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1999 Polaris Service Manual

1. 10 98 2 50 Polaris Industries Inc MAINTENANCE TUNE UP Fuel Pump and Fuel Line Routing 500 500 Classic Classic Touring To Fuel Shut Off Valve Rea ls fe ee OS CN dei REVEL Torque age 5 gef 4 6 in Ibs a c Ed T A Impulse Line Polaris Industries Inc 2 51 10 98 MAINTENANCE TUNE UP Carburetor Vent Line Routing 500 500 Classic Classic Touring Carburetor arburetor Air Box 10 98 2 52 Polaris Industries Inc MAINTENANCE TUNE UP Cooling System 500 500 Classic Classic Touring Keep Away From Exhaust Hats Maintin Approx 1 4 Gap Between Hose amp Sway Keep Hose From Looping Way Polaris Industries Inc 2 53 10 98 MAINTENANCE TUNE UP Fuel Pump and Fuel Line Routing Widetrak LX x Impulse Line 10 98 2 54 Polaris Industries Inc MAINTENANCE TUNE UP Cooling System Widetrak LX Secure to clamp with tie strap Maintain approx 1 4 Check For gap between hose Clearance and sway bar Keep Hose From Looping Way Polaris Industries Inc 2 55 10 98 MAINTENANCE TUNE UP Fue Tank Oil Tank Routing Widetrak LX To Fuel Tank Cable Tie Vent Line Routing Cable Tie Steering Hoop To Oil Tank Vent Torque nut Cable Tie 4 6 ft Ibs 10 98 2 56 Polaris Industries Inc MAINTENANCE TUNE UP Fuel Tank Oil Tank Vent Line Routing XLT Classic XLT Touring XLT Special To Fuel Tank Cable Tie Ven
2. 345 8 75mm The water pump belt on all 600 amp 700 domestic twins Es snowmobile engines should be inspected every 1500 miles Belts should be inspected by measuring the width at several locations around the belt Belt width at any location should not be thinner than 250 6 35mm Re place the belt if you notice any loose cords broken cracked or missing cogs and variations in width If the water pump belt fails serious engine damage could re sult Nominal thickness of a new belt should be approxi mately 345 8 75mm Check belt tension by rotating crankshaft 1 8 turn ata time The tension should be equal at all points of rota tion 1 A weight is needed to test belt deflection Construct a weight out of wire and weights such as thick washers Use the illustration to assist you The finished weight should weigh 2 Ibs Weight Construction 2 Measure the belt deflection using the following procedure a Hang weight midway between pulleys Weight 062 to 090 must hang free and not rest on any part of ma Wire Suggested chine f Wide Enough b Lay a straight edge or straight piece of stiff materi to Span Belt al steel is suggested across the top of both pul leys The straight edge should measure approxi mately 1 8 x 8 x 1 c Measure the gap between the belt and the Weight should equal 2 lbs straight edge at the point where the weight is hanging Hang Weight Here d Measure
3. 5 Replace handlebar cover Handlebar Adjuster Block Bolt Torque i 11 13 ft Ibs 1 5 1 8 kgm A WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosen ing of the handlebars resulting in loss of control Polaris Industries Inc 2 23 10 98 MAINTENANCE TUNE UP Brakes Replenishing Brake Fluid Remove brake fluid master cylinder reservoir cover Add Polaris brake fluid as required to bring the level up to the top of the fluid level mark on the inside of the reservoir B The proper fluid level 1 4 5 16 is 1 4 5 16 6 8 cm below the lip of the reservoir opening 6 8 cm NOTE On some models the brake fluid level can be seen through the plastic reservoir The fluid should be maintained be tween the minimum and maximum marks on the reservoir for those models Inspect the reservoir to be sure it contains the correct amount of fluid Use only Polaris DOT 3 high temperature brake fluid Change fluid every 2 years or whenever the fluid is dark or con tamination is suspected Master Cylinder Fluid Level Polaris DOT 3 High Temp Brake Fluid 1 4 5 16 6 8 cm below lip of PN 2870990 reservoir opening A WARNING Do not over fill the master cylinder Fluid expansion could cause brakes to lock resulting in serious injury or death Once a bottle of brake fluid is opened use what is necessary and discard the rest
4. Do not store or use a partial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air This causes the boiling temperature of the brake fluid to drop leading to early brake fade and the possibility of serious injury Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause a springy or spongy brake lever action Bleeding is necessary to re move air from the system 1 Remove brake fluid master cylinder reservoir cover and gasket CAUTION Brake fluid is a hazardous material Contact with decals paint and many plastics will cause damage Use proper precautions when handling brake fluid 2 Fill the master cylinder reservoir B and replace gasket and cover Keep the fluid level 1 4 5 16 6 8 cm below lip of reservoir opening 3 Slip a rubber tube over the ball of the bleeder valve and direct the flow of fluid into a container A WARNING Never re use brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air This causes the boiling temperature of the brake fluid to drop leading to early brake fade and the possibility of serious injury 4 Squeeze brake lever a full stroke Then unscrew bleeder valve A 3 4 of a turn to release air Bleeder Tube 5 Close bleeder valve first and then release brake lever Repeat steps 4 and 5 until fluid flows from bleeder valve in a solid stream free of air bubbles Do not allow reservoir to run
5. MAINTENANCE TUNE UP Hood Alignment Evolved Up to 10 gap C allowable q b di oes S 25 06 WC Cheek Area 1 Ensure front of hood and side bumper are flush Maintain 25 06 gap 2 Center rear of hood to console 3 After steps 1 amp 2 are complete adjust hood overhang if needed by pushing or pulling side panel at bracket in Cheek Area to achieve required gap Polaris Industries Inc 2 35 10 98 MAINTENANCE TUNE UP Side Bumper Panel and Console Mounting Evolved Torque 4 6 in lbs Torque 4 6 in Ibs Torque 6 ft Ibs 10 98 2 36 Polaris Industries Inc MAINTENANCE TUNE UP Handlebar Assembly Evolved Aggressive Handlebar cable tie location When adjusting the handlebars tighten all screws evenly until bars are held in the desired position Torque the front handlebar screws first and then the rear screws 11 13 ft Ibs NOTE The slightly wider gap at the rear of the block is normal Sel tapping SC EWs E With throttle and brake blocks donor gvemignien S aligned in riding position position heater grip flush with end Align wires with channel in throttle and brake respectively Polaris Industries Inc 2 37 10 98 MAINTENANCE TUNE UP Routing Diagram 340 340 Deluxe 340 Touring Cil line e Push excess vent line into steering post ae y P To fuel tank To oil tank 10 98 2 38 Pola
6. Rear suspension pivot shafts Lubricate both front ski pivots at fitting as shown using low temperature grease Grease jackshaft and driveshaft clutch side bearings Grease steering post support bracket bushings Typical Spindle Leading Type e Grease center steering arm bell crank pitman arm and idler arm where applicable NOTE A grease gun kit complete with grease and adaptors is available to lubricate all fittings on Polaris snowmobiles Polaris Premium All Season Grease 14 oz PN 2871423 Steering Post Center Steering Arm Bushings Grease Gun Kit PN 2871312 Bell Crank A Jackshaft Bearing Greasing Loosen driven clutch retaining bolt and pull clutch outward to ex pose bearing Use a point type grease gun fitting to inject grease Grease through hole in flangette into bearing until grease purges out in side or outside bearing seal Push clutch back onto shaft and re place clutch retaining bolt Grease Gun Adapter 2871174 Point Type Jackshaft Bearing Driveshaft Bearing Greasing inject grease into fitting on speedometer drive adaptor until grease purges out inside or outside bearing seal Driveshaft Bearing Greasing WideTrak Jackshaft coupler bo Drive e WideTrak Polaris Industries Inc 2 5 10 98 MAINTENANCE TUNE UP Water Pump Water Pump Belt Tension Replace if width is less than 25 600 700 Domestic Twins 6 35mm Nominal new width is
7. surfaces Clean sheaves repair clutch as necessary B Check brake pad and brake disc condition and mounting reassemble clutches and torque to specifications C Adjust brake to proper specifications 8 Check belt condition 22 Check auxiliary shut off switch A perform throttle safety 259 Check and adjust belt deflection switch tests 10 inspect rubber engine mounts 23 Inspect brake light tail light oil light and all electrical accessories 11 Torque engine mounting plate to chassis fasteners __24 Inspect Hi Lo beam operation and aim headlight check fasteners 12 Adjust engine torque stop if equipped 0 10 0 30 25 Liquid cooled models 13 Carburetor Inspections A Check coolant level and specific gravity A Adjust choke plungers B Check water pump drive belt condition amp deflection B Adjust pilot air screw where applicable C Synchronize carburetor slide valves at idle C Check coolant hose routing and clamps and off idle D inspect heat exchangers condition and fasteners D Adjust engine idle RPM E Check cooling system for proper coolant circulation E Adjust throttle lever free play F Replace recovery line filter NOTE Must use correct filter F Synchronize oil pump lever G Check coolant recovery line one way check valve must hold G Inspect Choke Throttle Cables pressure where applicable H Inspect vent lines for wear or kinking H Pressure test cooling system 14 Remove chaincase
8. 50 or 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 Inspect coolant filter annually for contamination and replace if necessary COOLANT LO Check Valves tapered side points in flow direction BOTTLE Filter Filter is located before the check valve Bleeding the Cooling System Pressure Caps If the cooling system should become low in the tank and or filler neck the system should be bled of any trapped air us Lift Lock Lever To Bleed ing the following procedure Remote Filler Neck 1 Allow the system to cool completely Fill the reservoir Bleed at 600 RPM with coolant to the maximum indicated mark Filler Neck On 2 With pressure cap removed add coolant and fill to the Cylinder Head top of the filler neck Bleed at fast idle 3 Install the pressure cap with the lever lock up in its release position and run the engine at fast idle for two to three minutes This will purge the system of trapped air Close the lever lock and check recovery tank fluid level CAUTION On models equipped with remote filler neck ow idle RPM must be used for bleeding 600 RPM 100 to allow all air to purge and prevent trapped air which can lead to overheating Reset idle to specified RPM after bleeding Caution Increase RPM slowly when leve
9. can be adjusted by turning the adjustment knob located inside the hood just below the headlamp opening Turn knob in or out as needed for proper aim Removing the Center Bulb 1 Push down on spring until it releases from spring retainer 2 With wire harness attached to bulb withdraw bulb from housing 3 Grasp bulb by metal base and carefully separate bulb from Headlight Adjustment Knob harness Installing the Center Bulb NOTE Do not touch a halogen bulb with bare fingers Oil from skin Wire leaves a residue causing a hot spot which will shorten the life of the Harness P lamp e 1 Hold bulb by metal base only and install into wire harness Bulb 2 Insert bulb into housing 7 3 Push spring down until it is secured by spring retainer Spring 4 Verify headlight aim Removing the Side Bulbs 1 Disconnect terminal from back of bulb 2 Turn bulb assembly 1 4 turn to right and withdraw from housing Installing the Side Bulbs NOTE Do not touch a halogen bulb with bare fingers Oil from skin leaves a residue causing a hot spot which will shorten the life of the lamp Hold bulb assembly by plastic base and plug into wire terminal Insert bulb assembly into housing Turn bulb assembly 1 4 turn to left to secure in housing Verify headlight operation BONS Polaris Industries Inc 2 21 10 98 MAINTENANCE TUNE UP Headlight Adjustment Aggressive Style Models Headlight Adjustment The headlight can be adjust
10. chaincase lubricant PN 2871478 through the dipstick opening to the level described above NOTE Clean the magnetic plug E every 500 miles 800 km and whenever checking or changing lubricant 10 98 2 8 Polaris Industries Inc MAINTENANCE TUNE UP Chaincase Chaincase Oil Level WideTrak Models Using Polaris Synthetic Chaincase Lubricant maintain the proper oil level Proper oil level is determined by checking the level on the dip stick A with the machine placed on a level surface The oil level should be between the safe marks on the dipstick Add oil through the dipstick opening to maintain proper oil level Do not overfill NOTE Clean the magnetic plug B every 500 miles 800 km and whenever checking or changing lubricant Polaris Synthetic Chaincase Lubricant Gallon PN 2871477 12 oz PN 2871 478 Garg B Polaris Synthetic Chaincase Lubricant is compatible with our petro leum based chaincase oil and can be mixed However do not mix or use other types of lubricant Excessive wear to chain sprockets and bearings may result Polaris Industries Inc 29 10 98 MAINTENANCE TUNE UP Suspension Lubrication Suspension Lubrication To maintain rider comfort and to retard wear of the pivot shafts the suspension pivot shafts should be lubricated with Polaris Premium All Season Grease PN 2871423 at 500 miles 800 km initially 1000 miles 1600 km and before summer storage each year The riding chara
11. dry or air will be drawn into system 6 Re fill reservoir to proper level after bleeding operation Do not overfill the master cylinder 7 Replace gasket and cover During the bleeding procedure make sure to keep the reservoir as lev el as possible to minimize the possibility of air entering the system 10 98 2 24 Polaris Industries Inc MAINTENANCE TUNE UP Brakes Brake Adjustment Mechanical Disc Brakes If excessive brake lever to brake block clearance is evident the caliper adjuster should be adjusted using the following method A WARNING Adjust brake with caliper adjuster bolt only Do not adjust cable or cable sleeve length Improper brake adjustment could result in brake failure which could result in severe injury or death Caliper Adjustment 1 Bend locking tab A away from lock nut B and loosen lock nut 2 Push down on actuating lever C and insert a 015 feeler gauge between the brake disc and outer brake pad 3 Turn adjusting bolt D in until a slight pressure is felt against the feeler gauge 4 While holding adjusting bolt D tighten locknut B 5 Bend locking tab A against locknut A WARNING Be certain locking tab is correctly positioned in actuating lever After locknut is tightened check pad to disc clearance to be certain there is 015 clearance Be certain brake pads are not dragging on disc and brake lever travel is not excessive Improper brake adjustment could
12. replaced A WARNING Broken track rods are a serious hazard since they can cause a ro tating track to come off the machine Never operate or rotate a torn or damaged track under power Serious personal injury or death may occur Track window Track Alignment Track alignment affects track tension Misalignment will cause ex cessive wear to the track and slide rail A periodic check should be made to see that the track is centered and running evenly on the slide rails Misalignment will cause ex cessive wear to the track and slide rail NOTE If excessive hi fax wear occurs due to poor snow conditions additional wheel kits are available 1 Safely support the rear of the machine with the track off the ground 2 Start the engine and apply a small amount of throttle until the track turns s owly at least five complete revolutions Stop the engine 3 Inspect track alignment by looking through the track window to Looking through make sure the rails are evenly spaced on each side If the track track window runs to the left loosen left locknut and tighten the left adjusting ee dch bolt If the track runs to the right loosen right locknut and spaced on each tighten the right adjusting bolt side 4 After adjustments are complete be sure to tighten locknuts and idler shaft bolts Torque to specification Lock
13. representation only Your model may differ In order to understand the operation and function of the V E S we must first consider the characteristics of a two stroke engine The height of the exhaust port in a two stroke engine cylinder has an affect on the total power output of an engine as well as the RPM at which the power occurs Exhaust systems are tuned by design to match engine exhaust port configuration and desired power delivery charac teristics Engines with relatively high exhaust ports and exhaust pipe to match produce more horsepower at high RPM but only at the expense of low to midrange fuel economy and torque On the other hand low port engines provide good fuel economy in the midrange and make their power at relatively lower RPM but will not produce as much peak horsepower for a given displacement range In general an engine designed for a racing or high perfor mance snowmobile will have a relatively high exhaust port compared to an engine of the same displacement range designed for touring Although the V E S does not in itself increase horsepower it does allow an engine to be designed for maximum horsepower without the inherent disadvantages of a high exhaust port The main components of the V E S are the exhaust valve valve housing bellows piston return spring and cov er A guillotine style exhaust valve is connected to a moveable piston This piston is attached to a flexible bellows forming two c
14. result in brake failure which could result in severe injury or death Brake Pad to Disc Clearance 015 38 mm 015 Feeler Gauge NOTE Replace pads when worn beyond service limit Minimum Pad Thickness Brake Pad Thickness Type M3 250 shown 6 35mm Service Limit 250 6 35mm _ All brake pads 1 Polaris Industries Inc 2 25 10 98 MAINTENANCE TUNE UP Brakes WT 2 Brake Adjustment Bracket 1 Checkto ensure floating parts move freely and that all other parts are mounted securely Tighten hardware as required 2 Check actuator linkage to ensure there is adequate freedom of movement for positive brake operation Periodic adjustment of pad gap can be performed using actuating cable 3 Loosen lock nuts Move cable up or down in bracket to adjust freeplay 4 To increase brake lever free play turn nuts counterclockwise to move cable down in bracket To decrease lever free play move cable up in bracket Tighten lock nuts Brake Lever Free Play 1 4 3 8 in 6 10mm 5 lf cable adjuster has reached maximum used up the lever arm can be re indexed Loosen lock nuts and turn counterclockwise as viewed from top to obtain the maximum amount of cable freeplay Straighten tab on tab washer and loosen bolt enough to disengage actuator lever spline 6 Slip long leg of lever spring off caliper and rotate to the side 7 Rotate the lever one tooth in the direction opposite the a
15. screws B as necessary to provide equal adjustment on both sides of the track NOTE Track alignment affects track tension Misalignment will cause excessive wear to the track and slide rail Excessive Hi Fax wear will appear on units with track tension set too tight Polaris Industries Inc 2 15 10 98 MAINTENANCE TUNE UP Track Maintenance Adjustment A WARNING When performing the following checks and adjustments stay clear of all moving parts to avoid serious personal injury Track Tension XTRA 10 Style 1 Turn the machine off 2 Lift the rear of the machine and safely support it off the ground 3 Place a 10 Ib 4 5 kg weight on the track at a point approximately 16 40 6 cm ahead of the center of the rear idler wheel D 4 Check for 3 8 1 2 1 1 3 cm slack between the inside of the track clip and the hi fax C NOTE Measure at the point where the weight is hanging XTRA 10 121 133 amp 136 Style Track Tension 3 8 1 2 slack 1 1 3 cm w 10 Ib 4 54 kg weight g weig 10 Ib Weight S 4 5 kg If the track needs adjustment 5 Loosen rear idler shaft bolts D on both sides of the machine Loosen track adjusting bolt locknuts A 7 Tighten or loosen the track adjusting bolts B evenly as necessary to obtain proper track tension 8 Tighten idler shaft bolts and adjuster bolt locknuts Always inspect track alignment after track tension adjustment NOTE Track alignme
16. shaft bolts D on both sides of the machine 6 Loosen track adjusting bolt locknuts A 7 Tighten or loosen the track adjusting bolts B evenly as necessary to obtain proper track tension 8 Tighten idler shaft bolts and adjuster bolt locknuts NOTE Track alignment affects track tension Misalignment will cause excessive wear to the track and slide rail Excessive Hi Fax wear will appear on units with track tension set too tight 10 98 2 14 Polaris Industries Inc MAINTENANCE TUNE UP Track Maintenance Adjustment A WARNING When performing the following checks and adjustments stay clear of all moving parts to avoid serious personal injury Track Tension WideTrak LX Tension adjustments should be made only after the track is warmed up and limber 1 Tum the machine off 2 Lift the rear of the machine and safely support it off the ground 3 Place a 10 Ib 4 5 kg weight on the track at a point approximately 16 40 6 cm ahead of the center of the rear idler wheel 4 Check for 3 4 1 1 9 2 5 cm slack between the inside of the track clip and the plastic hi fax C 10 Ib Weight 4 5 kg NOTE Measure at the point where the weight is hanging WideTrak LX Track Tension 3 4 1 slack 1 9 2 5 cm w 10 Ib 4 54 kg weight if the track needs adjustment 5 Loosen rear idler shaft bolt D 6 Loosen locknuts A 7 Tighten or loosen the track adjusting
17. 5 Gallon Drum 2871954 Threadlock 271 36cc 6 MAINTENANCE PRODUCTS j 2871955 Instant Adhesive Prism 401 3cc 30 2871326 Carbon Clean Plus 12 oz 12 H 2871956 Pipe Sealant 565 50cc 6 2871478 Premium Synthetic Gearcase Lube 12 02 12 2871957 Silicone Black RTV 3 oz tube 12 2871477 Premium Synthetic Gearcase Lube Gallon 4 2871958 Silicone Black RTV 11 oz Cartridge 12 g 2872275 Premium Synthetic Gearcase Lube 2 5 Gallon 2 d 2871959 Ultra Blue RTV 3 35 oz 12 2871280 Chain Case Lubricant Quart 12 2871960 Ultra Blue RTV 13 oz Cartridge 12 2870464 Chain Case Lubricant Gallon 6 2871961 518 Flange Sealant 50cc 10 Synthetic 2 Cycle Premium Gold 2871064 2870632 2871076 Battery Tender 2870585 Primer N Aerosol 2870584 680 Retaining Compound 2871949 Threadlock 242 50cc 10 T 9 Metal Protectant Metal Polish each 10 oz each el d 2 Di o o EN o ke E eo 5 8 oz 25 gr 1 10cc each 2871323 Premium Antifreeze 60 40 Premix Gallon 6 CRANKCASE SEALANTS 2871534 Quart 12 518 Gasket Eliminator 50cc 2870995 Quart 6 3 Bond 1215 2872279 2 5 Gallon 2 VALUE PACKS 12 o0z 12 Synthetic Lube Value Pack 27637 Premium Fein EE WAX AND POLIS Peete tose Gan AUS unu s C E Gestore pale oat ontoves 2871322 Premium All Season Grease 30z 24 2871965 Reflect Wax Final Finish i i o N 4 Value pack 4 Value pack 2871423 P
18. CHAPTER 2 MAINTENANCE TUNE UP Maintenance Schedule 500 Mile 2 1 Maintenance Schedule 1500 Mile 2 2 Recommended Maintenance Products 2 3 Intake Piller au cesso op RE Eee ela eds 2 4 Lubrication werent atk uas s UE Py dac ete at 2 5 Water Pump Belt Domestic 2 6 Water Pump Belt Fuji 000 2 7 C aincase uiri soe scm ePi EDS Nap 2 8 2 9 Suspension Lubrication 0 0 02 eae 2 10 2 11 Cooling System EE 2 12 Track Maintenance Alignment 2 13 2 17 Spark Plugs cube Dur ke wna RT ERAI Kee 2 18 Drive Belt Removal Installation 2 19 Backrest Adjustment 0c eee eee 2 20 Headlight Adjustment 2 21 2 22 Bulb Replacement 0 2 cece ee eens 2 22 Handlebar Adjustment eee 2 23 l1 PC nade Ehe att 2 24 2 26 Reverse Maintenance 2 27 2 28 Off Season Storage cruce e es Sek eredi 2 29 2 31 Variable Exhaust Systems 2 32 2 34 Routing Diagrams cecxsxas Rav ee ek RATER 2 35 2 71 A 12 13 14 15 16 MAINTENANCE TUNE UP Maintenance Schedule 500 Mile 805 km Initial Maintenance Inspection Check cylinder head and base area for signs of exhaust or coolant leaks Re torque cylinder heads cold amp cylinder base nuts Check ignition timing observed BTDC corrected BTDC Check clutch offset belt removed Check belt condition Check and adjust belt ten
19. Fuel Tank Cable Tie Cable Tie Oil Tank Vent Line Cable Tie Polaris Industries Inc 2 45 10 98 MAINTENANCE TUNE UP Wire Harness And Speedometer Cable Routing Trail Trail Touring Rosebud Clip A Panduit T bf Hood LO Ses AIR hs SRA Speedometer Cable Panduit Wire Harness In nosepan area speedometer cable is routed as shown with no other panduits in this area 10 98 2 46 Polaris Industries Inc MAINTENANCE TUNE UP Fuel Pump and Fuel Line Routing Trail Trail Touring To Fuel Shut Off Valve c Torque 4 6 in Ibs QP Impulse Line Polaris Industries Inc 2 47 10 98 MAINTENANCE TUNE UP Carburetor Vent Line Routing Trail Trail Touring Carburetor Carburetor Air Box 10 98 2 48 Polaris Industries Inc MAINTENANCE TUNE UP Fuel Tank Oil Tank Vent Line Routing 500 500 Classic Classic Touring To Fuel Tank Cable Tie Vent Line Routing Cable Tie X To Oil Tank Vent Steering Hoop Cable Tie Es Torque 4 6 ft Ibs EL Ve zb Lee P d Polaris Industries Inc 2 49 10 98 MAINTENANCE TUNE UP Wire Harness and Speedometer Cable Routing 500 500 Classic Classic Touring Rosebud Clip 7 amp Panduit CES Sh WI SN s Panduit Speedometer Cable Panduit Wire Harness In nosepan area speedometer cable is routed as shown with no other panduits in this area
20. Nut Idler Shaft Bolt Torque 35 40 ft Ibs 4 8 5 5 kgm Idler Shaft Bolt Polaris Industries Inc 2 13 10 98 MAINTENANCE TUNE UP Track Maintenance Adjustment Track Tension Data XTRA 12 121 none 2 behind rail bumper 1 2 1 3 cm free hanging XTRA 12 133 none 16 ahead of rear idler shaft 1 1 1 8 2 5 2 9 cm free hanging XTRA 10 121 133 136 10 Ibs 4 54 kg 16 ahead of rear idler shaft 3 8 1 2 1 1 3 cm WideTrak 10 Ibs 4 54 kg 16 ahead of rear idler shaft 3 4 1 1 9 2 5 cm XTRA Lite 121 and 133 10 Ibs 4 54 kg 16 ahead of rear idler shaft 3 8 1 2 1 1 3 cm XTRA Lite 136 When performing the following checks and adjustments stay clear of all moving parts to avoid serious personal injury 10 Ibs 4 54 kg 16 ahead of rear idler shaft 3 8 1 1 2 5 cm Track Tension XTRA Lite Style 1 Turn the machine off 2 Lift the rear of the machine and safely support it off the ground 3 Place a 10 Ib 4 5 kg weight on the track at a point approximately 16 40 6 cm ahead of the center of the rear idler wheel 4 Check for proper slack between the inside of the track clip wear surface and the hi fax C NOTE Measure at the point where the weight is hanging XTRA Lite 121 and 133 3 8 1 2 slack 1 1 3 cm w 10 10 Ib Weight o Ib 4 54 kg weight 4 5 kg If the track needs adjustment 5 Loosen rear idler
21. arbonization will result Always use resistor type spark plugs NOTE Incorrect fuel mixture can often cause a spark plug to appear to be too dark or too light in color Before changing spark plug heat ranges be sure the correct main jet is installed in the carburetor s The spark plug and its condition is indicative of engine operation The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds Immediately check the spark plug for correct color Normal The insulator tip is gray tan or light brown There will be a few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service NOTE The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetion adjustments Wet Fouled The insulator tip is black A damp oily film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes are excessive oil use of non recommended injec tion oil excessive idling idle too low or too rich or weak ignition output 1 Inspect electrodes for wear and carbon buildup Look for a sharp outer edge with no rounding or erosion of the electrodes 2 Clean with electrical contact cleaner or a glass bead spark plug cleaner only A wire brush or coated abrasive should not be use
22. cover flush chaincase inspect 26 Fan Cooled inspect cooling fins and shrouds and adjust chain refill with new chaincase oil 27 Remove chaincase cover flush chaincase inspect chain amp sprock ue Change primary fuel filter and oil filter ets and adjust chain Inspect Geiss seals 16 Check fuel and oil line condition and routing 28 eese Deo Wh Penn Al Sein ee Lubricate 7 Inspect fuel and oil tank vent lines routing 29 Inspect and adjust reverse cable if applicable 218 Inspect airbox fitair filter Clean or replace 80 Remove ski pivot bushings and lubricate 19 Change shock oil Fox annually before storage 31 Inspect ski wear bars 20 MES Ee Ee EE 32 Check camber alignment and lubricate spindles n Disassempie arid clean components 33 Remove radius rod end bushings lubricate and reinstall inspect all 21 ACCS radius rod ends A Inspect vent lines 94 Reinstall skis and inspect adjust toe alignment 35 Check handlebar centering and lubricate all steering pivots Polaris Service Technician 86 Torque tie rod end bolts and jam nuts Authorized Dealer __37 Inspect steering arms and torque bolts inspect handlebar bolt Base Inspection Price torque Date Parts Labor 38 Lubricate rear suspension pivot shafts 39 Torque suspension mounting bolts and check all rear suspension fasteners and components 40 Inspect rear suspension wheels bearings and hi fax 41 Inspect track for da
23. cteristics of the snowmobile will be affected by lack of lubrica tion of these shafts NOTE A grease gun kit complete with grease and adaptors is available to lubricate all fittings on Polaris snowmobiles Order PN 2871312 Polaris Premium Grease PN 2871 423 E Grease Gun Kit PN 2871312 Refer to the following diagrams for suspension lubrication points LUBRICATION POINTS WideTrak Grease all fittings Forward _ LUBRICATION POINTS XTRA Lite Grease all fittings 10 98 2 10 Polaris Industries Inc Suspension Lubrication XTRA 10 Style Grease at fittings LUBRICATION POINTS Forward _ XTRA 12 Style Forward Both sides Polaris Industries Inc 2 11 MAINTENANCE TUNE UP Suspension Lubrication LUBRICATION POINTS 10 98 MAINTENANCE TUNE UP Cooling System A WARNING Never remove the pressure cap when the engine is warm or hot If the pressure cap is to be removed the engine must be cool Severe personal injury could result from steam or hot liquid Use of a non standard pressure cap will not allow the recovery system to function properly If the cap should need replacement install the correct Polaris cap with the same pressure rating Refer to the appropriate parts manual Coolant Level Coolant level in the reservoir or surge tank must be maintained between the minimum and maximum levels to prevent overheating and serious engine damage Recommended Coolant Use a 50
24. ctuation direction and tighten bolt making sure spline teeth are properly engaged 8 Bend up a tab aligning with one of the bolt head flats to prevent bolt rotation 9 Return the spring to its original position on the Lifter Balls caliper Both lever and linkage must be free to return to original position Separator 10 Perform steps 3 and 4 to adjust lever freeplay 11 Verify proper brake operation Disc should rotate freely without drag 12 Check disc surface condition Refer to Brake Final Drive section to inspect disc and pad condition and thickness 10 98 2 26 Polaris Industries Inc Adjustment Due to break in or replacement of components the re verse shift mechanism may require adjustment Gen Il Style 1 Loosen jam nuts on linkage rod A 2 Turn the threaded linkage rod B to lengthen or shorten the throw until reverse engages fully 3 Tighten jam nuts and re check adjustment Evolved and Aggressive Style 1 Lift shift lever slowly while observing shift arm on transmission 2 If adjustment is correct shift will move 1 1 1 2 before the shift arm begins to move If adjustment is required proceed with step 3 3 Loosen jam nuts on lower end of cable 4 Adjust cable end at transmission until the end of the shift lever has 1 1 1 2 2 5 3 8 cm of freeplay before the cable starts to move the shift arm Do not adjust beyond this point 5 Tighten jam nuts and re check adjus
25. d D Torque nut e 4 6 ft Ibs X 8 cm 10 98 2 66 Polaris Industries Inc MAINTENANCE TUNE UP Wire Harness and Speedometer Cable Routing 500 RMK Rosebud Clip 74 Panduit Geer SK A Hood 5 N ALLER Wh GER AS NOR Speedometer Cable Panduit Wire Harness In nosepan area speedometer cable is routed as shown with no other panduits in this area Polaris Industries Inc 2 67 10 98 MAINTENANCE TUNE UP Cooling System 500 RMK Keep Away From Exhaust Hats Maintin Approx 1 4 Gap Between Hose amp Sway Keep Hose From Looping Way 10 98 2 68 Polaris Industries Inc MAINTENANCE TUNE UP Fuel Pump and Fuel Line Routing 500 RMK To Fuel Shut Off Valve eec a ko Torque d 5 4 6 in Ibs p e Impulse Line Polaris Industries Inc 2 69 10 98 MAINTENANCE TUNE UP ACCS System 500 RMK i To handlebars Torque to d 4 to 6 in Ibs 10 98 270 Polaris Industries Inc MAINTENANCE TUNE UP Fuel Tank and Coolant Bottle Vent Line Routing 600 RMK 700 RMK 700 SKS To Fuel Tank Vent Line Routing SS Cable Tie Steering Hoop Torque 50 o ec in Ibs Torque 40 in Ibs Polaris Industries Inc 2 71 10 98
26. d 3 Measure gap with a wire gauge and adjust to specifications by bending side electrode carefully 4 Coat spark plug threads with a small amount of anti seize compound 5 Install spark plug and torque to specification Spark Plug Torque 11 Ft Lbs 1 52 kg m 10 98 2 18 Polaris Industries Inc MAINTENANCE TUNE UP Drive Belt Removal Installation Drive Belt A WARNING Inspect the condition of the drive belt Inspect clutch sheaves for damage wear or belt residue Clean with non oil base cleaner such as isopropyl alcohol To ensure satisfactory belt life install belts so they operate in the same direction of rotation Position the identifica tion numbers so that you can read them This will keep the belt rotating in the same direction Belt Removal 1 Be sure key switch is off and engine has come to a complete R i stop Remove the retaining knob or pin and open the clutch eve guard 2 Apply brake or lock parking brake if so equipped 3 Grasp belt firmly midway between clutches and pull upward and rearward to open the driven clutch sheaves Remove the belt from the driven clutch and then from the drive clutch Belt Installation 1 Drop the drive belt over the drive clutch and pull back the slack 2 Turn the driven clutch moveable sheave clockwise while at the same time pushing inward and forcing the belt down between the sheaves 3 Hold the belt down between the sheaves and roll the bottom port
27. d distance must be between 1 and 25 If the measured distance is more than the specification try another waterpump belt NOTE Do not use tools to assemble belt on pulleys Damage can occur which could shorten belt life Before installing new belt check pulley teeth remove all foreign material dirt and oil Never install a used belt on a differ ent engine Install belt so writing on the belt can be read from the right side of the machine 10 98 26 Polaris Industries Inc Water Pump Belt Tension Fuji Loosen pump mounting bolts Push on pump housing to apply tension to belt and hold in this position Tighten pump mounting bolts Apply light pressure at center of belt span Check tota deflection of belt span and compare to specifications Re adjust if necessary Water Pump Belt Tension ug aner G mm Oil Pump Adjustment Refer to Page 3 83 for oil pump adjustment procedure Polaris Industries Inc 2 7 MAINTENANCE TUNE UP Water Pump 10 98 MAINTENANCE TUNE UP Chaincase Chaincase Oil Level All Except WideTrak Models The Indy models have a silent chain design The drive chain is contin uously immersed in oil Proper oil level is determined by checking the level on the dipstick with machine placed on a level surface The oil level should be between the safe marks on the dipstick Add oil through dipstick opening to maintain proper level Use Polaris syn thetic chaincase oil Do not overfil
28. ed for vertical aim using the following proce dure 1 Place snowmobile on a leve surface with headlight approximately 25 25 7 62 m 7 6m from a wall 2 Measure distance from floor to center of headlight and make a mark on the wall 3 Start engine and turn headlight switch to high beam 4 Observe headlight aim The most intense part of the headlight beam should be aimed 2 5 1 cm below the mark placed on the wall in Step 2 NOTE Rider weight must be included on the seat 5 If necessary headlight aim can be adjusted by inserting a Phillips screwdriver into the boss in the top of the console and turning the screw until correct adjustment is achieved Removing the Bulb 1 Push down on left side of spring until it releases from spring retainer 2 Lift spring carefully around wire harness and flip to outside of housing 3 With the wire harness attached to the bulb withdraw bulb from Insert screwdriver into access housing hole and turn screw to adjust 4 Grasp bulb by metal base and carefully separate bulb from harness Installing the Bulb Hold bulb by metal base and install into wire harness Insert bulb into housing Carefully flip spring back into housing placing it around wire harness Ke Push spring down until it is secured by spring retainer Verify headlight aim gv Sa bz Spring Taillight Bulb Replacement 1 Remove 5 Phillips screws from taillight lens 2 Working from front to back carefu
29. ervice and operating machine Chaincase Lubricant Change chaincase lubricant as outlined in this section Remove the outer cover and clean the chaincase thoroughly Polaris Industries Inc 2 29 10 98 MAINTENANCE TUNE UP Off Season Storage Lubrication Refer to page 2 6 2 11 for complete lubrication information To prevent corrosion always grease jackshaft and drive Ee shaft clutch side bearings with premium all season Ski Spindle fi grease Loosen driven clutch retaining bolt and pull and Bush clutch outward to expose bearing Use a point type ings j grease gun fitting to inject grease through hole in flangette into bearing until grease purges out inside or outside bearing seal Push clutch back on shaft and EE replace clutch retaining bolt Inject grease into fitting on lil 1 ackshaft speedometer drive adaptor until grease purges out Bearing inside or outside bearing seal Lubricate both front ski pivots at bushings and spindles See Ill 1 and 2 Driveshaft Bearing Polaris Premium All Season Grease __ PN 2871423 14 1 2 oz Located on left side ill 2 of machine clutch side Grease Gun Adapter 2871174 Point Type Use T 9 Metal Protectant or equivalent on shock absorber shafts to help prevent corrosion T9 Metal Protectant PN 2871064 Under normal conditions moderate track tension should be maintained during summer storage Rubber track tension should be maintained at the prescribed n
30. hambers The lower chamber is connected to the cylinder by a drilled passageway located just above the exhaust port The upper chamber is vented to atmospheric pressure A valve return spring is located in the upper chamber between the piston and cover At idle and low speeds the exhaust valve is held in the ow port position by the return spring When throttle is applied and RPM begins to increase rising cylinder pressure is applied to the under side of the bellows via the actuation port This forces the exhaust valve upward against spring pressure The valve continues to move upward toward the High Port position as cylinder pressure horsepower and RPM increase 10 98 2 32 Polaris Industries Inc MAINTENANCE TUNE UP Variable Exhaust System Exhaust pue m Spring Adjuster amp UN Bellows S s t E Piston Ci xm SC S Housing DX 4 Gasket N Exhaust Valve Cylinder 440 XCR V E S Maintenance Due to the simplicity of V E S design maintenance is limited to a periodic inspection and cleaning of system compo nents The V E S should be disassembled inspected and cleaned remove carbon deposits every 1000 to 2000 miles depending on operating conditions To ensure maximum performance and minimize required maintenance Polaris recommends the use of Premium Gold Synthetic 2 Cycle lubricant PN 2871721 only The use of other lubri cants may cause improper function of the valve mechanism and increa
31. ion over the outer clutch sheave Once installed be sure to work the belt to the outer edge of the sheave Be sure to release parking brake if applied 4 Close the clutch guard and reinstall the retaining knob or pin Belt Inspection 5 Refer to PVT Section for belt inspection and width measurement 6 Measure belt length with a tape measure around the outer circumference of the belt Belts which measure shorter or longer than a nominal length may require driven clutch or engine adjustment to obtain proper belt deflection 7 Replace belt if worn past the service limit Belts with thin spots burn marks etc should be replaced to eliminate noise vibration or erratic operation See Troubleshooting Chart at the back of this chapter for possible causes NOTE If a new belt is installed check belt deflection Install so part numbers are easily read Refer to the specification charts for belt specifications and measurement procedures Center Distance gt Polaris Industries Inc 2 19 10 98 MAINTENANCE TUNE UP Backrest Adjustment Backrest Adjustment The passenger backrest on the Classic Touring and XLT Touring Models is adjustable To move the backrest forward or backward lift the adjustment lever on the left side To lengthen or shorten the back rest cable lift the cable until spring tension is felt and lock the jamb nut When adjusting the backrest from a passenger position to a single rider po
32. ipper toward seat cushion Cut and remove zipper tab SNAM Cable Ties Switch Switch on Connect wiring and tuck in behind Right Hand taillight housing so not visible from Side side Wiring to be separated at bottom one wire per slot Polaris Industries Inc 261 10 98 MAINTENANCE TUNE UP Fuel Tank and Coolant Bottle Vent Line Routing 440 XCR 500 XC SP 600 XC SP 700 XC SP To Fuel Tank Cable Tie Vent Line Routing Cable Tie Steering Hoop Torque 50 pa in lbs in Ibs 10 98 2 62 Polaris Industries Inc MAINTENANCE TUNE UP Fuel Tank and Coolant Bottle Vent Line Routing 700 XCR 800 XCR To Fuel Tank Cable Tie Cable Tie Steering Hoop Torque nut 4 6 ft lbs Torque nut OMRE 4 6 ft Ibs Polaris Industries Inc 2 63 10 98 MAINTENANCE TUNE UP Fuel Tank Oil Tank Vent Line Routing Trail RMK To Fuel Tank Cable Tie Cable Tie Cable Tie Torque 50 p gt in lbs Torque 40 SS in Ibs a cu 10 98 2 64 Polaris Industries Inc MAINTENANCE TUNE UP ACCS System Trail RMK Polaris Industries Inc 2 65 10 98 MAINTENANCE TUNE UP Fuel Tank Oil Tank Vent Line Routing 500 RMK To Fuel Tank Cable Tie Cable Tie INS Zs ME Sot ZE Vent Line Routing To Oil Tank Vent Steering Hoop ff Torque Cable Tie 4 6 ft Ibs Ron SG f 36 cm ad 8 cm ky Coolant Bottle amp Hose P 8 cm i
33. l Polaris Synthetic Chaincase Lubricant Gallon PN 2871477 s 1202 PN 2871478 do A A 7 Bo p Magnetic Plug Il 1 Polaris Synthetic Chaincase Lubricant is compatible with our petro leum based chaincase oil and can be mixed However do not mix or use other types of lubricant Excessive wear to chain sprockets and bearings may result Drive Chain Tension Chaincase cover on To obtain correct chain tension 1 Elevate rear of machine so track is off floor 2 Loosen locknut and chain adjuster 3 Back off adjuster bolt 1 2 turn For models with reverse back off adjuster bolt 1 1 4 to 1 1 2 turns 4 Hold adjuster bolt in position and tighten locknut Drive Chain Tension Chaincase cover removed To obtain correct chain tension 1 Remove drain plug F and drain oil into a suitable container Dispose of properly 2 Remove the chaincase cover 3 While putting a slight reverse tension on the chain by turning brake disc as indicated by the arrow A there should be approximately 1 4 3 8 6 1 cm deflection on the chain at point B Refer to illlustration 1 4 The chain is adjusted by loosening the adjusting bolt locknut C and turning adjusting bolt D until correct chain deflection is obtained 5 Lockthe adjusting bolt locknut C while holding a wrench on the adjusting bolt D to prevent it from turning 6 Reinstall the chaincase cover and drain plug Add Polaris synthetic
34. lly pry lens away from seal and remove lens 3 Pull bulb straight out from socket and insert new bulb 4 Reinstall lens 10 98 2 22 Polaris Industries Inc MAINTENANCE TUNE UP Handlebar Adjustment Handlebar Adjustment Evolved and Aggressive Style Models 1 Remove two plastic fasteners holding console cover located below handlebar cover on hood side of steering post 2 Using a 7 16 11 mm wrench loosen four nuts on bottom of adjuster block NOTE Turn handlebar to left or right for access to rear nuts 3 Adjust handlebar to the desired height Be sure that handlebars brake lever and throttle lever operate smoothly and do not hit the gas tank windshield or any other part of the machine when turned fully to the left or right 4 Torque the handlebar adjuster block bolts to specification Maintain an equal gap on front and back of block 5 Replace console cover Handlebar Adjustment All Other Models 1 Remove handlebar cover 2 Using a 7 16 11 mm wrench loosen four nuts on bottom of adjuster block NOTE Turn handlebar to left or right for access to back nuts 3 Adjust handlebar to the desired height Be sure that handlebars brake lever and throttle lever operate smoothly and do not hit the gas tank windshield or any other part of the machine when turned fully to the left or right 4 Torque the handlebar adjuster block bolts to specification Maintain an equal gap on front and back of block
35. mage Adjust tension and alignment For optimum performance and reliability repeat the above mainte nance and inspections annually preferably before off season stor age or every 1000 miles except where noted RECOMMENDATION 10 98 2 2 Polaris Industries Inc MAINTENANCE TUNE UP Recommended Maintenance Products Recommended Maintenance Products ENGINE OIL Description Packaging size quantity Quarts 6 Gallon 4 16 Gallon Drum RETAINING SEALING PRODUCTS Part Packaging size quantity 16 02 12 2 5 Gallon 2 202 2871721 2871722 2871723 Synthetic 2 Cycle Premium Gold 2870652 2872280 2871027 Fuel Stabilzer Synthetic 2 Cycle Premium Gold Fuel Stabilizer Synthetic 2 Cycle Premium Gold Corrosion Resistant DiElectric 2871884 55 Gallon Drum 2871098 Premium 2 Cycle Oil TC W3 Quart Cans 12 2871097 Premium 2 Cycle Oil TC W3 Gallon 6 2871240 Premium 2 Cycle Oil TC W3 2 5 Gallon 2 2871566 Premium 2 Cycle Oil TC W3 16 Gallon Drum 2871385 Premium 2 Cycle Oil TC W3 30 Gallon Drum 2871096 Premium 2 Cycle Cil TC W3 55 Gallon Drum 2871950 Threadlock 242 6cc 12 2871281 Premium 4 Synth 4 Cycle Oil OW 40 Quarts 12 2871951 Threadlock 262 50cc 10 2871567 Premium 4 Synth 4 Cycle Oil OW 40 16 Gallon Drum 2871952 Threadlock 262 6cc 12 2871844 Premium 4 Synth 4 Cycle Oil OW 40 Gallon 4 2871953 Threadlock 271 Premium 4 Synth 4 Cycle Oil OW 40 5
36. nt affects track tension Misalignment will cause excessive wear to the track and slide rail Excessive Hi Fax wear will appear on units with track tension set too tight 10 98 2 16 Polaris Industries Inc MAINTENANCE TUNE UP Track Maintenance Adjustment A WARNING When performing the following checks and adjustments stay clear of all moving parts to avoid serious personal injury Track Tension XTRA 12 Style 1 Turn the machine off 2 Lift the rear of the machine and safely support it off the ground 3 Take measurement with track free hanging at a point 2 behind rail bumper or 16 ahead of rear idler on 133 tracks The distance between the inside top of the track clip and the Hi Fax should be as shown below and in the illustration at right Repeat measurement on the other side of the track NOTE Check more frequently when machine is new adjusting idler bolt shaft XTRA 12 Style Track Tension bolt 121 1 2 1 3 cm free hanging Rail bumper 133 4 1 1 8 2 54 2 86 cm free j hanging If the track needs adjustment 4 Loosen rear idler shaft bolts on both sides of the machine 5 Loosen track adjusting bolt locknuts 121 1 2 e 133 z 1 1 1 8 6 Tighten or loosen the track adjusting bolts evenly as measured fe ahead necessary to obtain proper track tension of rear idler center 7 Tighten idler shaft bolts and adjuster bolt locknuts Always inspect track alignment after
37. ormal operating tension specified in this manual The rear of the machine should be supported off the ground to allow free hanging of track 10 98 2 30 Polaris Industries Inc MAINTENANCE TUNE UP Off Season Storage Engine and Carburetor Fog engine with Polaris Fogging Oil aerosol type according to directions on can On models with carburetor vacuum fittings the fogging oil can be sprayed through the fitting If you choose not to use Polaris Fogging Cil perform the following procedure Support front of snowmobile so engine is level or tilted slightly rearward Remove spark plug s Rotate piston to BDC and pour approximately two ounces 16 ml Polaris 2 Cycle Injector oil into the cylinder NOTE Allow ample time for oil to flow from top of piston down transfer ports and onto crankshaft bearings before proceeding to next cylinder Turn engine over several times to insure coverage of piston rings cylinder walls and crankshaft bearings See photo at right Polaris Fogging Oil PN 2870791 Carbon Clean PN 2871326 Treat the fuel system with Polaris Carbon Clean If Polaris fuel system additive is not used fuel tank fuel lines and carburetor should be completely drained of gas oline To eliminate any fuel remaining in the carburetor run the engine until it stops Battery Disconnect and remove battery Fill with distilled water Clean terminals and cables Apply dielectric grease Charge until specific gravity is
38. r lock is up to avoid loss of coolant Bleeding the Cooling System Surge Tanks If the cooling system should become low in the surge tank the system must be bled of any trapped air using the fol lowing procedure 1 Allow the system to cool completely Fill the surge tank with coolant to the maximum indicated mark 2 Start the engine and loosen the bleed screw on the top of the water pump until trapped air has been purged Tighten the bleed screw 3 Loosen the bleed screw at the end and top of the water outlet manifold until trapped air has been purged Tighten the bleed screw 4 Recheck the surge tank coolant level and add coolant Fill Surge Tank again if necessary 10 98 2 12 Polaris Industries Inc MAINTENANCE TUNE UP Track Maintenance Alignment A WARNING When performing the following checks and adjustments stay clear of all moving parts to avoid serious personal injury Track Maintenance A WARNING Never make this maintenance check with the engine running as se rious personal injury can result Using a hoist safely lift and support the rear of the snowmobile off the ground Rotate the track by hand to check for any possible dam age To inspect track rods carefully examine the track along the entire length of each rod bending the track and inspecting for breakage The three most common places where breakage occurs are shown in the illustration If any rod damage is found the track should be
39. remium All Season Grease 14 0z 10 2871964 Renew vinyl rubber protector 12 12 oz 2871460 Premium Starter Grease 2 02 12 871592 Barrel Pump for 16 30 55 gal drums Ree 2871285 Flex Spout fits gal and 2 5 gal jugs Isopropyl 10 oz 24 2870505 Polaris Industries Inc 23 10 98 MAINTENANCE TUNE UP Intake Filter The intake foam filter limits snow ingestion into the intake system When operating in loose powder snow check top of foam filter periodically to remove any accumulation of snow Do not operate machine with the intake filters removed This can cause carburetor icing resulting in poor fuel economy or carburetor malfunction 1 Intake Foam Filter 3 Air Plenum 2 Air Intake Box 4 Dash Cowl Under Hood Air Intake System The Indy 340 Indy 340 Deluxe and Indy 340 Tour ing are equipped with an under hood air intake sys tem which should normally be left open The door should be closed and latched above 35 F 2 C for maximum performance during warm weather op eration Simply pull the strap out and up to latch the door Reverse the procedure to open it 10 98 24 Polaris Industries Inc MAINTENANCE TUNE UP Lubrication Lubricate the following fittings with Polaris Premium All Season grease annually or approximately every 1000 miles 1600 km Remove weight from the component being greased to permit better penetration and flushing of the joint Spindles left and right
40. ris Industries Inc MAINTENANCE TUNE UP Cil Line Routing 340 340 Touring Recoil Rope Over the Top of Wire Harness and Oil Line Oil Tank Convoluted Wire Harness and Tubing Oil Line Secured to Bracket Stand with Cable Tie Oil Line Toward Outside BN Wire Harness J Polaris Industries Inc 2 39 10 98 MAINTENANCE TUNE UP Oil Line Routing 340 Deluxe Recoil Rope Oil Tank Wire Harness and Cil Line Cable Tied to Bracket Stand Wire Harness Oil Line Routed Convoluted Under Recoil Tubing Ring NOTE Be sure not to kink or pinch oil line 10 98 2 40 Polaris Industries Inc MAINTENANCE TUNE UP Fuel Tank Cil Tank Vent Line Routing Sport Sport Touring TranSport To Fuel Tank Cable Tie Vent Line Routing Cable Tie Steering Hoop To Oil Tank Vent Polaris Industries Inc 241 10 98 MAINTENANCE TUNE UP Fuel Pump and Fuel Line Routing Sport Sport Touring TranSport To Fuel Shut Off Valve Torque eg 4 6 in Ibs x X ES Impulse Line 10 98 2 42 Polaris Industries Inc MAINTENANCE TUNE UP Fuel Tank Oil Tank Vent Line Routing XCF Super Sport To Fuel Tank Cable Tie Cable Tie Panduit Polaris Industries Inc 2 43 10 98 MAINTENANCE TUNE UP Carburetor Vent Line Routing Super Sport Carburetor Carburetor Air Box 10 98 2 44 Polaris Industries Inc MAINTENANCE TUNE UP Fuel Tank Oil Tank Vent Line Routing Trail Trail Touring To
41. se the frequency of required cleaning due to excessive buildup of carbon deposits NOTE To ensure maximum performance and minimize required maintenance break in the engine using Polaris TC W3 oil premix and injection tank and then switch to Polaris Premium Gold Synthetic 2 cycle lubricant V E S Removal and Cleaning For VES removal and cleaning refer to 440 500 Domestic Case Reed Twin and 700 800 XCR section in chapter 3 Engines Adjuster nut Valve cap Bellows Washer Valve housing Dowel pin Gasket Valve 700 800 XCR Polaris Industries Inc 2 33 10 98 MAINTENANCE TUNE UP Variable Exhaust System V E S Troubleshooting Engine will not reach Valve not opening or not opening completely designed operating RPM 4 Exhaust valve sticking 1 Remove carbon deposits burrs etc 2 Clean port 2 Cylinder pressure feed port restricted 3 Bellows damaged or not sealing correctly 3 Inspect bellows fastener straps and gasket and repair as required 4 Inspect Inspect 4 Incorrect spring 5 Problem in clutch setup drive line engine etc Poor acceleration hesitation High RPM performance is normal or near normal Valve opening too early 1 Valve sticking open or partially open 2 Broken damaged or incorrect spring Clean Inspect Inspect Replace 10 98 2 34 Polaris Industries Inc
42. sion Inspect rubber engine mounts Torque engine mounting plate to chassis fasteners Adjust engine torque stop if equipped Carburetor Inspections A Adjust choke plungers B Adjust pilot air screw C Synchronize carburetor slide valves at idle and off idle Adjust engine idle RPM Adjust throttle lever free play Synchronize oil pump lever Inspect choke throttle cables Inpect vent lines for wear or kinking Check ski toe alignment Torque and inspect all steering fasteners Torque suspension to tunnel mounting bolts Check rear suspension fasteners for tightness Adjust track tension and align track rommeo Remove chaincase cover flush chaincase inspect and adjust chain refill with new chaincase oil Polaris Service Technician Authorized Dealer Date Polaris Industries Inc 2 1 __17a Brakes Hydraulic A B C D E Check brake fluid level Check for proper hose routing tighness of banjo bolts and line fasteners Check for system fluid leaks Visually inspect pads for wear damage or looseness Check security and surface condition of brake disc 17b Brake Mechanical 18 18 20 21 _ 22 28 _ 24 A B C Check cable condition routing Check brake pad and brake disc condition and mounting Adjust brake to proper specifications Check auxiliary shut off switch Perform throttle safety switch tests Check brake light for proper operation Check tail ligh
43. sition rotate the backrest cushion adjustment knobs until the proper angle is reached The grab bars have five height ad justments To raise or lower the grab bar remove the grab bar ad juster knob position the grab bar at the desired height and reinstall the knob The Classic Touring and XLT Tour ing models are also equipped with passenger handwarmers The handwarmer switch located un der the left hand wind deflector has three settings high off and low 10 98 Backrest Cushion Adjuster Backrest Cable Wind Deflector i d N e Adjuster Passenger Handwarmer Ll oe xe Backrest LE ee Switch Adjustment K Lever Grab Bar Adjustment Knob 2 20 Polaris Industries Inc MAINTENANCE TUNE UP Headlight Adjustment Gen Il Indy 340 and Evolved Style Models Headlight Adjustment The headlight can be adjusted for vertical aim using the following pro cedure 1 Place the snowmobile on a level surface with the headlight approximately 25 7 6 m from a wall 25 7 6 m Ee gl 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall 3 Start the engine and turn the headlight switch to high beam Lamp Center 4 ObDserve the headlight aim The most intense part of the headlight Height beam should be aimed 2 5 1 cm below the mark placed on the 2 5 1 cm wall in Step 2 NOTE Rider weight must be included on the seat 5 f necessary the headlight aim
44. t Line Routing v i Cable Tie SS ERR b LL PF To Oil Tank Vent CH Steering Hoop P4 Torque Cable Tie 4 6 ft Ibs Qo PA d e E se 36 cm C 9 cm E Coolant Bottle amp Hose FS pe se Ft SE E e Torque nut M Dose RE 4 6 ft Ibs D 26 cm Cil Tank d Polaris Industries Inc 2 57 10 98 MAINTENANCE TUNE UP Wire Harness and Speedometer Cable Routing XLT Classic XLT Touring Rosebud Clip A Panduit e A Hood gt KE By i Xi Se Panduit Speedometer Cable Panduit Wire Harness In nosepan area speedometer cable is routed as shown with no other panduits in this area Panduit f A JP Gi A 10 98 2 58 Polaris Industries Inc MAINTENANCE TUNE UP Fuel Pump and Fuel Line Routing XLT Classic XLT Touring To Shut Off Valve Oil Line Polaris Industries Inc 2 59 10 98 MAINTENANCE TUNE UP Backrest Classic Touring XLT Touring Leave cable on rear outside portion of backrest adjuster so it doesn t get pinched when backrest is put down Ba on seat for shipping J SS 37 ft Ibs 16 18 ft Ibs on 10 98 2 60 Polaris Industries Inc MAINTENANCE TUNE UP Handle Grip Heater Wire Routing Classic Touring XLT Touring Zipper Position Seat Cushion pe LH Grip RH Grip Locate center of grip heater Position 1 forward from center of handgrip with z
45. t least 1 270 each cell If machine is to be stored for one month or longer fill and charge battery monthly using Polaris Battery Tender or a 1 amp trickle charger to maintain at 1 270 specific gravity Polaris Battery Tender PN 2871076 Exhaust System At approximately 2000 miles or in preparation of off season storage it is a good idea to check the exhaust system for wear or damage To inspect allow the engine and exhaust system to cool completely Open the hood and inspect the muffler and pipes for cracks or damage Check for weak or missing retaining springs or damper sup port grommets A WARNING Exhaust system temperatures can exceed 900 F 500 C Serious burns may occur if this inspection is per formed without allowing adequate time for the exhaust system to cool Never perform this procedure with the engine running Polaris Industries Inc 2 31 10 98 MAINTENANCE TUNE UP Variable Exhaust System Variable Exhaust System V E S Some snowmobiles are equipped with the Polaris patent pending Variable Exhaust System V E S This unique exhaust valve management system changes the effective exhaust port height in the cylinder to pro vide maximum horsepower at high RPM without sacrificing fuel economy and engine torque at low to midrange throttle settings CYLINDER PRESSURE ACTUATION PORT HIGH RPM POSITION LOW RPM Ha Piston Bellows Exhaust Valve EXHAUST PORT CYLINDER This is a
46. tment Reverse Cable End Play 1 32 08 cm Reverse Shift Lever Freeplay 1 1 1 2 2 5 3 8 cm measured at end of shift lever muon MAINTENANCE TUNE UP Reverse Kit Maintenance Shift Lever Clevis Pin Shift Lever Actuator Chaincase Cover Assembly Gen II Models Evolved Aggressive Polaris Industries Inc 2 27 10 98 MAINTENANCE TUNE UP Reverse Kit Maintenance Adjustment Due to break in or replacement of components the re verse shift mechanism may require adjustment Adjust with the shifter in the forward position Indy 340 Style 1 Loosen jam nuts on lower end of cable 2 Adjust cable until endplay movement of cable housing at the handlebar bracket is 1 32 08 cm Do not adjust beyond this point 3 Tighten jam nuts and re check adjustment Reverse Cable End Play 1 32 08 cm 1 32 Adjustment 08 cm Reverse Shift Lever Freeplay 1 1 1 2 2 5 3 8 cm measured at end of shift lever 10 98 2 28 Polaris Industries Inc MAINTENANCE TUNE UP Off Season Storage Cleaning And Preservation Of Hood Chassis And Trim Proper storage starts by cleaning washing and waxing the hood chassis upholstery and plastic parts Clean and touch up with paint any rusted or bare metal surfaces Ensure that all corrosive salt and acids are removed from surfaces before beginning preservation with waxes and rust inhibi
47. tors grease oil or paint If the machine is equipped with a battery disconnect the battery cables and clean the cables and battery posts Fill battery to proper level with distilled water and charge to full capacity Remove and store the battery in a cool dry place The machine should be stored in a dry garage or shed out of the sunlight and covered with a fabric snowmobile cover Do not use plastic to cover the machine moisture will be trapped inside causing rust and corrosion problems Controls And Linkage All bushings spindle shafts and tie rod ends should be coated with a light coat of oil or grease Throttle controls and cables should be lubricated with Polaris Cable Lubricant Force a small amount of lubricant down cables Polaris Cable Lubricant PN 2870510 Electrical Connections Separate electrical connector blocks and clean corrosive build up from connectors Lubricate or pack connector blocks with dielectric grease and reconnect Replace worn or frayed electrical wire and connectors Dielectric Grease PN 2871027 Clutch And Drive System Remove drive belt and store in a cool dry location Lubricate sheave faces shaft and ramps of drive and driven clutches with light oil or rust inhibitor A generous amount of lubrication such as Polaris cable lubricant should be applied onto the rollers and weight pins All lubrication applied as a rust preventative measure must be cleaned off before installing belt for s
48. track tension adjustment NOTE Track alignment affects track tension Misalignment will cause excessive wear to the track and slide rail Excessive Hi Fax wear will appear on units with track tension set too tight Polaris Industries Inc 2 17 10 98 MAINTENANCE TUNE UP Spark Plugs Spark Plug Selection Original equipment parts or their equivalent should always be used However the heat range of spark plugs is of utmost importance A spark plug with a heat range which is too high will cause engine damage A spark plug with a heat range which is too low will cause excessive fouling and malfunction In selecting a spark plug heat range for production a manufacturer is forced to assume that the engine is going to be operated under extreme heavy duty conditions This protects the engine from internal damage in the event that the purchaser actually does operate the engine in this manner This selection however could cause the cus tomer who normally operates the engine under medium or light duty to have spark plug failure A plug with a heat range which is too high will always cause engine damage if the engine is operated in conditions more severe than that for which the spark plug was intended A new engine can cause temporary spark plug fouling even though the heat range is correct due to the preserva tive which has been added during assembly of the engine to combat rust and corrosion Avoid prolonged idle speeds as plug fouling and c
49. ts Check headlamp fasteners and high low beam operation Liquid cooled models A B C D E Check coolant level and specific gravity Check water pump drive belt condition amp deflection where applicable Check coolant hose routing and clamps Inspect heat exchangers condition and fasteners Check cooling system for proper coolant circulation V E S Variable Exhaust System if applicable A Disassemble and clean components ACCS A Inspect vent lines clamps Recommendations Base Inspection Price Parts Labor 10 98 MAINTENANCE TUNE UP Maintenance Schedule 1500 Mile 2400 km Maintenance Inspection Check cylinder head and base area for signs of exhaust or coolant leaks 21a Brakes Hydraulic A Check brake fluid level 2 Re torque cylinder heads amp cylinder base nuts cold B Check for proper hose routing tighness of banjo bolts and line 3 Check compression and record readings fasteners _4 Check ignition timing C Check for system fluid leaks observed BTDC D Visually inspect pads for wear damage or looseness corrected BTDC E Check security and surface condition of brake disc 5 Inspect recoil starter rope F Flush brake fluid and change every two years 6 Check drive to driven clutch offset belt removed 21b Brake Mechanical EN Remove clutches disassemble amp inspect all wear A Check cable conditions routing

1999 Polaris Service Manual

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