Polaris Model Year 2002 500/600 VES Snowmobiles Overheating
Contents
1. gt POLARIS The Way Out SNOW TEAM TIPS Published for Polaris Dealers Distributors and Service Staff Vol 10 No 8 August 2002 Polaris Model Year 2002 500 600 VES Snowmobiles Overheatin Much has been learned about the cooling system of the 2002 models that utilize the small block 500 600 VES engine Polaris would like to thank the many dealers who have assisted us this past season in identifying solutions to these cool ing issues Due to the overwhelming concern that customers will have overheating issues on their Model Year 2002 500 600 VES EDGE Snowmobile Polaris has decided to extend the warranty coverage regarding cooling on all 2002 model 500 600 VES EDGE snowmobiles with or without M 10 suspensions The following breaks down the steps in detail that MUST be performed The most important fact that we want to convey is that there is not just one fix for these overheating issues These steps need to take place to overcome the overheating scenario If all of these steps are taken and they are done thor oughly and completely these snowmobiles should run correctly the whole winter with adequate snow conditions Mar ginal snow conditions may still cause overheating issues The cooling warranty coverage on these units will expire on April 30 2003 to accommodate the 2002 2003 riding sea son Dealers may perform SAF 02 03 on any 500 600 VES EDGE model with or without M 10 suspensions Again this offer expires A2. d coolant to fill line if necessary Our testing has shown that after the machine has cooled down 3 ounces or more of cool IMPORTANT ALL LIQUID ant may have to be added This procedure should take approximately 15 COOLED SNOWMOBILES MUST BE minutes BLED DURING DEALER SET UP You may have to perform this operation more than one time The photos at right depict air in the rear crossover tube underneath the seat The top photo shows air remaining after one warm up cycle The bottom photo shows almost no air remaining after the second warm up cycle Note The clear tube shown in the photos has been installed for photogra phy purposes only Snow Team Tips Printed in USA 2 2002 Polaris Sales Inc August 2002 Step 4 Check the TPS specification and make sure it is between 3 9 and 4 0 volts at wide open throttle Use TPS tool PN 2201519 Order from SPX Tool Company Follow the procedure for testing the TPS in the appropriate Polaris Service Manual The TPS tool MUST be used to set the TPS correctly and accurately Step 5 Make sure track tension is set to specification Track tension specifications are 3 8 1 2 16 ahead of rear idler shaft with 10 lb weight for EDGE suspensions 3 4 1 16 ahead of rear idler shaft free hanging for M 10 suspensions NOTE Testing has shown that 1 track tension is desirable on M 10 models for reduced initial hyfax wear Step 6 Install new longer snow flap PN 5433521 1106 This longe
3. for warranty claim information Authorization will be required from the Polaris Technical Service Department SAF 02 04 is located and can be printed from the Service Bulletin section of the Dealer Website Warranty Claim Preparation File individual claims for each authorization number received PN 2202143 Snow Team Tips Printed in USA 4 2002 Polaris Sales Inc August 2002 SUMMARY MODELS AFFECTED 2002 500 XC SP EDGE 2002 500 XC SP with M 10 2002 600 XC SP EDGE 2002 600 XC SP with M 10 2002 600 Classic WHAT IS TO BE PERFORMED ON NON M 10 Models Perform the 10 step procedure in order outlined in this Team Tip for all models listed above that exhibit overheating problems File a warranty claim under the guidelines of Ser vice Alert Number SAF 02 03 WHAT IS TO BE PERFORMED ON MODELS WITH M 10 SUSPENSIONS Perform the 10 step procedure in or der outlined in this Team Tip for all models listed above that exhibit overheating problems File a warranty claim under the guidelines of Service Alert Number SAF 02 03 If the snowmobile still overheats after performing SAF 02 03 obtain warranty authorization and install cooler kit PN 2202143 File a claim under the guidelines of Service Alert Number SAF 02 04 WILL I NEED WARRANTY AUTHORIZATION You will NOT need warranty authorization to perform the 10 step procedure SAF 02 03 You WILL need warranty authorization to perform SAF 02 04 on models with M 10 suspen sions AFTER yo
4. iding it Without any snow reaching the cooling exchangers there is nothing to reduce operating temperatures People have reported that the snowmobile has overheated after the customer has stopped on the trail to read a map etc and left his snowmobile idle This idle period may be long enough for the sled to go into its overheat fail safe mode Rule of thumb If you stop turn the machine off Also remind your customers that if they do let the snowmobile idle too long and it starts to go into fail safe mode to aggres sively press the throttle so that more coolant starts to flow immediately Too many times people panic when their snowmobile starts to stutter because they are afraid something is wrong Generating immediate engine RPM will allow coolant to flow allowing the snowmobile to come out of its fail safe condition Step 10 If the TEMP light comes on but the engine is not overheating inspect the thermistor The thermistor should read 192 30 ohms at 212 F 100 C in a water bath Once you verify that step 1 and step 2 are not causing any issues inspecting the thermistor should be the third step The temperature thermis tor is easy to get to and removing it and testing it is easy if you have the right equipment Another option is to have a known good thermistor on hand and replace the one in question with the known good one Take the ma chine for a test ride trying to duplicate the riding situation that the customer has bee
5. n telling you about If the engine still shows signs of overheating continue to the next step If the snowmobile shows no signs of overheat ing replace the temperature thermistor Warranty Information After performing all of the above steps reference SAF 02 03 for warranty claim in formation SAF 02 03 is located and can be printed from the Service Bulletin section of the Dealer Website Warranty Claim Preparation File individual claims for each authorization number received TT Step 11 For 500 600 VES models with M 10 suspensions only The following is for 2002 500 600 EDGE with M 10 Suspension models only Also Reference Service Alert SAF 02 04 The possibility exists that after performing the steps listed previously some units with M 10 suspensions may still exhibit overheating issues in certain riding conditions If you find that the overheating issue still persists install kit PN 2202143 per SAF 02 04 You may only install this kit after SAF 02 03 has been performed and a warranty claim has been submitted You will need authorization from Polaris to install this kit to verify that SAF 02 03 has been performed on the unit Please perform all items thoroughly and completely Read and understand the kit instructions completely before attempting the procedure Parts Required Qty Part Description Part No 1 Cooler Kit EDGE 2202143 Warranty Information After installing Cooler Kit PN 2202143 reference SAF 02 04
6. occurs replace the original rear suspen sion torsion springs coil over spring for M 10 models with optional lighter springs Optional Lighter Rear Torsion Springs EDGE 7041629 067 L H 359 77 7041630 067 R H 359 77 3 76 2 mm Optional Lighter Rear Coil Over Spring M 10 WITH RIDER f 7042010 216 135 240 variable Obtain a ride in setting of 3 76 2 mm maximum from the bottom edge of the snow flap to the ground with the rider on the sled in full gear Step 8 Liquid cooled snowmobiles require adequate amounts of snow for cooling Hard snow windswept snow icy snow hard packed trails or marginal overall snow may be inadequate for proper cooling With the advent of long travel suspensions it is more difficult for adequate amounts of snow to reach the cooling extrusions to remove the heat generated by these engines and components We have found that most customer complaints were directly related to customers driving below 30 MPH on tight trails with minimal and or hard packed snow or ice Inspect the hi fax for excessive wear which may be an indication of snow and cooling conditions If the hi fax are worn it may be due to inadequate snow conditions Adequate cooling snow is a MUST for proper cooling Snow Team Tips Printed in USA 3 2002 Polaris Sales Inc August 2002 Step 9 Keep idle periods to a minimum We strongly recommend that your customers DO NOT leave their snowmobiles idle while they are not r
7. olds 12 psi Tension flap Tank pressure 500 XC SP Yes Yes Yes if Yes No Edge necessary 500 XC SP Yes Yes Yes if Yes Yes w M 10 necessary 600 XC SP Yes Yes Yes if Yes No Edge necessary 600 XC SP Yes Yes Yes if Yes Yes w M 10 necessary 600 Classic Yes Yes Yes if Yes Yes necessary Install cooler kit only if necessary Prior authorization required Snow Team Tips Printed in USA 5 2002 Polaris Sales Inc August 2002
8. ow the system to cool completely Fill the reservoir with coolant to the E aE maximum indicated mark and install the pressure cap nog jee warm up bleeding c Apply parking brake and run the engine at specified idle RPM until the ther mostat opens approximately 5 to 8 minutes NOTE t is important that the thermostat stays open When the thermostat opens it will draw in cold coolant from the heat exchangers and the cold coolant may close the ther mostat again Make sure the thermostat opens and stays open Once the thermostat is open tip the snowmobile slightly on its right side Cycle the RPM from idle to enough RPM 4000 to get coolant to flow but not enough RPM to engage the clutch This allows air to bleed from the rear crossover tube as shown in photos at right Then tilt the machine slightly on its left side so that the coolant bottle is the highest point in the cooling system Cycle the RPM from idle to enough RPM 4000 to get coolant to flow but not enough RPM to engage the clutch t is important to get enough cool ant flow to purge the air from the front close off cooler and observe this air reaching the bottle Place the snowmobile in its normal position and loosen the bleed screw at the top of the water outlet manifold until trapped air has been purged Tighten the bleed screw Turn off the machine and release parking brake Allow the system to cool completely Re check the coolant level after the cap has been removed and ad
9. pril 30 2003 Dealers may perform SAF 02 04 EDGE Cooler Kit Small Block PN 2202143 Installation on any 2002 500 600 VES model with M 10 suspensions only under warranty SAF 02 03 MUST be performed prior to installing the cooler kit outlined in SAF 02 04 You will need warranty authorization from a Polaris Technical Service Representative to per form SAF 02 04 regardless This offer also expires on April 30 2003 The following is for 2002 500 600 EDGE models with or without M 10 Suspensions Also Reference Service Alert SAF 02 03 These steps MUST be performed on every 500 600 EDGE with M 10 suspensions prior to installing cooling kit PN 2202143 The integrity of the cooling system will be compromised if it doesn t hold pressure If it does not hold the recommended pressure when warmed up the snowmobile will overheat Step 1 Inspect the coolant surge bottle to see if the sealing surface between the cap and bottle or the threads of the bottle is distorted or damaged If the coolant bottle is severely distorted due to heat replace the bottle with new coolant bottle PN 2520314 Inspect the threads on the coolant bottle thoroughly If the pressure cap has been installed and turned too far the seal ing surface has been damaged and the surge bottle WILL NOT hold pressure see photo at right If the threads of the surge bottle are damaged replace the bottle amage from turning cap O far onto bottle New Coolant Bot
10. r snow flap keeps snow in the tunnel lon ger enhancing cooling and helps to obtain and maintain the clearance required for adequate snow retention inside the tunnel IMPORTANT The possibility exists that the new snow flap PN 5433521 1106 may become damaged when operating unit in reverse or when backing unit off of a trailer Use cau tion to ensure snow flap does not curl under the tunnel when backing the snowmobile For units with reverse you can es ae use snow flap support PN 5812229 with 5 longer rivets ae Serene PN 7621418 J jf PN 5433521 1106 Step 7 After the new snow flap has been installed adjust the suspension ride in for the customer This procedure is outlined on the decal located on the underside of the hood any 2002 Snowmobile Owners Manual or Performance Service Manual PN 9917367 Our testing has shown that the clearance between the round and the bottom edge of the snow flap should be maximum of 3 inches 76 2 mm with the rider on the sled and in full gear Have the customer sit on the sled and adjust the suspension until there are 3 inches 76 2 mm or less of clearance between the ground and the bottom of the snow flap If you are unable to reach a maximum of 3 inches 76 2 mm of clearance install lighter weight springs NOTE lf the rider is a light person and the suspension is set too stiff there could be an overheat issue because the suspension will not collapse enough for snow to reach the rear strip coolers If this
11. tle PN 2520314 Snow Team Tips Printed in USA l 2002 Polaris Sales Inc August 2002 Step 2 Verify that the coolant system will hold at least 12 psi of pressure If the coolant surge bottle is not distorted and the sealing surface looks fine pressure test the coolant system If the cap cannot hold at least 12 psi of pressure the system will overheat very quickly The coolant may boil in an otherwise normal operating temperature range disrupting thermistor readings to the CDI box Test the cooling system as outlined below HOW TO PRESSURE TEST COOLANT BOTTLES 12 psi 1 With the pressure cap firmly in place remove the over flow tube 1 4 O D from the neck of the coolant bottle and insert the Mighty Vac hose in its place 2 Set the Mighty Vac to apply pressure with the selector lever and pump the gauge to the specified lbs for the pressure cap you are testing The gauge should indicate full pressure and then slowly release the pressure after speci fied pressure is reached If the bottle will not hold 12 psi replace the coolant bottle ame Over Flow Tube Faget i fate Cap Pressure Specification A ape a j Step 3 Bleed the system correctly and completely This is the most important step in this whole cooling system process We cannot stress enough the importance of proper cooling system bleeding The system should be bled of any trapped air using the following procedure 7 7 D f All
12. u have performed SAF 02 03 on that snowmobile and overheating problems still exist WHERE DO I FIND SAF 02 02 AND SAF 02 04 Both of these Service Alerts are located on the Dealer Website www polarisdealers com under Service amp Warranty Service Bulletins DO THESE SERVICE ALERTS EXPIRE Yes both Service Alerts expire April 30 2003 SUMMARY OF PROCEDURE STEPS Step 1 Inspect the coolant surge bottle to see if the sealing surface between the cap and bottle or the threads of the bottle is distorted or damaged Step 2 Verify that the coolant system will hold at least 12 psi of pressure Step 3 Bleed the system correctly and completely Step 4 Check the TPS specification and make sure it is between 3 9 and 4 0 volts at wide open throttle Step 5 Make sure track tension is set to specification Step 6 Install a new longer snow flap PN 5433521 1106 and 5 rivets PN 7621472 Step 7 Adjust the suspension ride in for the customer Step 8 Liquid cooled snowmobiles require adequate amounts of snow for cooling Step 9 Keep idle periods to a minimum Step 10 If the TEMP light comes on but the engine is not overheating inspect the thermistor Step 11 For 500 600 VES models with M 10 suspensions only Install Cooler Kit PN 2202143 Year 2000 Inspect Re Verify cool Verify TPS Adjust Adjust Install Inspect Install Model place Cool ing system spec Track Ride in longer snow thermistor Cooler Kit ant Surge h
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