794

85.0

3.346

70.0

2.756

2

Liquid

87*

800 XCR

EC79PL012

794

72

2.835

65.0

2.559

3

Liquid

87*

* Non-oxygenated. Use minimum 89 octane when using oxygenated fuel. ** 92 Octane Premium Unleaded minimum. Model

Cyl. Head CC’s Uninstalled

Cyl. Head CC’s Installed

Piston/Cylinder Bore Clearance +.05 mm --.00 mm (MM / Inch)

Engine Recommended Operating Idle RPM RPM ¦200

XCF

24.2

21.2

.07-.105 (.0028-.0041〉)

7750

1600

440 Edge Pro X

18.1

15.8

.11--.13 (.0045--.0053)

8250

1600

500 XC SP

26.50.5

25.20.5

.11-.14 (.0045-.0055〉)

8500

1500

600 Edge Pro X

36.50.5

31.00.5

.11-.150 (.0045-.0059〉)

8250

1400

600 XC SP

36.50.5

31.00.5

.11-.150 (.0045-.0059〉)

8250

1400

700 XC SP

40.20.5

32.0-33.0

.12-.15 (.0047-.0060〉)

8000

1500

800 XC SP

50.00.5

36.0--37.0

0.15--0.188 (.006--.0074)

8000

1300

600 RMK

34.0

26.0

.11-.15 (.0044-.0058〉)

8000

1500

700 RMK

40.20.5

32.0-33.0

.12-.15 (.0047-.0060〉)

8000

1500

800 RMK

50.00.5

36.0-37.0

.15-.188 (.006-.0074〉)

8000

1300

800 XCR

28.1

23.9

.07-.105 (.0027-.0041〉)

8500

1500

2.1


ENGINE When tightening bolts, nuts, or screws, a torque pattern should be followed to insure 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 assures optimum performance from precision machined, close tolerance assemblies. On vital engine parts, torquing negligence could be costly. Torque is a force which tends to produce rotation. The measurement of this force is expressed in units of force and length. There are at present two basic systems of units used to express torque, English and Metric. In the English system, the units of force are the pound or ounce, and the length is the foot or inch. In the Metric system, the unit of force is expressed in grams (gm) or Newton meters (Nm), and length as centimeters (cm) or meters (m). 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 Nm. Multiply foot pounds by 1.382 to obtain Nm. See page 2.3 for engine torque sequences Engine EC-45 S44** SN60-44** SN50** SN60-70** SN70** SN80** EC79PL

Cylinder Head* 18-19 ft. lbs. (25-26.5 Nm) 20-24 ft. lbs. (28 - 33 Nm)

Cylinder Base Nuts 24-28 ft. lbs. (33-39 Nm) 30-34 ft.lbs (42-47 Nm)

Crankcase 8 mm 17-18 ft. lbs. (22-23 Nm) 20-24 ft.lbs. (28 - 33 Nm)

Crankcase 10 mm 23-25 ft. lbs. (32-35 Nm) N/A

18-22 ft. lbs. (25 - 30 Nm)

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

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

26-30 Ft lbs (36-42 Nm)

90 ft. lbs. (124 Nm)

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

23-25 ft. lbs. (32-35 Nm)

20-22 ft. lbs. (28-30 Nm)

23-25 ft. lbs. (32-35 Nm)

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

**Torque head bolts prior to torquing cylinder base nuts. Apply loctitet 242. All 6mm Crankcase Bolts . . . . . 108 in. lbs. (12.4 Nm) All 7/16-14 Engine Mount Strap Bolts . . . . . 44-48 ft. lbs. (60-66 Nm)

2.2

Flywheel 60-65 ft. lbs. (83-90 Nm) 90 ft. lbs. (124 Nm)


ENGINE

8

5 9

1

4

12

3

5

6

4

10

2

3

11

7

1

2

8

6

7 CYLINDER BASE Domestic Twins 600/700/800 XCF SP

CYLINDER HEAD Domestic Twins 500 XC SP, 600 XC SP, 440/600 Pro X 5

9 10

4

2 12

3

1 6

8

7

2

11

4

9

3

6

12

CYLINDER HEAD - XCF

1

3

6

2

4

13 17

16 12

3

8

6 2

7

4

10

10 6

1

4

12

14

11

3

2

10

13

6

CRANKCASE - 500 XC SP, 600 XC SP

14

15

9

5

1

3

7

11

18

10

6

2

4

8

12

CYLINDER BASE- 800 Fuji Triple

CYLINDER HEAD -800 Fuji Triple

1

13 17

16

2

9

11

5

4

15

1

9

11

8

7 CRANKCASE Domestic Twins 600 RMK/700/800

3

CRANKCASE - XCF

5 5

1

8

1 CYLINDER HEAD Domestic Twins 600 RMK/700/800

7

5

5

12

9

3

8

6 2

11

5

7

4

10

19 15 18

14

20

CRANKCASE - 800 Fuji Triple

2.3


ENGINE Choose a well known performance company. Explain that you need a reliable enduro engine, not a sprint motor. An enduro engine should not exceed 9800 RPM. Sprint motors are too “peaky” and have a short life. Remember, the race is won at the finish line, and most high horsepower engines don’t get there. If the track or course requires running long distances in limited snow conditions, it is advisable to install a temperature gauge to monitor coolant out temperature. Secure the fuel valve in the “on” position with a cable tie strap. This will prevent the valve handle from moving when operating in rough conditions.

Front Engine Mount Accelerated wear of the rubber engine mounts may be caused by a rough surface on the holes of the front engine mount plate. Burrs in the holes of the engine mount plate will reduce the service life of the rubber mount, and increase the amount of engine movement under load. Inspect the mounts for wear periodically and replace as necessary. The holes in the plate and the area of the rubber mount should be deburred and polished if necessary.

High Performance Spark Plug Cap A high performance spark plug cap is available for competition or performance-minded individuals. The red cap fits very tightly on the spark plug wire and spark plug to positively seal out moisture and prevent the cap from jarring loose in the rough. Order part number 3240108.

Spark Plug Caps Must Be Clean and Dry A drop in engine RPM may be caused by moisture collecting in the spark plug caps. The caps should be cleaned with electrical contact cleaner and dried with compressed air. Be sure the cap is screwed tightly onto the high tension lead. Coat the inside of the cap with Polaris Nyogelt Grease (PN 2871329).

Honing Ni-Ca-Sil Cylinders Ni-Ca-Sil cylinders can be lightly honed if the proper stone is used. Use only 400 grit silicon carbide soft stones and follow normal honing procedures. Polaris Part Number

Spark Plug

3070156

NGK BR8ES

3070157

NGK BR7ES

3070160

NGK B7ES

3070161

NGK B8ES

3070162

NGK B9ES

3070163

NGK BR9ES

3070165

Champion RN2C

3070166

Champion RN3C

3070184

Champion RN57YC

3070190

Champion RN57YCC

2.4


ENGINE

17

FULL STROKE COMPRESSION RATIO

16 15

DANGER ZONE 14 13

SAFE ZONE

12 11

UNNECESSARY OCTANE 10 9 8 REGULAR

PREMIUM

RACE FUEL

7 84

86

88

90

92

100

105

110

115

120

PUMP OCTANE NUMBER

R = (IHV+DISP) IHV I = S (DISP*25.4) DISP = (PI*B*B*S) 4

IHV = DISP= R = S = I = B = PI =

INSTALLED HEAD VOLUME [CC] CYLINDER DISPLACEMENT [CC] COMPRESSION RATIO FULL ENGINE STROKE [CM] INCHES PER CC OF IHV CYLINDER BORE [CM] 3.1416

2.5


ENGINE

Bore = 6.5 cm

Stroke = 6.0 cm

IHV = 17.1 cc

Displacement = ↓ Bore ′ Stroke

σ↓ ″ ♣ψϒ♦ϒ♠τ

♦ Displacement = 199.098 cc

IHV + Displacement

R=

IHV

Full Stroke Compression Ratio

R = 12.643

To calculate the Effective Compression Ratio, substitute the exhaust port height for the stroke in the formulas above:

Exhaust = 2.95 cm

Exhaust port height 29.5 mm

Eff Disp = ↓ Bore′ Stroke ♦

Effective Displacement

Eff Disp = 97.89 cc

Eff Comp =

IHV + Eff Disp IHV

Effective Compression Ratio

Eff Comp = 6.725

In order to increase the Full Stroke Compression Ratio to 13.6, how much material do you need to remove from the cylinder head?

You know that: R =

IHV + Displacement

, and you want to find out IHV.

IHV

Displacement = 199.098 cc, and we want R = 13.6, so then IHV2 =

Displacement (R -- 1)

IHV2 = 15.801 cc desired IHV to have 13.6:1 Full Stroke Compression Ratio

2.6


ENGINE HEAD CC REMOVAL EXAMPLE

Total number of CCs to remove from the head = Old IHV -- Desired IHV Removed CCs = IHV -- IHV2 Removed CCs = 1.299 cc Stroke I= cm Displacement ⋅ 2.54 ⋅ in

I = 0.01186 ⋅

Number of inches to remove from the cylinder head to equal 1 cc

in cc

To find out how much to cut off, multiply the number of CCs you need to remove by the number of inches to remove per CC: Thickness to remove = I ⋅ Removed CCs Thickness to remove = 0.015 in

PORT OPENING DURATION This indicates the degrees after TDC that the exhaust port opens (and also the degrees before TDC that the port closes).

Port open = 81.5

Duration closed = 2 ⋅ Port open Duration closed = 163 Total duration = 360 Duration open = Total duration -- Duration closed Duration open = 197

Percent open =

Duration open Total duration

⋅ 100

Percent open = 54.722

2.7


ENGINE 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

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, 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. 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.

2.8


ENGINE 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 Polaris Synthetic 2 Cycle lubricant only. 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.

Adjuster nut O-ring Valve cover Spring Valve cap Bellows Washer

Valve housing Dowel pin Gasket

V.E.S. Removal and Cleaning Removal and cleaning is covered later in this chapter.

Bolt

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

2.9


ENGINE Variable Exhaust System (V.E.S.) - 2001 440 Edge Pro X 2001 440 Edge Pro X Variable Exhaust System: The exhaust valve system on the new 440 Edge Pro X is electronically controlled by solenoids. Pressure from the cylinders is routed through the solenoids to the atmosphere. During this time the exhaust valves are down. When the CDI senses 6800 RPM, it triggers the solenoids to shut off the bypassed air going to the atmosphere. Pressure then builds inside the exhaust valve bellows, causing the valves to fully open. When RPM drops below 6800, the solenoids open to allow air to bypass through to atmosphere and the exhaust valves close.

Below 6800 RPM

Above 6800 RPM

Exhaust Valves Closed

Yellow Wire to Wiring Harness

Yellow Wire to Wiring Harness

CDI Box

CDI Box Wire

Wire

Wire

Solenoid Open

Solenoid Open

Hose

Hose

T-Fitting

Inlet Hole from Cylinder

Balance Tube

Solenoid Closed

Solenoid Closed

Exhaust Valve

2.10

Hose

Spring Bellows

Balance Tube

T-Fitting

Inlet Hole from Cylinder

T-Fitting

Inlet Hole from Cylinder

Spring

Spring Bellows

Bellows

Bellows

Outlet Hole

Wire

Hose

T-Fitting

Inlet Hole from Cylinder

Spring

Exhaust Valves Fully Open

Exhaust Valve

Exhaust Valve

Outlet Hole

Exhaust Valve


ENGINE Exhaust System Temperature sender - 2001 440 Edge Pro X

Temp sender The temp sender that is on the 440 Edge Pro X will read the exhaust temperature and adjust the timing according to the temperature range. To Test the sensor: Unplug sensor. At room temperature the temperature sender will have a HIGH resistance (may read Open Line (OL)) depending on your meter. As the pipe gets hotter, the resistance keeps lowering resulting in optimum timing for a given RPM and pipe temperature, If the sender resistance is not responding to pipe heat the sensor may need to be replaced. LOW PIPE TEMP = HIGH RESISTANCE MEDIUM PIPE TEMP = MEDIUM RESISTANCE HIGH PIPE TEMP = LOW RESISTANCE

Measure resistance here

2.11


ENGINE Changing the Timing curve

CAUTION This engine is jetted for operation at 0 degrees _F and warmer. Re-jetting is required for temperatures colder than 0_F.

TIMING INFORMATION The PRO X 440 has been equipped with two switches that will change the timing curve. The first switch is an ignition switch located on the console. This switch is used to match the timing curve to the type of fuel you are using. The fuel types are 92 octane non-ethanol premium fuel and 110 octane fuel. Do not run the machine in the wrong ingnition key position or engine damage may occur.

CAUTION Mis-use of the timing selector switch can cause serious engine damage. Running the machine in the wrong ignition key position may cause engine damage.

Ignition Switch Positions

OFF ON 110 OCT. ON 92 OCT.

The second switch is located on the airbox and has seven optional curves. These seven options are used to match the fuel type and the racing conditions which may vary, depending on the race. The standard position is “D� and should not be moved unless you are a knowledgeable engine tuner. Position

Timing Effect

A

+3

B

+2

C

+1

D (Standard Position)

0

E

--2

F

--3

G

--4

The exhaust system has a temperature sensor in the body of the pipe that effects the timing curve as the temperature changes. This feature helps the pipe tune quickly and is not adjustable.

2.12


ENGINE NOTE: Inspect all parts for wear or damage during disassembly. Replace all seals, O-rings, and gaskets with Genuine Polaris parts during assembly. Refer to pages 2.49-2.60 for general inspection procedures. Disassembly -- 440 Liquid, 500, 600 small block 1. Remove carburetor mount adaptors, reed cages, stuffers, and oil pump. Note position of stator wire guide. Measure air gap between fiber reed and reed block as shown. The air gap should not exceed .015 (.4 mm). If clearance is excessive DO NOT attempt to reverse the reeds to reduce the air gap. Always replace them if damaged. Check each fiber reed for white stress marks or missing material. Replace if necessary.

Reed Pedal Clearance .015

(.38 mm) max.

Exaggerated for illustration

2. Remove V.E.S. (if applicable).

3. Remove cylinder head cover and inspect O-rings and sealing surfaces for damage or debris. Use new O-rings upon assembly.

2.13


ENGINE Disassembly, Cont. 4. Remove cylinder base nuts. Note location of acorn nuts on exhaust side (where applicable). 5. Carefully remove cylinders while supporting pistons and connecting rods to prevent piston damage. Refer to General Inspection Procedures in this chapter. 6. Remove outer piston pin C-clips using a scribe through access slot in piston.

7. Place support block under piston and remove piston pins using pin puller.

Piston Pin Puller

PN 2870386

Support Block

PN 2870390

8. Remove water pump cover from front of engine.

2.14


ENGINE Disassembly, Cont. 9. Remove recoil housing and drive hub.

10. Remove flywheel using heavy-duty flywheel puller. Use drive clutch puller T-handle or a wrench to hold puller.

Flywheel Puller

PN 2871043

T-Handle

PN 5020326

11. Before removing stator plate, note where ignition timing marks are located, or scribe additional marks for reference upon reassembly.

12. Mark or note location of engine mount straps and remove.

2.15


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2001 polaris 600 rmk snowmobile service repair manual  
2001 polaris 600 rmk snowmobile service repair manual  
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