2005 Deep Snow Polaris 900 Service Manual

5/21/2018 2005 Deep Snow Polaris 900 Service Manual

1/308

PN 991

2005 DEEP SNOW

SERVICE MANUATRAIL R

600 R

700 R

800 R

900 R

600 SWITCHBA

800 SWITCHBA


2/308

UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS

Throughout these instructions, important information is brought to your attention by the following symbols:

NOTE: S A NOTE provides key information to clarify instructions.

CAUTION: A CAUTION indicates special precautions that must be taken to avoid personal injury,

or snowmobile or property damage.

DANGERFailure 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


3/308

i

2005 DEEP SNOWMANUAL

SPECIFICATIONS

GENERAL

MAINTENANCE

FUEL DELIVERY

ENGINE

CLUTCHING

FINAL DRIVE

BRAKE SYSTEM

STEERING

FRONT SUSPENSION

REAR SUSPENSION

CHASSIS / HOOD

ELECTRICAL SYSTEM

WIRING DIAGRAMS

oreword

This manual is designed primarily for use by certifiedPolaris snowmobile service technicians in a properlyequipped shop. Persons using this manual should havea sound knowledge of mechanical theory, tool use, andshop procedures in orderto perform the work safely andcorrectly. The technician should readthe textand be fa-miliar with service procedures before starting the work.Certain procedures require the use of special tools. Useonly the proper tools, as specified. Cleanliness of partsand tools as well as the work area is of primary impor-tance.

All references to left and right side of the vehicle are

from the operators perspective when seated in a normalriding position.

This manual includes 2005 Model Year information,along with service specifications. A table of contentsisplaced at the beginning of each chapter, and analphabetic indexis provided at the endof the manualforlocation of specific page numbers and serviceinformation. Keep this manual available for referencein the shop area.

At the time of publication all information contained inthis manual was technically correct. However, allmaterials and specifications are subject to changewithout notice.

Comments or suggestions about this manual may bedirected 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.


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INTRODUCTION

ii

NOTES


5/308

TRAIL RMK 1.2 -- 1.3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .600 RMK 1.4 -- 1.5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

700 RMK 1.6 -- 1.7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

800 RMK 1.8 -- 1.9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

900 RMK 1.10 -- 1.11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

600 SWITCHBACK 1.12 -- 1.13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

800 SWITCHBACK 1.14 -- 1.15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


6/308

SPECIFICATIONS

1.1

NOTES


7/308

SPECIFICATIONS

1.2

MODEL: TRAIL RMK . . . . . . . . . . . . . .

MODEL NUMBER: S05NJ5BS(A). . . .ENGINE MODEL: EC55PM071. . . . .

ENGINE CARBURETION

Engine Type Libertyt Type Mikuni

VM34SS w/ACCSEngine Displacement ccs 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 Clearancein / mm

.0045 -- .0053

.114 -- .135mmThrottle 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 1.5Operating RPM200 7000 Fuel Screw N/A

Idle RPM200 1600 Pilot Air Jet N/A

Air Screw 1.0 Turns

Engagement RPM300 3800Fuel Octane (R+M/2)

87 Oct. NonOxy /89 Oct. Oxy

AMBIENT TEMPERATURE

Altitude Below -30F -30_ to --10_F --10_to +10_F +10_to +30_F +30_to +50_F Above +50_F-Below -34C

- o ---34_to -23_C

-- o +-23_ to --12_C

+ o +-12_to --1_C

+ o +-1_to +10_C

ove +Above +10_C

0--600

(0--2000)

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 290/280 280/270 270/260 260/250 250/240 240/230--(4000--6000) #3 #3 #3 #3 #3 #3

MetersFeet

1800--2400290/280 280/270 270/260 260/250 250/240 240/230ee

(6000--8000)#3 #3 #3 #3 #3 #3

2400--3000290/280 280/270 270/260 260/250 250/240 240/230

(8000--10000)#3 #3 #3 #3 #3 #3

3000--3700290/280 280/270 270/260 260/250 250/240 240/230

(10000--12000)#3 #3 #3 #3 #3 #3

DRIVE CLUTCH DRIVEN CLUTCH

Altitude Shift Clutch Clutch Driven Chaincase

Weightu c

Springu c

Springr ven

Helixa ncase

Gearing

0-900 Dark Blue / 40-(0-3000)

10--64 BushedWhite

Red / BlueTeam Reverse

19--43 74P

900-1800 Dark Blue / 40

Meters -

(3000-6000) 10--62 Bushed

White Red / Blue

Team Reverse 19--43 74P

(Feet)1800-2700 Dark Blue / 40-

(6000-9000) 10--60 Bushed

White Red / Blue


2700-3700 Dark Blue / 40-(9000-12000)

10--58 Bushed ar ue

White Red / Blue



8/308

SPECIFICATIONS

1.3

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

DRIVEN CLUTCH Brake Pads Type 81

Type Team Roller Reverse

Spring Dark Blue/White Brake Type A r Cooled

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. SLED DIMENSION

Center Distance 11.5 / 29.2cm. Unit Length / Height /

Width in / cm.121 / 48 / 48

308 / 122 / 122 cm.

FRONT SUSPENSION 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--Load2.98 (7.57cm) from bottomof shock body to bottom of

spring retainer

Standard RTS Select / PN 7042058

ront ert ca rave . . cm.Premium RTS Arvin IFP C/A 7042176

TRACK Torsion Spring .347 (Sq) x 77_

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

Flywheel I.D. FP9312 Spark Plug / Gap NGK BR9ES

.028 / .70mm

CDI Marking CU7236 Voltage RegulatorLR7

Alternator Output 240 watts Magneto Pulses 6

Ignition Timing see conver- 27_@3000 RPM1.5_ Standard Accessory

sion chart page 13.4).

14_@6500 RPM1.5_ ectr c tart

Premuim Optional


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SPECIFICATIONS

1.4

MODEL: 600 RMK 144. . . . . . . . . . . . . .

MODEL NUMBER: S05NK6ES(A). . . .ENGINE MODEL: S2712--6044--PI6E. . . . .

ENGINE CARBURETION


TM 38

Engine Displacement ccs 599 Main Jet 310Bore 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


.0045 -- .0059

.115 -- .149mmThrottle Gap UnderCutaway

in / mm.11

2.7mm


.14 -- .20mm Cutaway 1.5 (N)

Piston PN 3021308 Valve Seat 1.5

Piston Ring Marking N/A Starter Jet 140

Operating RPM200 8000 Fuel Screw 1.0 TurnsIdle RPM200 1500 Pilot Air Jet N/A

Engagement RPM300 3900 Air Screw .75

Exhaust Valve Spring Green/White Fuel Octane (R+M/2) 87 Oct. NonOxy /

89 Oct. Oxy

AMBIENT TEMPERATURE


- o ---34_to -23_C

-- o +-23_ to --12_C

+ o +-12_to --1_C

+ o +-1_to +10_C

ove +Above +10_C

0--600

(0--2000)

450

#4

430

#4

420

#3

400

#3

380

#3

370

#3

600--1200

(2000--4000)

410

#4

390

#3

380

#3

360

#3

340

#3

330

#2

1200--1800 380 360 350 330 320 300--(4000--6000) #3 #3 #3 #3 #2 #2

MetersFeet

1800--2400360 340 320 310 290 280ee

(6000--8000)#3 #3 #3 #2 #2 #2

2400--3000340 320 300 290 270 260

(8000--10000)#3 #3 #2 #2 #2 #2

3000--3700330 310 290 280 260 240

(10000--12000)#3 #2 #2 #2 #2 #2



Weight Spring Spring Helix Gearing0--900--

(0-3000) 10-60 Bushed

900-1500-(3000-5000)

10-58 Bushed

1500-2100

Meters

-(5000-7000)

10-56 Bushed--

(Feet) 2100-2700 Blac k/Gree n 70 4306 3

56 / 42 -- .36ER

19--39 : 72P-

(7000-9000) 10-54 Bushed

2700-3350(9000-11000)

10AL Bushed

3350-4000(11000-13000)

10 Bushed


10/308

SPECIFICATIONS

1.5


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



Spring 7043063 Brake Type L qu d Cooled

Helix Angle 54 / 42 -- .36 Reverse CAPACITIES



Belt Width (Projected) 1.438 / 3.65cm. Coolant 5 Qts / 4.7 Liters

Side Angle (Overall) 28_ Chain Case Oil 9 fl. oz. / 299ml



Width in / cm.124 / 48 / 45.5315 / 122 / 116cm.




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 Spring Rate 100# Premium Spring Rate 170#

Premium Spring Pre-- Load 4.25/10.8cm Premium Spring Pre-- Load 2.98/7.6cm

Standard RTS 7042085 Select

ront ert ca rave . . cmPremium RTS 7042176 Arvin IFP C/A

TRACK Torsion Spring .359/47_

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


Ignition Timing see conver- 24_@3500 RPM1.5_ Standard Accessory

sion chart on page 13.4).

w/TPS Disconnected Electr c Start

Premium Optional


11/308

SPECIFICATIONS

1.6

MODEL: 700 RMK . . . . . . . . . . . . . .

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

ENGINE CARBURETION


TM 40

Engine Displacement ccs 701 Main Jet 340Bore in / mm 3.19 / 81mm Pilot Jet 45

Stroke in / mm 2.68 / 68mm Jet Needle 9DGN5--57 / 2



.0044 -- .0058.111 -- .147mm

Throttle Gap UnderCutawayin / mm

0.0982.5mm

Piston Ring End Gapin / mm

.012 -- .018.304 -- .457 mm

Cutaway 2.0




Engagement RPM300 3800 Air Screw 1.0 Turns

Exhaust Valve Spring Orange Fuel Octane (R+M/2) 87 Oct. NonOxy /

89 Oct. Oxy

AMBIENT TEMPERATURE


- o ---34_to -23_C

-- o +-23_ to --12_C

+ o +-12_to --1_C

+ o +-1_to +10_C

ove +Above +10_C

0--600

(0--2000)

500

#4

490

#4

470

#3

450

#3

430

#3

410

#3

600--1200

(2000--4000)

470

#4

450

#3

430

#3

410

#3

390

#3

380

#2

1200--1800 440 420 400 380 370 350--(4000--6000) #3 #3 #3 #3 #2 #2

MetersFeet

1800--2400400 380 360 340 330 310ee (6000--8000)#3 #3 #3 #2 #2 #2

2400--3000360 340 320 300 290 270

(8000--10000)#3 #3 #2 #2 #2 #2

3000--3700320 300 290 270 250 230

(10000--12000)#3 #2 #2 #2 #2 #2




(0-2000) 10--64 Bushed Black/Green

600-1200-(2000-4000)

10-62 Bushed Black/Green

1200-1800

Meters

-(4000-6000)

10-60 Bushed Black/Green--

(Feet) 1800-2400 7043063

56 / 42 -- .36ER

19--39 : 72P-

(6000-8000) 10-58 Bushed Black/Green

2400-3000(8000-10000)

10--56 Bushed Black/Green

3000-3600(11000-12000)

10--54 Bushed Black/Green

EV Spring

RecommendationAltitude EV

Spring

0--1200

(0--4000)Green/Yello

1200 --3600(4000--12000)

Orange

meters(feet)


12/308

SPECIFICATIONS

1.7






Type Team Roller Reverse Brake Type Liquid Cooled

Driven Spring 7043063 CAPACITIES

Helix Angle 58 / 42 -- .36 Reverse Fuel Tank 11.8 Gal. / 45 Liters

BELT 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_ SLED DIMENSION

Outside Diameter 46.625 / 118.4cm. Unit Length / Height /

Width in / cm. (144)124 / 48 / 45.5

315 / 122 / 116 cm.


Width in / cm. (151)130 / 48 / 45.5

330 / 122 / 116 cm.









Standard RTS 7042085 SelectFront Vert cal Travel 7.6/19.3cmPremium RTS 7042176 Arvin IFP C/A

TRACK Torsion Spring .359/47_


cm./5 cm.)


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 .025

/ .70mm



Ignition Timing(see conver-sion chart on page 13.4)

20 @ 2000 RPMw/ TPS Disconnected

Electric Start Standard Accessory

Premium Optional


13/308

SPECIFICATIONS

1.8

MODEL: 800 RMK . . . . . . . . . . . . . .

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

ENGINE CARBURETION


TM40


Stroke in / mm 2.76 / 70mm Jet Needle 9DGN6--57 / 2



.006 -- .0074.152 --.188mm


0.1022.6mm


.016 -- .022.40 -- .559mm

Cutaway 2.0




Engagement RPM300 3800 Air Screw .75 Turns

Exhaust Valve Spring Pink Fuel Octane (R+M/2) 87 Oct. NonOxy /

89 Oct. Oxy

AMBIENT TEMPERATURE


- o ---34_to -23_C

-- o +-23_ to --12_C

+ o +-12_to --1_C

+ o +-1_to +10_C

ove +Above +10_C

0--600

(0--2000)

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 450 430 410 390 370 350--(4000--6000) #4 #4 #3 #3 #2 #2

MetersFeet

1800--2400410 390 370 350 330 310ee (6000--8000)#4 #3 #3 #2 #2 #2

2400--3000370 350 330 310 290 270

(8000--10000)#3 #3 #2 #2 #2 #2

3000--3700340 320 300 280 260 240

(10000--12000)#3 #2 #2 #2 #2 #1




(0-3000) 10-66 Bushed

900-1500-(3000-5000)

10-64 Bushed

1500-2100

Meters

-(5000-7000)

10-62 Bushed--

(Feet) 2100-2700 Blac k/Gree n 70 4306 3

58 / 42 -- .36Rev.

19--39 : 72P-

(7000-9000) 10-60 Bushed

ev.

2700-3350(9000-11000)

10--58 Bushed

3350-4000(11000-13000)

10--56 Bushed

EV Spring

RecommendationAltitude EV

Spring

0--1200

(0--4000)Pink/Yellow

1200 --3600(4000--12000)

Pink

meters(feet)


14/308

SPECIFICATIONS

1.9


Type P--85 Center DIstance 7.92 / 20.12cm.




Type Team Roller Reverse Brake Type Liquid Cooled

Driven Spring 7043063 CAPACITIES

Helix Angle 58 / 42 -- .36 Reverse Fuel Tank 11.8 Gal. / 45 Liters

BELT 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_ SLED DIMENSION

Outside Diameter 46.625 / 118.4cm.Unit Length / Height /

124 / 48 / 45.5315 / 122 / 116 cm.

Center Distance 11.5 / 29.2cm. Width in / cm. 130 / 48 / 45.5

330 / 122 / 116 cm.









Standard RTS 7042085 Select

Front Vert cal Travel 7.6/19.3cm Premium RTS 7042176 Arvin IFP C/A

TRACK TORSION SPRINGS


cm./5 cm.) Torsion Spring .359/47_


cm./5 cm.) See page 11.7 for optional springs.

Track Tens on See Page 3.10

ELECTRICAL

Flywheel PN 4010677 Spark Plug / Gap Champion RN57YCC/ .025

/ .64mmCDI PN 4010842 Voltage Regulator T1


Ignition Timing(see conver- 29_@3250 RPM1.5_ Standard Accessory

sion chart on page 13.4).

w/ TPS disconnected ectr c tart

Premium Optional


15/308

SPECIFICATIONS

1.10

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 THROTTLE BODY

Stroke in / mm 3.15 / 80mm Throttle Body Bore Size in/cm 2 / 51mm

Cylinders 2 TPS voltage @ idle .92 -- .94


.0045 -- .0098.114 -- .249

Throttle Body Manufacture Mikuni


.406--.56 DRIVE CLUTCH

Piston Marking 3021327 Type P--85

Piston Ring Marking N/A Center Distance in/cm 11.5 / 29.2

Operating RPM200 7400 Spring Black / Green

*Idle RPM200 1400 Shift Weight 10--70

Engagement RPM300 3700 DRIVEN CLUTCH

Exhaust Valve Spring Purple Type TEAM

CHAINCASE Spring 7043058

Center Distance in/cm 11.35 / 28.83cm Helix 62/46--36 ER

Gearing 19 : 39 -- 90P BELT

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

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 / 325.3t n cm .



Weightu c

Springu c

Springr ven

Helixa ncase

Gearing

0-900-(0-3000)

10--74

900-1500-(3000-5000)

10--74

1500-2100

Meters

-(5000-7000)

10--72e ers

(Feet) 2210-2700

Black/Green 7043058 62/46 -- 36 ER 19 : 39 -- 90P-

(7000-9000) 10--70

2700--3350(9000--11000)

10--68

3350--4000(11000--13000 )

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.


16/308

SPECIFICATIONS

1.11


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 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

TRACK Premium RTS 7043046 Arvin IFP/Res CA

Width in/cm 15/38.1 TORSION SPRINGS

Length in/cm151/384159/404166/422

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-_

sion chart on page 13.4) 14_ @ 3000RPM Electr c Start TBD


17/308

SPECIFICATIONS

1.12

MODEL: 600 SWITCHBACK t. . . . . . . . . . . . . .

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

ENGINE CARBURETION


TM 38

Engine Displacement ccs 599 Main Jet 420Bore in / mm 3.04 / 77.25mm Pilot Jet 50

Stroke in / mm 2.52 / 64mm Jet Needle 9DGI01--60 / 4



.0045--.0059.115 -- .149mm.


0.0792.0mm


.014--.020.356 -- .508mm

Cutaway 1.5





Exhaust Valve Spring Green/White Fuel Octane (R+M/2) 87 Oct. NonOxy /

89 Oct. Oxy

AMBIENT TEMPERATURE


- o ---34_to -23_C

-- o +-23_ to --12_C

+ o +-12_to --1_C

+ o +-1_to +10_C

ove +Above +10_C

0--600

(0--2000)

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 380 360 350 330 320 300--(4000--6000) #4 #4 #4 #4 #3 #3

MetersFeet

1800--2400360 340 320 310 290 280ee (6000--8000)#4 #4 #4 #3 #3 #3

2400--3000340 320 300 290 270 260

(8000--10000)#4 #4 #3 #3 #3 #3

3000--3700330 310 290 280 260 240

(10000--12000)#4 #3 #3 #3 #3 #3




(0-3000) 10-60 Bushed 22--40:74P

900-1500-(3000-5000)

10-58 Bushed 22--40:74P

1500-2100

Meters

-(5000-7000)

10-56 Bushed--

22--40:74P

(Feet) 2100-2700 Blac k/Gree n 70 4306 3

56 / 42 -- .36ER-

(7000-9000) 10-54 Bushed 19--39:72P

2700-3350(9000-11000)

10AL Bushed 19--39:72P

3350-4000(11000-13000)

10 Bushed 19--39:72P


18/308

SPECIFICATIONS

1.13




Drive Spring Black / Green Reverse Electronic Reverse



Driven Spring 7043063 Brake Type L qu d Cooled

Helix Angle 56 / 42 -- .36 Reverse CAPACITIES



Belt Width (Projected) 1.438 / 3.65cm. Coolant 5 Qts / 4.7 Liters




Width in / cm.124 / 48 / 47

315 / 122 / 119 cm.


Type EDGE RMK Type EDGE RMK

IFS Shocks 7043083 Alum IFP FTS 7042084 Arvin IFP

pr ng ate n. pr ng ate n.

IFS Spring Pre--Load 10.5 / 26.7cm Installed

Front Vertical Travel 7.1--7.4 / 18 -- 18.8cm.re-- oa . . cm.

TRACK

Width 15 / 38 cm.rv n

Length 144 / 366 cm. Torsion Spring .359 (Sq) x 47_

Lug Height 1.25 / 3.175 cm.

Optional springs see page 11.7rac ens on ee page .

ELECTRICAL

Flywheel I.D. 4010677 Spark Plug / Gap Champion RN57YCC .028

/ .70mm



Ignition Timing(see conver- 24_@3000 RPM1.5_sion chart on page 13.4)

.w/TPS Disconnected

ectr c tart ccessory


19/308

SPECIFICATIONS

1.14

MODEL: 800 SWITCHBACK t. . . . . . . . . . . . . .

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

ENGINE CARBURETION


TM 40


Stroke in / mm 2.76 / 70mm Jet Needle 9DGN6--57/4



.006 -- .0074.152 -- .188mm


0.0792.0mm


.016 -- .022.406 -- .559mm

Cutaway 2.0





Exhaust Valve Spring Pink / Yellow Fuel Octane (R+M/2) 87 Oct. NonOxy /

89 Oct. Oxy

AMBIENT TEMPERATURE


- o ---34_to -23_C

-- o +-23_ to --12_C

+ o +-12_to --1_C

+ o +-1_to +10_C

ove +Above +10_C

0--600

(0--2000)

510N

#5

490

#4

470

#4

450

#4

430

#3

410

#3

600--1200

(2000--4000)

480

#4

470

#4

450

#4

430

#3

410

#3

390

#2

1200--1800 450 430 410 390 370 350--(4000--6000) #4 #4 #3 #3 #2 #2

MetersFeet

1800--2400410 390 370 350 330 310ee (6000--8000)#4 #3 #3 #2 #2 #2

2400--3000370 350 330 310 290 270

(8000--10000)#3 #3 #2 #2 #2 #2

3000--3700340 320 300 280 260 240

(10000--12000)#3 #2 #2 #2 #2 #1




(0-2000) 10-66 Bushed 23--39:74P

600-1200-(2000-4000)

10-64 Bushed 23--39:74P

1200-1800

Meters

-(4000-7000)

10-62 Bushed--

23--39:74P

(Feet) 1800-2400 Blac k/Gree n 70 4306 3

58 / 42 -- .36ER-

(6000-8000) 10-60 Bushed 21--41:74P

2400-3000(8000-10000)

10--58 Bushed 21--41:74P

3000-3600(10000-12000)

10--56 Bushed 21--41:74P


20/308

SPECIFICATIONS

1.15




Drive Spring Black / Green Reverse Electronic Reverse



Driven Spring 7043063 Brake Type L qu d Cooled

Driven Helix Angle 58/42-- .36 ER CAPACITIES



Belt Width (Projected) 1.438 / 3.65cm. Coolant 5 Qts/ 4.7 Liters




Width in / cm.124 / 48 / 47

315 / 122 / 119 cm.


Type EDGE RMK Type EDGE RMK

IFS Shocks 7043083 Alum IFP FTS 7042084 Arvin IFP

pr ng ate n. pr ng ate n.

IFS Spring Pre--Load 10.5 / 26.7cm Installed

Front Vertical Travel 7.1--7.4 / 18 -- 18.8cm.re-- oa . . cm.

TRACK

Width 15 / 38 cm.rv n

Length 144 / 366 cm. Torsion Spring .359 (Sq) x 47_

Lug Height 1.25 / 3.175 cm.

Optional springs see page 11.7rac ens on ee page .

ELECTRICAL

Flywheel PN 4010677 Spark Plug / Gap Champion RN57YCC /

.025 / .70mm

CDI PN 4010841 Voltage Regulator T1


Ignition Timing(see conver- 29_@3250 RPM1.5_sion chart on page 13.4)

.w/TPS Disconnected

ectr c tart ccessory


21/308

SPECIFICATIONS

1.16

NOTES


22/308

2005 Model Number Designation 2.1. . . . . . . . . . . . . . . . . . . . . . . . .Tunnel Decal 2.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vehicle Identification Number 2.2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

2005 Publication Part Numbers 2.3. . . . . . . . . . . . . . . . . . . . . . . . . . .

General Service Precautions 2.4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standard Torque Specifications 2.5. . . . . . . . . . . . . . . . . . . . . . . . . . .

Decimal Equivalents 2.6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tap Drill Sizes 2.7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Conversion Chart 2.8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston Wash and Spark Plug Color 2.9. . . . . . . . . . . . . . . . . . . . . . . .Cylinder Inspections 2.10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston Measurements 2.11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder Honing 2.12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Port Chamfering 2.13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting Rod Bearing Inspection 2.14. . . . . . . . . . . . . . . . . . . . . . .

Crankshaft Indexing 2.15 -- 2.17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Pump Operation and Troubleshooting 2.18. . . . . . . . . . . . . . . . . . .

Oil Pump Bleeding 2.19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Pump Adjustment 2.20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling System Overview 2.21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

900 Fusion Cooling System 2.22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


23/308

GENERAL INFORMATION

2.1

2005 MODEL NUMBER DESIGNATION

EXAMPLE: S05NB4BS

S 05 N B 4 B S #

Identifier(1st Digit)

ModelYear(2nd/3rd Dig-

it)

Model Line(4th Digit)

Model Type(5th Digit)

Engine Size(cc)

(6th Digit)

Engine modifier(6th/7th Digit)

VINIdentifier(8th Digit)

OptionIdentifier

(9thDigit)

S=Snow 05=2005 M=Fusion A=50th Anniv Spe -cial

0=0--99cc 1A=121 F/C OHV 4 cycle Fuji E=Europe unit

N=Edge B=Basic or Stan-dard

1=100-- 199 3A= 340 F/C Piston Port S= Sta ndardProduction

Unit

P=IQ RMK D= Classic 2=200-- 299c c 4B= 488 L/C Piston Port

S=Gen II E=M--10 Perfor-mance

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

MODEL NO.

V.I.N. NO.

MFD. DATE:

THIS VEHICLE CONFORMS TO ALL APPLICABLEU.S. FEDERAL AND STATE REQUIREMENTS ANDCANADA MOTOR VEHICLE SAFETY STANDARDSIN EFFECT ON THE DATE OF MANUFACTURE.

MADE IN U.S.A.

7072133

Mfd. by Polaris Industries Inc.. in Roseau, MN under one ormore of the following patents:

U.S. Patents3,605,511 3,613,810 5,050,5593,580,647 3,867,991 5,048,5033,483,766 4,793,950 5,056,4823,533,662 5,038,881 5,099,8133,545,821 5,172,675 5,074,2713,605,510 5,090,386 5,191,5313,525,412 5,050,564 3,613,811

PATENT NOTICE

Patented Canada882,491/71883,694/71864,394/71

Canadian Rd.34,573/7134,572/71

1,227,823/87

TUNNEL DECAL

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 ipermanently 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 engrave

model and serial numbers are located on the crankcase (intake side).


24/308

GENERAL INFORMATION

2.2

VEHICLE IDENTIFICATION NUMBER

Current snowmobiles have a 17 digit Vehicle Identification Number (VIN). The VIN is organized as follows: Digits 1-3: WorldManufacturer Identifier. For Polaris, this is SN1. Digits 4-9: Vehicle Descriptor Section. Digits10-17: 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 withany correspondence regarding service or repair.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17S N 1 S B 5 B S 0 2 2 0 0 0 0 0 0

Vehicle Descriptor Vehicle Identifier

Type

EngineSize Engine

Modifier

ModelYear

Manufacturing.Location Code

Individual Serial No.Body Style Series

World Mfg. ID

Example ofCurrentVIN Number

CheckDigit

Vehicle Identification Number / Model Number Key

Body St

yle Type Engine Size Engine Modifier Series

L=Lite B=Base Model 1=100-199 ccs A=Fan S=Domestic

N=Edge D=Deluxe 2=200-299 ccs B=Liquid Twin U=Europe

S=Gen II P=Performance 3=300-399 ccs C=Case Reed Twin

W=Mini R=RMK 4=400-499 ccs D=Liquid Triple

S=SKS 5=500-599 ccs E=Case Reed Triple

T=Touring 6=600-699 ccs

U=Utility 7=700-799 ccs

X=Racer 8=800-899 ccs


25/308

GENERAL INFORMATION

2.3

PUBLICATION PART NUMBERS

Model Model No. Owners Manual Owners Manual

SupplementParts

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

800 RMK S05N(M,K,L)8CS(A,B) 9919706

9919383 (144)

9919384 (151)

9919385 (159)

9919278 9919279

900 RMK S05P(L,M)8DS(A,B,C,D) 9919077

9919104 (151)

9919105 (159)

9919106 (166)

9919292 9919293

600 Switchback S05NS6ES(A) 9919076 9919095 9919280 9919281

800 Switchback S05NSCS(A) 9919076 9919095 9919280 9919281

SERVICE MANUALS

Service Manuals 2004

2000--2005120 XC SP / PRO X

9919307

Trail Sport500 Indy, Supersport

9919300

Touring340 Edge Touring, Trail Touring (Deluxe), Widetrak LX, 600 Edge Touring (50th), 800 Edge Touring

9919304

FrontierFrontier Touring

9919305

Classic

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

9919301

Deep SnowTrail RMK, 600/700/800 RMK, 600/800 Switchbackt, 900 RMK

9919302

Performance500/600/700/800 XC SP, 900 Fusion

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


26/308

GENERAL INFORMATION

2.4

GENERAL SERVICE PRECAUTIONS

In order to perform service work efficiently and to prevent costly errors, the technician should read the text in this manual,thoroughlyfamiliarizing him/herself with procedures before beginning. Photographsand illustrationshave beenincluded with thetext as an aid. Notes, cautions and warnings have also been included for clarification of text and safety concerns. However, aknowledge 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 partsand toolsas well as theworkarea is of primary importance.Dirtand foreign matterwill actas an abrasiveand cause damage to precision parts. Clean the snowmobile before beginning service. Clean new parts before installing.

Watch for sharp edgeswhich can cause personal injury, particularly in the area of the tunnel. Protect handswith gloves whenworking 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 isnecessary to tap the part into place, use a soft face hammer and tap lightly.

Some of the fastenersin the snowmobile were installed with locking agents.Use of impact drivers or wrenches will helpavoiddamage to fasteners.

Always follow torque specifications as outlined throughout this manual. Incorrect torquing may lead to serious machinedamage 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, followingthe method and sequence indicated in this manual, tighten evenly to the specified torque value. When removing nuts, bolts orscrews from a part with several fasteners, loosen them all about 1/4 turn before removing them.

If the condition ofany gasket or O-Ringis inquestion,replaceit witha newone. Besurethe matingsurfacesaround thegasketare 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, theyshould always be replaced with newparts. When installing new retaining rings and clips use care not to expandor compress thembeyond 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 performanceand best protection of our machines. In some applications, such as the engine, warranty coverage may become void if other brandsare substituted.

Grease should be cleaned from parts and fresh grease applied before reassembly of components. Deteriorating grease loseslubricity and may contain abrasive foreign matter.

Whenever removing or reinstalling batteries, care should be taken to avoid the possibility of explosion resulting in seriousburns. Always disconnect the negative (black) cable first and reconnect it last. Battery electrolyte contains sulphuric acid and ispoisonous! 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 physicianimmediately. Eyes - Flush with water for 15 minutes and get prompt medical attention.


27/308

GENERAL INFORMATION

2.5

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. . . . . .


28/308

GENERAL INFORMATION

2.6

STANDARD TORQUE SPECIFICATIONS

The following torque specifications are to be used as a general guideline when torque value is not specified. There areexceptionsin the steering, suspension, and engine areas. Always consult the torque chart and the specific manual section for torque values offasteners.

Bolt Size Threads/In Grade 2 Grade 5 Grade 8

(MM/Thread)

Torque in. lbs. (Nm)

#10 - 24 27 (3.1) 43 (5) 60 (6.9). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .#10 - 32 31 (3.6) 49 (5.6) 68 (7.8). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Torque ft. lbs. (Nm)*

1/4 - 20 5 (7) 8 (11) 12 (16). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1/4 - 28 6 (8) 10 (14) 14 (19). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5/16 - 18 11 (15) 17 (23) 25 (35). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5/16 - 24 12 (16) 19 (26) 29 (40). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3/8 - 16 20 (27) 30 (40) 45 (62). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3/8 - 24 23 (32) 35 (48) 50 (69). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7/16 - 14 30 (40) 50 (69) 70 (97). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7/16 - 20 35 (48) 55 (76) 80 (110). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1/2 - 13 50 (69) 75 (104) 110 (152). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1/2 - 20 55 (76) 90 (124) 120 (166). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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


29/308

GENERAL INFORMATION

2.7

SAE TAP DRILL SIZES

Thread Size Drill Size Thread Size Drill Size

#0-80 3/64#1-64 53#1-72 53#2-56 51#2-64 50#3-48 5/64#3-56 45#4-40 43#4-48 42#5-40 38#5-44 37#6-32 36#6-40 33#8-32 29#8-36 29#10-24 24#10-32 21#12-24 17#12-28 4.6mm1/4-20 71/4-28 35/16-18 F5/16-24 I3/8-16 O3/8-24 Q7/16-14 U7/16-20 25/64

1/2-13 27/64

1/2-20 29/64

9/16-12 31/64

9/16-18 33/64

5/8-11 17/325/8-18 37/64

3/4-10 21/32

3/4-16 11/16

7/8-9 49/64

7/8-14 13/16

1-8 7/8

1-12 59/64

1 1/8-7 63/64

1 1/8-12 1 3/64

1 1/4-7 1 7/64

1 1/4-12 1 11/64

1 1/2-6 1 11/321 1/2-12 1 27/64

1 3/4-5 1 9/16

1 3/4-12 1 43/64

2-4 1/2 1 25/32

2-12 1 59/64

2 1/4-4 1/2 2 1/32

2 1/2-4 2 1/4

2 3/4-4 2 1/2

3-4 2 3/4

METRIC TAP DRILL SIZES

Tap Size Drill Size Decimal Equivalent Nearest Fraction

3 x .503 x .604 x .704 x .755 x .805 x .906 x 1.007 x 1.008 x 1.008 x 1.25

9 x 1.009 x 1.2510 x 1.2510 x 1.5011 x 1.5012 x 1.5012 x 1.75

#393/32#301/8#19#20#916/64J17/64

5/165/1611/32R3/813/3213/32

0.09950.09370.12850.1250.1660.1610.1960.2340.2770.265

0.31250.31250.34370.3390.3750.4060.406

3/323/321/81/811/645/3213/6415/649/3217/64

5/165/1611/3211/323/813/3213/32


30/308

GENERAL INFORMATION

2.8

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)

ccs x .03381 = Fluid Ounces (oz)

lb. x .454 = kg

kg x 2.2046 = lb.

Cubic inches (cu in) x 16.387 = Cubic centimeters (ccs)

Cubic centimeters (ccs) 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 =FF toC: 5 (F + 40) 9 -- 40 =C


31/308

GENERAL INFORMATION

2.9

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 performancof yourengine. That is why using Exhaust Gas Temperatures(EGTs) are important for maintaining optimum performance. Therare two methods for helping you determine what the EGTs are for your machine. Piston wash and the coloring of your sparkplug.The piston wash is by far the most valuable tool in concluding EGTs, with the spark plug color running a distant secondUse the illustrations below to help you establish the EGTs for your machine.

n If the wash is 1/4 - 3/8 and cocoabrown, the machines EGTs are just right.

n Wet and Black wash indicates too rich a fuelmixture

n A dry, ash colored piston indicates too lean a

mixture for the operating conditions.

n If the plug is light to cocoa brown, the ma-chines EGTs are just right.

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

n A ash white plug with speckles indicates toolean a mixture for the operating conditions.

Piston Wash Spark Plug Color

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

Correct

Correct

Wash

Dry


32/308

GENERAL INFORMATION

2.10

CYLINDER INSPECTIONS

CYLINDER HEAD INSPECTION

Inspecteach piston dome areaof the cylinderhead forwarping by plac-ing 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 roundwith 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 and90_ to the pin to determine if the bore is out of round. Repeat the measurements at the middle of the cylinder and the bottomof the cylinder to determine taper or out of round at the bottom. Use the chart below and record all measurements.

TOP

Tx Ty

MIDDLE

Mx My

BOTTOM

Bx By

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

Taper Limit=Ty--By and Tx--Bx

Limit .003 (.08mm)

Top

Middle

Bottom

Tx

Mx

Bx

Ty

My

By

Cylinder Taper Limit: .002 MAX

Cylinder Out of Round Limit: .002


33/308

GENERAL INFORMATION

2.11

PISTON INSPECTION / MEASUREMENT

90to pin

DOMESTIC ENGINES - Measure 3/8(10.0mm)up from bottom of skirt

Piston Ring

Feeler Gauge

1/2(1.3cm.)

Straight Edge

Keystone Piston Ring Cutaway

Up

FUJI ENGINES - Measure 1/2(12.7mm) upfrom bottom of skirt

1/2(1.3cm.)Cylinder

Piston RingA B C

D

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 _ anglto 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_ anglto 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 tpiston 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 gapwith 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.


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GENERAL INFORMATION

2.12

CYLINDER HONING

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

CYLINDER HONE SELECTION

A Nikasil cylinder can be lightly honed with

a soft stone hone but can not be oversized.NOTE:

DE--GLAZING

If cylinderwear or damage is minimal, honing the cylinderlightly withfinish stones. Follow the procedure outlined above

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. Thismay be accomplished by either boring the cylinder and then finish honing to the final bore size, or by rough honing followed byfinish honing.

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

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 gritstones 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 manufacturers 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, runthe hone in and out of the cylinder rapidly until cutting tension decreases. Remember to keep the hone drive shaft centered toprevent 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.

EXAMPLE OF A CROSS HATCH PATTERN


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GENERAL INFORMATION

2.13

PORT CHAMFERING

Remove the sharp edges at thebottom andtop of each port whenever boring or honing is performed. Make sure there are no sharedges.

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 cylindersleeve meets the aluminum casting (transfer port area). Use electrical contact cleaner if necessary toclean 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 cylinderbe thoroughlycleaned after honing to remove all grit material. Washthe cylinderin a solventhen 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.

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

complete!NOTE:

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 usingthe following procedure.

With case halvescleaned, press a replacement bearing into each of themain bearing journals to determine a basic amount of press fit.

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 recommendedinterference fit. If the bearing falls out of the case when the case is inverted, or if the crankcase bear-

ing surface is severely galled or damaged, the case should be replaced

NOTE:

CRANKSHAFT MAIN BEARING INSPECTIONClean crankshaft thoroughly and oil mainand connecting rod bearingswith Polaris engine oil.Carefully check each main bearinon the shaft.

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

NOTE:


36/308

GENERAL INFORMATION

2.14

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 rodon crankshaft and check for rough spots. Check radial end play in rod by supporting rod against one thrust washer andalternatelyapplying up and down pressure. Replace bearing, pin, and thrust washers if side clearance is excessive or if there is any up anddown movement detectable in the big end bearing.

Specialized equipment and a sound knowledge

of crankshaft repair and straightening is requiredto perform crankshaft work safely and correctly.

Crankshaft repair should be performed by

trained Polaris service technicians in a properly

equipped shop.

NOTE:

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 replacethem if piston damage has occurred.

Visually inspect piston pin for damage, discoloration,or wear. Runyourfingernail 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 magni-fying 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 pinslowly and check for rough spots or any resistance to movement. Slidepin back and forth through bearing while rotating and check for roughspots.

With pin and bearing centered in rod, twist ends back and forth in alldirections to check for excessive axial play. Pull up and down evenlyon both ends of pin to check for radial play. Replace pinandbearingif there is any resistance to rotation or excessive axial or radial move-ment. If playor roughness is evident with a newpinand bearing, replacethe connecting rod.

Within .002 (.05mm)


37/308

GENERAL INFORMATION

2.15

CRANKSHAFT INDEXING

Dial Indicator

DegreeWheel

.100 ATDC

Cra

nkshaft center line

Dial Indicator

DegreeWheel

.100 ATDC

MAG PTO

CAUTION:Disconnect battery ground cable and ALL spark plug high tension leads: ground high tensionleads to engine. Disconnect lanyard (if equipped) and or press engine stop switch before proceed-ing 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 failureREQUIRED 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 maksure 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 perimeteof 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 diaindicator 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 degreewheel and pointer aresecured andwill not move outof position. Re-check accuracy of this location a fewtimes. 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 thedial indicator andinstall in PTO cylinder.Repeat finding TDC. Note the degree wheel indication when the dialindicator reads .100 ATDC. It should be 180_ (2_) from the MAG cylinder mark.


38/308

GENERAL INFORMATION

2.16

Symptoms of an out of index crankshaft can include:

S Difficulty calibrating carburetor (repetitive plug fouling on one cylinder with no other cause)

S Unexplained piston failure on one cylinder (i.e. severe detonation, broken ring lands, piston holing)

S Excessive vibration of engine, backfiring, etc.

S 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 ahammer, always be sure to re-check previously straightened areas to verify truing. Refer to the illustrations below. UseCrank-shaft 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.

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

To correct a situation like the one shown in illustration 2, squeeze thecrankshaft at point A. you will use the tool from the alignment kit PN2870569.

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

A

B

HIGH .004 (.1mm)

HIGH .004 (.1mm)

SUPPORT CRANKSHAFTAT THESE TWO BEARINGS

1

A A

HIGH .002 (.05mm)HIGH .005 (.13mm)

2

A

HIGH .002 (.05mm)

HIGH .005(.13mm)A

3


39/308

GENERAL INFORMATION

2.17

CRANKSHAFT RUNOUT INSPECTION

1/2 (12.7mm)

Flywheel (MAG) side

Measure where taper starts

PTO Side

When checking the crankshaft runout on theMAG side measure the runout 1/2 (12.7mm) from the bearing flat.

When checking the crankshaft runout from the PTOside, measure runout where the taper starts after the bearing flat.

Acceptable crankshaft runout

(in crank fixture) is

Libertyt Engines .000 -- .00015 (0--.04mm)

FUJI Engines .000 -- .0024 (0--.07mm)

NOTE:


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GENERAL INFORMATION

2.18

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.

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.

NOTE:

With engine in chassis, oil reservoir full, and pump bled, remove two oil feed line banjo bolts (A) from their location on themanifold 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 occurringapproximately 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, thecheck 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.


41/308

GENERAL INFORMATION

2.19

OIL PUMP BLEEDING

(A)

(A)

FUSION OIL PUMP

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

to the engine be checked.

IMPORTANT: 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.


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GENERAL INFORMATION

2.20

OIL PUMP ADJUSTMENT PROCEDURE

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

Throttle Freeplay

Figure 2 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 cablemovement, 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 mayhave 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 posi-tions. 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 cableat 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.


43/308

GENERAL INFORMATION

2.21

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 overheatingand 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 coolantfrom the heat exchangers and the cold coolant may close the thermostat again. Make sure the thermo-stat 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 engagethe clutch. This allows air to bleed from the rear crossover tube. Then tilt the machine slightly on itsleft side so that the coolant bottle is the highest point in the cooling system. Cycle the RPM from idle toenough 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 thebottle.

Place the snowmobile in its normal riding position and loosen the bleed screw at the top of the water outlet manifold until trapped aihas 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 ounceor more of coolant may have to be added.

This procedure should take approximately 15 minutes.

NOTE: It is important to get enough coolant flow to purge the air from the crossover hose or rear

cooler and observe this air reaching the bottle.

DANGER

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.


44/308

GENERAL INFORMATION

2.22

900 FUSION* COOLING SYSTEM

E 2004 Polaris Sales Inc.

1.

3.

5.

7.

11.

13.

17.18.

19.

21.

26.

2.

4.

6.

12.

14.

16.

9.

9.

9.

15.

15.

15.

8.8.

8.

4.

2.

22.

22.

10.

9.

9.

9.

9.20.

23.

24.

9.

9.

25.

27.

1. Mount, Radiator, Rubber 2. Exchanger, Gripper/Cooler, LHExchanger, Gripper/Cooler, RH

3. Asm., Radiator 4. Hose, Gripper/Rear Cooler, LHHose, Gripper/Rear Cooler, RH

5. Mount, Radiator, Foam 6. Asm., Rear Cooler, Long

7. Hose, Tee/Radiator Inlet 8. Clamp, Springband, Brown

9. Clamp, Springband, Black 10. Rivet

11. Hose, Radiator/Bottle 12. Hose, Tube/Gripper, LH

13. Fitting, Tee 14. Cooler, Center

15. Clamp, Springband, Black 16. Hose, Tee/Center Cooler

17. Hose, Coolant Bottle/Engine

18. Hose, Engine Out/Tee

19. Cap, Pressure

20. Line, Fuel

21. Bottle, Coolant

22. Clamp, HoseClamp, Narrow

23. Nut

24. Clamp, Rubber Coated, .75

25. Tube, Coolant, Front, RH

26. Hose, Bottle/Tube

27. Hose, Gripper, Front, RH

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


45/308

Maintenance Program Chart 3.1 -- 3.3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Air Filter 3.4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water Sediment Trap 3.4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Filter 3.5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Filter 3.5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication Points 3.6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Suspension Lubrication 3.7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chaincase 3.8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Track 3.9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Track Tension 3.10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spark Plug Reading 3.11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Clutch Removal 3.12 -- 3.13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Headlight 3.14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bulb Replacement 3.15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Handlebar Adjustment 3.16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake System 3.17 -- 3.18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Throttle Lever Free Play 3.19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Care 3.20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust System 3.21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IQ Air Intake System 3.22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Edge Exhaust Valve Maintenance 3.23. . . . . . . . . . . . . . . . . . . . . . . . . .

IQ Exhaust Valve Maintenance 3.24. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Thermostat / Temperature Sensor 3.25. . . . . . . . . . . . . . . . . . . . . . . . . .

900 Liberty Coolant 3.26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

900 Liberty Oil Pump/Line Bleeding 3.27. . . . . . . . . . . . . . . . . . . . . . .

Typical Recoil Service 3.28 -- 3.29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

700/800 Liberty Water Pump Service 3.30. . . . . . . . . . . . . . . . . . . . . . .

5/21/2018 2005 Deep Snow Polaris 900 S

2005 Deep Snow Polaris 900 Service Manual

Documents

Transcript of 2005 Deep Snow Polaris 900 Service Manual