2001 Polaris 500 XC SP SNOWMOBILE Service Repair Manual PDF

2001 HIGH PERFORMANCE
SERVICE MANUAL
Foreword
This manual is designed primarily for use by Polaris snowmobile service technicians in a properly equipped
shop. Persons using this manual should have a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. The technician should read the text and be famil-
iar with service procedures before starting the work. Certain procedures require the use of special tools. Use
only the proper tools, as specified. Cleanliness of parts and tools as well as the work area is of primary impor-
tance.
All references to left and right side of the vehicle are from the operator’s perspective when seated in a normal
riding position.
This manual includes procedures for maintenance operations, component identification and unit repair, along
with service specifications for the 2001 Polaris snowmobiles. A table of contents is placed at the beginning of
each chapter, and an alphabetic index is provided at the end of the manual for location of specific page
numbers and service information. Keep this manual available for reference in the shop area.
At the time of publication all information contained in this manual was technically correct. However, all
materials and specifications are subject to change without notice.
Comments or suggestions about this manual may be directed to: Polaris Sales Inc., Service Publications
Department, 2100 Hwy 55 Medina, Minnesota 55340.
2001 High Performance Snowmobile Service Manual (PN 9916690)
Copyright 2000 Polaris Sales Inc. Printed in U.S.A.
UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS
Throughout these instructions, important information is brought to your attention by the following symbols:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
DANGER
Failure to follow DANGER instructions will result in severe injury or death to the operator, bystander or person
inspecting or servicing the snowmobile.
WARNING
Failure to follow WARNING instructions could result in severe injury or death to the operator, bystander or
person inspecting or servicing the snowmobile.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid personal injury, or snowmobile or prop-
erty damage.
NOTE:
A NOTE provides key information to clarify instructions.
Trademarks
Polaris acknowledges the following products mentioned in this manual:
FLEXLOC, Registered Trademark of SPS Technologies

Loctite, Registered Trademark of the Loctite Corporation
STA-BIL, Registered Trademark of Gold Eagle
FOX, Registered Trademark of Fox Shox
Nyogel, Trademark of Wm. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity Vac, Registered Trademark of Neward Enterprises, Inc.
Ammco, Registered Trademark of Ammco Tools, Inc.
Torx, Registered Trademark of Textron
Hilliard, Trademark of the Hilliard Corporation
Willwood, Trademark of the Willwood Corporation
Foreword
Welcome to the 2001 Polaris racing season! Thank you for selecting Polaris as your racing machine.
The enclosed technical information, which is based on our past experience, should be reviewed by your team
for machine preparation. Do not feel that these suggestions are a must, but use them as a starting point. This
information has been outlined with reference to the sections in our 2001 Snowmobile Service Manuals. You
will want to refer to them regularly to ensure correct procedures are followed.
The section index enables the user to quickly locate the component unit section desired. A table of contents is
placed at the beginning of each chapter to aid the user in locating general areas of information. Keep this
manual available for reference.
In order to provide you with the best support possible, Polaris racing, engineering, and testing department
personnel must have timely and accurate data from the field. The weekly racing report form is a valuable
source of this data. As a part of the Polaris team, your input is highly valued and never ignored.
A Race Report Form is included with this manual for your convenience. We request that you fill out the race
forms and return them by mail or facsimile (715)355--8797 within 48 hours after every race. We want to read
or hear all of your comments, so feel free to use the back of the form or attach another sheet if necessary.
Even if you aren’t on the race program, please send us your comments.
At Polaris, we are committed to your racing effort. We wish you the best of luck in the season ahead!
CHAPTER INDEX
CHAPTER 1 . . . . . . . . . . . . . . . . General Information
CHAPTER 2 . . . . . . . . . . . . . . . . Engines
CHAPTER 3 . . . . . . . . . . . . . . . . Fuel / Carburetion
CHAPTER 4 . . . . . . . . . . . . . . . . Drive / Driven Clutches
CHAPTER 5 . . . . . . . . . . . . . . . . Chassis, Brakes and

Final Drive
CHAPTER 6 . . . . . . . . . . . . . . . . Front Suspensions
CHAPTER 7 . . . . . . . . . . . . . . . . Rear Suspensions
CHAPTER 8 . . . . . . . . . . . . . . . . Electrical/Wiring
Diagrams
CHAPTER 1
GENERAL INFORMATION
1
High Performance parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1--1.2

Initial Break--In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
Race Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
Publication numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5--1.6
Specifications, XCF SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8--1.9
Specifications, 440 EDGE Pro X . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10--1.1
Specifications, 600 EDGE Pro X . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12--1.13
Specifications, 500 XC EDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14--1.15
Specifications, 500 XC SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16-1.17
Specifications, 600 XC SP, EDGE X . . . . . . . . . . . . . . . . . . . . . . . . . 1.18--1.19
Specifications, 700 XC SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20--1.21
Specifications, 800 XC SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22--1.23
Specifications, 800 XCR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.24--1.25
Specifications, 500 RMK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.26--1.27
Specifications, 800 RMK, S.C. SP . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.32--1.33
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.34
Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.35
Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.36
Tap Drill Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.37
Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.38--1.40
General Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.41
General Set Up Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.42--1.49
GENERAL INFORMATION
PART DESCRIPTION
NUMBER
PART DESCRIPTION
Fox Shocks
NUMBER
2900153 REMOTE RESERVOIR REAR TRACK (RACE)
2900152 REMOTE RESERVOIR REAR TRACK (TRAIL)

2900049 XTRA LITE COMPETITION PACKAGE
Clutch Components
2900068 TORSION BAR,9/16”, 2000--01 EDGE
2900178 ROLLER DRIVEN CLUTCH
Roller Clutch Components 2900069 TORSION BAR,5/8”, 2000--01 EDGE

2900169 HELIX,DRIVEN, 34--DEG,ROLLER
2900071 Lightweight Sway Bar Kit Tubular (5/8 EDGE 00--01)
2900177 HELIX,DRIVEN, R3,ROLLER
2900172 HELIX,DRIVEN, R12, ROLLER

2900070 Lightweight Sway Bar Kit Tubular (5/8 RMK 00--01)
2900176 HELIX,DRIVEN, R4, ROLLER 2900183 Lighweight Sway Bar Kit,5/8” Tubular, 01 EDGE Racer
2900170 HELIX,DRIVEN, 36--DEG, ROLLER

2900184 Lightweight Sway Bar Kit Tubular, 9/16”, (01 EDGE Racer)
2900171 HELIX,DRIVEN, R32, ROLLER 2900156 KIT--IDLER WHEEL,4TH

5521587--309 EDGE EXTRA WIDE RAIL SLIDERS (01 EDGE Racer)
Button Clutch Components
2900034 Ramp, driven, 40--36 Combo 5521556--309 EDGE EXTRA WIDE RAIL SLIDERS (00--01 EDGE)
2900035 Ramp, driven, R1, 40--32

2900067 TIE DOWN KIT,HOOD
2900036 Ramp, driven, 42--32
2900037 Ramp, driven, R3, 45--32 Hood/Seat
2900038 Ramp, driven, R4, 50--32

2900129--293 Lightweight Composite Hood EDGE Racing (Red)
2900039 Ramp, driven, R5, 40--34
2900040 Ramp, driven, R6, 42--34 2900128--070 Lightweight Composite Hood RMK (Black)
2900041 Ramp, driven, R7, 45--34

2900128--293 Lightweight Composite Hood RMK (Red)
2900042 Ramp, driven, R8, 50--34
2900043 Ramp, driven, R9, 40--36 2900128--246 Lightweight Composite Hood RMK (Rigel Blue)
2900044 Ramp, driven, R10, 42--36

2900124 Lightweight Seat RMK
2900045 Ramp, driven, R11, 45--36
2900046 Ramp, driven, R32, 50--34 2900181 Lightweight Seat EDGE
2900047 Ramp, driven, R12, 50--36

Torsion Spring Kits (90
2900048 Ramp, driven, 42 / 36 / 34
Weights 2900063 TORSION SPRING KIT .347, 90 Deg. Square

2900026 WEIGHT,SHIFT,MATCHED,10--60
2900064 TORSION SPRING KIT .359, 90 Deg. Square
2900028 WEIGHT,SHIFT,MATCHED,10--54 2900065 TORSION SPRING KIT .375, 90 Deg. Square

Belts
3211086 Belt, Close Tolerance Standard Compound, EDGE 2900095 TORSION SPRING KIT .347, 77 Deg. Square
3211087 Belt, Close Tolerance CVT Compound, EDGE
Engine Kits
2900151 HIGH ALTITUDE HEAD (2000 800 RMK)
2900127 Electric E.V. Kit (500 E.V. Engines)
2900126 Electric E.V. Kit (600 E.V. Engines) 2900098 TORSION SPRING KIT .405, 77 Deg. Square
1.1
GENERAL INFORMATION
2900002 18 Tooth HYVO, Cut Metal Gear
2900138 43 Tooth, Lightweight Cut Metal Gear, HYVO
2900025 Lightweight Jackshaft Kit
HYVO Chain
3221108 Chain HYVO, 76 PITCH
Motor Mounts
2900180 MOTOR--MOUNT,KIT,AGGR,TRAIL,65 EDGE
2900179 MOTOR--MOUNT,KIT, DRAG,65 EDGE
2900020 MOTOR--MOUNT,KIT,AGGR,TRAIL,70D
2900021 MOTOR--MOUNT,KIT,DRAG,90D
2900023 MOTOR--MOUNT,KIT,AGGR,TRAIL,70D
Tracks
2900019 TRACK,121”X1.5 --NOTCHED
2900018 TRACK,121”X--1.75 --NOTCHED
2900017 TRACK,121X2” NOTCHED
5411825 TRACK--121”X15”X1”MOD LIGHTNING
5411963 TRACK--121X1.25 SHOCKWAVE
5411994 TRACK--121X15X1,SHOCKWAVE
5411995 TRACK--144”X2” Series 3 (Hard Lug)
1.2
GENERAL INFORMATION
Polaris’ new 440 Edge Pro X and XCF SP edge models have been designed and tested to endure the toughest
of all races. Many hours of testing have gone into development, and engineering has decided to use a predeter-
mined weight rider and snow cross racing for stock setup. After uncrating your machine, be sure to test ride so
setup can be determined for your riding style and characteristics. The following are setup tips for your brand new
440 Edge Pro X or XCF SP.
1. Stock suspension setup for the 2001 440/600 Pro X and XCF SP is geared to a 170 lb (77.18 kg) pro rider.
2. Stock carburetion, clutching and gearing is for 0-3000 ft. (0-900 m).
3. In this manual, there are numerous optional springs, optional carburetor jets, optional clutch weights, and
optional gears to suit your riding preference and location. When changing to optional parts, always test what
you have done. Do not be afraid to experiment.
4. Be sure to use good quality studs and a pattern to maximize your traction and safety.
Break-in
The new 440/600 Edge Pro X and XCF SP are high performance snowmobiles, and break-in is a vital step to
ensure the performance of your machine will be at its peak.
1. Always break-in any new part for 50-75 miles before using it for racing.
2. Clutch springs and belts need to be broken in to reach their peak in performance.
3. On the 440 Edge Pro X, always use the correct type of fuel for the timing system you are using.
4. Always use the recommended Polaris oil for your snowmobile.
5. Always break-in a new or rebuilt engine to ensure durability.
6. Maintain your exhaust valves frequently to ensure they are operating to their fullest capability.
440 Jetting for Temperature and Altitude
1.3
GENERAL
GENERAL INFORMATION
INFORMATION
South Side Race Support:
Contact: Bruce Gaspardi
546 Curran Hwy.
North Adams, MA 01247
Phone: (413) 664-7111
Racing: Cross country, Snowcross
Service Capabilities: OEM parts, Foxt shock rebuilding and valving, lubricants, Woody’s traction products,
clutch disassembly tools mounted in trailer, Hot Seat clutch parts, OEM clutch parts, NGK spark plugs, miscella-
neous hardware.
Wahl Brothers Racing:

Contact: Dave
Hwy 11 West
Greenbush, MN 56726
Phone: (218) 782-2295
Racing: All
Service Capabilities: OEM parts, Foxt shock rebuilding and valving, lubricants, traction products, clutch disas-
sembly, miscellaneous hardware.
Karkoulas Racing:
Contact: Troy Karkoulas
S2225 Scugog Brock Town Line
Sunderland ON Canada L0C 1H0
Phone: (705) 357--1226
Racing: All
Polaris Racing
10303 Calumet Ave.
Suite # 3
Mosinee, WI 54455
Phone: (715) 355--5157
Fax: (715) 355--8797
1.4
GENERAL INFORMATION
2001 Publication Numbers
Model Model No. Owner’s Manual Parts Parts

Supplement Manual Microfiche
XCF S01NX4FS 9916161 9916162 9916163
440 Edge Pro X S01NX4CS 9916166 9916167 9916168
600 Edge Pro X S01NX6ES 9916884 9916885 9916886
500 XC SP S01NP5CS 9915889 9916040 9916041
600 XC SP / X S01NP6ES 9915623 9916153 9916154
700 XC SP S01NP7AS 9915929 9916090 9916091
800 XC SP S01NP8BS 9915925 9916110 9916111
600 RMK 136 S01SR6DS 9916022 9916023 9916024
700 RMK 136 S01SR7AS 9916027 9916028 9916029
800 RMK 144, 151 S01SM8BS 9916143, 9916148 9916144 9916145
800 XCR S01SB8AS 9916067 9916068 9916069
2000 Publication Numbers
Model Model No. Owner’s Manual Parts Parts

Supplement Manual Microfiche
XCF XC SP S00NX4FS 9915615 9915616 9915617
440 XC SP S00NX4CS 9915372 9915402 9915430
500 XC SP 45th S00SP5CS 9915373 9915403 9915431
Anniversary
600 XC SP S00SP6ES 9915374 9915404 9915432
700 XC SP S00SP7AS 9915377 9915407 9915435
600 RMK S00SR6DS 9915382 9915412 9915440
700 RMK S00SR7AS(A) 9915380 9915410 9915438
800 RMK S00SR8BS 9915381 9915411 9915439
800 XCR S00SB8AS 9915371 9915401 9915429
2001 Snowmobile Owner’s Manual (All) - 9915622
2000 Snowmobile Owner’s Manual (All) - 9915247
2000 High Performance Manual - 9915985
1.5
GENERAL
GENERAL INFORMATION
INFORMATION
Service Manuals
120 XC SP 2001 9916684
Trail Sport
2001 9916685
340 DLX, Indy 500 EDGE, SuperSport EDGE
Two-Up / Touring
Wide Trak LX, 340 Touring, Sport Touring, Sport Touring ES, 500 2001 9916686
Classic Touring, 600 Classic Touring
Trail Luxury
2001 9916687
500 Classic, 600 Classic, 700 Classic, 800 LE
Deep Snow
700 SKS, Trail RMK, 500/600/700/800 RMK, 800 RMK Snow- 2001 9916688
check Special
Performance
2001 9916689
500 XC, 500/600/700/800 XC SP, 600 EDGE X, 800 XCR
High Performance (Race)
440 XCF SP, 440/600 Edge Pro X, 500/600/700/800 XC SP, 2001 9916690
600/700/800 RMK, 800 XCR
Wallcharts 2001 9916692
2000 Snow Complete Set 2000 9915986

w/wallcharts (all models except
race)
Fan Cooled Models 2000 9915980
Mid Range Liquid Cooled (500s, 2000 9915981
600 triple)
Performance Liquids (600 2000 9915982
twins,700s, 800s)
120 XCR 2000 9915983
High Performance (Race) 2000 9915985
Wall Chart Packet only 2000 9915984
1.6
GENERAL INFORMATION
2001 Specifications
440 XCF SP
440 Edge Pro X
600 Edge Pro X
500 XC Edge
500 XC SP Edge
600 XC SP, X Edge
700 XC SP Edge
800 XC SP Edge
500 RMK
600 RMK
700 RMK
800 RMK, S.C. Special
1.7
GENERAL
GENERAL INFORMATION
INFORMATION
MODEL: . . . . . . . . . . XCF SP
MODEL NUMBER: . S01NX4FS
ENGINE MODEL: . . EC45PM022
JETTING CHART
AMBIENT TEMPERATURE
Altitude Below -20
-20F
F -20 to +10_F
-20_ +10 F +10 to +40_F
+10_to +40 F Above +40
+40_F
F
CARBURETION Below -29C -29_to -12_C -12_ to +5_C Above 5_C
Meters 0-900 PTO 360

Type . . . . . . . . . . . . . . . . VM34AL Mikuni (Feet) (0-3000)
PTO 340 PTO 320 PTO 300
MAG 350 MAG 330 MAG 310 MAG 290
Main Jet . . . . . . . . . . . . 340 PTO/330 MAG #3 #3 #3 #3
Pilot Jet . . . . . . . . . . . . . 45 900-1800 PTO 320 PTO 310 PTO 290 PTO 270
Jet Needle . . . . . . . . . . . 6DHK06--03 (3000-6000)
MAG 310 MAG 300 MAG 280 MAG 260
Needle Jet . . . . . . . . . . . Q-2(286) #3 #3 #3 #2
Cutaway . . . . . . . . . . . . 3.0 1800-2700
(6000-9000)
PTO 290 PTO 270 PTO 260 PTO 240
MAG 280 MAG 260 MAG 250 MAG 230
Air Screw . . . . . . . . . . . 1.0 Turns #3 #3 #2 #2
Valve Seat . . . . . . . . . . . 1.5 Viton 2700-3700 PTO 260 PTO 250 PTO 230 PTO 220
Fuel Octane (R+M/2) . 87 Non-Oxygenated or (9000-12000)
MAG 250 MAG 240 MAG 220 MAG 210
89 Oxygenated #3 #2 #2 #2
Throttle Gap XXX
#X
Under Cutaway . . . . . . .244〉 -(6.2mm) - # refers to the clip position from top of jet needle.
Idle Sync Gap
Under Cutaway . . . . . . .218〉 - (5.54mm) - Production Setting
CLUTCH CHART
DRIVE DRIVEN
CLUTCH Altitude Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Chaincase
Gearing
Type . . . . . . . . . . . . . . . . P-85 Meters 0-900 10-54 Almond/ Silver R5 22--43 P
Belt . . . . . . . . . . . . . . . . . 3211078 (Feet) (0-3000) Bushed Red Blue #-2 HYVO
Belt Width (Projected) . 1 7/16〉 900-1800 10-54 Almond/ Silver R5 22--43 74 P
(3000-6000) Bushed Red Blue #-2 HYVO
Side Angle (Overall) . . 28
22--43 74 P
Outside Circumference 56 5/8〉 1800-2700
(6000-9000)
10 Almond/
Red
Silver
Blue
R5
#-2 HYVO
Center Distance . . . . . . 11.50〉 22--43 74 P
2700-3700 Almond/ Silver R5
Shift Weights . . . . . . . . 10-54 (9000-12000)
10
Red Blue #-2 HYVO
Primary Spring . . . . . . . Almond Red
Secondary Spring . . . . Silver/Blue
Driven Helix . . . . . . . . . R5 #2
ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . Fan Cooled Cylinder Reed
Displacement . . . . . . . . . . . . . . . 438 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 2.579〉 (65.5mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.559〉 (65mm)
Piston / Cylinder Clearance . . . 0.0028〉 - 0.0041〉 (0.070 - 0.105 mm)
Piston Marking . . . . . . . . . . . . . . 4RA
Piston Ring Marking . . . . . . . . . 4N
Piston Ring End Gap . . . . . . . . 0.012 - 0.018 (.3 - .45 mm)
Head cc’s .4cc (Uninstalled) . . . . . . . . 24.2 cc
Head cc’s.4cc (Installed) . . . . . . . . . . . 21.2 cc
Operating RPM200 . . . . . . . . . 7750 RPM
Idle RPM200 . . . . . . . . . . . . . . 1600 RPM
Engagement RPM300 . . . . . . 4600 RPM
Cylinder Head Torque . . . . . . . . 18-19 ft.lbs (2.5-2.8 kg-m)
Cylinder Base Nut Torque . . . . 24-28 ft.lbs (3.3-3.9 kg-m)
Crankcase Torque (8mm) . . . . . 17-18 ft.lbs (2.2-2.3 kg-m)
Crankcase Torque (10mm) . . . 23-25 ft.lbs (3.2-3.5 kg-m)
Flywheel Torque . . . . . . . . . . . . . 60-65 ft.lbs (8.3-9 kg-m)
1.8
GENERAL INFORMATION
MODEL: . . . . . . . . . . XCF SP
MODEL NUMBER: . S01NX4FS
ENGINE MODEL: . . EC45PM022
ELECTRICAL CAPACITIES
Flywheel I.D. . . . . . . F004T32971 Fuel Tank . . . . . . . . . . 11.8 Gal. (45.4 L)
CDI Marking . . . . . . . 17620201 Oil Tank . . . . . . . . . . . . 3.5 Quarts (3.3 L)
Alternator Output . . . 240 Watts @ 4000 RPM Coolant . . . . . . . . . . . . N/A
Ignition Timing . . . . . 27 BTDC@3000RPM1.5 Chaincase Oil . . . . . . . 8 oz.
0.175〉 BTDC (0.157〉-0.195〉)
4.45mm BTDC (3.97-4.93mm)
Spark Plug / Gap . . . NGK BR9ES / 0.028” (0.7mm)
Lights: Head . . . . . . 2 60 High/50 Low
Tail . . . . . . . . 2@3 watts
Brake . . . . . . 18 watts
Voltage Regulator . . LR7
Electric Start . . . . . . . Option
*LR9= Half wave voltage regulator
SUSPENSION / CHASSIS CHAINCASE

Body Style . . . . . . . . EDGE Pro X Sprockets / Chain . . . 22-43, 74 P 3/4HYVO
Front Suspension . . EDGE Pro X Reverse . . . . . . . . . . . . Option
Front Shocks . . . . . . Arvin Ryde FXt Brake Pads . . . . . . . . . Type 81
IFS Spring Rate . . . . 130#/in. Chaincase Center Dist.7.658 (19.45cm)
Front Spring Preload 1.88〉 Thread Adjust Driveshaft Sprockets . 2 Drivers
Front Vertical Travel 9.36〉 (23.77 cm.) Brake Type . . . . . . . . . Polaris HPB
Rear Suspension . . . EDGE Pro X
Rear Travel . . . . . . . . 13.86〉 (35.20 cm.)
Front Track Shock . . Arvin Emulsiont
Spring Rate . . . . . . . . 170#/in.
Rear Track Shock . . Arvin Ryde FXt Clicker
Rear Springs . . . . . . .359〉 / 77
Track Type . . . . . . . . 15〉x121〉x.82〉 (38.1x307.34x2.08cm.)
Track Tension . . . . . . 1 1/2” (38mm) slack with 10# (4.54kg) weight 16” (40.64cm.) ahead of rear idler shaft
OPTIONAL REAR TORSION SPRINGS
2001 XCF SP/440 Edge Pro X Rear Torsion Springs

SOFT MEDIUM(STD) FIRM
.347〉(sq.) diameter/77 .359〉(sq.) diameter/77 .375〉(sq.) diameter/77
L.H 7041627-067 L.H. 7041629-067 L.H. 7041631-067
R.H. 7041628-067 R.H 7041630-067 R.H. 7041632-067
1.9
GENERAL
GENERAL INFORMATION
INFORMATION
MODEL: . . . . . . . . . . 440 Edge Pro X

MODEL NUMBER: . S01NX4CS
ENGINE MODEL: . . S44-44-PO 2093
JETTING CHART
AMBIENT TEMPERATURE
Altitude Below -20
-20F
F -20 to +10_F
-20_ +10 F +10 to +40_F
+10_to +40 F Above +40
+40_F
F
Below -29C -29_to -12_C -12_ to +5_C Above 5_C
CARBURETION Meters 0-900
0 900 390 370 340 320
(Feet) (0-3000)
(0 3000)
#3 #3 #3 #3
Type . . . . . . . . . . . . . . . . TMX-34 Mikuni
900-1800
900 1800 350 330 310 290
Main Jet . . . . . . . . . . . . 350 (3000-6000)
(3000 6000)
#3 #3 #3 #3
Pilot Jet . . . . . . . . . . . . . 22.5 1800-2700
1800 2700 320 300 280 260
Jet Needle . . . . . . . . . . . 6GL64--61--3 (6000-9000)
(6000 9000)
#3 #3 #3 #3
Needle Jet . . . . . . . . . . . Q-8 (Fixed) 2700-3700
2700 3700 280 270 250 230
(9000-12000)
(9000 12000)
Cutaway . . . . . . . . . . . . 2.5 #3 #3 #3 #3
Air Screw . . . . . . . . . . . 1.0 Turns XXX
#X
Valve Seat . . . . . . . . . . . 1.5 Viton - # refers to the clip position from top of jet needle.
Fuel Octane w/o Ethanol (R+M/2) 92 Octane Prem.
Unlead.
Throttle Gap
Under Cutaway . . . . . . .098〉(2.5 mm) CLUTCH CHART
(Engine side) DRIVE DRIVEN
Exhaust Valve Spring Red/White Altitude Shift Clutch Clutch Driven Chaincase
Weight Spring Spring Helix Gearing
CLUTCH Meters 0-900 Almond Blue/ R49 22:43
S53H
Type . . . . . . . . . . . . . . . . P-85 (Feet) (0-3000) Red Orange #2 74P
Belt . . . . . . . . . . . . . . . . . 3211080 900-1800
S51H Almond Blue/ R49 22:43
(3000-6000) Red Orange #3 74P
Belt Width (Projected) . 1.438〉 (34.93mm)
1800-2700 22:43
Side Angle (Overall) . . 28 (6000-9000)
S49H Almond
Red
Blue/
Orange
R49
#3 74P
Outside Circumference 46.625” (118.43cm.) 2700-3700 22:43
Almond Blue/ R49
Center Distance . . . . . . 11.5〉 (305mm) (9000-12000)
S49H
Red Orange #3 74P
Shift Weights . . . . . . . . S53H
Primary Spring . . . . . . . Almond/Red Note: Production main jet is a 350 for 92 octane
Secondary Spring . . . . Blue/Orange fuel. Do not run below 0_F at 0--1000 feet. Standard tim-
Driven Helix . . . . . . . . . R-49 #2
ing curve position = “D”.
Timing positions pg 2.12
Fine Tuning jetting chart p1.3
ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . Liquid Cooled Case Reed w/V.E.S.
Displacement . . . . . . . . . . . . . . . 438 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 2.598〉 (66mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.520〉 (64mm)
Piston / Cylinder Clearance . . . 0.0023〉 - 0.0037〉(0.06 - 0.095mm)
Service Limit . . . . . . . . . . . . . . . . 0.0059〉 (0.15mm)
Piston Marking . . . . . . . . . . . . . . EK2185/28
Piston Ring Marking . . . . . . . . . “o” faces upward
Piston Ring End Gap . . . . . . . . .008〉-.020〉(.20-.51mm)
Head cc’s (Uninstalled) . . . . . . . TBA
Head cc’s (Installed) . . . . . . . . . TBA
Idle RPM200 . . . . . . . . . . . . . . 1600 RPM
Cylinder Head Torque . . . . . . . . 20-24 ft.lbs(2.8-3.3 kgm)
Cylinder Base Nut Torque . . . . 30-34 ft.lbs(4.15-4.7 kgm)
Crankcase Torque (8mm) . . . . . 20-24 ft.lbs(2.8-3.3 kgm)
Crankcase Torque (10mm) . . . N/A
Flywheel Torque . . . . . . . . . . . . . 90 ft.lbs(12.4 kgm)
1.10
GENERAL INFORMATION
MODEL: . . . . . . . . . . 440 Edge Pro X

MODEL NUMBER: . S01X4CS
ENGINE MODEL: . . S44-44-PO 2093
Flywheel I.D. . . . . . . 4010523 Fuel Tank . . . . . . . . . . 11.8 Gal. (45.4 L)
Alternator Output . . . 280 Watts Coolant . . . . . . . . . . . . 4 Quarts (3.78 L)
.with pipe sensor unplugged
Spark Plug / Gap . . . Champion RN-57YCC / 0.028” (0.7mm) PN 3070190
Lights: Head . . . . . . 2 60High/50Low
Tail . . . . . . . . 2@2 watts
Brake . . . . . . 1@17 watts
Electric Start . . . . . . . N/A
*LR7= Full wave voltage regulator

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

L.H 7041627-067 L.H. 7041629-067 L.H. 7041631-067
R.H. 7041628-067 R.H 7041630-067 R.H. 7041632-067
1.11
GENERAL
GENERAL INFORMATION
INFORMATION
MODEL: . . . . . . . . . . 600 Edge Pro X

MODEL NUMBER: . S01NX6ES
ENGINE MODEL: . . S60--44--PO--6E--2234
CARBURETION JETTING CHART

Type . . . . . . . . . . . . . . . . (2) TM 38 Mikuni w/TPS AMBIENT TEMPERATURE
Main Jet . . . . . . . . . . . . 420 Altitude Below -20
-20F
F -20 to +10_F
-20_ +10 F +10 to +40_F
+10_to +40 F Above +40
+40_F
F
Below -29C -29_to -12_C -12_ to +5_C Above 5_C
Pilot Jet . . . . . . . . . . . . . 45
Meters 0-900 450 420 390 370
Jet Needle . . . . . . . . . . . J8--9DFH7-60-2 (F )
(Feet) (0-3000)
(0 3000)
#3 #3 #3 #3
Needle Jet . . . . . . . . . . . P-8
900-1800
900 1800 410 380 360 340
Cutaway . . . . . . . . . . . . 1.5 (3000-6000)
(3000 6000)
#3 #3 #3 #2
Air Screw . . . . . . . . . . . N/A 1800-2700
1800 2700 370 340 320 300
Valve Seat . . . . . . . . . . . 1.5 Viton (6000-9000)
(6000 9000)
#3 #3 #2 #2
Fuel Octane (R+M/2) . Key Switch Adjustable 2700-3700
2700 3700 320 310 290 270
(9000-12000)
(9000 12000)
Throttle Gap #3 #2 #2 #2
Under Cutaway . . . . . . .091”(2.3mm) XXX
Pilot Air Jet . . . . . . . . . . 0.7 Long #X
- # refers to the clip position from top of jet needle.
Starter Jet . . . . . . . . . . . 140
Fuel Screw . . . . . . . . . . 1.5 Turns - Production Setting
Exhaust Valve Spring . Green/Yellow
CLUTCH CHART
DRIVE DRIVEN
CLUTCH Altitude Shift Clutch Clutch Driven Chaincase
Type . . . . . . . . . . . . . . . . P-85
Meters 0-900 Almond Silver/ R11 24--41 74 P
Belt . . . . . . . . . . . . . . . . . 3211080 (Feet) (0-3000)
10 -58
10- 58
Red Blue #2 HYVO
Belt Width (Projected) . 1.438〉 (34.93mm) 900-1800 Almond Silver/ R11 24-41 74 P
10 -56
10- 56
Side Angle (Overall) . . 28 (3000-6000) Red Blue #2 HYVO
Outside Circumference 46.625“(118.43) 1800-2700
10 -54
10- 54 Almond Silver/ R11 24 41 74 P
(6000-9000)
Center Distance . . . . . . 11.5〉 (305mm) Red Blue #2 HYVO
Shift Weights . . . . . . . . 10--58 2700-3700

(9000-12000)
10 -54
10- 54 Almond Silver/ R11 24-41 74 P
Red Blue #3 HYVO
Primary Spring . . . . . . . Almond Red
Driven Helix . . . . . . . . . R-11 #2
ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . Liquid Cooled Case Reed w/VES Engine Compression . . . 120 psi
Displacement . . . . . . . . . . . . . . . 600cc Fuel Pump Manuf. . . . . . Walbro
Bore . . . . . . . . . . . . . . . . . . . . . . . 3.041〉 (77.25mm) Fuel Pump Mark . . . . . . . E-806
Stroke . . . . . . . . . . . . . . . . . . . . . 2.520 (64mm) Oil Pump Manuf. . . . . . . . Mikuni
Piston / Cylinder Clearance . . . .0045〉-.0059〉 (.11-.15mm) Oil Pump Mark . . . . . . . . 02A
Piston Marking . . . . . . . . . . . . . . 2202a Cylinder Head Mark . . . . 3022057
Piston Ring Marking . . . . . . . . . N/A
Piston Ring End Gap . . . . . . . . .014〉-.020〉 (.38-.51mm)
Head ccs (Uninstalled) . . . . . . . 36-37cc
Head ccs (Installed) . . . . . . . . . 29-30cc
Operating RPM200 . . . . . . . . . 8000
Idle RPM100 . . . . . . . . . . . . . . 1500
Engagement RPM200 . . . . . . 4800
Cylinder Head Torque . . . . . . . . 20-24 ft.lbs. (28-33 Nm)
Cylinder Base Nut Torque . . . . 30-34 ft.lbs. (41-47 Nm)
Crankcase Torque (8mm) . . . . . 20-24 ft.lbs. (28-33 Nm)
Flywheel Torque . . . . . . . . . . . . . 90 ft.lbs. (124 Nm)
1.12
GENERAL INFORMATION
MODEL: . . . . . . . . . . 600 Edge Pro X

MODEL NUMBER: . S01NX6ES
ENGINE MODEL: . . S60--44--PO--6E2234
Flywheel I.D. . . . . . . 4060223 Fuel Tank . . . . . . . . . . 11.8 Gal. (45.4 L)
Alternator Output . . . 280 Watts Coolant . . . . . . . . . . . . 4 Quarts (3.78 L)
.Spark Plug / Gap . . Champion RN-57YCC / 0.025” (0.7mm)
Lights: Head . . . . . . 2 60High/50 Low
Tail . . . . . . . . 2@2 watts
Brake . . . . . . 1@17 watts
Electric Start . . . . . . . N/A

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

L.H 7041627-067 L.H. 7041629-067 L.H. 7041631-067
R.H. 7041628-067 R.H 7041630-067 R.H. 7041632-067
1.13
GENERAL
GENERAL INFORMATION
INFORMATION
MODEL: . . . . . . . . . . INDY 500 XC EDGE

MODEL NUMBER: . S01NP5AS
ENGINE MODEL: . . S5044POA1-1947
JETTING CHART
AMBIENT TEMPERATURE
Altitude Below -20
-20F
F -20 to +10_F
-20_ +10 F +10 to +40_F
+10_to +40 F Above +40
+40_F
F
Meters 0-900
0 900 410 390 370 340
Type . . . . . . . . . . . . . . . . (2) TM 38 Mikuni (Feet) (0-3000)
(0 3000)
#2 #2 #2 #2
Main Jet . . . . . . . . . . . . 390 900-1800
900 1800 380 350 330 310
Pilot Jet . . . . . . . . . . . . . 40 (3000-6000)
(3000 6000)
#2 #2 #2 #1
Jet Needle . . . . . . . . . . . 9EFHI-60-2 1800-2700
1800 2700 340 320 300 280
(6000-9000)
(6000 9000)
Needle Jet . . . . . . . . . . . P-6 #2 #2 #1 #1
Cutaway . . . . . . . . . . . . 1.5 2700-3700
2700 3700
(9000-12000)
(9000 12000)
300 280 270 250
#2 #1 #1 #1
Fuel Screw . . . . . . . . . . 1.5 Turns
Valve Seat . . . . . . . . . . . 1.5 Viton XXX
#X
Fuel Octane (R+M/2) . 87 Non-Oxygenated or - # refers to the clip position from top of jet needle.
89 Oxygenated
Throttle Gap - Production Setting
Under Cutaway . . . . . . 0.098〉 (2.5mm)
Starter Jet . . . . . . . . . . . 145
Pilot Air Jet . . . . . . . . . . 0.7 Long CLUTCH CHART
DRIVE DRIVEN
Altitude Shift Clutch Clutch Driven Chaincase
CLUTCH Weight Spring Spring Helix Gearing
Meters 0-900 Dark Blue / R-32 22-40-74P
10 54
10-54 Silver
Type . . . . . . . . . . . . . . . . P-85 (Feet) (0-3000) White #2 HYVO
Belt . . . . . . . . . . . . . . . . . 3211080 900-1800
10 54
10-54 Dark Blue / Silver R-32 21-40-74P
(3000-6000)
Belt Width (Projected) . 1.438〉 (36.52mm) White #3 HYVO
Side Angle (Overall) . . 28 1800-2700

(6000-9000)
10 AL Dark Blue / Silver / R-32 20-40-74P
White Blue #1 HYVO
Outside Circumference 46.625〉
2700-3700 Dark Blue / Silver / R-32 20-40-74P
Center Distance . . . . . . 11.50 (9000-12000)
10
White Blue #1 HYVO
Shift Weights . . . . . . . . 10-54
Primary Spring . . . . . . . Dark Blue / White
Secondary Spring . . . . Silver
Driven Helix . . . . . . . . . R-32 #2
ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . Liquid Cooled Case Reed Engine Compression . . . 125 psi
Bore . . . . . . . . . . . . . . . . . . . . . . . 2.776〉 (70.5mm) Fuel Pump Mark . . . . . . . FPA-3
Stroke . . . . . . . . . . . . . . . . . . . . . 2.520〉 (64mm) Oil Pump Manuf. . . . . . . . Mikuni
Piston / Cylinder Clearance . . . 0.0045〉 - 0.0063〉 (0.11 - 0.16mm) Oil Pump Mark . . . . . . . . 01B
Service Limit . . . . . . . . . . . . . . . . N/A Cylinder Head Mark . . . . 3021048
Piston Marking . . . . . . . . . . . . . . EK 2205
Piston Ring End Gap . . . . . . . . 0.012〉 - 0.018〉 (0.30 - 0.46mm)
Head ccs (Uninstalled) . . . . . . . 27.50.5cc
Head ccs (Installed) . . . . . . . . . 24.4cc
Idle RPM200 . . . . . . . . . . . . . . 1500 RPM
1.14
GENERAL INFORMATION
MODEL: . . . . . . . . . . INDY 500 XC EDGE

MODEL NUMBER: . S01NP5AS
Flywheel I.D. . . . . . . Kokusan 4060223 Fuel Tank . . . . . . . . . . 11.8 gallons (44.7 liters)
CDI Marking . . . . . . . 4010438 Oil Tank . . . . . . . . . . . . 4 quarts (3.8 liters)
Alternator Output . . . 280 Watts Coolant . . . . . . . . . . . . 4 quarts (3.8 liters)
Ignition Timing . . . . . 12 BTDC@3000RPM1.5 Chaincase Oil . . . . . . . 11 fl. oz.(325cc)
0.343〉 BTDC (0.008〉)
0.872mm BTDC (0.208mm)
Spark Plug / Gap . . . Champion RN57YCC / 0.025〉 (0.64mm)
Lights: Head . . . . . . PN 2870448 (x2)
Tail . . . . . . . . PN 4030024 (x2)
Brake . . . . . . PN 4030045 (x1)
Voltage Regulator . . T1
Magneto Pulses . . . . 6

Body Style . . . . . . . .
EDGE Sprockets / Chain . . . 22-40, 74P HYVO
Front Suspension . .EDGE Reverse . . . . . . . . . . . . Option
Front Shocks . . . . . .
Indy Select Brake Pads . . . . . . . . . Type 81, Large
IFS Spring Rate . . . .
100#/in. Chaincase Center Dist.7.92〉 (20.12cm.)
Front Spring Preload1/4〉 Thread Adjust Driveshaft Sprockets . 2 Drivers Wide
Front Vertical Travel
10〉 (25.4cm.) Brake Type . . . . . . . . . Polaris HPB, Liquid Cooled
Rear Suspension . . .
Improved Travel EDGE
Rear Axle Travel . . .
13.9〉 (35.3cm.)
Front Track Shock . .
FOX IFP
Spring Rate . . . . . . . .
200#/in. variable
Rear Track Shock . .Position Sensitive
Rear Springs . . . . . .
.375〉 (sq.) / 77
Track Type . . . . . . . .
15〉x121〉x.82〉 (38.1x307.34x2.08cm.)
Track Tension . . . . . .
3/8〉 - 1/2〉 (1-1.3 cm.) slack with 10# (4.54kg) weight 16〉 (40.64cm.) ahead of rear idler
shaft.
Overall Snowmobile Length . . . . . . . . . . . . . . . . . 113〉 (287cm.)
Overall Snowmobile Height . . . . . . . . . . . . . . . . . 45〉 (114cm.)
Maximum Snowmobile Width . . . . . . . . . . . . . . . 48〉 (122cm.)

.359〉(Sq.) Diameter x 77 .375〉(Sq.) Diameter x 77 .405〉(Sq.) Diameter x 77
L.H . 7041629-067 L.H. 7041942-067 L.H. 7041940-067
R.H. 7041630-067 R.H. 7041943-067 R.H. 7041941-067
1.15
GENERAL
GENERAL INFORMATION
INFORMATION
MODEL: . . . . . . . . . . INDY 500 XC SP EDGE

MODEL NUMBER: . S01NP5CS (A, B)
JETTING CHART
AMBIENT TEMPERATURE
Altitude Below -20
-20F
F -20 to +10_F
-20_ +10 F +10 to +40_F
+10_to +40 F Above +40
+40_F
F
Meters 0-900
0 900 420 400 380 350
Type . . . . . . . . . . . . . . . . (2) TM 38 w/TPS Mikuni (Feet) (0-3000)
(0 3000)
#3 #3 #3 #3
Main Jet . . . . . . . . . . . . 400 900-1800
900 1800 390 360 340 320
Pilot Jet . . . . . . . . . . . . . 40 (3000-6000)
(3000 6000)
#3 #3 #3 #2
Jet Needle . . . . . . . . . . . 9EFH01-60-3 1800-2700
1800 2700 350 330 310 290
(6000-9000)
(6000 9000)
Needle Jet . . . . . . . . . . . P-6 #3 #3 #2 #2
Cutaway . . . . . . . . . . . . 1.5 2700-3700
2700 3700
(9000-12000)
(9000 12000)
310 290 270 260
#3 #2 #2 #2
Fuel Screw . . . . . . . . . . 1.25 Turns
#X
Fuel Octane (R+M/2) . Key Switch Adjustable - # refers to the clip position from top of jet needle.
91 Premium
89 Regular - Production Setting
Throttle Gap
Under Cutaway . . . . . . 0.0787〉 (2.0mm)
Starter Jet . . . . . . . . . . . 145 CLUTCH CHART
Pilot Air Jet . . . . . . . . . . 0.7 Long DRIVE DRIVEN
Exhaust Valve Spring . Purple / White Altitude Shift Clutch Clutch Driven Chaincase
Meters 22-40 74P
CLUTCH (Feet)
0-900
(0-3000)
10 54
10-54 Dark Blue /
White
Silver /
Blue
R-8
#2 HYVO
Type . . . . . . . . . . . . . . . . P-85 900-1800
10 AL Dark Blue / Silver / R-8 22-40 74P
(3000-6000) White Blue #3 HYVO
Belt . . . . . . . . . . . . . . . . . 3211080
21-40 74P
Belt Width (Projected) . 1.438〉 (36.52mm) 1800-2700
(6000-9000)
10M Dark Blue /
White
Silver /
Blue
R-8
#3 HYVO
Side Angle (Overall) . . 28 21-40 74P
2700-3700 Dark Blue / Silver / R-8
Outside Circumference 46.625〉 (9000-12000)
10B
White Blue #3 HYVO
Center Distance . . . . . . 11.50〉
Shift Weights . . . . . . . . 10-54
Primary Spring . . . . . . . Dark Blue / White
Secondary Spring . . . . Silver / Blue
Driven Helix . . . . . . . . . R-8 #3
ENGINE
Piston / Cylinder Clearance . . . 0.0045〉 - 0.0055〉 (0.11 - 0.14mm) Oil Pump Mark . . . . . . . . 06
Piston Marking . . . . . . . . . . . . . . 2252c
Head ccs (Installed) . . . . . . . . . 25.20.5cc
Idle RPM200 . . . . . . . . . . . . . . 1500 RPM
1.16
GENERAL INFORMATION

MODEL NUMBER: . S01NP5CS (A, B)
With TPS Unplugged.
0.0944〉 (0.0811 - 0.11)
2.3986mm (2.0584 - 2.7664)
Lights: Head . . . . . . PN 2870448 (x2)
Tail . . . . . . . . PN 4030024 (x2)
Brake . . . . . . PN 4030045 (x1)

Body Style . . . . . . . .
EDGE Sprockets / Chain . . . 22-40-74P HYVO
Fox IFP Brake Pads . . . . . . . . . Type 81, Large
68/160#/in. Chaincase Center Dist.7.92〉 (20.12cm.)
Front Spring Preload1 3/4〉 Thread Adjust Driveshaft Sprockets . 2 Drivers Wide
10.3〉 (26.2cm.) Brake Type . . . . . . . . . Polaris HPB, Liquid Cooled
13.9〉 (35.3cm.)
Fox IFP
Spring Rate . . . . . . . .
160#/in. variable
.375〉 (sq.) / 77
Track Type . . . . . . . .
15〉x121〉x.91〉 (38.1x307.34x2.31cm.)
shaft.

L.H . 7041629-067 L.H. 7041942-067 L.H. 7041940-067
R.H. 7041630-067 R.H. 7041943-067 R.H. 7041941-067
1.17
GENERAL
GENERAL INFORMATION
INFORMATION
MODEL: . . . . . . . . . . INDY 600 XC SP EDGE / 600 EDGE X

MODEL NUMBER: . S01NP6ES (A, B, X)
JETTING CHART
AMBIENT TEMPERATURE
Altitude Below -20
-20F
F -20 to +10_F
-20_ +10 F +10 to +40_F
+10_to +40 F Above +40
+40_F
F
Type . . . . . . . . . . . . . . . . (2) TM 38 Mikuni w/TPS Meters 0-900

0 900
(0-3000)
(0 3000)
460 430 400 380
(Feet) #3 #3 #3 #3
Main Jet . . . . . . . . . . . . 430
900-1800
900 1800 410 390 360 340
Pilot Jet . . . . . . . . . . . . . 40 (3000-6000)
(3000 6000)
#3 #3 #3 #2
Jet Needle . . . . . . . . . . . 9DFH-60-3 1800-2700
1800 2700 370 340 310 290
Needle Jet . . . . . . . . . . . P-8 (6000-9000)
(6000 9000)
#3 #3 #2 #2
Cutaway . . . . . . . . . . . . 2.5 2700-3700
2700 3700 320 290 270 260
(9000-12000)
(9000 12000)
Air Screw . . . . . . . . . . . N/A #3 #2 #2 #2
Fuel Octane (R+M/2) . Key Switch Adjustable #X
Throttle Gap
Under Cutaway . . . . . . 0.0787〉 (2mm) - Production Setting
Pilot Air Jet . . . . . . . . . . 0.9 Long
Starter Jet . . . . . . . . . . . 140
Fuel Screw . . . . . . . . . . 1.5 Turns CLUTCH CHART
Exhaust Valve Spring . Pink DRIVE DRIVEN
Meters
Type . . . . . . . . . . . . . . . . P-85 (Feet)
0-900
(0-3000)
10 58
10-58 Dark Blue / Silver / R-11 23-39 74P
White Blue #2 HYVO
Belt . . . . . . . . . . . . . . . . . 3211080
Belt Width (Projected) . 1.438〉 (36.52mm) (3000-6000)
10 56
10-56
White Blue #2 HYVO
Side Angle (Overall) . . 28 1800-2700 Dark Blue / Silver / R-11 32-39 74P
10 54
10-54
Outside Circumference 46.625〉 (6000-9000) White Blue #2 HYVO
Center Distance . . . . . . 11.50〉 2700-3700
10 54
(9000-12000) White Blue #3 HYVO
Shift Weights . . . . . . . . 10-58
Primary Spring . . . . . . . Dark Blue/White
Driven Helix . . . . . . . . . R-11 #2
ENGINE
Bore . . . . . . . . . . . . . . . . . . . . . . . 3.041〉 (77.25mm) Fuel Pump Mark . . . . . . . E-806
Stroke . . . . . . . . . . . . . . . . . . . . . 2.520 (64mm) Oil Pump Manuf. . . . . . . . Mikuni
Piston / Cylinder Clearance . . . .0045〉-.0059〉 (.11-.15mm) Oil Pump Mark . . . . . . . . 02A
Piston Marking . . . . . . . . . . . . . . 2202a Cylinder Head Mark . . . . 3022057
Piston Ring End Gap . . . . . . . . .014〉-.020〉 (.38-.51mm)
Head ccs (Uninstalled) . . . . . . . 36-37cc
Head ccs (Installed) . . . . . . . . . 29-30cc
Operating RPM200 . . . . . . . . . 8000
Idle RPM100 . . . . . . . . . . . . . . 1400
Engagement RPM200 . . . . . . 4250
1.18
GENERAL INFORMATION
MODEL: . . . . . . . . . . INDY 600 XC SP EDGE / 600 EDGE X

MODEL NUMBER: . S01NP6ES (A, B, X)
Ignition Timing . . . . . 24 BTDC@3250RPM500 RPM Chaincase Oil . . . . . . . 11 fl. oz.(325cc)
With TPS unplugged
0.1350〉
3.430mm
Lights: Head . . . . . . PN 2870448 (x2)
Tail . . . . . . . . PN 4030024 (x2)
Brake . . . . . . PN 4030045 (x1)

Body Style . . . . . . . .
13.9〉 (35.3cm.)
Fox IFP
Spring Rate . . . . . . . .
160#/in. variable
.375〉 (sq.) / 77
Track Type . . . . . . . .
15〉x121〉x.91〉 (38.1x307.34x2.31cm.)
shaft.

L.H . 7041629-067 L.H. 7041942-067 L.H. 7041940-067
R.H. 7041630-067 R.H. 7041943-067 R.H. 7041941-067
1.19
GENERAL
GENERAL INFORMATION
INFORMATION

MODEL NUMBER: . S01NP7AS (A, B)
JETTING CHART
AMBIENT TEMPERATURE
Altitude Below -20
-20F
F -20 to +10_F
-20_ +10 F +10 to +40_F
+10_to +40 F Above +40
+40_F
F
Meters 0-900
0 900 490 460 430 400
Type . . . . . . . . . . . . . . . . (2) TM40 Mikuni (Feet) (0-3000)
(0 3000)
#2 #2 #2 #2
Main Jet . . . . . . . . . . . . 460 900-1800
900 1800 440 410 380 360
Pilot Jet . . . . . . . . . . . . . 45 (3000-6000)
(3000 6000)
#2 #2 #2 #1
Jet Needle . . . . . . . . . . . 9DFH06-57-2 1800-2700
1800 2700 390 360 330 310
(6000-9000)
(6000 9000)
Needle Jet . . . . . . . . . . . P-8 #2 #2 #1 #1
Cutaway . . . . . . . . . . . . 2.0 2700-3700
2700 3700
(9000-12000)
(9000 12000)
330 310 280 260
#2 #1 #1 #1
Fuel Screw . . . . . . . . . . 1.25 Turns
Valve Seat . . . . . . . . . . . 1.8 XXX
#X
89 Oxygenated
Under Cutaway . . . . . . 0.0787〉 (2.0mm)
Starter Jet . . . . . . . . . . . 145
DRIVE DRIVEN
Meters 0-900 10-60 Almond Silver / R-11 23-39 74P
Type . . . . . . . . . . . . . . . . P-85 (Feet) (0-3000) Bushed Round Blue #2 HYVO
Belt . . . . . . . . . . . . . . . . . 3211080 900-1800 10-58 Almond Silver / R-11 23-39 74P
(3000-6000)
Belt Width (Projected) . 1.438〉 (36.52mm) Bushed Round Blue #2 HYVO

(6000-9000)
10-56 Almond Silver / R-11 22-39 74P
Bushed Round Blue #3 HYVO
2700-3700 10-54 Almond Silver / R-11 22-39 74P
Center Distance . . . . . . 11.50〉 (9000-12000) Bushed Round Blue #3 HYVO
Shift Weights . . . . . . . . 10-60 Bushed
Primary Spring . . . . . . . Almond / Round
Driven Helix . . . . . . . . . R-11 #2
ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . Liquid Cooled Case Reed Twin Engine Compression . . . 125 psi
Bore . . . . . . . . . . . . . . . . . . . . . . . 3.1889〉 (81mm) Fuel Pump Mark . . . . . . . FPA-4
Piston / Cylinder Clearance . . . 0.0047〉 - 0.0060〉 (0.12 - 0.15mm) Oil Pump Mark . . . . . . . . 03A
Piston Marking . . . . . . . . . . . . . . 2108
Head ccs (Installed) . . . . . . . . . 31 - 32cc
Idle RPM200 . . . . . . . . . . . . . . 1500 RPM
Crankcase Torque (10mm) . . . 26-30 ft.lbs. (36-42 Nm)
1.20
GENERAL INFORMATION

MODEL NUMBER: . S01NP7AS (A, B)
0.0907〉 (0.077〉 - 0.11〉)
2.3036mm (2.0 - 2.7mm)
Lights: Head . . . . . . PN 2870448 (x2)
Tail . . . . . . . . PN 4030024 (x2)
Brake . . . . . . PN 4030045 (x1)

Body Style . . . . . . . .
68/160#/in. Chaincase Center Dist 7.92〉 (20.12cm.)
13.9〉 (35.3cm.)
Fox IFP
Spring Rate . . . . . . . .
160#/in. variable
.375〉 (sq.) / 77
Track Type . . . . . . . .
15〉x121〉x.91〉 (38.1x307.34x2.31cm.)
shaft.

L.H . 7041629-067 L.H. 7041942-067 L.H. 7041940-067
R.H. 7041630-067 R.H. 7041943-067 R.H. 7041941-067
1.21
GENERAL
GENERAL INFORMATION
INFORMATION

MODEL NUMBER: . S01NP8BS (A, B)
JETTING CHART
AMBIENT TEMPERATURE
Altitude Below -20
-20F
F -20 to +10_F
-20_ +10 F +10 to +40_F
+10_to +40 F Above +40
+40_F
F
Meters 0-900
0 900 490 460 430 400
Type . . . . . . . . . . . . . . . . (2) TM 40 Mikuni (Feet) (0-3000)
(0 3000)
#3 #3 #3 #3
Main Jet . . . . . . . . . . . . 460 900-1800
900 1800 440 420 390 370
Pilot Jet . . . . . . . . . . . . . 45 (3000-6000)
(3000 6000)
#3 #3 #3 #2
Jet Needle . . . . . . . . . . . 9EFY2-61-3 1800-2700
1800 2700 400 380 350 330
(6000-9000)
(6000 9000)
Needle Jet . . . . . . . . . . . P-8 #3 #3 #2 #2
Cutaway . . . . . . . . . . . . 2.0 2700-3700
2700 3700
(9000-12000)
(9000 12000)
360 340 320 300
#3 #2 #2 #2
Fuel Screw . . . . . . . . . . 1.75 Turns
Valve Seat . . . . . . . . . . . 1.8 XXX
#X
91 Premium
Throttle Gap
Under Cutaway . . . . . . 0.0787〉 (2.0mm)
Pilot Air Jet . . . . . . . . . . 0.7 Long DRIVE DRIVEN
Meters 0-900 Almond R-12 25-41 76P
10 64
10-64 Silver
Type . . . . . . . . . . . . . . . . P-85 Roller (Feet) (0-3000) Round #2 HYVO
Belt . . . . . . . . . . . . . . . . . 3211080 900-1800
10 62
10-62 Almond Silver R-12 25-41 76P
(3000-6000)
Belt Width (Projected) . 1.438〉 (36.52mm) Round #2 HYVO

(6000-9000)
10 60
10-60 Almond Silver R-12 25-41 76P
Round /Blue #2 HYVO
2700-3700 Almond Silver R-12 25-41 76P
Center Distance . . . . . . 11.50〉 (9000-12000)
10 58
10-58
Round /Blue #2 HYVO
Shift Weights . . . . . . . . 10-64
Primary Spring . . . . . . . Almond / Round
Secondary Spring Silver
Driven Helix . . . . . . . . . R-12 #2
ENGINE
Piston Marking . . . . . . . . . . . . . . 2261
Head ccs (Installed) . . . . . . . . . 36.0 - 37.0cc
Idle RPM200 . . . . . . . . . . . . . . 1300 RPM
1.22
GENERAL INFORMATION

MODEL NUMBER: . S01NP8BS (A, B)
Ignition Timing . . . . . 13 BTDC@3000500RPM Chaincase Oil . . . . . . . 11 fl. oz.(325cc)
0.0443〉
1.1251mm
Lights: Head . . . . . . PN 2870448 (x2)
Tail . . . . . . . . PN 4030024 (x2)
Brake . . . . . . PN 4030045 (x1)

Body Style . . . . . . . .
13.9〉 (35.3cm.)
Fox IFP
Spring Rate . . . . . . . .
160#/in. variable
.375〉 (sq.) / 77
Track Type . . . . . . . .
15〉x121〉x.91〉 (38.1x307.34x2.31cm.)
shaft.

L.H . 7041629-067 L.H. 7041942-067 L.H. 7041940-067
R.H. 7041630-067 R.H. 7041943-067 R.H. 7041941-067
1.23
GENERAL INFORMATION
MODEL: . . . . . . . . . . INDY 800 XCR

MODEL NUMBER: . S01SB8AS
ENGINE MODEL: . . EC79-PL013
JETTING CHART
AMBIENT TEMPERATURE
Altitude Below -20
-20F
F -20 to +10_F
-20_ +10 F +10 to +40_F
+10_to +40 F Above +40
+40_F
F
Meters 0-900
0 900 460 440 420 390
Type . . . . . . . . . . . . . . . . (3) TM 38Mikuni (Feet) (0-3000)
(0 3000)
#3 #3 #2 #2
Main Jet . . . . . . . . . . . . 440 900-1800
900 1800 420 400 380 350
Pilot Jet . . . . . . . . . . . . . 50 (3000-6000)
(3000 6000)
#3 #3 #2 #2
Jet Needle . . . . . . . . . . . 9DH6-54-3 1800-2700
1800 2700 380 360 340 320
(6000-9000)
(6000 9000)
Needle Jet . . . . . . . . . . . P-4 Fixed #3 #2 #2 #2
Cutaway . . . . . . . . . . . . 2.0 2700-3700
2700 3700
(9000-12000)
(9000 12000)
340 320 300 280
#2 #2 #2 #2
Idle Mixture Screw . . . . 0.75 Turns
#X
91 Premium
Throttle Gap
Under Cutaway . . . . . . 0.059〉 (1.5mm)
Pilot Air Jet . . . . . . . . . . 0.9 DRIVE DRIVEN
Exhaust Valve Spring . Blue Altitude Shift Clutch Clutch Driven Chaincase
Meters 0-900 10-60 Silver / R-12 24-39 70P
CLUTCH (Feet) (0-3000) Bushed
Almond
Blue #2 HYVO
Type . . . . . . . . . . . . . . . . P-85 900-1800

(3000-6000)
10-58 Almond Silver / R-12 24-39 70P
Bushed Blue #2 HYVO
Belt . . . . . . . . . . . . . . . . . 3211075
1800-2700 10-58 Silver / R-12 23-41 70P
Belt Width (Projected) . 1.438〉 (36.52mm) (6000-9000) Bushed
Almond
Blue #2 HYVO
Side Angle (Overall) . . 28 2700-3700 10-56 Silver / R-12 23-41 70P
Almond
Outside Circumference 47.625〉 (9000-12000) Bushed Blue #2 HYVO
Shift Weights . . . . . . . . 10-60 Bushed
Primary Spring . . . . . . . Almond
Driven Helix . . . . . . . . . R-12 #2
ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . L/C Case Reed Triple w/VES Engine Compression . . . 140 psi
Displacement . . . . . . . . . . . . . . . 794cc Fuel Pump Manuf. . . . . . Mikuni
Bore . . . . . . . . . . . . . . . . . . . . . . . 2.8346〉 (72mm) Fuel Pump Mark . . . . . . . DF62
Service Limit . . . . . . . . . . . . . . . . 0.0078〉 (0.20mm) Cylinder Head Mark . . . . N / 79
Piston Marking . . . . . . . . . . . . . . 79B
Piston Ring Marking . . . . . . . . . 79A
Head ccs (Uninstalled) . . . . . . . 28.1cc
Idle RPM200 . . . . . . . . . . . . . . 1500 RPM
Cylinder Head Torque . . . . . . . . 18-19.5 ft.lbs. (25-27 Nm)
Flywheel Torque . . . . . . . . . . . . . 60-65 ft.lbs. (83-90 Nm)
1.24
GENERAL INFORMATION
MODEL: . . . . . . . . . . INDY 800 XCR

MODEL NUMBER: . S01SB8AS
ENGINE MODEL: . . EC79-PL013
Flywheel I.D. . . . . . . FP9103 Fuel Tank . . . . . . . . . . 11.8 gallons (44.7 liters)
CDI Marking . . . . . . . CU7312 Oil Tank . . . . . . . . . . . . 2.4 quarts (2.3 liters)
0.163〉 BTDC (0.008〉)
4.138mm BTDC (0.021mm)
Spark Plug / Gap . . . Champion RN2C / 0.028〉 (0.7mm)
Lights: Head . . . . . . Low: PN 2870448 (x1), High: PN 4010253 (x2)
Tail . . . . . . . . PN 4032084 (x2)
Brake . . . . . . PN 4030045 (x2)

Body Style . . . . . . . .
Gen II Sprockets / Chain . . . 24-39-70P HYVO
Front Suspension . .Indy XC-10 Reverse . . . . . . . . . . . . Option
120#/in. Chaincase Center Dist.7.05〉 (17.91cm.)
Front Spring Preload1 7/8〉 Thread Adjust Driveshaft Sprockets . 4 Drivers
10〉 (25.4cm.) Brake Type . . . . . . . . . Polaris HPB, Liquid Cooled
XTRA-10 121〉
10.2〉 (25.9cm.)
Fox IFP
Spring Rate . . . . . . . .
200#/in. variable
Rear Track Shock . .Electronic Adjustable Shock
.359〉 (sq.) / 77
Track Type . . . . . . . .
15〉x121〉x.91〉 (38.1x307.34x2.31cm.)
shaft.

L.H. 7041763-067 L.H. 7041629-067 L.H. 7041631-067
R.H. 7041764-067 R.H. 7041630-067 R.H. 7041632-067
1.25
GENERAL INFORMATION
MODEL: . . . . . . . . . . INDY 500 RMK

MODEL NUMBER: . S01SR5AS
ENGINE MODEL: . . S5044POB2-1985
JETTING CHART
AMBIENT TEMPERATURE
Altitude Below -20
-20F
F -20 to +10_F
-20_ +10 F +10 to +40_F
+10_to +40 F Above +40
+40_F
F
Meters 0-900
0 900 430 410 390 370
Type . . . . . . . . . . . . . . . . (2) TM38 Mikuni (Feet) (0-3000)
(0 3000)
#3 #3 #3 #3
Main Jet . . . . . . . . . . . . 270 900-1800
900 1800 370 350 330 310
Pilot Jet . . . . . . . . . . . . . 45 (3000-6000)
(3000 6000)
#3 #3 #2 #2
Jet Needle . . . . . . . . . . . 9FH4-57-2 1800-2700
1800 2700 310 290 270 250
(6000-9000)
(6000 9000)
Needle Jet . . . . . . . . . . . P-6 #2 #2 #2 #2
Cutaway . . . . . . . . . . . . 1.5 Notched 2700-3700
2700 3700
(9000-12000)
(9000 12000)
280 260 240 220
#2 #2 #2 #2
Fuel Screw . . . . . . . . . . 0.5 Turns
#X
89 Oxygenated
Under Cutaway . . . . . . 0.098〉 (2.5mm)
Starter Jet . . . . . . . . . . . 155
DRIVE DRIVEN
Meters 0-900 Silver / R-32 18-41-68P
10 56
10-56 Almond
Type . . . . . . . . . . . . . . . . P-85 (Feet) (0-3000) Blue #3 HYVO
Belt . . . . . . . . . . . . . . . . . 3211074 900-1800
10 AL
10-AL Almond Silver / R-32 18-41-68P
(3000-6000)
Belt Width (Projected) . 1.438〉 (36.52mm) Blue #3 HYVO

(6000-9000)
10 Almond Silver / R-32 18-41-68P
Blue #3 HYVO
Outside Circumference 47.625〉 (121cm)
2700-3700 Silver / R-32 18-41-68P
Center Distance . . . . . . 12.00〉 (9000-12000)
10M Almond
Blue #3 HYVO
Shift Weights . . . . . . . . 10
Primary Spring . . . . . . . Almond
Driven Helix . . . . . . . . . R-32 #3
ENGINE
Piston / Cylinder Clearance . . . 0.0045〉 - 0.0063〉 (0.11 - 0.16mm) Oil Pump Mark . . . . . . . . 01B
Piston Marking . . . . . . . . . . . . . . EK2205
Idle RPM200 . . . . . . . . . . . . . . 1500 RPM
1.26
GENERAL INFORMATION
MODEL: . . . . . . . . . . INDY 500 RMK

MODEL NUMBER: . S01SR5AS
0.034〉 BTDC (0.008〉)
0.872mm BTDC (0.208mm)
Spark Plug / Gap . . . Champion RN2C / 0.025〉 (0.64mm)
Tail . . . . . . . . PN 4030024 (x2)
Brake . . . . . . PN 4030045 (x1)

Body Style . . . . . . . .
Gen II Sprockets / Chain . . . 18-41, 68P HYVO
Front Suspension . .Indy X-10 38〉 CRC Reverse . . . . . . . . . . . . Option
Nitrogen Cell Brake Pads . . . . . . . . . Type 81, Large
80#/in. Chaincase Center Dist.7.05〉 (17.91cm)
Front Spring Preload5/8〉 Thread Adjust Driveshaft Sprockets . 2 Drivers Wide, XHS
8.25 in.(21cm) Brake Type . . . . . . . . . Polaris HPB
XTRA-Lite 136〉
12〉 (30.5cm)
Nitrogen Cell
Spring Rate . . . . . . . .
200#/in. variable
Rear Track Shock . .Indy Select
.347〉 (sq.) / 77
Track Type . . . . . . . .
15〉x136〉x1.5〉 (38.1x345.44x3.81cm)
3/8〉 - 1/2〉 (1-1.3 cm) slack with 10# (4.54kg) weight 16〉 (40.64cm) ahead of rear idler
shaft.
Overall Snowmobile Length . . . . . . . . . . . . . . . . . 116〉 (295cm)
Overall Snowmobile Height . . . . . . . . . . . . . . . . . 45〉 (114cm)
Maximum Snowmobile Width . . . . . . . . . . . . . . . 43.5〉 (110.4cm)

L.H .7041911-067 L.H. 7041627-067 L.H. 7041629-067
R.H. 7041912-067 R.H. 7041628-067 R.H. 7041630-067
1.27
GENERAL INFORMATION
MODEL: . . . . . . . . . . INDY 600 RMK

MODEL NUMBER: . S01SR6DS
JETTING CHART
AMBIENT TEMPERATURE
Altitude Below -20
-20F
F -20 to +10_F
-20_ +10 F +10 to +40_F
+10_to +40 F Above +40
+40_F
F
Meters 0-900
0 900 460 430 400 380
Type . . . . . . . . . . . . . . . . (2) TM 40 w/TPS Mikuni (Feet) (0-3000)
(0 3000)
#4 #4 #3 #3
Main Jet . . . . . . . . . . . . 310 900-1800
900 1800 400 370 350 330
Pilot Jet . . . . . . . . . . . . . 40 (3000-6000)
(3000 6000)
#3 #3 #2 #2
Jet Needle . . . . . . . . . . . 8BEYI-57-2 1800-2700
1800 2700 350 330 310 290
(6000-9000)
(6000 9000)
Needle Jet . . . . . . . . . . . P-8 (825) #3 #2 #2 #2
Cutaway . . . . . . . . . . . . 2.0 2700-3700
2700 3700
(9000-12000)
(9000 12000)
320 310 290 270
#2 #2 #2 #2
Fuel Screw . . . . . . . . . . 2.0 Turns
Valve Seat . . . . . . . . . . . 1.8 XXX
#X
Premium 91
Regular 87 Non-Oxygen - Production Setting
ated
Throttle Gap
Under Cutaway . . . . . . 0.137〉 (3.5mm) CLUTCH CHART
Starter Jet . . . . . . . . . . . 145 DRIVE DRIVEN
Pilot Air Jet . . . . . . . . . . 0.6 Long Altitude Shift Clutch Clutch Driven Chaincase
CLUTCH Meters
(Feet)
0-900
(0-3000)
10-58
Bushed
Almond
Round
Silver /
Blue
R-8
#2
19-40 68P
HYVO
Type . . . . . . . . . . . . . . . . P-85 900-1800 10-56 Almond Silver / R-8 19-40 68P
Belt . . . . . . . . . . . . . . . . . 3211065 (3000-6000) Bushed Round Blue #2 HYVO
Belt Width (Projected) . 1.438〉 (36.53mm) 1800-2700

(6000-9000)
10-54 Almond Silver / R-8 19-40 68P
Bushed Round Blue #2 HYVO
2700-3700 10 Almond Silver / R-8 19-40 68P
Outside Circumference 48.375〉 (122.87cm) (9000-12000) Bushed Round Blue #3 HYVO
Shift Weights . . . . . . . . 10-54
Primary Spring . . . . . . . Almond Round
Driven Helix . . . . . . . . . R-8 #2
ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . Liquid Cooled Case Reed w/TPS Engine Compression . . . 125 psi
Bore . . . . . . . . . . . . . . . . . . . . . . . 2.9930〉 (74.5mm) Fuel Pump Mark . . . . . . . FPA
Piston Marking . . . . . . . . . . . . . . 2171
Head ccs (Uninstalled) . . . . . . . 34.0cc
Idle RPM200 . . . . . . . . . . . . . . 1400 RPM
1.28
GENERAL INFORMATION
MODEL: . . . . . . . . . . INDY 600 RMK

MODEL NUMBER: . S01SR6DS
Alternator Output . . . 280 Watts Coolant . . . . . . . . . . . . 5.5 quarts (5.2 liters)
With TPS Unplugged.
0.1003〉 BTDC (0.0861〉 - 0.1157〉)
2.5485mm BTDC (2.188 - 2.939mm)
Tail / Brake . PN 4030043 (x1)

Body Style . . . . . . . .
Gen II Sprockets / Chain . . . 19-40-68P HYVO
Front Suspension . .Indy XC-10 38” CRC Reverse . . . . . . . . . . . . Option
7.4〉 - 7.8〉 (18.8 - 19.8cm) Brake Type . . . . . . . . . Polaris HPB Liquid Cooled
XTRA-Lite 136〉
11.5〉 (29.2cm)
Ryde FX
Spring Rate . . . . . . . .
200#/in. variable
.359〉 (sq.) / 85
Track Type . . . . . . . .
15〉x136〉x 1.75〉 (38.1x307.34x2.08cm)
shaft.
Overall Snowmobile Length . . . . . . . . . . . . . . . . . 116〉 (295cm)

L.H .7041911-067 L.H. 7041763-067 L.H. 7041629-067
R.H. 7041912-067 R.H. 7041764-067 R.H. 7041630-067
1.29
GENERAL INFORMATION
MODEL: . . . . . . . . . . INDY 700 RMK

MODEL NUMBER: . S01SR7AS (S01SM7AS)
JETTING CHART
AMBIENT TEMPERATURE
CARBURETION Altitude Below -20
-20F
F
Below -29C
-20 to +10_F
-20_ +10 F
-29_to -12_C
+10 to +40_F
+10_to +40 F
-12_ to +5_C
Above +40
+40_F
Above 5_C
F
Type . . . . . . . . . . . . . . . . (2) TM 40 w/TPS Mikuni Meters 0-900 MAG 490 MAG 460 MAG 430 MAG 400
Main Jet . . . . . . . . . . . . MAG 340 / PTO 320 (Feet) (0-3000)
PTO 470 PTO 440 PTO 410 PTO 380
Pilot Jet . . . . . . . . . . . . . 45 #4 #4 #4 #4
900-1800 MAG 440 MAG 420 MAG 390 MAG 370
Jet Needle . . . . . . . . . . . 8DGY1-57-2 (3000-6000)
PTO 420 PTO 400 PTO 370 PTO 350
Needle Jet . . . . . . . . . . . P-8 (825) #3 #3 #3 #2
Cutaway . . . . . . . . . . . . 2.0 1800-2700 MAG 390 MAG 370 MAG 340 MAG 320
(6000-9000)
Idle Mixture . . . . . . . . . . 2.5 Turns PTO 370 PTO 350 PTO 320 PTO 300
#3 #3 #2 #2
Valve Seat . . . . . . . . . . . 1.8
2700-3700 MAG 360 MAG 340 MAG 320 MAG 300
Fuel Octane (R+M/2) . Key Switch Adjustable (9000-12000)
PTO 340 PTO 320 PTO 300 PTO 280
Throttle Gap #2 #2 #2 #1
Under Cutaway . . . . . . 0.118〉 (3.0mm) XXX
Starter Jet . . . . . . . . . . . 145 #X
- Production Setting
CLUTCH
CLUTCH CHART
Type . . . . . . . . . . . . . . . . P-85
Belt . . . . . . . . . . . . . . . . . 3211065 DRIVE DRIVEN
Belt Width (Projected) . 1.438〉 (36.53mm) Altitude Shift Clutch Clutch Driven
Chaincase Chaincase
Gearing Gearing
Side Angle (Overall) . . 28 Weight Spring Spring Helix
(136”) (144”)
Outside Circumference 48.375〉 Meters 0-900 10-60 Almond Silver / R-11 20-39 68P 19 40 68P
19-40-68P
Center Distance . . . . . . 12.5〉 (Feet) (0-3000) Bushed Round Blue #2 HYVO HYVO
Shift Weights . . . . . . . . 10-56 Bushed 900-1800 10-58 Almond Silver / R-11 20-39 68P 19 40 68P
19-40-68P
(3000-6000) Bushed Round Blue #2 HYVO HYVO
Primary Spring . . . . . . . Almond Round
20-39 68P 19 40 68P
19-40-68P
Secondary Spring . . . . Silver / Blue 1800-2700
(6000-9000)
10-56
Bushed
Almond
Round
Silver /
Blue
R-11
#2 HYVO HYVO
Driven Helix . . . . . . . . . R-11 #2 19 40 68P
19-40-68P
2700-3700 10-54 Almond Silver / R-11 20-39 68P
(9000-12000) Bushed Round Blue #3 HYVO HYVO
ENGINE
Piston Marking . . . . . . . . . . . . . . 2108
Head ccs (Installed) . . . . . . . . . 32.0 - 33.0cc
Idle RPM200 . . . . . . . . . . . . . . 1500 RP”M
1.30
GENERAL INFORMATION
MODEL: . . . . . . . . . . INDY 700 RMK

MODEL NUMBER: . S01SR7AS (S01SM7AS)
With TPS Unplugged.
0.1003〉 BTDC (0.0861〉 - 0.1157〉)
2.5485mm BTDC (2.188 - 2.939mm)

Body Style . . . . . . . .
Gen II Sprockets / Chain . . . 19-40 68P HYVO
Front Suspension . .Indy XC-10 38〉 CRC Reverse . . . . . . . . . . . . Option
7.4〉 - 7.8〉 (18.8 - 19.8cm) Brake Type . . . . . . . . . Polaris HPB Liquid Cooled
XTRA-Lite 136” or 144〉
11.5〉 - 12〉 (29.2 - 30.5cm)
Nitrogen Cell
Spring Rate . . . . . . . .
190#/in.
.359〉 (sq.) / 85
Track Type . . . . . . . .
15〉x136〉x1.75〉 (38.1x345.44x4.44cm) or 15〉x144〉x2.0〉 (38.1x365.76x5.08cm)
shaft.
Overall Snowmobile Length . . . . . . . . . . . . . . . . . 136〉 Track= 116〉 (295cm) 144〉 Track= 119.75〉 (304.2cm)
Maximum Snowmobile Width . . . . . . . . . . . . . . . 44.25〉 (122cm)

L.H .7041911-067 L.H. 7041763-067 L.H. 7041629-067
R.H. 7041912-067 R.H. 7041764-067 R.H. 7041630-067
1.31
GENERAL
GENERAL INFORMATION
INFORMATION
MODEL: . . . . . . . . . . INDY 800 RMK / 800 RMK S.C. SPECIAL

MODEL NUMBER: . S01SM8BS (A, B)
JETTING CHART
AMBIENT TEMPERATURE
Altitude Below -20
-20F
F -20 to +10_F
-20_ +10 F +10 to +40_F
+10_to +40 F Above +40
+40_F
F
Meters 0-900 MAG 450 MAG 420 MAG 390 MAG 370
Type . . . . . . . . . . . . . . . . (2) TM 40 w/ TPS Mikuni (Feet) (0-3000)
PTO 430 PTO 400 PTO 370 PTO 350
Main Jet . . . . . . . . . . . . MAG 330 / PTO 310 #4 #4 #4 #3
Pilot Jet . . . . . . . . . . . . . 55 900-1800 MAG 420 MAG 390 MAG 360 MAG 340
(3000-6000)
Jet Needle . . . . . . . . . . . 9EFY8-61-2 PTO 410 PTO 370 PTO 340 PTO 310
#3 #3 #3 #2
Needle Jet . . . . . . . . . . . P-8 (825) 1800-2700 MAG 390 MAG 360 MAG 330 MAG 310
Cutaway . . . . . . . . . . . . 2.0 Notched (6000-9000)
PTO 370 PTO 340 PTO 310 PTO 290
Idle Mixture Screw . . . . 1.0 Turn #3 #3 #2 #2
Valve Seat . . . . . . . . . . . 1.8 2700-3700
(9000-12000)
MAG 350 MAG 320 MAG 290 MAG 270
PTO 330 PTO 300 PTO 370 PTO 250
Fuel Octane (R+M/2) . Key Switch Adjustable #2 #2 #2 #1
91 Premium
XXX
89 Regular #X
Throttle Gap - # refers to the clip position from top of jet needle.
Under Cutaway . . . . . . 0.098〉 (2.5mm)

- Production Setting
Starter Jet . . . . . . . . . . . 145
CLUTCH CHART
CLUTCH DRIVE DRIVEN
Type . . . . . . . . . . . . . . . . P-85 Altitude Shift Clutch Clutch Driven Chaincase
Belt . . . . . . . . . . . . . . . . . 3211065
Meters 20-39 68P
Belt Width (Projected) . 1.438〉 (Feet)
0-900
(0-3000)
10 64
10-64 Almond
Round
Silver /
Blue
R-8
#2 HYVO
900-1500 Almond Silver / R-8 20-39 68P
Outside Circumference 48.375〉 (3000-5000)
10 62
10-62
Round Blue #2 HYVO
Center Distance . . . . . . 12.50〉 1500-2100 Almond Silver / R-8 20-39 68P
10 60
10-60
Shift Weights . . . . . . . . 10-60 (5000-7000) Round Blue #2 HYVO
Primary Spring . . . . . . . Almond / Round 2100-2700

10 58
10-58 Almond Silver / R-8 20-39 68P
(7000-9000) Round Blue #2 HYVO
2700-3300 10-56 Almond Silver / R-8 20-39 68P
Driven Helix . . . . . . . . . R-8 #2 (9000-11000) Round Blue #2 HYVO
3300-3900 10-54 Almond Silver / R-8 20-39 68P
(11000-13000) Round Blue #2 HYVO
ENGINE
Piston Marking . . . . . . . . . . . . . . 2261
Head ccs (Uninstalled) . . . . . . . 46 - 47cc
Head ccs (Installed) . . . . . . . . . 33 - 33cc
Operating RPM200 . . . . . . . . . 8000RPM
Idle RPM200 . . . . . . . . . . . . . . 1400 RPM
Flywheel Torque . . . . . . . . . . . . . 90 ft.lbs. (124 nm)
1.32
GENERAL INFORMATION
MODEL: . . . . . . . . . . INDY 800 RMK / 800 RMK S.C. SPECIAL

MODEL NUMBER: . S01SM8BS (A, B, C)
0.1609〉 BTDC (0.1429〉 - 0.1803〉)
4.0860mm BTDC (3.6223 - 4.578mm)

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

L.H .7041911-067 L.H. 7041763-067 L.H. 7041629-067
R.H. 7041912-067 R.H. 7041764-067 R.H. 7041630-067
1.33
GENERAL
GENERAL INFORMATION
INFORMATION
Bolt Size Threads/In Grade 2 Grade 5 Grade 8

(MM/Thread)
Torque in. lbs. (Nm)
#10 - 24 . . . . . . . . . . . . . . 27 (3.1) . . . . . . . . . . . . . . . . 43 (5.0) . . . . . . . . . . . . . . 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 1.382.
*To convert Nm to ft.lbs. multiply Nm by .7376.
1.34
GENERAL INFORMATION
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 . . . . . . . . . . . .1250
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 . . . . . . . . . . . .25
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 . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . .75
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 ............ 1.0
1.35
GENERAL
GENERAL INFORMATION
INFORMATION
Unit of Measure Multiplied by Converts to

ft. lbs. x 12 = in. lbs.
in. lbs. x .0833 = ft. lbs.
ft. lbs. x 1.382 = Nm
in. lbs. x .0115 = kg-m
Nm x .7376 = ft.lbs.
kg-m x 7.233 = ft. lbs.
kg-m x 86.796 = in. lbs.
kg-m x 10 = Nm
in. x 25.4 =mm
mm x .03937 = in.
in. x 2.54 = cm.
mile (mi.) x 1.6 = km
km x .6214 = mile (mi.)
Ounces (oz) x 28.35 = Grams (g)
Grams (g) x 0.035 = Ounces (oz)
lb. x .454 = kg
kg x 2.2046 = lb.
Cubic inches (cu in) x 16.387 = Cubic centimeters (cc)
Cubic centimeters (cc) x 0.061 = Cubic inches (cu in)
Imperial pints (Imp pt) x 0.568 = Liters (l)
Liters (l) x 1.76 = Imperial pints (Imp pt)
Imperial quarts (Imp qt) x 1.137 = Liters (l)
Liters (l) x 0.88 = Imperial quarts (Imp qt)
Imperial quarts (Imp qt) x 1.201 = US quarts (US qt)
US quarts (US qt) x 0.833 = Imperial quarts (Imp qt)
US quarts (US qt) x 0.946 = Liters (l)
Liters (l) x 1.057 = US quarts (US qt)
US gallons (US gal) x 3.785 =Liters (l)
Liters (l) x 0.264 = US gallons (US gal)
Pounds - force per square inch (psi) x 6.895 = Kilopascals (kPa)
Kilopascals (kPa) x 0.145 = Pounds - force per square inch (psi)
Kilopascals (kPa) x 0.01 = Kilograms - force per square cm.
Kilograms - force per square cm. x 98.1 = Kilopascals (kPa)
C to F: 9 (C + 40) 5 -- 40 = F

F to C: 5 (F + 40) 9 -- 40 = C
1.36
GENERAL INFORMATION
SAE Tap Drill Sizes

Thread Size Drill Size Thread Size Drill Size
#0-80 3/64 1/2-13 27/64
#1-64 53 1/2-20 29/64
#1-72 53 9/16-12 31/64
#2-56 51 9/16-18 33/64
#2-64 50 5/8-11 17/32
#3-48 5/64
5/8-18 37/64
#3-56 45
#4-40 43 3/4-10 21/32
#4-48 42 3/4-16 11/16
#5-40 38 7/8-9 49/64
#5-44 37 7/8-14 13/16
#6-32 36 1-8 7/8
#6-40 33 1-12 59/64
#8-32 29 1 1/8-7 63/64
#8-36 29 1 1/8-12 1 3/64
#10-24 24
1 1/4-7 1 7/64
#10-32 21
1 1/4-12 1 11/64
#12-24 17
#12-28 4.6mm 1 1/2-6 1 11/32
1/4-20 7 1 1/2-12 1 27/64
1/4-28 3 1 3/4-5 1 9/16
5/16-18 F 1 3/4-12 1 43/64
5/16-24 I 2-4 1/2 1 25/32
3/8-16 O 2-12 1 59/64
3/8-24 Q 2 1/4-4 1/2 2 1/32
7/16-14 U 2 1/2-4 2 1/4
7/16-20 25/64
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 .50 #39 0.0995 3/32
3 x .60 3/32 0.0937 3/32
4 x .70 #30 0.1285 1/8
4 x .75 1/8 0.125 1/8
5 x .80 #19 0.166 11/64
5 x .90 #20 0.161 5/32
6 x 1.00 #9 0.196 13/64
7 x 1.00 16/64 0.234 15/64
8 x 1.00 J 0.277 9/32
8 x 1.25 17/64 0.265 17/64
9 x 1.00 5/16 0.3125 5/16
9 x 1.25 5/16 0.3125 5/16
10 x 1.25 11/32 0.3437 11/32
10 x 1.50 R 0.339 11/32
11 x 1.50 3/8 0.375 3/8
12 x 1.50 13/32 0.406 13/32
12 x 1.75 13/32 0.406 13/32
1.37
GENERAL
GENERAL INFORMATION
INFORMATION
ACV: Alternating current voltage.
Air Gap Spark Test: A good check for ignition voltage and general ignition system condition. Spark should arc 3/8” (1
cm.) minimum from end of high tension lead to ground. Several testers are available commercially.
Alternator: Electrical generator producing alternating current voltage.
Bore: Diameter of cylinder.
BTDC: Before Top Dead Center.
Bump Steer: When skis toe in and toe out through suspension travel.
CDI: Capacitor Discharge Ignition. Ignition system which stores voltage generated by the stator plate exciter coil in a
capacitor or condenser (in CDI box). At the proper moment a voltage generated by the stator plate pulser coil closes an
electronic switch (thyristor) in the CDI box and allows the voltage in the capacitor to discharge into the primary windings
of the ignition coil.
Center Cylinder: On three cylinder engines, the cylinder between Mag and PTO ends.
Center Distance: Distance between center of crankshaft and center of driven clutch shaft.
Chain Pitch: Distance between chain link pins. Polaris measures chain length in number of pitches.
Clutch Buttons: Plastic bushings which transmit rotation of the clutch to the movable sheave in the drive and driven
clutch.
Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch
face as the engine torques back.
Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive
clutch to close.
Coil: A winding of wire around an iron core which has the ability to generate an electrical current when a magnetic field
passes through it.
Combustion Chamber: Space between cylinder head and piston dome at TDC.
Compression: Reduction in volume or squeezing of a gas.
Condenser/Capacitor: A storage reservoir for electricity, used in both E.T. and CDI systems.
Crankshaft Run-Out: Run-out or “bend” of crankshaft measured with a dial indicator while crankshaft is supported
between centers on V blocks or resting in lower half of crankcase. Measure at various points especially at PTO.
Maximum allowable run-out is .006” (.02 cm.).
DCV: Direct current voltage.
Detonation: The spontaneous ignition of the unburned fuel/air mixture after normal spark ignition. Piston looks
“hammered” through, rough appearance around hole. Possible causes: 1) too high a compression ratio for the fuel
octane; 2) low octane fuel; 3) over-advanced ignition timing; 4) lean fuel/air mixture.
Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and
out-of-round in the cylinder bore.
Displacement: The volume of the cylinder displaced by
the piston as it travels from BDC to TDC. The formula is: Bore2 x Stroke x 3.1416 = Displacement in
4 CCs
Effective Compression Ratio: Compression ratio measured from after the piston closes the exhaust port.
Electrical Open: Open circuit. An electrical circuit which isn’t complete. (i.e. poor connections or broken wire at hi-lo
beam switch resulting in loss of headlights.
Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended
component. (i.e. a bare wire touching the snowmobile chassis under the seat resulting in loss of taillights and brake
lights).
End Seals: Rubber seals at each end of the crankshaft.
Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt.
E.T. Ignition: Energy Transfer ignition. Generates primary ignition voltage through electro magnetic induction.
1.38
GENERAL INFORMATION
Flat Head Bolt: To be used where finished surfaces require a flush fastening unit. Countersunk.
Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction.
g: Gram. Unit of weight in the metric system.
Head Volume: Cylinder head capacity in cc, head removed from engine with spark plug installed.
Heat Exchanger: A device used to transfer heat. Mounted under running boards, they dissipate engine heat to the
atmosphere.
Hex Head Bolt: Standard type of wrench-applied hexagon head, characterized by clean, sharp corners trimmed
to close tolerances. Recommended for general commercial applications.
Hi-Fax: Trademark of Himont Advanced Materials. The special slide material which fits onto the bottom of the
suspension rails.
High Side: Sled pushes or tips up.
High Tension Wire: The heavy insulated wire which carries the high secondary voltage from the coil to the spark plug.
Hole Shot: A term used when machine starts a race from a dead stop.
Holed Piston: Piston in which a hole has formed on the dome. Possible causes: 1) detonation; 2) pre-ignition.
Ignition Coil: A type of transformer which increases voltage in the primary windings (approx. 200V) to a higher voltage
in the secondary windings (approx. 14KV - 32KV) through inductions. Secondary voltage is high enough to arc the air
gap at the spark plug.
Ignition Generating Coil: Exciter coil, primary charge coil. Stator plate coil which generates primary ignition voltage.
CDI system uses one ignition generating coil. Twin cylinder E.T. ignition systems use two ignition generating coils. Coil
is mounted at the top of the stator plate.
Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb.
Kg/cm.2: Kilograms per square centimeter. Metric equivalent of PSI.
Keystone Ring: A piston ring with bevel on upper inside surface.
Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction.
Metric equivalent of ft. lbs.
L Ring: A wide face piston ring with an ”L” shaped cross section. Leg of ”L” goes up when installing on piston.
Labyrinth Seal: A pressure type center seal identified by series of grooves and lands. Polaris engines us this type of
seal to separate the cylinders in the crankcase halves.
Left Side: Always referred to based on normal operating position of the driver.
Lighting Coil: Generates voltage for lights, battery charging, etc by electromagnetic induction.
Loose: When the rear of the vehicle slides outward in a turn. The track does not grab sufficiently.
mm: Millimeter. Unit of length in the metric system. 1mm = .040”.
Mag End: Flywheel side of engine.
Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the
windings. This is how mechanical energy in our engines is converted to electrical energy in the lighting coil, ignition
generating coils and trigger coil.
Ohm: The unit of electrical resistance opposing current flow.
Oval Head Screw: Fully specified as ”oval countersunk”, this head is identical to the standard flat head, but
possesses a rounded upper surface for attractiveness of design.
PTO End: Power Take Off drive (clutch side).
Pan Head Screw: Provides a low, large diameter head, but with characteristically high outer edges along the
outer edge of the head where driving action is most effective. Slightly different head contour when supplied with Phillips
Recess. See dotted line.
Piston Clearance: Total distance between piston and cylinder wall.
Piston Erosion: Piston dome melts. Usually occurs at the exhaust port area. Possible causes: 1) lean fuel/air mixture;
2) improper spark plug heat range.
1.39
GENERAL
GENERAL INFORMATION
INFORMATION
Pre-Ignition: A problem in combustion where the fuel/air mixture is ignited before normal spark ignition. Piston looks
melted at area of damage. Possible causes: 1) too hot a spark plug; 2) spark plug not properly torqued; 3) “glowing”
piece of head gasket, metal burr or carbon in the combustion chamber; 4) lean fuel/air mixture; 5) Incorrect ignition
timing.
Primary Circuit: This circuit is responsible for the voltage build up in the primary windings of the coil. Parts of this circuit
include the exciter coil, points and condenser, wires from the stator plate to the small primary winding in the ignition coil.
In the CDI system the parts include the exciter coil, the trigger coil, the wires from stator plate to CDI box and to the low
resistance primary windings in the ignition coil.
Primary Clutch: Drive clutch on engine.
Primary Compression: Pressure built up in the crankcase of a two stroke engine.
psi.: Pounds per square inch.
Pushing: When the front of the vehicle does not steer as much as the driver desires. The skis do not grab sufficiently.
R & R: Remove and replace.
RFI: Radio Frequency Interference. Caused by high voltage from the ignition system. There are special plug caps and
spark plugs to help eliminate this problem. Required in Canada.
RPM: Revolutions Per Minute.
Relay Coils: Electromagnetic device in an EFI system which controls circuit connection with input from another circuit.
Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms. Both result in energy conversion to
heat.
Right Side: Always referred to based on normal operating position of the driver.
Round Head Screw:The familiar head most universally used for general application. Good slot depth, ample
underhead bearing surface and finished appearance are characteristic of this head.
Running Time: Ignition timing when fully advanced or at specified RPM.
Secondary Circuit: This circuit consists of the large secondary coil windings, high tension wire and ground through the
spark plug air gap.
Secondary Clutch: Driven clutch on chaincase or jackshaft.
Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder
wall. Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck
piston rings.
Self Steer: Pulling the machine to the inside of the track.
Spark Plug Reach: Length of threaded portion of spark plug. Polaris uses 3/4” (2 cm.) reach plugs.
Static Timing: Ignition timing when engine is at zero RPM.
Stator Plate: The plate mounted under the flywheel supporting the primary ignition components and lighting coils.
Stroke: The maximum movement of the piston from bottom dead center to top dead center. It is characterized by 180
of crankshaft rotation.
Surge Tank: The fill tank in the liquid cooling system.
TDC: Top Dead Center. Piston’s most outward travel from crankshaft.
Transfer: The movement of fuel/air from the crankcase to the combustion chamber in a two stroke engine.
Trigger Coil: Pulser coil. Generates the voltage for triggering (closing) the thyristor and timing the spark in CDI
systems. Small coil mounted at the top of the stator plate next to the ignition generating coil.
V Regulator: Voltage regulator. Maintains maximum lighting coil output at approx. 14.5 ACV as engine RPM
increases.
Venturi: An area of air constriction. A venturi is used in carburetors to speed up air flow which lowers pressure in venturi
to below atmospheric pressure, causing fuel to be pushed through jets, etc., and into the venturi to be mixed with air and
form a combustible air/fuel mixture.
Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the
circuit.
Watt: Unit of electrical power. Watts = amperes x volts.
1.40
GENERAL INFORMATION
Handling Problems
Handling problems usually require several changes in setup to correct. Most problems can be traced to improper
suspension adjustment. If the problem is encountered when entering a corner, adjust the front end. If the problem
is encountered when exiting a corner, adjust the rear suspension.
Service
In order to perform service work efficiently and to prevent costly errors, the technician should read the text in this
manual, thoroughly familiarizing him/herself with procedures before beginning. Pictures and illustrations have
been included with the text as an aid. Notes, cautions and warnings have also been included for clarification of text
and safety concerns. However, a knowledge of mechanical theory, tool use and shop procedures is necessary to
perform the service work safely and satisfactorily. Use only genuine Polaris service parts.
Cleanliness of parts and tools as well as the work area is of primary importance. Dirt and foreign matter will act
as an abrasive and cause damage to precision parts. Clean the snowmobile before beginning service. Clean new
parts before installing.
Watch for sharp edges which can cause personal injury, particularly in the area of the tunnel. Protect hands
with gloves when working with sharp components.
If difficulty is encountered in removing or installing a component, look to see if a cause for the difficulty can be
found. If it is necessary to tap the part into place, use a soft face hammer and tap lightly.
Some of the fasteners in the snowmobile were installed with locking agents. Use of impact drivers or
wrenches will help avoid damage to fasteners.
Always follow torque specifications as outlined throughout this manual. Incorrect torquing may lead to serious
machine damage or, as in the case of steering components, can result in injury or death for the rider(s).
If a torquing sequence is indicated for nuts, bolts or screws, start all fasteners in their holes and hand tighten.
Then, following the method and sequence indicated in this manual, tighten evenly to the specified torque value.
When removing nuts, bolts or screws from a part with several fasteners, loosen them all about 1/4 turn before
removing them.
If the condition of any gasket or O-Ring is in question, replace it with a new one. Be sure the mating surfaces
around the gasket are clean and smooth in order to avoid leaks.
Some procedures will require removal of retaining rings or clips. Because removal weakens and deforms
these parts, they should always be replaced with new parts. When installing new retaining rings and clips use care
not to expand or compress them beyond what is required for installation.
Because removal damages seals, replace any oil or grease seals removed with new parts.
Polaris recommends the use of Polaris lubricants and greases, which have been specially formulated for the
top performance and best protection of our machines. In some applications, such as the engine, warranty
coverage may become void if other brands are substituted.
Grease should be cleaned from parts and fresh grease applied before reassembly of components.
Deteriorating grease loses lubricity and may contain abrasive foreign matter.
Whenever removing or reinstalling batteries, care should be taken to avoid the possibility of explosion
resulting in serious burns. Always disconnect the negative (black) cable first and reconnect it last. Battery
electrolyte contains sulphuric acid and is poisonous! Serious burns can result from contact with the skin, eyes or
clothing. ANTIDOTE: External - Flush with water. Internal - Drink large quantities or water or milk. Follow with
milk of magnesia, beaten egg, or vegetable oil. Call physician immediately. Eyes - Flush with water for 15 minutes
and get prompt medical attention.
1.41
GENERAL
GENERAL INFORMATION
INFORMATION
The following information is provided as a general guide for starting set ups for various machines and race types.
Much of it is gathered from the race reports turned in after each race. Don’t forget to turn in your race report!
NOTE: All setups are initial starting points or recommendations only, and should be adjusted according to driver
preference and style. Your preferred set up may vary to suit track conditions, riding style, and weight.
Ice racing is a team sport requiring a quality pit crew. Select a crew that not only has the knowlegde to support
the team effort, but also has the ability to be there for every race. The following pages list a few things that may
help your team operate more efficiently and professionally.
Each team member of the pit crew has his or her duties that are critical to the teams efficiency. Although an ice
race may last for hours it is often won by saving seconds. Here are a few tips that may help you save a few.
Team Members and Their Duties

1. Pit crew members and their responsibilities
These individuals should know the racing machine and its setups inside and out. On race day they should also
keep track of what heat, semi’s, and finals you are in. They should also keep track of staging. This can be simpli-
fied if only one member is in control of knowing when and where the driver should be. This person should also
be a motivated coach.
2. Track crew members break down and responsibilities:
A. One track spotter
This individual will be placed in the areas where the most incidences have happened in the past, and
communicates information to the driver so he may avoid any unnecessary pit stops for repair. In shorter
ice races, the spotter gives the driver information on other drivers lines in the corners and also helps the
driver find smooth spots on the track.
B. One “Team Manager”
This is probably your most important team member. Not only should he/she be able to plan, schedule,
order, request, push papers, and be a politician, this person has to know the set up of the support trailer
and where everything is stored. He or she must anticipate and organize the tools that will most likely be
needed. The driver listens to other crew members opinions, but the manager is the one who makes the
final decisions.
3. Optional Crew Equipment
SNascar style wireless communicator
SLap top computer
SClip board with counter
SStop watch
1.42
GENERAL INFORMATION
Front Suspension
Camber
Banked race tracks require more camber than flat race tracks because the rear end of the sled seems to get more
of a bite due to the banking of the race track, keeping it from washing out. Also keep in mind the length of the
race track, sharpness of the corners, and ice conditions. All of these factors will come into play in order to properly
align the skis for your style of driving. Don’t be afraid to experiment and always test your setup.
Camber measurement should be taken when machine is supporting its own weight; i.e. with jack stands under
the rear bumper and under each trailing arm, for the most accurate measurement.
Degree Wheel Parallel Bar

S Camber (flat track) - right 2, left 0 2 = about 1/8〉
S Camber (banked track) - right 4, left 2 4 = about 1/4〉
When setting camber with a degree wheel, find zero
camber and set your dial to zero. Mount your dial to Degree Wheel
spindle housing and adjust upper and lower radius
rods until degree wheel reads desired camber.
When setting camber with a parallel bar, make your-

self two identical 3 1/2〉 x 1〉 square blocks to fit on top
of the ski saddle. Insert the blocks just in front of the
spindle and line up your parallel bar. Adjust your ra-
dius rods until you achieve your desired camber mea- Adjust radius
surements Do not take the measurement off of the rods
ski plastic. When skis are molded, there are
variences in depth and thickness of the plastic.
3 1/2〉
1〉
Block Block
Saddle Measure here Saddle

(Ski on) (Ski on)
1.43
GENERAL
GENERAL INFORMATION
INFORMATION
Toe In/Toe Out
Never toe the machine in. Try to run 1/16〉 to 1/8〉 toe
out, depending on the amount of bump steer. This Support Sled
measurement should be taken off of the ski’s carbide
when the machine is supporting its own weight (i.e.
with jack stands under the rear bumper and under
each trailing arm) for the most accurate measurement.
When setting toe out, in ice racing only, use the inside
ski for adjustment. This will help your sled corner by
pulling to the inside of the race track (self steer). Measure at front
and rear of carbide
Caster
Stock caster can be changed if building new trailing arms. Tip the spindle angle back 2 to give more camber
change throughout the turning radius. This creates quicker, heavier, more aggressive steering and will help the
machine track better in rough portions of the race track.
It is important to note that when caster is altered the stock suspension geometry is changed, resulting in bump
steer. To correct this, shim tie rods and change steering arm lengths.
Reinforcement
Reinforcement is a very important part of ice racing. Be sure to use good quality material, don’t just double lower
quality material. This will help keep weight down as well as give your machine a quality appearance.
Sway Bar - Adjustable

When setting up the sway bar, pre-load neutral by positioning the sway bar parallel with the trailing arms when
possible. Take out play in Heim joints by shortening the left Heim until the joints are tight (Ice oval only).
Sway Bar Options:
Reinforcement
Reinforcing is a very important part of ice racing. Try to strengthen by using good grades of mat, not by doubling
up poor quality grades of parts. This will keep the weight of the machine down and give a professional appear-
ance. Listed are just a few ways of strengthening your machine.
S 7/8〉 O.D. radius rods
S 7/16〉 fine thread grade 5 ski bolts
S Good grade aluminum ski reinforced with 1〉 O.D. metal or nylon hoop. (Cover hoop with padding)
S Check all stock welds throughout. Re-weld if necessary
S Use loctitet on bolts where needed, or safety wire
S 1/2〉 fine thread grade 5 rear trailing arm bolts
S 7/16〉 fine thread grade 5 front trailing arm, front radius rod bolts
S Chrome moly steering post with wood dowel in center
S Hardened spindles
S Aluminum throttle housing control
1.44
GENERAL INFORMATION
Shocks
Why gas shocks? Because one race is equal to one season of trail riding. Gas shocks such as FOX are a must
because the valving can be changed and they can be rebuilt. This is important because conditions vary from track
to track. Also, because of the length of an ice race, it’s important to have a shock you can rebuild and maintain
from race to race. Quality shocks are as important as having a fresh engine. Remember, a lot of horse power
won’t help if you can’t keep the machine on the ground.
Valving
Stock front shock valving does not allow the front suspension to follow the contour of the track and doesn’t react
quickly enough at high race speeds.
Track conditions, driver weight and driving style have a great deal to do with the shock valving combination you
choose. Smooth, high speed tracks require heavier valving than slower, rougher tracks. If you notice your skis
are not maintaining contact with the ice, you may want to lighten valving to make the machine react more quickly.
Remember to take advantage of travel. The reason you have four to five inches of travel is to provide a smooth
ride.
Spring Rate
Spring rate also changes with track conditions, driver weight, and driving style. A good place to start for a 470
lb. machine with a 180 lb. driver is a 146 lb., 7 1/2〉 long spring.
Remember that preload doesn’t affect spring rate unless you are using progressive rate springs. Also, straight
rate springs are easier to work with than progressive rate springs. Following are a few helpful hints:
S Always use a quality Polaris spring
S Length of spring changes rate.
S Don’t use a spring that is too heavy - springs should allow at least 1〉 of ride in
S Hard ice requires softer springs. Soft ice requires harder springs. The same is true for sway
bars. Less wall thickness (.065 to .058) might be needed if ice is hard and the machine
tends to push when entering the corner. Too light a wall thickness tends to tip machine up at
the start of the apex, causing a loose condition off the corner. Going to a lighter spring or
swaybar allows the machine to roll into the corner causing the inside of track studs to be
pulled out of the ice, making the machine loose. Be carefuel not to go too soft. This will
cause highsiding and very aggressive handling.
S Springs can lose their rate even after one weekend of racing. Always keep notes on spring
length and rates.
S Racing and qualifying set ups should differ. A softer suspension with more travel is a must
as track conditions change and the track deteriorates. Sometimes a medium set up for both
qualifying and race day is best.
S Most tracks require different springs, so have a good selection of springs on hand.
S See Suspension Section for optional springs and spring kits.
1.45
GENERAL
GENERAL INFORMATION
INFORMATION
Rear Suspension
Shocks
You will need a good quality gas shock, such as Fox or Arvin 〉 , Stock rear shock valving usually works well.
Rear Suspension Springs

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

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

Rear torque arm springs control ski pressure when exiting the corner or when getting back on the power. Measure
from the rail rubber to the bottom of the suspension torque arm. Use the stock limiter strap for adjustment.
Lubrication
Mount two lube lines on each rail, for a total of four lube lines. Remove and disassemble the engine. Drill and
tap another impulse hole in crankcase in line with rod pin. Install another fuel pump into this hole to pressurize
the system lube lines.
Be aware that the lube runs dry by the time the track is snowy enough for the lube system to be turned off. For
this reason, a minimum of idler wheels are a must.
1.46
GENERAL INFORMATION
Track and Traction
CAUTION:
Avoid placing studs too close to the edge of the track or track damage and/or failure may occur.
Be sure to use a good grade of Loctite (for example high strength red), and allow a curing time of at least 24
hours. When possible, burn holes in the track with a 1/4〉 awl. This helps seal the holes and keep moisture out.
If you do not burn the holes, use a hole cutter. Never use a drill bit. The cords will rip and make studding very
difficult.
Carbides
The first thing to look at when your machine doesn’t corner is carbides. Woody’s 10〉 comp bars are a good choice.
Using the old style 464 stud pattern with this style seems to keep bars straighter. Always keep carbides sharp.
Make sure when resharpening to keep a 60 angle. Less of an angle will prevent carbides from penetrating ice.
Never exceed 60.
Using more carbide on the right ski is not recommended for ice racing since the machine will not track straight.
1.47
GENERAL
GENERAL INFORMATION
INFORMATION
Clutching
There are unlimited combinations in clutching. The best way to find the ideal set up for you is to test and experi-
ment. Remember that no two machines are alike. To clutch your machine properly you need to know at what
RPM your engine puts out its peak performance. The best way to find this out is to put your engine on a Dyno.
If this is not possible, you can get the information from your manufacturer or dealer.
Assume your engine reaches peak power at 9000 RPM. You want to clutch your machine so the engine goes
from clutch engagement RPM to 9000 RPM as quickly as possible without exceeding 9000 RPM, and staying
at 9000 RPM until the clutches reach a 1:1 ratio. The difference between OEM clutching and race clutching would
look something like the example shown below. When clutching do not be afraid to experiment.
10 10
9 9
8 8
7 7
6 6
5 5
4 4
3 3
2 2
1 1
1 2 3 4 5 6 1 2 3 4 5 6
TIME IN SECONDS TIME IN SECONDS

OEM CLUTCHING RACE CLUTCHING
Gearing
Gearing will vary from track to track. Ideally you want your clutches to reach a 1:1 ratio at the end of the longest
straightaway on the track. A good way to find proper gearing is find top speed on the track with a radar gun and
then refer to the Polaris gearing chart in the Chassis/Brake/Final Drive chapter.
1.48
GENERAL INFORMATION
Race Strategy
Know the track and conditions. Monitor track conditions as the day goes on. Make sure you know where good
ice is on the starting line before you pull up to the line. Know where the good and bad lines are in the corners.
Every time the track is plowed you should check track conditions. This is the best way to find a good line or an
edge over the competition.
Keep a journal of race set ups and notes for each race track. This will save you a lot of time when you come back
to a track in following years.
Get to know how the flagman starts a race. Watch him closely when you’re not racing. Some flagmen tip off when
they’re going to throw the flag. This can give you a good jump on the starting line.
Get in shape. You can’t go fast around the race track if you’re too tired to hang onto the machine. If you want
to win races, you have to be as fast at the end of the race as you are at the beginning. This requires strength
and conditioning. Some good strength exercises for racing are pull ups, biceps curls, wrist curls, rowing, bench
press, leg curls, and squats. Good conditioning exercises include running, racquetball, running stairs, biking,
motocross riding, etc.
Details
Make sure the tachometer is in a location which allows clear visibility so you can read it at a glance.Check handle-
bar bends and length. It is very important to you as the driver to have a comfortable grip at all times to avoid
fatigue. Make sure the tether cord is mounted out of the way so that it won’t be knocked off while you are racing.
Racing style, track length, sharpness of corners, and ice conditions all come into play when setting up your ma-
chine. Experimentation is the only way to achieve the best set up. Following are some tips for ice racing:
S Recommended chaincase oil - Polaris Synthetic Chaincase Lubricant (PN 2871478 - 12 oz. bottle).
S 7/16〉 ID spring, approximately 1 1/2〉 long, loose fit, over 3/8〉 chain tightener bolt to keep tension
on chain after stretch
S Check overflow bottle at every other pit stop for correct fluid level; also replace return lines from en-
gine to bottle with high pressure line
S Check track tension at every other pit stop NOTE: Alternate maintenance checks at stops to save
time
S Drill ski bushing out to 7/16〉 for larger Grade 5 ski bolt to prevent thread damage when quick changing
skis with 1/2〉 impact wrench
S Install quick change fuel system and use a Nascar style can
1.49
CHAPTER 2
ENGINE
2
Improvements and Specifications . . . . . . . . . . . 2.1
Torque Patterend and Specifications . . . . . . . . 2.2--2.3
General Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
Full Stroke Compression Ratio Chart . . . . . . . . 2.5
Compression Ratio Example . . . . . . . . . . . . . . . 2.6
Head CC Removal Example . . . . . . . . . . . . . . . 2.7
Port Opening Duration Example . . . . . . . . . . . . 2.7
VES System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8-2.10
440 Edge Pro X Pipe Temp Sensor . . . . . . . . . 2.11
440 Edge Pro X Timing . . . . . . . . . . . . . . . . . . . . 2.12
Engine Repair - 440/500/600 XC SP . . . . . . . . 2.13-2.22
VES Maintenance - 440/500/600 XC SP . . . . . 2.23-2.26
Engine Repair - 600 RMK/700/800 Twins . . . . 2.27-2.38
Engine Repair - 800 XCR . . . . . . . . . . . . . . . . . . 2.39-2.45
VES Maintenance - 800 XCR . . . . . . . . . . . . . . 2.46-2.49
General Inspection Procedures . . . . . . . . . . . . . 2.50-2.61
Cooling System Bleeding Procedures . . . . . . . 2.62
Cooling System Exploded Views . . . . . . . . . . . 2.63-2.67
Water Pump Belt - 600 RMK/700/800 Twins . . 2.68
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 2.69
ENGINE
Improvements for 2001 440 / 600 Edge Pro X

1. New Cylinders
Ignition Switch
2. 6mm shorter Rod
Positions
3. New head Profile
4. Different crankcase to accommodate the shorter rod
5. All new manifold and pipe OFF
6. new CDI options with pipe sensor ON

110 OCT.
7. New exhaust valve guillotine ON

92 OCT.
8. Octane switches 92 oct is for 92 non--oxygenated

pump fuel. 110 oct is for Polaris Fuel 110 octane
9. Koyo upper rod bearings
2001 Model Specifications

Machine Model Engine Model Cyl. Bore Bore Stroke Stroke No. of Type of Fuel
Disp. MM Inches MM Inches Cyl. Cooling Octane
CC’s (Min)
XCF EC45PM021 438 65.5 2.579 65 2.559 2 Fan 87*
440 Edge Pro X S44-44-00A1 438 66 2.598 64 2.520 2 Liquid 92**
500 XC SP SN50-44-00A1AEV 500 70.5 2.776 64.0 2.520 2 Liquid 87*
600 Edge Pro X SN60-44-PO6E2234 600 77.25 3.041 64.0 2.520 2 Liquid 87*
600 XC SP SN60-44-00A1EV 600 77.25 3.041 64.0 2.520 2 Liquid 87*
700 XC SP SN70-70-00A1 700 81.0 3.189 68.0 2.677 2 Liquid 87*
800 XC SP S8070POA1--1952 800 85.0 3.3464 70 2.7559 2 Liquid 89*
600 RMK SN60-70-00A2 593 74.5 2.993 68.0 2.677 2 Liquid 87*
700 RMK SN70-70-00A2 700 81.0 3.189 68.0 2.677 2 Liquid 87*
800 RMK SN80-70-00A2 794 85.0 3.346 70.0 2.756 2 Liquid 87*
800 XCR EC79PL012 794 72 2.835 65.0 2.559 3 Liquid 87*
* Non-oxygenated. Use minimum 89 octane when using oxygenated fuel.

** 92 Octane Premium Unleaded minimum.
Model Cyl. Head Cyl. Head Piston/Cylinder Engine Recommended

CC’s CC’s Bore Clearance Operating Idle RPM
Uninstalled Installed +.05 mm RPM ¦200
--.00 mm
(MM / Inch)
XCF 24.2 21.2 .07-.105 (.0028-.0041〉) 7750 1600
440 Edge Pro X 18.1 15.8 .11--.13 (.0045--.0053) 8250 1600
500 XC SP 26.50.5 25.20.5 .11-.14 (.0045-.0055〉) 8500 1500
600 Edge Pro X 36.50.5 31.00.5 .11-.150 (.0045-.0059〉) 8250 1400
600 XC SP 36.50.5 31.00.5 .11-.150 (.0045-.0059〉) 8250 1400
700 XC SP 40.20.5 32.0-33.0 .12-.15 (.0047-.0060〉) 8000 1500
800 XC SP 50.00.5 36.0--37.0 0.15--0.188 (.006--.0074) 8000 1300
600 RMK 34.0 26.0 .11-.15 (.0044-.0058〉) 8000 1500
700 RMK 40.20.5 32.0-33.0 .12-.15 (.0047-.0060〉) 8000 1500
800 RMK 50.00.5 36.0-37.0 .15-.188 (.006-.0074〉) 8000 1300
800 XCR 28.1 23.9 .07-.105 (.0027-.0041〉) 8500 1500
2.1
ENGINE
When tightening bolts, nuts, or screws, a torque pattern should be followed to insure uniform equal tension is
applied to all fasteners. Proper torque application prevents fasteners from loosening or breaking in critical service.
It also minimizes wear and eliminates premature or needless repair costs. Following uniform torque application
sequence patterns assures optimum performance from precision machined, close tolerance assemblies. On vital
engine parts, torquing negligence could be costly.
Torque is a force which tends to produce rotation. The measurement of this force is expressed in units of force and
length. There are at present two basic systems of units used to express torque, English and Metric. In the English
system, the units of force are the pound or ounce, and the length is the foot or inch.
In the Metric system, the unit of force is expressed in grams (gm) or Newton meters (Nm), and length as
centimeters (cm) or meters (m). The most common units of torque in the English system are ft. lb. and in. lb. In the
Metric system, torque is commonly expressed in units of Nm. Multiply foot pounds by 1.382 to obtain Nm.
See page 2.3 for engine torque sequences
Engine Cylinder Head* Cylinder Crankcase Crankcase Flywheel

Base Nuts 8 mm 10 mm
EC-45 18-19 ft. lbs. 24-28 ft. lbs. 17-18 ft. lbs. 23-25 ft. lbs. 60-65 ft. lbs.
(25-26.5 Nm) (33-39 Nm) (22-23 Nm) (32-35 Nm) (83-90 Nm)
S44** 20-24 ft. lbs. 30-34 ft.lbs 20-24 ft.lbs. N/A 90 ft. lbs.
(28 - 33 Nm) (42-47 Nm) (28 - 33 Nm) (124 Nm)
SN60-44**
SN50**
SN60-70** 18-22 ft. lbs. 30-34 ft.lbs 20-24 ft.lbs. 26-30 Ft lbs 90 ft. lbs.
SN70** (25 - 30 Nm) (42-47 Nm) (28 - 33 Nm) (36-42 Nm) (124 Nm)
SN80**
EC79PL 18-19.5 ft. lbs. 23-25 ft. lbs. 20-22 ft. lbs. 23-25 ft. lbs. 60-65 ft. lbs.
(25-27 Nm) (32-35 Nm) (28-30 Nm) (32-35 Nm) (83-90 Nm)
**Torque head bolts prior to torquing cylinder base nuts. Apply loctitet 242.
All 6mm Crankcase Bolts . . . . . 108 in. lbs. (12.4 Nm)
All 7/16-14 Engine Mount Strap Bolts . . . . . 44-48 ft. lbs. (60-66 Nm)
2.2
ENGINE
5 8 5 4
12 3 6
9 1 4
2 3 11 7 1 2 8
10
6 7
CYLINDER HEAD CYLINDER BASE

Domestic Twins 500 XC SP, 600 XC Domestic Twins 600/700/800
SP, 440/600 Pro X XCF SP
9 5 4 8 2 5 7
5 4 9 1 3 11
10 1 3 12
6 2 7 11 6 12 4 2 10
3
1 8 6
CYLINDER HEAD CYLINDER HEAD - XCF CRANKCASE - XCF
Domestic Twins 600 RMK/700/800
5 8
5 1 9 1 4 12 14
3
2 11 3 2 10 13
6 4
7 6
CRANKCASE 15
Domestic Twins 600 RMK/700/800 CRANKCASE - 500 XC SP, 600 XC SP
13 1 11
17 9 3 5 9 5 1 3 7 11
7 15
16 8 6 4 10 18 10 6 2 4 8 12
12 2 14
CYLINDER HEAD -800 Fuji Triple CYLINDER BASE- 800 Fuji Triple
13 1 11 19
17 9 3 5 7 15
16 8 6 4 10 18
12 2 14
20
CRANKCASE - 800 Fuji Triple
2.3
ENGINE
Choose a well known performance company. Explain that you need a reliable enduro engine, not a sprint motor.
An enduro engine should not exceed 9800 RPM. Sprint motors are too “peaky” and have a short life. Remember,
the race is won at the finish line, and most high horsepower engines don’t get there.
If the track or course requires running long distances in limited snow conditions, it is advisable to install a tempera-
ture gauge to monitor coolant out temperature.
Secure the fuel valve in the “on” position with a cable tie strap. This will prevent the valve handle from moving
when operating in rough conditions.
Front Engine Mount

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

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

A drop in engine RPM may be caused by moisture collecting in the spark plug caps. The caps should be cleaned
with electrical contact cleaner and dried with compressed air. Be sure the cap is screwed tightly onto the high
tension lead. Coat the inside of the cap with Polaris Nyogelt Grease (PN 2871329).
Honing Ni-Ca-Sil Cylinders

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

Number
3070156 NGK BR8ES
3070157 NGK BR7ES
3070160 NGK B7ES
3070161 NGK B8ES
3070162 NGK B9ES
3070163 NGK BR9ES
3070165 Champion RN2C
3070166 Champion RN3C
3070184 Champion RN57YC
3070190 Champion RN57YCC
2.4
ENGINE
17
16
15
FULL STROKE COMPRESSION RATIO
DANGER ZONE
14
13 SAFE ZONE
12
11
UNNECESSARY OCTANE
10
8
REGULAR PREMIUM RACE FUEL
7
84 86 88 90 92 100 105 110 115 120
PUMP OCTANE NUMBER
R = (IHV+DISP) IHV = INSTALLED HEAD VOLUME [CC]

DISP= CYLINDER DISPLACEMENT [CC]
IHV
R = COMPRESSION RATIO
I = S S = FULL ENGINE STROKE [CM]
(DISP*25.4) I = INCHES PER CC OF IHV
DISP = (PI*B*B*S) B = CYLINDER BORE [CM]
PI = 3.1416
4
2.5
ENGINE
Bore = 6.5 cm Stroke = 6.0 cm IHV = 17.1 cc
Displacement = ↓ Bore ′ Stroke σ↓ ″ ♣ψϒ♦ϒ♠τ

♦
Displacement = 199.098 cc
IHV + Displacement
R=
IHV
R = 12.643 Full Stroke Compression Ratio
To calculate the Effective Compression Ratio, substitute the exhaust port height for the stroke in the
formulas above:
Exhaust = 2.95 cm Exhaust port height 29.5 mm
Eff Disp = ↓ Bore′ Stroke Effective Displacement

♦
Eff Disp = 97.89 cc
IHV + Eff Disp

Eff Comp = Effective Compression Ratio
IHV
Eff Comp = 6.725
In order to increase the Full Stroke Compression Ratio to 13.6, how much material do you need to
remove from the cylinder head?
IHV + Displacement , and you want to find out IHV.

You know that: R =
IHV
Displacement = 199.098 cc, and we want R = 13.6, so then
IHV2 = Displacement
(R -- 1)
IHV2 = 15.801 cc desired IHV to have 13.6:1 Full Stroke Compression Ratio
2.6
ENGINE
HEAD CC REMOVAL EXAMPLE
Total number of CCs to remove from the head = Old IHV -- Desired IHV
Removed CCs = IHV -- IHV2
Removed CCs = 1.299 cc
Stroke
I= Number of inches to remove from the
cm cylinder head to equal 1 cc
Displacement ⋅ 2.54 ⋅
in
in
I = 0.01186 ⋅
cc
To find out how much to cut off, multiply the number of CCs you need to remove
by the number of inches to remove per CC:
Thickness to remove = I ⋅ Removed CCs

Thickness to remove = 0.015 in
PORT OPENING DURATION
Port open = 81.5 This indicates the degrees after TDC that the exhaust port
opens (and also the degrees before TDC that the port
closes).
Duration closed = 2 ⋅ Port open
Duration closed = 163
Total duration = 360
Duration open = Total duration -- Duration closed
Duration open = 197
Duration open
Percent open = ⋅ 100
Total duration
Percent open = 54.722
2.7
ENGINE
Variable Exhaust System (V.E.S.)
Some snowmobiles are equipped with the Polaris Variable Exhaust System (V.E.S.)
This unique exhaust valve management system changes the effective exhaust port height in the cylinder to pro-
vide maximum horsepower at high RPM without sacrificing fuel economy and engine torque at low to midrange
throttle settings.
Spring
Cover
Bellows
Housing
Exhaust Valve
In order to understand the operation and function of the V.E.S. we must first consider the characteristics of a two
stroke engine. The height of the exhaust port in a two stroke engine cylinder has an affect on the total power output
of an engine, as well as the RPM at which the power occurs.
Exhaust systems are “tuned” by design to match engine exhaust port configuration and desired power delivery
characteristics. Engines with relatively “high” exhaust ports (and exhaust pipe to match) produce more horse-
power at high RPM, but only at the expense of low to midrange fuel economy and torque. On the other hand,
“low” port engines provide good fuel economy in the midrange and make their power at relatively lower RPM, but
will not produce as much peak horsepower for a given displacement range. In general, an engine designed for
a racing or high performance snowmobile will have a relatively high exhaust port compared to an engine of the
same displacement range designed for touring.
Although the V.E.S. does not in itself increase horsepower, it does allow an engine to be designed for maximum horse-
power without the inherent disadvantages of a high exhaust port.
The main components of the V.E.S. are the exhaust valve, valve housing, bellows, return spring, and cover.
A guillotine style exhaust valve is connected to a moveable piston. This piston is attached to a flexible bellows,
forming two chambers. The lower chamber is connected to the cylinder by a drilled passageway located just above
the exhaust port. The upper chamber is vented to atmospheric pressure. A valve return spring is located in the
upper chamber between the piston and cover.
At idle and low speeds, the exhaust valve is held in the “low port” position by the return spring. When throttle is
applied (and RPM begins to increase) rising cylinder pressure is applied to the under side of the bellows via the
actuation port. This forces the exhaust valve upward against spring pressure. The valve continues to move up-
ward toward the “High Port” position as cylinder pressure, horsepower, and RPM increase.
2.8
ENGINE
V.E.S. Maintenance
Due to the simplicity of V.E.S. design, maintenance is limit-
ed to a periodic inspection and cleaning of system compo-
nents. The V.E.S. should be disassembled, inspected, and Adjuster nut
cleaned (remove carbon deposits) every 1000 to 2000 O-ring
miles, depending on operating conditions. To ensure maxi- Valve cover
mum performance and minimize required maintenance, Spring
Polaris recommends the use of Polaris Synthetic 2 Cycle Valve cap
lubricant only. The use of other lubricants may cause im- Bellows Bolt
proper function of the valve mechanism, and increase the Washer
frequency of required cleaning due to excessive buildup of
carbon deposits.
Valve housing
Dowel pin
V.E.S. Removal and Cleaning Gasket
Removal and cleaning is covered later in this chapter.
Valve
V.E.S. Troubleshooting
Symptom Possible Cause Remedy
Engine will not reach Valve not opening or not opening completely:
designed operating RPM 1. Exhaust valve sticking
1. Remove carbon deposits,
2. Cylinder pressure feed port burrs etc.
restricted 2. Clean port
3. Bellows damaged or not sealing 3. Inspect bellows, fastener
correctly straps, and gasket and
repair as required
4. Incorrect spring 4. Inspect
5. Problem in clutch setup, drive 5. Inspect
line, engine, etc.
Poor acceleration; Valve opening too early:
hesitation; High RPM
performance is normal or 1. Valve sticking open or partially 1. Clean, Inspect
near normal open
2. Broken, damaged, or incorrect, 2. Inspect, Replace
spring
2.9
ENGINE
Variable Exhaust System (V.E.S.) - 2001 440 Edge Pro X
2001 440 Edge Pro X Variable Exhaust System:
The exhaust valve system on the new 440 Edge Pro X is electronically controlled by solenoids. Pressure
from the cylinders is routed through the solenoids to the atmosphere. During this time the exhaust valves
are down. When the CDI senses 6800 RPM, it triggers the solenoids to shut off the bypassed air going to
the atmosphere. Pressure then builds inside the exhaust valve bellows, causing the valves to fully open.
When RPM drops below 6800, the solenoids open to allow air to bypass through to atmosphere and the
exhaust valves close.
Below 6800 RPM Exhaust Valves Closed Above 6800 RPM Exhaust Valves Fully Open
Yellow Wire to Yellow Wire to

Wiring Harness Wiring Harness
CDI Box CDI Box
Wire Wire Wire Wire
Solenoid Solenoid Solenoid

Solenoid
Open Closed Closed
Open
Hose
Hose Hose Hose
Balance Tube Balance Tube T-Fitting

T-Fitting T-Fitting T-Fitting
Inlet Hole Spring Inlet Hole Inlet Hole

Inlet Hole
Spring from Cylinder from Cylinder Spring from Cylinder Spring
from Cylinder Bellows
Bellows
Bellows Bellows
Exhaust Exhaust
Outlet Hole Outlet Hole
Valve Valve
Exhaust Exhaust
Valve Valve
2.10
ENGINE
Exhaust System Temperature sender - 2001 440 Edge Pro X
Temp sender
The temp sender that is on the 440 Edge Pro X will read the exhaust temperature and ad-
just the timing according to the temperature range.
To Test the sensor:
Unplug sensor. At room temperature the temperature sender will have a HIGH resistance
(may read Open Line (OL)) depending on your meter.
As the pipe gets hotter, the resistance keeps lowering resulting in optimum timing for a
given RPM and pipe temperature,
If the sender resistance is not responding to pipe heat the sensor may need to be re-
placed.
LOW PIPE TEMP = HIGH RESISTANCE

MEDIUM PIPE TEMP = MEDIUM RESISTANCE
HIGH PIPE TEMP = LOW RESISTANCE
Measure resistance here
2.11
ENGINE
Changing the Timing curve
CAUTION
This engine is jetted for operation at 0 degrees _F and warmer. Re-jetting is required for temperatures colder than 0_F.
TIMING INFORMATION
The PRO X 440 has been equipped with two switches that will change the timing curve.
The first switch is an ignition switch located on

the console. This switch is used to match the tim- CAUTION Ignition Switch
Positions
ing curve to the type of fuel you are using. The
Mis-use of the timing se-
fuel types are 92 octane non-ethanol premium lector switch can cause
fuel and 110 octane fuel. Do not run the machine serious engine damage.
OFF
in the wrong ingnition key position or engine Running the machine in ON
damage may occur. the wrong ignition key 110 OCT.
ON
position may cause en- 92 OCT.
gine damage.
The second switch is located on the airbox and has seven optional curves. These seven options are used to match
the fuel type and the racing conditions which may vary, depending on the race. The standard position is “D” and
should not be moved unless you are a knowledgeable engine tuner.
Position Timing Effect

A +3
B +2
C +1
D (Standard Position) 0
E --2
F --3
G --4
The exhaust system has a temperature sensor in the body of the pipe that effects the timing curve as the tempera-
ture changes. This feature helps the pipe tune quickly and is not adjustable.
2.12
ENGINE
NOTE: Inspect all parts for wear or damage during disassembly. Replace all seals, O-rings,
and gaskets with Genuine Polaris parts during assembly. Refer to pages 2.49-2.60 for gen-
eral inspection procedures.
Disassembly -- 440 Liquid, 500, 600 small block
1. Remove carburetor mount adaptors, reed cages,

Reed Pedal Exaggerated
stuffers, and oil pump. Note position of stator wire
Clearance .015 for illustration
guide. (.38 mm) max.
Measure air gap between fiber reed and reed block
as shown. The air gap should not exceed .015 (.4
mm). If clearance is excessive DO NOT attempt to
reverse the reeds to reduce the air gap. Always
replace them if damaged. Check each fiber reed for
white stress marks or missing material. Replace if
necessary.
2. Remove V.E.S. (if applicable).
3. Remove cylinder head cover and inspect O-rings

and sealing surfaces for damage or debris. Use
new O-rings upon assembly.
2.13
ENGINE
Disassembly, Cont.
4. Remove cylinder base nuts. Note location of acorn

nuts on exhaust side (where applicable).
5. Carefully remove cylinders while supporting pistons
and connecting rods to prevent piston damage.
Refer to General Inspection Procedures in this
chapter.
6. Remove outer piston pin C-clips using a scribe
through access slot in piston.
7. Place support block under piston and remove piston

pins using pin puller.
Piston Pin Puller PN 2870386
Support Block PN 2870390
8. Remove water pump cover from front of engine.
2.14
ENGINE
Disassembly, Cont.
9. Remove recoil housing and drive hub.
10. Remove flywheel using heavy-duty flywheel puller.

Use drive clutch puller T-handle or a wrench to hold
puller.
Flywheel Puller PN 2871043
T-Handle PN 5020326
11. Before removing stator plate, note where ignition

timing marks are located, or scribe additional marks
for reference upon reassembly.
12. Mark or note location of engine mount straps and

remove.
2.15
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2001 HIGH PERFORMANCE

Polaris acknowledges the following products mentioned in this manual:

FLEXLOC, Registered Trademark of SPS Technologies

CHAPTER 1 . . . . . . . . . . . . . . . . General Information

CHAPTER 3 . . . . . . . . . . . . . . . . Fuel / Carburetion

CHAPTER 4 . . . . . . . . . . . . . . . . Drive / Driven Clutches

CHAPTER 5 . . . . . . . . . . . . . . . . Chassis, Brakes and

CHAPTER 6 . . . . . . . . . . . . . . . . Front Suspensions

CHAPTER 7 . . . . . . . . . . . . . . . . Rear Suspensions

High Performance parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1--1.2

2900152 REMOTE RESERVOIR REAR TRACK (TRAIL)

Roller Clutch Components 2900069 TORSION BAR,5/8”, 2000--01 EDGE

2900172 HELIX,DRIVEN, R12, ROLLER

2900170 HELIX,DRIVEN, 36--DEG, ROLLER

2900171 HELIX,DRIVEN, R32, ROLLER 2900156 KIT--IDLER WHEEL,4TH

2900175 HELIX,DRIVEN, R5, ROLLER

2900035 Ramp, driven, R1, 40--32

2900037 Ramp, driven, R3, 45--32 Hood/Seat

2900038 Ramp, driven, R4, 50--32

2900041 Ramp, driven, R7, 45--34

2900044 Ramp, driven, R10, 42--36

2900046 Ramp, driven, R32, 50--34 2900181 Lightweight Seat EDGE

2900047 Ramp, driven, R12, 50--36

Weights 2900063 TORSION SPRING KIT .347, 90 Deg. Square

2900028 WEIGHT,SHIFT,MATCHED,10--54 2900065 TORSION SPRING KIT .375, 90 Deg. Square

2900002 18 Tooth HYVO, Cut Metal Gear

2900003 19 Tooth HYVO, Cut Metal Gear

2900004 20 Tooth HYVO, Cut Metal Gear

2900005 21 Tooth HYVO, Cut Metal Gear

2900006 22 Tooth HYVO, Cut Metal Gear

2900007 23 Tooth HYVO, Cut Metal Gear

2900008 24 Tooth HYVO, Cut Metal Gear

2900009 25 Tooth HYVO, Cut Metal Gear

2900010 37 Tooth HYVO, Cut Metal Gear

2900011 38 Tooth HYVO, Cut Metal Gear

2900012 39 Tooth HYVO, Cut Metal Gear

2900013 40 Tooth HYVO, Cut Metal Gear

2900014 41 Tooth HYVO, Cut Metal Gear

2900015 42 Tooth HYVO, Cut Metal Gear

2900016 43 Tooth HYVO, Cut Metal Gear

2900138 43 Tooth, Lightweight Cut Metal Gear, HYVO

2900139 42 Tooth, Lightweight Cut Metal Gear, HYVO

2900140 41 Tooth, Lightweight Cut Metal Gear, HYVO

2900141 40 Tooth, Lightweight Cut Metal Gear, HYVO

2900142 39 Tooth, Lightweight Cut Metal Gear, HYVO

2900143 38 Tooth, Lightweight Cut Metal Gear, HYVO

2900144 37 Tooth, Lightweight Cut Metal Gear, HYVO

2900025 Lightweight Jackshaft Kit

3221108 Chain HYVO, 76 PITCH

3221109 Chain HYVO, 74 PITCH

3221110 Chain HYVO, 72 PITCH

3221112 Chain HYVO, 68 PITCH

3221113 Chain HYVO, 66 PITCH

3221114 Chain HYVO, 64 PITCH

3221115 Chain HYVO, 70 PITCH

2900180 MOTOR--MOUNT,KIT,AGGR,TRAIL,65 EDGE

2900179 MOTOR--MOUNT,KIT, DRAG,65 EDGE

2900019 TRACK,121”X1.5 --NOTCHED

2900018 TRACK,121”X--1.75 --NOTCHED

2900017 TRACK,121X2” NOTCHED

5411825 TRACK--121”X15”X1”MOD LIGHTNING

5411963 TRACK--121X1.25 SHOCKWAVE

5411995 TRACK--144”X2” Series 3 (Hard Lug)