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2005 Polaris 900 RMK 159 SNOWMOBILE Service Repair Manual .pdf



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CVR_9919302

9/23/04

9:17 AM

Page 1

2005 DEEP SNOW SERVICE MANUAL

2005 DEEP SNOW

SERVICE MANUAL

TRAIL RMK
600 RMK
700 RMK
800 RMK
900 RMK
600 SWITCHBACK™
800 SWITCHBACK™

PART #

9919302

9919302

PN 9919302

UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS
Throughout these instructions, important information is brought to your attention by the following symbols:
NOTE:

CAUTION:

DANGER

S A NOTE provides key information to clarify instructions.

A CAUTION indicates special precautions that must be taken to avoid personal injury,
or snowmobile or property damage.

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

2005 DEEP SNOW
MANUAL
Foreword

This manual is designed primarily for use by certified
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 2005 Model Year information,
along with service specifications. 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.
Snow Engineering Publications Department
2100 Hwy 55 Medina, Minnesota 55340.

2005 DEEP SNOW MANUAL
(PN9919302)
Copyright 2004 Polaris Sales Inc. Printed in U.S.A.

SPECIFICATIONS

1

GENERAL

2

MAINTENANCE

3

FUEL DELIVERY

4

ENGINE

5

CLUTCHING

6

FINAL DRIVE

7

BRAKE SYSTEM

8

STEERING

9

FRONT SUSPENSION

10

REAR SUSPENSION

11

CHASSIS / HOOD

12

ELECTRICAL SYSTEM

13

WIRING DIAGRAMS

14

i

INTRODUCTION
NOTES

ii

TRAIL RMK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
600 RMK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
700 RMK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
800 RMK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
900 RMK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
600 SWITCHBACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
800 SWITCHBACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 - 1.3
1.4 - 1.5
1.6 - 1.7
1.8 - 1.9
1.10 - 1.11
1.12 - 1.13
1.14 - 1.15

SPECIFICATIONS
NOTES

1.1

SPECIFICATIONS
MODEL: . . . . . . . . . . . . . . TRAIL RMK
MODEL NUMBER: . . . . S05NJ5BS(A)
ENGINE MODEL: . . . . . EC55PM071
ENGINE

CARBURETION

Engine Type

Libertyt

Type

Mikuni
VM34SS w/ACCS

Engine Displacement cc’s

544

Main Jet

260 PTO / 250 MAG

Bore in / mm

2.87” / 73mm

Pilot Jet

35

Stroke in / mm

2.56” / 65mm

Jet Needle

6DEH11 / 3

Cylinders

2

Needle Jet

Q-- 0 (480)

Piston / Cylinder Clearance
in / mm

.0045 - .0053”
.114 - .135mm

Throttle Gap UnderCutaway
in / mm

.250”
6.35mm

Piston Ring End Gap in / mm

.015 - .022”
.4 - .55mm

Cutaway

3.0

Piston Marking

5MD

Valve Seat

1.5 Viton

Piston Ring Marking

N

Starter Jet

1.5

Operating RPM ±200

7000

Fuel Screw

N/A

Idle RPM ±200

1600

Pilot Air Jet

N/A

Air Screw

1.0 Turns

Fuel Octane (R+M/2)

87 Oct. NonOxy /
89 Oct. Oxy

Engagement RPM ±300

3800

AMBIENT TEMPERATURE

Altitude

Below -30°F
-30 F
Below -34°C

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

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

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

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

Above +50_F
Above +10_C

290/280
#3

280/270
#3

270/260
#3

260/250
#3

250/240
#3

240/230
#3

600--1200
(2000--4000)

290/280
#3

280/270
#3

270/260
#3

260/250
#3

250/240
#3

240/230
#3

1200--1800
(4000--6000)

290/280
#3

280/270
#3

270/260
#3

260/250
#3

250/240
#3

240/230
#3

290/280
#3

280/270
#3

270/260
#3

260/250
#3

250/240
#3

240/230
#3

290/280
#3

280/270
#3

270/260
#3

260/250
#3

250/240
#3

240/230
#3

290/280
#3

280/270
#3

270/260
#3

260/250
#3

250/240
#3

240/230
#3

0--600
(0--2000)

Meters
(Feet)

1800--2400
(6000--8000)
(6000
8000)
2400--3000
(8000--10000)
(8000
10000)
3000--3700
(10000--12000)
(10000
12000)

Altitude

Meters
M
t
(Feet)

1.2

DRIVE CLUTCH

DRIVEN CLUTCH

Shift
Weight

Clutch
Spring

Clutch
Spring

Driven
Helix

Chaincase
Gearing

0-900
(0-3000)

10 64 Bushed
10--64

Dark Blue /
White

Red / Blue

40°
40
Team Reverse

19 43 74P
19--43

900-1800
(3000-6000)

10 62 Bushed
10--62

Dark Blue /
White

Red / Blue

40°
40
Team Reverse

19 43 74P
19--43

1800-2700
(6000-9000)

10 60 Bushed
10--60

Dark Blue /
White

Red / Blue

40°
40
Team Reverse

19 43 74P
19--43

2700-3700
(9000-12000)

10 58 Bushed
10--58

Dark Blue /
White

Red / Blue

40°
40
Team Reverse

19 43 74P
19--43

SPECIFICATIONS
DRIVE CLUTCH

CHAINCASE

Type

P-- 85

Center DIstance

7.92” / 20.12cm.

Shift Weights

10-- 60 Bushed

Gearing : Chain

19-- 43 :74P

Drive Spring

Red/Blue

Reverse

Electronic Reverse

Brake Pads

Type 81

Brake Type

Air Cooled

DRIVEN CLUTCH
Type

Team Roller Reverse

Spring

Dark Blue/White

Helix Angle

40_
Team Reverse

CAPACITIES

BELT

Fuel Tank

11.8 Gal. / 45 Liters

Belt Part Number

3211078

Oil Tank

3.25 Qts / 3 Liters

Belt Width (Projected)

1.438” / 3.65cm.

Coolant

N/A

Side Angle (Overall)

28_

Chain Case Oil

9 fl. oz. / 266 ml

Outside Diameter

46.625” / 118.4cm.

Center Distance

11.5” / 29.2cm.

SLED DIMENSION
Unit Length / Height /
Width in / cm.

FRONT SUSPENSION

121” / 48” / 48”
308 / 122 / 122 cm.

REAR SUSPENSION

Type

EDGE RMK (V/ESC)

Type

EDGE RMK

Standard IFS Shocks

7042197 Nitrex

Standard FTS

7042085 Nitrex

Standard IFS Spring Rate

80#/in.

Standard FTS Spring Rate

170#

Standard Spring Pre-- Load

.75”/1.9cm

Standard Spring Pre-- Load

N/A

Premium IFS Shocks

7042059 Arvin IFP

Premium FTS

7042084 Arvin IFP

Premium Spring Rate

75#/In.

Premium Spring Rate

170#

Premium Spring Pre-- Load

9.75”/24.8cm Installed
length

Premium Spring Pre-- Load

2.98” (7.57cm) from bottom
of shock body to bottom of
spring retainer

Front Vertical Travel

7 6” / 19.3cm.
7.6”
19 3cm

Standard RTS

Select / PN 7042058

Premium RTS

Arvin IFP C/A 7042176

Torsion Spring

.347” (Sq) x 77_

TRACK
Width / Length / Lug Height

15”/136”/1.25” (38 cm./345
cm./3.18 cm.)

See page 11.7 for optional springs

Track Tension See page 3.10
ELECTRICAL
NGK BR9ES
.028” / .70mm

Flywheel I.D.

FP9312

Spark Plug / Gap

CDI Marking

CU7236

Voltage Regulator

Alternator Output

240 watts

Magneto Pulses

6

Ignition Timing (see conver
conversion chart page 13.4)

27 @3000 RPM±1.5_
27_@3000
RPM±1.5
14_@6500 RPM±1.5_

Electric Start

Standard Accessory
y
Premuim Optional

LR7

1.3

SPECIFICATIONS
MODEL: . . . . . . . . . . . . . . 600 RMK 144”
MODEL NUMBER: . . . . S05NK6ES(A)
ENGINE MODEL: . . . . . S2712--6044--PI6E
ENGINE

CARBURETION

Engine Type

Libertyt

Type

Mikuni
TM 38

Engine Displacement cc’s

599

Main Jet

310

Bore in / mm

3.04” / 77.25mm

Pilot Jet

45

Stroke in / mm

2.52” / 64mm

Jet Needle

9DGI01-- 60 / 2

Cylinders

2

Needle Jet

P-- 8

Piston / Cylinder Clearance
in / mm

.0045 - .0059”
.115 - .149mm

Throttle Gap UnderCutaway
in / mm

.11”
2.7mm

Piston Ring End Gap in / mm

.014 - .020”
.14 - .20mm

Cutaway

1.5 (N)

Piston PN

3021308

Valve Seat

1.5

Piston Ring Marking

N/A

Starter Jet

140

Operating RPM ±200

8000

Fuel Screw

1.0 Turns

Idle RPM ±200

1500

Pilot Air Jet

N/A

Engagement RPM ±300

3900

Air Screw

.75

Exhaust Valve Spring

Green/White

Fuel Octane (R+M/2)

87 Oct. NonOxy /
89 Oct. Oxy

AMBIENT TEMPERATURE

Altitude

Below -30°F
-30 F
Below -34°C

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

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

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

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

Above +50_F
Above +10_C

450
#4

430
#4

420
#3

400
#3

380
#3

370
#3

600--1200
(2000--4000)

410
#4

390
#3

380
#3

360
#3

340
#3

330
#2

1200--1800
(4000--6000)

380
#3

360
#3

350
#3

330
#3

320
#2

300
#2

360
#3

340
#3

320
#3

310
#2

290
#2

280
#2

340
#3

320
#3

300
#2

290
#2

270
#2

260
#2

330
#3

310
#2

290
#2

280
#2

260
#2

240
#2

0--600
(0--2000)

Meters
(Feet)

1800--2400
(6000--8000)
(6000
8000)
2400--3000
(8000--10000)
(8000
10000)
3000--3700
(10000--12000)
(10000
12000)

Altitude

Meters
(Feet)

1.4

DRIVE CLUTCH
Shift
Weight

0--900
(0-3000)

10 60 Bushed
10-60

900-1500
(3000-5000)

10 58 Bushed
10-58

1500-2100
(5000-7000)

10 56 Bushed
10-56

2100-2700
(7000-9000)

10 54 Bushed
10-54

2700-3350
(9000-11000)

10AL Bushed

3350-4000
(11000-13000)

10 Bushed

DRIVEN CLUTCH

Clutch
Spring

Clutch
Spring

Driven
Helix

Chaincase
Gearing

Black/Green

7043063

56 / 42 -- .36
36
ER

19--39 : 72P

SPECIFICATIONS
DRIVE CLUTCH

CHAINCASE

Type

P-- 85

Center Distance

7.92” / 20.12cm.

Shift Weights

10-- 54 Bushed

Gearing : Chain

19-- 39 : 72 P

Drive Spring

Black/Green

Reverse

Electronic Reverse

Brake Pads

Type 81

Brake Type

Liquid Cooled

DRIVEN CLUTCH
Type

Team Roller Reverse

Spring

7043063

Helix Angle

54 / 42 - .36 Reverse

CAPACITIES

BELT

Fuel Tank

11.8 Gal. / 45 Liters

Belt Part Number

3211080

Oil Tank

3.25 Qts / 3 Liters

Belt Width (Projected)

1.438” / 3.65cm.

Coolant

5 Qts / 4.7 Liters

Side Angle (Overall)

28_

Chain Case Oil

9 fl. oz. / 299ml

Outside Diameter

46.625” / 118.4cm.

Center Distance

11.5” / 29.2cm.

SLED DIMENSION
Unit Length / Height /
Width in / cm.

FRONT SUSPENSION

124” / 48” / 45.5”
315 / 122 / 116cm.

REAR SUSPENSION

Type

EDGE RMK (V/ESC)

Type

EDGE RMK

Standard IFS Shocks

7042197 Nitrex

Standard FTS

7042058 Nitrex

Standard IFS Spring Rate

100#

Standard FTS Spring Rate

170#

Standard Spring Pre-- Load

9.75”/24.7cm Installed

Standard Spring Pre-- Load

7.375”/18.7 Installed

Premium IFS Shocks

7042059 Arvin IFP

Premium FTS

7042084 Arvin IFP

Premium Spring Rate

100#

Premium Spring Rate

170#

Premium Spring Pre-- Load

4.25”/10.8cm

Premium Spring Pre-- Load

2.98”/7.6cm

Front Vertical Travel

7 6”/19 3cm
7.6”/19.3cm

Standard RTS

7042085 Select

Premium RTS

7042176 Arvin IFP C/A

Torsion Spring

.359/47_

TRACK
Width / Length / Lug Height

15”/144”/2” (38 cm./366
cm./5 cm.)

See page 11.7 for optional springs

Track Tension See page 3.10
ELECTRICAL
Flywheel I.D.

4010677

Spark Plug / Gap

Champion RN57YCC /
.028” / .70mm

CDI Marking

4010834

Voltage Regulator

T1

Alternator Output

280 watts

Magneto Pulses

6

Ignition Timing (see conver
conversion chart on page 13.4)

24 @3500 RPM±1.5_
24_@3500
RPM±1.5
w/TPS Disconnected

Electric Start

Standard Accessory
y
Premium Optional

1.5

SPECIFICATIONS
MODEL: . . . . . . . . . . . . . . 700 RMK
MODEL NUMBER: . . . . S05N(K,L)7CS(A)
ENGINE MODEL: . . . . . S2775--7070--PI7C
ENGINE

CARBURETION

Engine Type

Libertyt

Type

Mikuni
TM 40

Engine Displacement cc’s

701

Main Jet

340

Bore in / mm

3.19” / 81mm

Pilot Jet

45

Stroke in / mm

2.68” / 68mm

Jet Needle

9DGN5-- 57 / 2

Cylinders

2

Needle Jet

P-- 8

Piston / Cylinder Clearance
in / mm

.0044” - .0058”
.111 - .147mm

Throttle Gap UnderCutaway
in / mm

0.098”
2.5mm

Piston Ring End Gap
in / mm

.012” - .018”
.304 - .457 mm

Cutaway

2.0

Piston PN

3021307

Valve Seat

1.8

Piston Ring Marking

N/A

Starter Jet

145

Operating RPM ±200

8000

Fuel Screw

1.75 Turns

Idle RPM ±200

1500

Pilot Air Jet

N/A

Engagement RPM ±300

3800

Air Screw

1.0 Turns

Exhaust Valve Spring

Orange

Fuel Octane (R+M/2)

87 Oct. NonOxy /
89 Oct. Oxy

AMBIENT TEMPERATURE

Altitude

Below -30°F
-30 F
Below -34°C

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

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

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

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

Above +50_F
Above +10_C

500
#4

490
#4

470
#3

450
#3

430
#3

410
#3

600--1200
(2000--4000)

470
#4

450
#3

430
#3

410
#3

390
#3

380
#2

1200--1800
(4000--6000)

440
#3

420
#3

400
#3

380
#3

370
#2

350
#2

400
#3

380
#3

360
#3

340
#2

330
#2

310
#2

360
#3

340
#3

320
#2

300
#2

290
#2

270
#2

320
#3

300
#2

290
#2

270
#2

250
#2

230
#2

0--600
(0--2000)

Meters
M
t
(Feet)

1800--2400
(6000--8000)
(6000
8000)
2400--3000
(8000--10000)
(8000
10000)
3000--3700
(10000--12000)
(10000
12000)

Altitude

Meters
(Feet)

1.6

DRIVE CLUTCH
Shift
Weight

Clutch
Spring

0--600
(0-2000)

10 64 Bushed
10--64

Black/Green

600-1200
(2000-4000)

10 62 Bushed
10-62

Black/Green

1200-1800
(4000-6000)

10 60 Bushed
10-60

Black/Green

1800-2400
(6000-8000)

10 58 Bushed
10-58

Black/Green

2400-3000
(8000-10000)

10--56 Bushed

Black/Green

3000-3600
(11000-12000)

10--54 Bushed

Black/Green

DRIVEN CLUTCH
Clutch
Spring

Driven
Helix

Chaincase
Gearing

EV Spring
Recommendation
Altitude

EV Spring

meters(feet)

7043063

56 / 42 -- .36
36
ER

0--1200
(0--4000)

Green/Yellow

19--39 : 72P

1200--3600
(4000--12000)

Orange

SPECIFICATIONS
DRIVE CLUTCH

CHAINCASE

Type

P-- 85

Center Distance

7.92” / 20.12cm.

Shift Weights

10-- 58 Bushed

Gearing : Chain

19-- 39 : 72 P

Drive Spring

Black/Green

Reverse

Electronic Reverse

Brake Pads

Type 81

Brake Type

Liquid Cooled

DRIVEN CLUTCH
Type

Team Roller Reverse

Driven Spring

7043063

Helix Angle

58 / 42 - .36 Reverse

CAPACITIES

BELT

Fuel Tank

11.8 Gal. / 45 Liters

Oil Tank

3.25 Qts / 3 Liters

Belt Part Number

3211080

Coolant

5 Qts. / 4.7 Liters

Belt Width (Projected)

1.438” / 3.65cm.

Chain Case Oil

9 fl. oz. / 266ml

Side Angle (Overall)

28_

Outside Diameter

46.625” / 118.4cm.

Unit Length / Height /
Width in / cm. (144”)

124” / 48” / 45.5”
315 / 122 / 116 cm.

Center Distance

11.5” / 29.2cm.

Unit Length / Height /
Width in / cm. (151”)

130” / 48” / 45.5”
330 / 122 / 116 cm.

SLED DIMENSION

FRONT SUSPENSION

REAR SUSPENSION

Type

EDGE RMK (V/ESC)

Type

EDGE RMK

Standard IFS Shocks

7042197 Nitrex

Standard FTS

7042058 Nitrex

Standard IFS Spring Rate

100#

Standard FTS Spring Rate

170#

Standard Spring Pre-- Load

9.75”/24.7cm Installed

Standard Spring Pre-- Load

7.375”/18.7 Installed

Premium IFS Shocks

7042059 Arvin IFP

Premium FTS

7042084 Arvin IFP

Premium Spring Rate

100#

Premium Spring Rate

170#

Premium Spring Pre-- Load

4.25”/10.8cm

Premium Spring Pre-- Load

2.98”/7.6cm

Front Vertical Travel

7 6”/19 3cm
7.6”/19.3cm

Standard RTS

7042085 Select

Premium RTS

7042176 Arvin IFP C/A

Torsion Spring

.359/47_

TRACK
Width / Length / Lug Height

15”/144”/2” (38 cm./366
cm./5 cm.)

Width / Length / Lug Height

15”/151”/2” (38 cm./384
cm./5 cm.)

Track Tension

See Page 3.10

See page 11.7 for optional springs

ELECTRICAL
Flywheel I.D.

4010677

Spark Plug / Gap

Champion RN57YCC .025”
/ .70mm

CDI Marking

4010835

Voltage Regulator

T1

Alternator Output

280 watts

Magneto Pulses

6

Ignition Timing(see conversion chart on page 13.4)

20 @ 2000 RPM
w/ TPS Disconnected

Electric Start

Standard Accessory
Premium Optional

1.7

SPECIFICATIONS
MODEL: . . . . . . . . . . . . . . 800 RMK
MODEL NUMBER: . . . . S05N(M,K,L)8CS(A,B)
ENGINE MODEL: . . . . . S2776--8070--PI8C
ENGINE

CARBURETION

Engine Type

Libertyt

Type

Mikuni
TM40

Engine Displacement cc’s

794

Main Jet

350

Bore in / mm

3.35” / 85mm

Pilot Jet

45

Stroke in / mm

2.76” / 70mm

Jet Needle

9DGN6-- 57 / 2

Cylinders

2

Needle Jet

P-- 8

Piston / Cylinder Clearance
in / mm

.006 - .0074”
.152 - .188mm

Throttle Gap UnderCutaway
in / mm

0.102”
2.6mm

Piston Ring End Gap
in / mm

.016 - .022”
.40 - .559mm

Cutaway

2.0

Piston PN

3021315

Valve Seat

1.8

Piston Ring Marking

N/A

Starter Jet

145

Operating RPM ±200

8000

Fuel Screw

1.5 Turns

Idle RPM ±200

1500

Pilot Air Jet

N/A

Engagement RPM ±300

3800

Air Screw

.75 Turns

Exhaust Valve Spring

Pink

Fuel Octane (R+M/2)

87 Oct. NonOxy /
89 Oct. Oxy

AMBIENT TEMPERATURE

Altitude

Below -30°F
-30 F
Below -34°C

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

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

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

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

Above +50_F
Above +10_C

510N
#5

490
#3

470
#4

450
#4

430
#3

410
#3

600--1200
(2000--4000)

480
#4

470
#4

450
#4

430
#3

410
#3

390
#2

1200--1800
(4000--6000)

450
#4

430
#4

410
#3

390
#3

370
#2

350
#2

410
#4

390
#3

370
#3

350
#2

330
#2

310
#2

370
#3

350
#3

330
#2

310
#2

290
#2

270
#2

340
#3

320
#2

300
#2

280
#2

260
#2

240
#1

0--600
(0--2000)

Meters
M
t
(Feet)

1800--2400
(6000--8000)
(6000
8000)
2400--3000
(8000--10000)
(8000
10000)
3000--3700
(10000--12000)
(10000
12000)

Altitude

Meters
(Feet)

1.8

DRIVE CLUTCH
Shift
Weight

0--900
(0-3000)

10 66 Bushed
10-66

900-1500
(3000-5000)

10 64 Bushed
10-64

1500-2100
(5000-7000)

10 62 Bushed
10-62

2100-2700
(7000-9000)

10 60 Bushed
10-60

2700-3350
(9000-11000)

10--58 Bushed

3350-4000
(11000-13000)

10--56 Bushed

Clutch
Spring

DRIVEN CLUTCH
Clutch
Spring

Driven
Helix

Chaincase
Gearing

EV Spring
Recommendation
Altitude

EV Spring

meters(feet)

Black/Green

7043063

58 / 42 -- .36
36
Rev.

0--1200
(0--4000)

Pink/Yellow

19--39 : 72P

1200--3600
(4000--12000)

Pink

SPECIFICATIONS
DRIVE CLUTCH

CHAINCASE

Type

P-- 85

Center DIstance

7.92” / 20.12cm.

Shift Weights

10-- 60 Bushed

Gearing : Chain

19-- 39 : 72 P

Drive Spring

Black/Green

Reverse

Electronic Reverse

Brake Pads

Type 81

Brake Type

Liquid Cooled

DRIVEN CLUTCH
Type

Team Roller Reverse

Driven Spring

7043063

Helix Angle

58 / 42 - .36 Reverse

CAPACITIES

BELT

Fuel Tank

11.8 Gal. / 45 Liters

Oil Tank

3.25 Qts / 3 Liters

Belt Part Number

3211080

Coolant

5 Qts / 4.7 Liters

Belt Width (Projected)

1.438” / 3.65cm.

Chain Case Oil

9 fl. oz. / 266 ml

Side Angle (Overall)

28_

Outside Diameter

46.625” / 118.4cm.

Center Distance

11.5” / 29.2cm.

SLED DIMENSION
Unit Length / Height /
Width in / cm.

FRONT SUSPENSION

124” / 48” / 45.5”
315 / 122 / 116 cm.
130” / 48” / 45.5”
330 / 122 / 116 cm.

REAR SUSPENSION

Type

EDGE RMK (V/ESC)

Type

EDGE RMK

Standard IFS Shocks

7042197 Nitrex

Standard FTS

7042058 Nitrex

Standard IFS Spring Rate

100#

Standard FTS Spring Rate

170#

Standard Spring Pre-- Load

9.75”/24.7cm Installed

Standard Spring Pre-- Load

7.375”/18.7 Installed

Premium IFS Shocks

7042059 Arvin IFP

Premium FTS

7042084 Arvin IFP

Premium Spring Rate

100#

Premium Spring Rate

170#

Premium Spring Pre-- Load

4.25”/10.8cm

Premium Spring Pre-- Load

2.98”/7.6cm

Front Vertical Travel

7 6”/19 3cm
7.6”/19.3cm

Standard RTS

7042085 Select

Premium RTS

7042176 Arvin IFP C/A

TRACK

TORSION SPRINGS

Width / Length / Lug Height

15”/144”/2” (38 cm./366
cm./5 cm.)

Width / Length / Lug Height

15”/151”/2” (38 cm./384
cm./5 cm.)

Track Tension

See Page 3.10
3 10

Torsion Spring

.359/47_

See page 11.7 for optional springs

ELECTRICAL
Flywheel PN

4010677

Spark Plug / Gap

Champion RN57YCC/ .025”
/ .64mm

CDI PN

4010842

Voltage Regulator

T1

Alternator Output

280 watts

Magneto Pulses

6

Ignition Timing(see conver
conversion chart on page 13.4)

29 @3250 RPM±1.5_
29_@3250
RPM±1.5
w/ TPS disconnected

Electric Start

Standard Accessory
y
Premium Optional

1.9

SPECIFICATIONS
MODEL: . . . . . . . . . . . . . . 900 RMK
MODEL NUMBER: . . . . S05P(L,M)8DS(A,B,C,D)
ENGINE MODEL: . . . . . S2884--8686--PI8D
ENGINE

FUEL SYSTEM

Engine Type

Liberty

Type

Clean Fire Injection

Engine Displacement cc

866

Regulator Pressure

4 Bar (58psi)

Bore in / mm

3.46”/ 83mm

Stroke in / mm

3.15” / 80mm

Throttle Body Bore Size in/cm

2” / 51mm

Cylinders

2

TPS voltage @ idle

.92 - .94

Piston / Cylinder Clearance
in / mm

.0045” - .0098”
.114 - .249

Throttle Body Manufacture

Mikuni

Piston Ring End Gap in / mm

.016” - .022”
.406-- .56

Piston Marking

3021327

Type

P-- 85

Piston Ring Marking

N/A

Center Distance in/cm

11.5” / 29.2

Operating RPM ±200

7400

Spring

Black / Green

*Idle RPM ±200

1400

Shift Weight

10-- 70

Engagement RPM ±300

3700

Exhaust Valve Spring

Purple

THROTTLE BODY

DRIVE CLUTCH

DRIVEN CLUTCH

CHAINCASE

Type

TEAM

Spring

7043058

Helix

62/46-- 36 ER

Center Distance in/cm

11.35” / 28.83cm

Gearing

19 : 39 - 90P

Reverse

Electronic

Width in/cm

1.438” / 3.652cm

Brake Pads

2202727

Length in/cm

46.625” / 118.4275cm

Brake Type

Type 94 (DOT 4)

Part Number

3211080

BELT

CAPACITIES

DIMENSIONS

Fuel Tank gal./l

10.8 / 40.9

Length in/cm

128 / 325
134 / 340

Oil Tank qts./l

3 / 2.8

Height in/cm

46.5 / 118

Coolant qts. / l

6.7 - 6.9 / 6.3 - 6.4

Chain Case Oil oz. / ml

11 / 325.3

Width in/cm

46 33 / 118
46.33

Altitude

Meters
(Feet)

DRIVE CLUTCH
Shift
Weight

0-900
(0-3000)

10 -74
1074

900-1500
(3000-5000)

10 -74
1074

1500-2100
(5000-7000)

10 -72
1072

2210-2700
(7000-9000)
2700--3350
(9000--11000)
3350--4000
(11000--13000)

DRIVEN CLUTCH

Clutch
Spring

Clutch
Spring

Driven
Helix

Chaincase
Gearing

Bl k/G
Black/Green

7043058

62/46 -36
62/4636 ER

19 : 39 -- 90P

10 -70
1070
10--68
10--66

Idle RPM is factory set and is adjusted automatically through the barometric sensor inside the ECU. DO NOT attempt to adjust
idle on the throttle body or engine performance may be affected.

1.10

SPECIFICATIONS
FRONT SUSPENSION

REAR SUSPENSION

Type

IQ

Type

IQ

Standard IFS Shocks

7043049 AFX

Standard FTS

7043048 FX

Stock IFS Spring Rate

110#

Standard FTS Spring Rate

170#

Stock Spring Pre-- Load

11.38” / 29cm Installed

Standard Spring Pre-- Load

Fixed

Premium IFS Shocks

7043090 Arvin IFP

Premium FTS

7042335 Arvin IFP

Premium Spring Rate

100#

Premium FTS Spring Rate

170#

Premium Spring Pre-- Load

10” / 25.4cm Installed

Premium FTS Spring Pre-Load

7.25” / 18.4 cm Installed

Front Vertical Travel

8.84 in / 22.4cm

Standard RTS

7043047 AFX

Premium RTS

7043046 Arvin IFP/Res CA

TRACK

TORSION SPRINGS

Width in/cm

15/38.1

Length in/cm

151/384
159/404
166/422

Stock Torsion Spring

.359/77_

Lug Height in/cm

(151) 2 or 2.4/5 or 6.1
(159) 2 or 2.4/5 or 6.1
(166) 2.4/6.1

Light Torsion Spring

.347/77_

Track Tension

See page 3.10

Heavy Torsion Spring

.375/77_

ELECTRICAL
Flywheel I.D.

4011119

Spark Plug / Gap

Champion RN57YCC /
.025mm(.003”)

Base ECU

4011081

Voltage Regulator

4010866

Alternator Output

400watts

Stator

4010727

Ignition Timing(see conver
conversion chart on page 13.4)

14_ @ 3000RPM

Electric Start

TBD

1.11

SPECIFICATIONS
MODEL: . . . . . . . . . . . . . . 600 SWITCHBACKt
MODEL NUMBER: . . . . S05NS6ES(A)
ENGINE MODEL: . . . . . S2709--6044--PI6E
ENGINE

CARBURETION

Engine Type

Libertyt

Type

Mikuni
TM 38

Engine Displacement cc’s

599

Main Jet

420

Bore in / mm

3.04” / 77.25mm

Pilot Jet

50

Stroke in / mm

2.52” / 64mm

Jet Needle

9DGI01-- 60 / 4

Cylinders

2

Needle Jet

P-- 6

Piston / Cylinder Clearance
in / mm

.0045”-- .0059”
.115 - .149mm.

Throttle Gap UnderCutaway
in / mm

0.079”
2.0mm

Piston Ring End Gap
in / mm

.014-- .020”
.356 - .508mm

Cutaway

1.5

Piston PN

3021308

Valve Seat

1.5

Piston Ring Marking

N/A

Starter Jet

140

Operating RPM ±200

8000

Fuel Screw

1.5 Turns

Idle RPM ±200

1500

Pilot Air Jet

N/A

Engagement RPM ±300

3800

Air Screw

0.5 Turns

Exhaust Valve Spring

Green/White

Fuel Octane (R+M/2)

87 Oct. NonOxy /
89 Oct. Oxy

AMBIENT TEMPERATURE

Altitude

Below -30°F
-30 F
Below -34°C

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

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

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

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

Above +50_F
Above +10_C

450
#5

430
#5

420
#4

400
#4

380
#4

370
#4

600--1200
(2000--4000)

410
#5

390
#4

380
#4

360
#4

340
#4

330
#3

1200--1800
(4000--6000)

380
#4

360
#4

350
#4

330
#4

320
#3

300
#3

360
#4

340
#4

320
#4

310
#3

290
#3

280
#3

340
#4

320
#4

300
#3

290
#3

270
#3

260
#3

330
#4

310
#3

290
#3

280
#3

260
#3

240
#3

0--600
(0--2000)

Meters
M
t
(Feet)

1800--2400
(6000--8000)
(6000
8000)
2400--3000
(8000--10000)
(8000
10000)
3000--3700
(10000--12000)
(10000
12000)

Altitude

Meters
(Feet)

1.12

DRIVE CLUTCH
Shift
Weight

Clutch
Spring

DRIVEN CLUTCH
Clutch
Spring

Driven
Helix

Chaincase
Gearing

0--900
(0-3000)

10 60 Bushed
10-60

22 40:74P
22--40:74P

900-1500
(3000-5000)

10 58 Bushed
10-58

22 40:74P
22--40:74P

1500-2100
(5000-7000)

10 56 Bushed
10-56

2100-2700
(7000-9000)

10 54 Bushed
10-54

2700-3350
(9000-11000)

10AL Bushed

19--39:72P

3350-4000
(11000-13000)

10 Bushed

19--39:72P

Black/Green

7043063

56 / 42 -- .36
36
ER

22 40:74P
22--40:74P
19 39:72P
19--39:72P

SPECIFICATIONS
DRIVE CLUTCH

CHAINCASE

Type

P-- 85

Center Distance

7.92” / 20.12cm.

Shift Weights

10-- 60 Bushed

Gearing : Chain

22-- 40 : 74 P

Drive Spring

Black / Green

Reverse

Electronic Reverse

Brake Pads

Type 81

Brake Type

Liquid Cooled

DRIVEN CLUTCH
Type

Team Roller Reverse

Driven Spring

7043063

Helix Angle

56 / 42 - .36 Reverse

CAPACITIES

BELT

Fuel Tank

11.8 Gal. / 45 Liters

Belt Part Number

3211080

Oil Tank

3.25 Qts / 3 Liters

Belt Width (Projected)

1.438” / 3.65cm.

Coolant

5 Qts / 4.7 Liters

Side Angle (Overall)

28_

Chain Case Oil

9 fl. oz. / 266 ml

Outside Diameter

46.625” / 118.4cm.

Center Distance

11.5” / 29.2cm.

SLED DIMENSION
Unit Length / Height /
Width in / cm.

FRONT SUSPENSION

124” / 48” / 47”
315 / 122 / 119 cm.

REAR SUSPENSION

Type

EDGE RMK

Type

EDGE RMK

IFS Shocks

7043083 Alum IFP

FTS

7042084 Arvin IFP

IFS Spring Rate

100#/in
100#/in.

FTS Spring Rate

170#/in
170#/in.

IFS Spring Pre-- Load

10.5” / 26.7cm Installed

Front Vertical Travel

7.1-- 7.4 / 18 - 18.8cm.

FTS PrePre - Load

2 98” / 7.6
2.98”
7 6 cm.
cm

RTS

7042176 Arvin IFP C/A

Torsion Spring

.359” (Sq) x 47_

TRACK
Width

15” / 38 cm.

Length

144” / 366 cm.

Lug Height

1.25” / 3.175 cm.

Track Tension

See page 3.10
3 10

Optional
p
springs
p g see ppage
g 11.7

ELECTRICAL
Flywheel I.D.

4010677

Spark Plug / Gap

Champion RN57YCC .028”
/ .70mm

CDI Marking

4010830

Voltage Regulator

T1

Alternator Output

280 watts

Magneto Pulses

6

Ignition Timing(see conver
conversion chart on page 13.4)

24 @3000 RPM±1.5_
24_@3000
RPM±1.5
w/TPS Disconnected

Electric Start

Accessory

1.13

SPECIFICATIONS
MODEL: . . . . . . . . . . . . . . 800 SWITCHBACKt
MODEL NUMBER: . . . . S05NSCS(A)
ENGINE MODEL: . . . . . S2708--8070--PI8C
ENGINE

CARBURETION

Engine Type

Libertyt

Type

Mikuni
TM 40

Engine Displacement cc’s

794

Main Jet

470

Bore in / mm

3.35” / 85mm

Pilot Jet

45

Stroke in / mm

2.76” / 70mm

Jet Needle

9DGN6-- 57/4

Cylinders

2

Needle Jet

P-- 8

Piston / Cylinder Clearance
in / mm

.006 - .0074”
.152 - .188mm

Throttle Gap UnderCutaway
in / mm

0.079”
2.0mm

Piston Ring End Gap
in / mm

.016 - .022”
.406 - .559mm

Cutaway

2.0

Piston PN

3021315

Valve Seat

1.8

Piston Ring Marking

N/A

Starter Jet

145

Operating RPM ±200

8000

Fuel Screw

1.0 Turns

Idle RPM ±200

1500

Pilot Air Jet

N/A

Engagement RPM ±300

3800

Air Screw

1.0 Turns

Exhaust Valve Spring

Pink / Yellow

Fuel Octane (R+M/2)

87 Oct. NonOxy /
89 Oct. Oxy

AMBIENT TEMPERATURE

Altitude

Below -30°F
-30 F
Below -34°C

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

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

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

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

Above +50_F
Above +10_C

510N
#5

490
#4

470
#4

450
#4

430
#3

410
#3

600--1200
(2000--4000)

480
#4

470
#4

450
#4

430
#3

410
#3

390
#2

1200--1800
(4000--6000)

450
#4

430
#4

410
#3

390
#3

370
#2

350
#2

410
#4

390
#3

370
#3

350
#2

330
#2

310
#2

370
#3

350
#3

330
#2

310
#2

290
#2

270
#2

340
#3

320
#2

300
#2

280
#2

260
#2

240
#1

0--600
(0--2000)

Meters
M
t
(Feet)

1800--2400
(6000--8000)
(6000
8000)
2400--3000
(8000--10000)
(8000
10000)
3000--3700
(10000--12000)
(10000
12000)

Altitude

Meters
(Feet)

1.14

DRIVE CLUTCH
Shift
Weight

Clutch
Spring

DRIVEN CLUTCH
Clutch
Spring

Driven
Helix

Chaincase
Gearing

0--600
(0-2000)

10 66 Bushed
10-66

23 39:74P
23--39:74P

600-1200
(2000-4000)

10 64 Bushed
10-64

23 39:74P
23--39:74P

1200-1800
(4000-7000)

10 62 Bushed
10-62

1800-2400
(6000-8000)

10 60 Bushed
10-60

2400-3000
(8000-10000)

10--58 Bushed

21--41:74P

3000-3600
(10000-12000)

10--56 Bushed

21--41:74P

Black/Green

7043063

58 / 42 -- .36
36
ER

23 39:74P
23--39:74P
21 41:74P
21--41:74P

SPECIFICATIONS
DRIVE CLUTCH

CHAINCASE

Type

P-- 85

Center Distance

7.92” / 20.12cm.

Shift Weights

10-- 66 Bushed

Gearing : Chain

23-- 39 : 74 P

Drive Spring

Black / Green

Reverse

Electronic Reverse

Brake Pads

Type 81

Brake Type

Liquid Cooled

DRIVEN CLUTCH
Type

Team Roller Reverse

Driven Spring

7043063

Driven Helix Angle

58/42-- .36 ER

CAPACITIES

BELT

Fuel Tank

11.8 Gal. / 45 Liters

Belt Part Number

3211080

Oil Tank

3.25 Qts / 3 Liters

Belt Width (Projected)

1.438” / 3.65cm.

Coolant

5 Qts/ 4.7 Liters

Side Angle (Overall)

28_

Chain Case Oil

9 fl. oz. / 266 ml

Outside Diameter

46.625” / 118.4cm.

Center Distance

11.5” / 29.2cm.

SLED DIMENSION
Unit Length / Height /
Width in / cm.

FRONT SUSPENSION

124” / 48” / 47”
315 / 122 / 119 cm.

REAR SUSPENSION

Type

EDGE RMK

Type

EDGE RMK

IFS Shocks

7043083 Alum IFP

FTS

7042084 Arvin IFP

IFS Spring Rate

100#/in
100#/in.

FTS Spring Rate

170#/in
170#/in.

IFS Spring Pre-- Load

10.5” / 26.7cm Installed

Front Vertical Travel

7.1-- 7.4 / 18 - 18.8cm.

FTS PrePre - Load

2 98” / 7.6
2.98”
7 6 cm.
cm

RTS

7042176 Arvin IFP C/A

Torsion Spring

.359” (Sq) x 47_

TRACK
Width

15” / 38 cm.

Length

144” / 366 cm.

Lug Height

1.25” / 3.175 cm.

Track Tension

See page 3.10
3 10

Optional
p
springs
p g see ppage
g 11.7

ELECTRICAL
Flywheel PN

4010677

Spark Plug / Gap

Champion RN57YCC /
.025” / .70mm

CDI PN

4010841

Voltage Regulator

T1

Alternator Output

280 watts

Magneto Pulses

6

Ignition Timing(see conver
conversion chart on page 13.4)

29 @3250 RPM±1.5_
29_@3250
RPM±1.5
w/TPS Disconnected

Electric Start

Accessory

1.15

SPECIFICATIONS
NOTES

1.16

2005 Model Number Designation . . . . . . . . . . . . . . . . . . . . . . . . .
Tunnel Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vehicle Identification Number . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2005 Publication Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Service Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .
Decimal Equivalents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tap Drill Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston Wash and Spark Plug Color . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Honing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Port Chamfering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Rod Bearing Inspection . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Indexing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump Operation and Troubleshooting . . . . . . . . . . . . . . . . . . .
Oil Pump Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
900 Fusion Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.15 - 2.17
2.18
2.19
2.20
2.21
2.22

GENERAL INFORMATION
2005 MODEL NUMBER DESIGNATION
EXAMPLE: S05NB4BS
S

05

N

B

Identifier
(1st Digit)

ModelYear
(2nd/3rd Digit)

Model Line
(4th Digit)

Model Type
(5th Digit)

S=Snow

05=2005

M=Fusion

4

B

S

#
Option
Identifier
(9th
Digit)

Engine Size
(cc)
(6th Digit)

Engine modifier
(6th/7th Digit)

VIN
Identifier
(8th Digit)

A=50th Anniv Special

0=0-- 99cc

1A=121 F/C OHV 4 cycle Fuji

E=Europe unit

N=Edge

B=Basic or Standard

1=100-- 199

3A=340 F/C Piston Port

S=Standard
Production
Unit

P=IQ RMK

D=Classic

2=200-- 299cc

4B=488 L/C Piston Port

S=Gen II

E=M-- 10 Performance

3=300-- 399cc

4C=440 EV L/C Case Reed (Dom)

W=Mini Indy

J=136 RMK

4=400-- 499cc

5B=544 F/C Cylinder Reed

K=144 RMK

5=500-- 599cc

5C=500 EFV L/C Case Reed 2 Cyl
(Dom)

L=151 RMK

6=600-- 600cc

6E=600 EV L/C Case Reed 2 Cyl
(Dom)

M=159 RMK

7=700-- 799cc

7C=700 EV L/C Case Reed 2 Cyl
(Dom)

N=166 RMK

8=800-- 899cc

7D=780 4-- stroke EFI 2 Cyl (Dom)

P=Performance

9=900+cc

8C=800 EV L/C Case Reed 2 Cyl
(Dom)

S=Switchback

8D=866 EV SDI Case Reed

T=Touring
U=Utility
X=Racer/Pro X

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

PATENT NOTICE

MADE IN U.S.A.

Mfd. by Polaris Industries Inc.. in Roseau, MN under one or
more of the following patents:
U.S. Patents
3,605,511
3,580,647
3,483,766
3,533,662
3,545,821
3,605,510
3,525,412

3,613,810
3,867,991
4,793,950
5,038,881
5,172,675
5,090,386
5,050,564

5,050,559
5,048,503
5,056,482
5,099,813
5,074,271
5,191,531
3,613,811

Patented Canada
882,491/71
883,694/71
864,394/71
Canadian Rd.
34,573/71
34,572/71
1,227,823/87
7072133

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

2.1

GENERAL INFORMATION
VEHICLE IDENTIFICATION NUMBER
Current snowmobiles have a 17 digit Vehicle Identification Number (VIN). The VIN is organized as follows: Digits 1-3: World
Manufacturer Identifier. For Polaris, this is SN1. Digits 4-9: Vehicle Descriptor Section. Digits 10-17: Vehicle Indicator Section.
Digits 4-8 of the VIN identify the body style, type, engine type, and series. The VIN and the model number must be used with
any correspondence regarding service or repair.

Example of
Current
VIN Number

World Mfg. ID

1
S

2
N

3
1

Vehicle Descriptor

4
S

Body Style

5
B

6
5

7
B

8
S

Vehicle Identifier

9 10 11 12
0 2 2
0

13 14 15 16 17
0 0
0 0 0

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

Vehicle Identification Number / Model Number Key
Body Style

Type

Engine Size

Engine Modifier

Series

L=Lite

B=Base Model

1=100-199 cc’s

A=Fan

S=Domestic

N=Edge

D=Deluxe

2=200-299 cc’s

B=Liquid Twin

U=Europe

S=Gen II

P=Performance

3=300-399 cc’s

C=Case Reed Twin

W=Mini

R=RMK

4=400-499 cc’s

D=Liquid Triple

S=SKS

5=500-599 cc’s

E=Case Reed Triple

T=Touring

6=600-699 cc’s

U=Utility

7=700-799 cc’s

X=Racer

8=800-899 cc’s

2.2

GENERAL INFORMATION
PUBLICATION PART NUMBERS
Model

Model No.

Owner’s Manual

Owners Manual
Supplement

Parts
Manual

Microfiche

Trail RMK

S05NJ5BS(A)

9919706

9919097

9919276

9919277

600 RMK

S05NK6ES(A)

9919706

9919098

9919278

9919279

700 RMK

S05N(K,L)7CS(A)

9919706

9919381

9919278

9919279

9919278

9919279

9919292

9919293

9919383 (144)
800 RMK

S05N(M,K,L)8CS(A,B)

9919706

9919384 (151)
9919385 (159)
9919104 (151)

900 RMK

S05P(L,M)8DS(A,B,C,D)

9919077

9919105 (159)
9919106 (166)

600 Switchback

S05NS6ES(A)

9919076

9919095

9919280

9919281

800 Switchback

S05NSCS(A)

9919076

9919095

9919280

9919281

SERVICE MANUALS
Service Manuals
2000-- 2005
120 XC SP / PRO X

Trail Sport
500 Indy, Supersport

Touring
340 Edge Touring, Trail Touring (Deluxe), Widetrak LX, 600 Edge Touring (50th), 800 Edge Touring

Frontier
Frontier Touring

Classic
340 Classic, 500 Classic, 550 Classic, 600 Classic, 800 Classic

Deep Snow
Trail RMK, 600/700/800 RMK, 600/800 Switchbackt, 900 RMK

Performance
500/600/700/800 XC SP, 900 Fusion

2004
9919307
9919300
9919304
9919305
9919301
9919302
9919303

2005 Specification Handbook

9919311

2005 Snowmobile Wallcharts

9919309

Track Poster

9918459

Flat Rate Manual

9919308

Snowmobile Care and Adjusting for the Perfect Ride (DVD) (2004)

9918923

Snowmobile Care and Adjusting for the Perfect Ride (VHS) (2004)

9918908

2005 Snowmobile Quick Start Guide (DVD) (2005)

9919129

2.3

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

2.4

GENERAL INFORMATION
DECIMAL EQUIVALENTS
1/64 . . . . . . . . . . . . . . . . . . .0156
1/32 . . . . . . . . . . . . . .0312 . . . . . . . . 1 mm = .0394″
3/64 . . . . . . . . . . . . . . . . . . .0469
1/16 . . . . . . . . . . . . .0625
5/64 . . . . . . . . . . . . . . . . . . .0781 . . . . . . . . 2 mm = .0787″
3/32 . . . . . . . . . . . . . .0938
7/64
. . . . . . . . . . . . . . . . .1094 . . . . . . . . 3 mm = .1181″
1/8 . . . . . .125
9/64 . . . . . . . . . . . . . . . . . . .1406
5/32 . . . . . . . . . . . . .1563 . . . . . . . . 4 mm = .1575″
11/64 . . . . . . . . . . . . . . . . . .1719
3/16 . . . . . . . . . . . . .1875 . . . . . . . . 5 mm = .1969″
13/64 . . . . . . . . . . . . . . . . . .2031
7/32 . . . . . . . . . . . . .2188
15/64 . . . . . . . . . . . . . . . . . .2344 . . . . . . . . 6 mm = .2362″
1/4 . . . . .250
17/64 . . . . . . . . . . . . . . . . . .2656 . . . . . . . . 7 mm = .2756″
9/32 . . . . . . . . . . . . .2813
19/64 . . . . . . . . . . . . . . . . . .2969
5/16 . . . . . . . . . . . . .3125 . . . . . . . . 8 mm = .3150″
21/64 . . . . . . . . . . . . . . . . . .3281
11/32 . . . . . . . . . . . .3438 . . . . . . . . 9 mm = .3543″
23/64 . . . . . . . . . . . . . . . . . .3594
3/8 . . . . .375
25/64 . . . . . . . . . . . . . . . . . .3906 . . . 10 mm = .3937″
13/32 . . . . . . . . . . . .4063
27/64 . . . . . . . . . . . . . . . . . .4219 . . . . . . . . 11 mm = .4331″
7/16 . . . . . . . . . . . . .4375
29/64 . . . . . . . . . . . . . . . . . .4531
15/32 . . . . . . . . . . . .4688 . . . . . . . . 12 mm = .4724″
31/64 . . . . . . . . . . . . . . . . . .4844
1/2 . . . . .5 00 . . . . . . . . . . . . . . . . . 13 mm = .5118″
33/64 . . . . . . . . . . . . . . . . . .5156
17/32 . . . . . . . . . . . .5313
35/64 . . . . . . . . . . . . . . . . . .5469 . . . . . . . . 14 mm = .5512″
9/16 . . . . . . . . . . . . .5625
37/64 . . . . . . . . . . . . . . . . . .5781 . . . . . . . . 15 mm = .5906″
19/32 . . . . . . . . . . . .5938
39/64 . . . . . . . . . . . . . . . . . .6094
5/8 . . . . .625 . . . . . . . . . . . . . . . . . 16 mm = .6299″
41/64 . . . . . . . . . . . . . . . . . .6406
21/32 . . . . . . . . . . . .6563 . . . . . . . . 17 mm = .6693″
43/64 . . . . . . . . . . . . . . . . .6719
11/16 . . . . . . . . . . . .6875
45/64 . . . . . . . . . . . . . . . . . .7031 . . . . . . . . 18 mm = .7087″
23/32 . . . . . . . . . . . .7188
47/64 . . . . . . . . . . . . . . . . . .7344 . . . . . . . . 19 mm = .7480″
3/4 . . . . .750
49/64 . . . . . . . . . . . . . . . . . .7656
25/32 . . . . . . . . . . . .7813 . . . . . . . . 20 mm = .7874″
51/64 . . . . . . . . . . . . . . . . . .7969
13/16 . . . . . . . . . . . .8125 . . . . . . . . 21 mm = .8268″
53/64 . . . . . . . . . . . . . . . . . .8281
27/32 . . . . . . . . . . . .8438
55/64 . . . . . . . . . . . . . . . . . .8594 . . . . . . . . 22 mm = .8661″
7/8 . . . . .875
57/64 . . . . . . . . . . . . . . . . . .8906 . . . . . . . . 23 mm = .9055″
29/32 . . . . . . . . . . . .9063
59/64 . . . . . . . . . . . . . . . . .9219
15/16 . . . . . . . . . . . .9375 . . . . . . . . 24 mm = .9449″
61/64 . . . . . . . . . . . . . . . . . .9531
31/32 . . . . . . . . . . . .9688 . . . . . . . . 25 mm = .9843″
63/64 . . . . . . . . . . . . . . . . . .9844
1 . . . . . . 1.000

2.5

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

Bolt Size
#10
#10

-

1/4
1/4
5/16
5/16
3/8
3/8
7/16
7/16
1/2
1/2

-

Threads/In
(MM/Thread)

Grade 2

Torque in. lbs. (Nm)
24 . . . . . . . . . . . 27 (3.1) . . . . . . . . . . . . .
32 . . . . . . . . . . . 31 (3.6) . . . . . . . . . . . . .
Torque ft. lbs. (Nm)*
20 . . . . . . . . . . . 5 (7) . . . . . . . . . . . . . . .
28 . . . . . . . . . . . 6 (8) . . . . . . . . . . . . . . .
18 . . . . . . . . . . . 11 (15) . . . . . . . . . . . . .
24 . . . . . . . . . . . 12 (16) . . . . . . . . . . . . .
16 . . . . . . . . . . . 20 (27) . . . . . . . . . . . . .
24 . . . . . . . . . . . 23 (32) . . . . . . . . . . . . .
14 . . . . . . . . . . . 30 (40) . . . . . . . . . . . . .
20 . . . . . . . . . . . 35 (48) . . . . . . . . . . . . .
13 . . . . . . . . . . . 50 (69) . . . . . . . . . . . . .
20 . . . . . . . . . . . 55 (76) . . . . . . . . . . . . .

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

*To convert ft. lbs. to Nm multiply foot pounds by 1.356.
*To convert Nm to ft. lbs. multiply Nm by .7376.

2.6

Grade 8

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

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

2.7

GENERAL INFORMATION
CONVERSION CHART
Unit of Measure

Multiplied by

Converts to

ft. lbs.

x 12

= in. lbs.

in. lbs.

x .0833

= ft. lbs.

ft. lbs.

x 1.356

= Nm

in. lbs.

x .0115

= kg-m

Nm

x .7376

= ft. lbs.

kg-m

x 7.233

= ft. lbs.

kg-m

x 86.796

= in. lbs.

kg-m

x 10

= Nm

in.

x 25.4

= mm

mm

x .03937

= in.

in.

x 2.54

= cm

mile (mi.)

x 1.6

= km

km

x .6214

= mile (mi.)

Ounces (oz)

x 28.35

= Grams (g)

Grams (g)

x 0.035

= Ounces (oz)

cc’s

x .03381

= Fluid Ounces (oz)

lb.

x .454

= kg

kg

x 2.2046

= lb.

Cubic inches (cu in)

x 16.387

= Cubic centimeters (cc’s)

Cubic centimeters (cc’s)

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

2.8

GENERAL INFORMATION
PISTON WASH AND SPARK PLUG COLOR
Changing temperature, barometer, altitude, and fuel supply are just a few of the factors that can affect the day to day performance
of your engine. That is why using Exhaust Gas Temperatures (EGTs) are important for maintaining optimum performance. There
are two methods for helping you determine what the EGTs are for your machine. Piston wash and the coloring of your spark
plug.The piston wash is by far the most valuable tool in concluding EGTs, with the spark plug color running a distant second.
Use the illustrations below to help you establish the EGTs for your machine.

Piston Wash

n

Spark Plug Color

Wet and Black wash indicates too rich a fuel
mixture
Wash

n If the plug is wet or very dark, the fuel is
running too rich.

Correct
Correct
n

n

If the wash is 1/4” - 3/8” and cocoa
brown, the machine’s EGTs are just right.
Dry

A dry, ash colored piston indicates too lean a
mixture for the operating conditions.

n

If the plug is light to cocoa brown, the machine’s EGTs are just right.

n

A ash white plug with speckles indicates too
lean a mixture for the operating conditions.

Once the proper jetting is established, you can reference the EGT gauge for your baseline numbers. Then, if there is a rise or
fall of 25 degrees, you must jet accordingly to return your EGTs to the baseline numbers.

2.9

GENERAL INFORMATION
CYLINDER INSPECTIONS
CYLINDER HEAD INSPECTION

Limit .003” (.08mm)

Inspect each piston dome area of the cylinder head for warping by placing a straight edge across the dome area.
With a feeler gauge measure any gap under the straight edge.
Replace cylinder head if measurement exceeds the service limit of
.003” (.08mm).

NOTE:

Cylinder Head Warp
Service Limit .003” (.08mm)

CYLINDER MEASUREMENT
Inspect each cylinder for wear, scratches, or damage. If no damage is evident, measure the cylinder for taper and out of round
with a telescoping gauge or a dial bore gauge. Measure the bore 1/2, from the top of the cylinder; in line with the piston pin and
90_ to the pin to determine if the bore is out of round. Repeat the measurements at the middle of the cylinder and the bottom
of the cylinder to determine taper or out of round at the bottom. Use the chart below and record all measurements.

S Cylinder Taper Limit: .002” MAX
S Cylinder Out of Round Limit: .002”
TOP
Tx

Ty

Ty
Top

Tx

MIDDLE
Mx

My
Middle

BOTTOM
Bx

Mx

By

Out of round =
Tx--Ty and By--Bx
Taper Limit=
Ty--By and Tx--Bx

2.10

My

By
Bottom

Bx

GENERAL INFORMATION
PISTON INSPECTION / MEASUREMENT
B

A

C

Piston Ring

Piston Ring

1/2″ (1.3cm.)

1/2″ (1.3cm.)

Cylinder

Feeler Gauge
90° to pin

DOMESTIC ENGINES - Measure 3/8″ (10.0mm)
up from bottom of skirt
FUJI ENGINES - Measure 1/2″ (12.7mm) up
from bottom of skirt

D

Up
Straight Edge
Keystone Piston Ring Cutaway

Check piston for scoring or cracks in piston crown or pin area. Excessive carbon buildup below the ring lands is an indication
of piston, ring or cylinder wear.
For Libertyt engines, measure piston outside diameter at a point 3/8” (10mm) up from the bottom of the skirt at a 90_ angle
to the direction of the piston pin (diagram A).
For Fuji engines, measure piston outside diameter at a point that is 1/2” (12.7mm) up form the bottom of the skirt at a 90_ angle
to the direction of the piston pin (diagram A).
NOTE:

The piston must be measured at this point to provide accurate piston to cylinder measurements.

Subtract this measurement from the minimum cylinder measurement recorded previously when you recorded the cylinder measurements. If clearance exceeds the service limit, the cylinder should be re-bored and new pistons and rings installed. Refer to
piston to cylinder clearance limits in the General Information section listed per model.

PISTON RING INSTALLED GAP
Position the ring 1/2“ (1.3 cm) from the top of the cylinder using the piston to push it squarely into place. Measure installed gap
with a feeler gauge at both the top and bottom of the cylinder (diagram B).
NOTE:

A difference in end gap indicates cylinder taper. The cylinder should be measured for excessive
taper and out of round. Replace rings if the installed end gap exceeds the service limit.

NOTE:

Always check piston ring installed gap after re-boring a cylinder or when installing new rings.

NOTE:

Piston rings are installed with marking or beveled side up see diagram D.

2.11

GENERAL INFORMATION
CYLINDER HONING
The cylinder bore must be de-glazed whenever new piston rings are installed. A light honing with fine stones removes only a
very small amount of material. A proper crosshatch pattern is important to provide a surface that will hold oil, and allow the rings
to seat properly. If the crosshatch is too steep, oil retention will be reduced. A crosshatch angle which is too shallow will cause
ring vibration, poor sealing, and overheating of the rings due to blow-by and reduced contact with the cylinder wall. Service life
of the pistons and rings will be greatly reduced.

CYLINDER HONE SELECTION

NOTE:

A Nikasil cylinder can be lightly honed with
a soft stone hone but can not be oversized.

DE--GLAZING
If cylinder wear or damage is minimal, honing the cylinder lightly with
finish stones. Follow the procedure outlined above

EXAMPLE OF A CROSS HATCH PATTERN

HONING TO OVERSIZE (340 AND 500 FUJI ENGINES ONLY)
If cylinder wear or damage is excessive, it will be necessary to oversize the cylinder using a new oversize piston and rings. This
may be accomplished by either boring the cylinder and then finish honing to the final bore size, or by rough honing followed by
finish honing.
NOTE:

Portable rigid hones are not recommended for oversizing cylinders, cylinder boring, and finish honing.
The use of an arbor type honing machine is recommended.

For oversize honing always wet hone using honing oil and a coarse roughing stone. Measure the new piston at room temperature
(see piston measurement) and rough hone to the size of the piston or slightly larger. Always leave .002” - .003“ (.05 - .07 mm)
for finish honing. Complete the sizing with fine grit stones to provide the proper cross-hatch finish and required piston clearance.
Inspect cylinder for taper and out-of-round. Taper or out-of-round on the finished bore should not exceed .0004“ (.002mm).
NOTE:

Always check piston to cylinder clearance and piston ring installed gap after boring/honing is complete.

HONING PROCEDURE
Wash the cylinder with solvent.
Clamp the cylinder in a soft jawed vise by the exhaust port studs.
Place hone in cylinder and tighten stone adjusting knob until stone contacts the cylinder walls (DO NOT OVERTIGHTEN).
Cylinders may be wet or dry honed depending on the hone manufacturer’s recommendations. Wet honing removes more material
faster and leaves a more distinct pattern in the bore. Using a 1/2“ (13 mm) drill motor rotating at a speed of 300-500 RPM, run
the hone in and out of the cylinder rapidly until cutting tension decreases. Remember to keep the hone drive shaft centered to
prevent edge loading and always bring the stone approximately 1/2“ (1.3 cm) beyond the bore at the end of each stroke.
Release the hone at regular intervals to inspect bore size and finish.

2.12

GENERAL INFORMATION
PORT CHAMFERING
Remove the sharp edges at the bottom and top of each port whenever boring or honing is performed. Make sure there are no sharp
edges.

IMPORTANT:

It is very important that the cylinder be thoroughly cleaned after honing to remove all grit material.
Wash the cylinder in a solvent, then in hot soapy water. Pay close attention to areas where the cylinder
sleeve meets the aluminum casting (transfer port area). Use electrical contact cleaner if necessary to
clean these areas. Rinse thoroughly, dry with compressed air, and oil the bore immediately with Polaris
Premium 2 Cycle Lubricant.

CLEANING THE CYLINDER AFTER HONING
It is very important that the cylinder be thoroughly cleaned after honing to remove all grit material. Wash the cylinder in a solvent,
then in hot soapy water. Pay close attention to areas where the cylinder sleeve meets the aluminum casting (transfer port area).
Use electrical contact cleaner if necessary to clean these areas. Rinse thoroughly, dry with compressed air, and oil the bore immediately with Polaris Premium 2 Cycle Lubricant.
NOTE:

Always check piston to cylinder clearance and piston ring installed gap after boring/honing is
complete!

CRANKCASE INSPECTION / BEARING FIT
Any time crankshaft bearing failure occurs and the case is to be reused,
Polaris recommends checking the bearing fit into the case halves using
the following procedure.
With case halves cleaned, press a replacement bearing into each of the
main bearing journals to determine a basic amount of press fit.

NOTE:

NOTE:

Crankcase Bearing Interference Fit:.001” - .002” (.026 - .051mm)
Do a comparison check of all journals by manually forcing the bearing into the bearing seats noting if
any are noticeably loose or tight. Normal hand installation will be an indication of the recommended
interference fit. If the bearing falls out of the case when the case is inverted, or if the crankcase bearing surface is severely galled or damaged, the case should be replaced

CRANKSHAFT MAIN BEARING INSPECTION
Clean crankshaft thoroughly and oil main and connecting rod bearings with Polaris engine oil. Carefully check each main bearing
on the shaft.

NOTE:

Due to extremely close tolerances, the bearings must be inspected visually, and by feel. Look for signs
of discoloration, scoring or galling. Turn the outer race of each bearing. The bearings should turn
smoothly and quietly. The inner race of each bearing should fit tightly on the crankshaft. The outer
race should be firm with minimal side to side movement and no detectable up and down movement.
Replace any loose or rough bearings.

2.13

GENERAL INFORMATION
CONNECTING ROD (BIG END) BEARING INSPECTION
Measure connecting rod big end side clearance with a feeler gauge. 500/600 Libertyt Engines should have a clearance of
(.28 - .75mm) and 700/800/900 Libertyt Engines should have (.28 - .70mm) and be equal on all rods (within .002″) Rotate rod
on crankshaft and check for rough spots. Check radial end play in rod by supporting rod against one thrust washer and alternately
applying up and down pressure. Replace bearing, pin, and thrust washers if side clearance is excessive or if there is any up and
down movement detectable in the big end bearing.
Within .002” (.05mm)

NOTE:

Specialized equipment and a sound knowledge
of crankshaft repair and straightening is required
to perform crankshaft work safely and correctly.
Crankshaft repair should be performed by
trained Polaris service technicians in a properly
equipped shop.

PISTON PIN / NEEDLE BEARING INSPECTION
Clean needle bearing in solvent and dry with compressed air.
Inspect needle cage carefully for cracks or shiny spots which indicate
wear. Replace needle bearings if worn or cracked, and always replace
them if piston damage has occurred.
Visually inspect piston pin for damage, discoloration, or wear. Run your
fingernail along the length of the pin and replace it if any rough spots,
galling or wear is detected.

CONNECTING ROD SMALL END INSPECTION
Clean small end of connecting rod and inspect inner bore with a magnifying glass. Look for any surface irregularities including pitting, wear,
or dents.
Run your fingernail around the inside of the rod and check for rough
spots, galling, or wear.
Oil and install needle bearing and pin in connecting rod. Rotate pin
slowly and check for rough spots or any resistance to movement. Slide
pin back and forth through bearing while rotating and check for rough
spots.
With pin and bearing centered in rod, twist ends back and forth in all
directions to check for excessive axial play. Pull up and down evenly
on both ends of pin to check for radial play. Replace pin and bearing
if there is any resistance to rotation or excessive axial or radial movement. If play or roughness is evident with a new pin and bearing, replace
the connecting rod.

2.14

GENERAL INFORMATION
CRANKSHAFT INDEXING

.100 ATDC

Dial Indicator

.100 ATDC

Dial Indicator

PTO

MAG
Degree
Wheel

Degree
Wheel
Crankshaft center line

CAUTION:

Disconnect battery ground cable and ALL spark plug high tension leads: ground high tension
leads to engine. Disconnect lanyard (if equipped) and or press engine stop switch before proceeding with this following procedure.

Polaris crankshafts are pressed together or ‘‘indexed” so the connecting rod journal center lines are 180_ (twins).
It is sometimes necessary to check multi-cylinder crankshafts to verify that one cylinder has not been forced out of position relative to the other cylinder or cylinders. Some causes for out-of-index crankshafts include but are not not limited to:

S

Hydraulock from water or fuel

S

Impact to drive clutch from foreign object or accident

S

Abrupt piston or other mechanical failure

S Engine lock-- up due to drive belt failure
REQUIRED SERVICE: Belt Removal, Drive Clutch Removal
Securely fasten a degree wheel on the flywheel or PTO end of crankshaft. Use a large degree wheel for more accuracy, and make
sure it is mounted concentrically with the crankshaft center line.
Sharpen a coat hanger or section of welding rod and anchor it to a convenient spot. Point the sharpened end at the outer perimeter
of the degree wheel.
Install a dial indicator into the magneto end cylinder spark plug hole. (The ignition timing is referenced by the magneto end.)
With the indicator installed on the MAG cylinder rotate the engine to bring the piston to top dead center (TDC).
Locate TDC as accurately as possible by finding the center of the point where there is no piston movement then ‘‘Zero” the dial
indicator at this point. Continue to rotate the crankshaft in the normal direction of rotation until the dial indicator reads .100”
(2.54mm) after top dead center (ATDC).
Bend the pointer or move the degree wheel until the pointer aligns with a 180_ mark on the degree wheel.
With the pointer aligned, make sure the degree wheel and pointer are secured and will not move out of position. Re-check accuracy of this location a few times. The pointer should align with the 180_ mark when the dial indicator reads .100“ (2.54mm) ATDC.

IMPORTANT:

Do not move the crankshaft, degree wheel or pointer after the initial setting on the MAG end cylinder simply read the wheel and dial indicator.

Remove the dial indicator and install in PTO cylinder. Repeat finding TDC. Note the degree wheel indication when the dial indicator reads .100” ATDC. It should be 180_ (± 2_) from the MAG cylinder mark.

2.15

GENERAL INFORMATION
Symptoms of an out of index crankshaft can include:

S
S
S
S

Difficulty calibrating carburetor (repetitive plug fouling on one cylinder with no other cause)
Unexplained piston failure on one cylinder (i.e. severe detonation, broken ring lands, piston holing)
Excessive vibration of engine, backfiring, etc.
Rough idle, poor top speed.

CRANKSHAFT TRUING
Lubricate the bearings and clamp the crankshaft securely in the holding fixture. If truing the crankshaft requires striking with a
hammer, always be sure to re-check previously straightened areas to verify truing. Refer to the illustrations below. Use Crankshaft alignment kit PN 2870569.
NOTE:

The Rod Pin position in relation to the dial indicator tells you what action is required to straighten
the shaft.
HIGH .004 (.1mm)
HIGH .004 (.1mm)
A

To correct a situation like the one shown in illustration 1, strike the
shaft at point A with a brass hammer.

B
SUPPORT CRANKSHAFT
AT THESE TWO BEARINGS

1

HIGH .002 (.05mm)
HIGH .005 (.13mm)
To correct a situation like the one shown in illustration 2, squeeze the
crankshaft at point A. you will use the tool from the alignment kit PN
2870569.
A

A
2

HIGH .002 (.05mm)
A

If the crank rod pin location is 180_ from the dial indicator (opposite
that shown in illustrating 2), it will be necessary to spread the crankshaft at the A position as shown in illustration 3. When rebuilding and
straightening a crankshaft, straightness is of utmost importance. Runout must be as close to zero as possible.

2.16

A

HIGH .005(.13mm)

3

GENERAL INFORMATION
CRANKSHAFT RUNOUT INSPECTION

1/2” (12.7mm)
Flywheel (MAG) side

Measure where taper starts
PTO Side

When checking the crankshaft runout on the MAG side measure the runout 1/2” (12.7mm) from the bearing flat.
When checking the crankshaft runout from the PTO side, measure runout where the taper starts after the bearing flat.

NOTE:

Acceptable crankshaft runout
(in crank fixture) is
Libertyt Engines .000” - .00015” (0-- .04mm)
FUJI Engines .000” - .0024” (0-- .07mm)

2.17

GENERAL INFORMATION
OIL PUMP OPERATION AND TROUBLESHOOTING

BANJO TYPE

PRESS IN TYPE

Any time the engine is disassembled or repaired, it is important that the oil supply from the pump to
the engine be checked.
NOTE:

Banjo type or pressed in valves should open with 2 to 7 lbs. of pressure. Perform this test with 40:1
premix in the fuel tank.
Install new sealing washers upon installation on either side of the banjo check valve.

With engine in chassis, oil reservoir full, and pump bled, remove two oil feed line banjo bolts (A) from their location on the
manifold or carburetors.
Loosely thread the banjo bolts back into the manifold or carburetors.
Place oil feed lines with their check valves away from the clutch area.
Start the engine and let it idle at normal idle RPM.
Drops of oil should be visible from the banjo check valves after the engine is idled one to two minutes, with a drop occurring
approximately every few seconds
If oil does not flow from one of the check valves, remove oil line from check valve and again idle engine. If oil then flows, the
check valve is defective and must be replaced.
If oil does not flow with check valves removed from their feed lines, the malfunction is one of the following:

S

Inline filter blocked.

S

Air not bled from oil pump.

S

Feed lines leaking.

S

Oil tank vent restricted or kinked.

S

Defective pump.

2.18

GENERAL INFORMATION
OIL PUMP BLEEDING
(A)
(A)

FUSION OIL PUMP

NOTE:
IMPORTANT:

Any time the engine is disassembled or repaired, it is important that the oil supply from the pump
to the engine be checked.
The oil pump must always be bled following any service to the injector system or engine.

Fill oil reservoir with the appropriate Polaris injector oil. This will add pressure to the oil lines to aid in bleeding the air out.
Loosen bleed screw (A). After :30 seconds or so, oil should flow from beneath the screw head to indicate the pump is free of air.
Tighten bleed bleed screw securely.

2.19

GENERAL INFORMATION
OIL PUMP ADJUSTMENT PROCEDURE

Figure 2

.010-.030, (.25-.8 mm)
Throttle Freeplay

Figure 3

Figure 4

REQUIRED SERVICE: Carburetor synchronization.
VM TYPE: Verify that carburetor slides leave their respective resting positions upon opening within .01, to .03, of throttle cable
movement, not throttle lever movement. See figure 2.
TM TYPE: Verify that carburetor slides are within .0625” of each other when passing the top of the carburetor throat. You may
have to move slides with the starter lever.
Adjust throttle cable freeplay to .010, - .030, (.25 - .8mm).
Set idle to specified idle speed listed in the specifications chapter.
Verify that the oil pump alignment lines are aligned at the point where the carburetor slides begin to raise from their resting positions. Note: Marks may not line up without throttle engagement. See figure 3.
Make adjustments so that the lines are at the position shown in figure 4.
Torque cable locknuts to 10 - 20 in.lbs.
NOTE:

Use a mirror when aligning the oil pump marks whenever the oil pump is difficult to view.

THROTTLE BODY TYPE (900)
All you need to do for the 900 oil pump is to verify that the oil pump marks line up (figure 4) when the throttle is in the idle position.
You may need a mirror to see the marks straight on. If the line does not line up (figure 3) you will need to adjust the oil cable
at the throttle bell housing.
To adjust this loosen the lock nut and thread the barrel nut in or out depending on the direction you need the line to move.
Moving the barrel nut in will adjust the line more to the top.
DO NOT adjust the idle. This is all set at the factory and should not be tapered with.

2.20

GENERAL INFORMATION
COOLING SYSTEM OVERVIEW

DANGER

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

COOLANT LEVEL
Coolant level in the coolant bottle must be maintained between the MINIMUM and MAXIMUM levels to prevent overheating
and serious engine damage.

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

BLEEDING THE COOLING SYSTEM
Allow the system to cool completely.
Loosen the bleed screw and full the reservoir to the indicated Full Cold mark.
Once Full, tighten the bleed screw.
Apply parking brake and run the engine at specified idle RPM until the thermostat opens (approximately 5 to 8 minutes).

NOTE:

It is important that the thermostat stays open! When the thermostat opens it will draw in cold coolant
from the heat exchangers and the cold coolant may close the thermostat again. Make sure the thermostat opens and stays open! Once the thermostat is open tip the snowmobile slightly on its right side.
Cycle the RPM from idle to enough RPM (4000) to get coolant to flow but not enough RPM to engage
the clutch. This allows air to bleed from the rear crossover tube. Then tilt the machine slightly on its
left side so that the coolant bottle is the highest point in the cooling system. Cycle the RPM from idle to
enough RPM (4000) to get coolant to flow but not enough RPM to engage the clutch. It is important to
get enough coolant flow to purge the air from the front close-off cooler and observe this air reaching the
bottle.

Place the snowmobile in its normal riding position and loosen the bleed screw at the top of the water outlet manifold until trapped air
has been purged.
Tighten the bleed screw. Turn off the machine and release parking brake. Allow the system to cool completely. Re-check the coolant level after the cap has been removed and add coolant to fill line if necessary. After the machine has cooled down, 3 ounces
or more of coolant may have to be added.
This procedure should take approximately 15 minutes.
NOTE:

DANGER

It is important to get enough coolant flow to purge the air from the crossover hose or rear
cooler and observe this air reaching the bottle.

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

2.21

GENERAL INFORMATION
900 FUSION* COOLING SYSTEM
E 2004 Polaris Sales Inc.
4.

24.

9.

9.

4.

26.

19.
21.

15.

23.

9.

18.
17.
22.15.
11.

6.

2.

25.

20.

9.

15.

27.

8.

9.

9.

13.
9.

2.
9.

7.
5.

9.

14.
16.

3.

22.

8.

12.

8.

10.

1.
1. Mount, Radiator, Rubber

2.

3. Asm., Radiator

4.

5.
7.
9.
11.
13.
15.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.

Mount, Radiator, Foam
Hose, Tee/Radiator Inlet
Clamp, Springband, Black
Hose, Radiator/Bottle
Fitting, Tee
Clamp, Springband, Black
Hose, Coolant Bottle/Engine
Hose, Engine Out/Tee
Cap, Pressure
Line, Fuel
Bottle, Coolant
Clamp, Hose
Clamp, Narrow
Nut
Clamp, Rubber Coated, .75
Tube, Coolant, Front, RH
Hose, Bottle/Tube
Hose, Gripper, Front, RH

6.
8.
10.
12.
14.
16.

*For other cooling diagrams please refer to the models parts book.

2.22

Exchanger, Gripper/Cooler, LH
Exchanger, Gripper/Cooler, RH
Hose, Gripper/Rear Cooler, LH
Hose, Gripper/Rear Cooler, RH
Asm., Rear Cooler, Long
Clamp, Springband, Brown
Rivet
Hose, Tube/Gripper, LH
Cooler, Center
Hose, Tee/Center Cooler

Maintenance Program Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Sediment Trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Suspension Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chaincase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spark Plug Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Clutch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handlebar Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Lever Free Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IQ Air Intake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Edge Exhaust Valve Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . .
IQ Exhaust Valve Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat / Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . .
900 Liberty Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
900 Liberty Oil Pump/Line Bleeding . . . . . . . . . . . . . . . . . . . . . . .
Typical Recoil Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
700/800 Liberty Water Pump Service . . . . . . . . . . . . . . . . . . . . . . .

3.1 - 3.3
3.4
3.4
3.5
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12 - 3.13
3.14
3.15
3.16
3.17 - 3.18
3.19
3.20
3.21
3.22
3.23
3.24
3.25
3.26
3.27
3.28 -- 3.29
3.30

MAINTENANCE
POLARIS RECOMMENDED MAINTENANCE PROGRAM
To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and service checks
outlined in this manual.The recommended maintenance schedule on your snowmobile calls for service and maintenance inspections at 150 miles (240 km), 1000 miles (1600 km), and 2000 miles (3200 km). These inspections should be performed by a
qualified service technician. For continued optimum performance and component life, continue maintenance checks at 1000 mile
(1600 km) intervals. All necessary replacement parts and labor incurred, with the exception of authorized warranty repairs, become the responsibility of the registered owner. If, during the course of the warranty period, part failures occur as a result of owner
neglect in performing recommended regular maintenance, the cost of repairs are the responsibility of the owner.
Personal safety is critical when attempting to service or adjust your snowmobile. If you’re not familiar with safe service or adjustment procedures and the use of tools, or if you don’t feel comfortable performing these tasks yourself, contact an authorized Polaris dealer for service.
The following chart is a guide based on average riding conditions. You may need to increase frequency based on riding conditions.
When inspection reveals the need for replacement parts, always use genuine Polaris parts, available from your Polaris dealer.

MAINTENANCE PROGRAM
MILEAGE
ITEM

C
L
U
T
C
H

PRE-- RIDE

150 MILES
(240 KM)

CLUTCH OFFSET ALIGNMENT (WITH OUT
BELT)
DRIVE BELT CONDITION

I

2000 MILES
(3200 KM)

I

I

I

I

PRE-- SEASON

I

C

C

BELT TENSION

I

I

I

CLUTCH SHEAVES

I

I

I

I

I

I

I

I

I

ENGINE MOUNTING PLATE

I

I

ENGINE TORQUE STOP

I

I

CYLINDER HEAD BOLTS

I

I

I

I

I

I

C

C

I

I

R

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

DISASSEMBLE AND CLEAN CLUTCHES

ENGINE MOUNTS
RECOIL ROPE

I

I

CYLINDER BASE NUTS

E
N
G
I
N
E

1000 MILES
(1600 KM)

IGNITION TIMING BTDC
VES SYSTEM
COOLANT LEVEL

I

WATER PUMP DRIVE BELT
COOLANT HOSE
HEAT EXCHANGERS

I

COOLANT CIRCULATION
COOLANT LEAKS
SPARK PLUG CONDITION

I

I

EXHAUST PIPE
EXHAUST RETAINING SPRINGS

I

I

I: Inspect and Clean, Adjust, Tighten or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate. T: Test

3.1

MAINTENANCE
MILEAGE
ITEM

B
R
A
K
E
S

1000 MILES
(1600 KM)

2000 MILES
(3200 KM)

PRE-- SEASON

HOSE ROUTING

I

I

I

HOSE CONDITION

I

I

I

FLUID LEAKS

I

I

I

BRAKE PADS

I

I

I

BRAKE DISC

I

I

I

I

I

I

PRE-- RIDE

150 MILES
(240 KM)

IGNITION SWITCH

I

TAIL LIGHT

T

I

BRAKE LIGHT

I

I

HEAD LIGHT OPERATION

I

PARKING BRAKES

T

BRAKE SYSTEM

I

I
I

M
A
N
A
G
E
M
E
N
T
F
U
E
L
M
A
N
A
G
E
M
E
N
T

I
I

R

BRAKE FLUID

F
U
E
L

I

PILOT AIR SCREWS

I

I

CARBURETOR SYNCHRONIZATION

I

I

IDLE RPM

I

I

THROTTLE LEVER FREE PLAY

I

I

SYNCHRONIZE OIL PUMP LEVER

I

I

THROTTLE CABLE LUBRICATION

L

L

L

OIL CABLE LUBRICATION

L

L

L

CHOKE CABLE LUBRICATION

L

L

VENT LINES

I

I

THROTTLE POSITION SENSOR

I

I

CHOKE

I

I

FUEL FILTER

I

I
I

FUEL LINES

I

OIL FILTER

AIR BOX
CHECK DRAIN AND WATER TRAPS

I

I

I
I

I

R

R

I

I

I

I

I

I

OIL LINES
CHANGE OIL

I

I: Inspect and Clean, Adjust, Tighten or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate. T: Test

3.2

MAINTENANCE
ITEM

MILEAGE
PRE-- RIDE

150

2000

I

I

I

I

I

STEERING FASTENERS

I

I

C

REAR SUSPENSION FASTENERS

I

I

I

SUSPENSION SHOCK OIL

I

I

I

COOLING FINS AND SHROUD

I

I

I

DRIVE SHAFT BEARINGS

L

L

I

L

L

I

SKI TOE ALIGNMENT
SUSPENSION MOUNTING BOLTS

I

JACKSHAFT BEARINGS

C
H
A
S
S
I
S

PRE - SEASON
PRE-

1000

SKI WEAR BARS

I

SKI SADDLE AND SPINDLE BOLTS

I

I

SKI PIVOTS

L

L

L

I

SKI SPINDLE

L

L

L

I

STEERING ARM(S)

L

L

L

I

UPPER / LOWER STEERING POST SUPPORT
BRACKET

L

L

L

I

DRIVE CHAIN TENSION

I

AUXILIARY SHUT--OFF SWITCH

T

THROTTLE SAFETY SWITCH

T

AUXILIARY SHUT--OFF SWITCH
HOOD STRAPS

I

THROTTLE LEVER

T

BATTERY FLUID LEVEL

I

REAR WHEEL IDLER BOLTS

I

IDLER ADJUSTING BOLT JAM NUT

I

REAR SUSPENSION PIVOT SHAFTS

L

CAMBER ALIGNMENT

I

L
I

RADIUS ROD BUSHINGS

I

HANDLE BAR CENTERING

I

TORQUE TIE ROD END NUTS

I

TETHER SWITCH AND STRAP

T

TRACK ALIGNMENT

I

TRACK TENSION

I

FRONT LIMITER STRAP

I

HYFAX CONDITION

I

CHAINCASE OIL

I

R

I

GEARCASE OIL

I

R

I

I

I: Inspect and Clean, Adjust, Tighten or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate. T: Test
Items in this chart require some mechanical knowledge. Items marked * and ** may require more technical information
and tools and should be performed by your authorized Polaris dealer.

RECOMMENDED MAINTENANCE PRODUCTS
Remember to use Pure Polaris parts and Lubricants to keep your sled running and looking like new. Pure Polaris products are
specifically engineered to rigid specifications that apply to the parts that wear and tear.

3.3

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