2008 polaris 340 transport snowmobile service repair manual by 1639701yu

2008 EDGE / WIDETRAK SNOWMOBILE SERVICE MANUAL FOREWORD This service manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator's perspective when seated in a normal riding position. Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper tools as specified. Comments or suggestions about this manual may be directed to: Service Publications Dept. @ Polaris Sales Inc. 2100 Hwy 55 Medina Minnesota 55340.

2008 EDGE / Widetrak Snowmobile Service Manual PN 9921481 ÂŠ Copyright 2007 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS Throughout this manual, important information is brought to your attention by the following symbols:

WARNING

SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle.

CAUTION

SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.

CAUTION

CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage. NOTE: NOTE provides key information by clarifying instructions. IMPORTANT: IMPORTANT provides key reminders during disassembly, assembly and inspection of components.

= In. / mm.

MEASUREMENT provides a key for a determined measurement specification.

TORQUE provides a key for a required torque value.

TRADEMARKS POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL: Loctite, Registered Trademark of the Loctite Corporation Nyogel, Trademark of Wm. F. Nye Co. Fluke, Registered Trademark of John Fluke Mfg. Co. Mity-Vac, Registered Trademark of Neward Enterprises, Inc. Torx, Registered Trademark of Textron M-10, Registered Trademark of FAST Inc. WD-40, Registered Trademark of WD-40 Company Rapid Reaction Driven Clutch, Registered Trademark of Team Industries Inc. VM and TM Carburetors, Registered Trademarks of Mikuni American Corporation

2008 EDGE / Widetrak Service Manual Chapters

Model Specifications........................... .... 1 General Information............................ .... 2 Maintenance....................................... .... 3 Fuel Systems...................................... .... 4 Engine Systems.................................. .... 5 Final Drive and Brake Systems.......... .... 6 PVT System........................................ .... 7 Front and Rear Suspensions.............. .... 8 Chassis............................................... .... 9 Electrical Systems.............................. .... 10 Wiring Schematics.............................. .... 11

Model Specifications

CHAPTER 1 Model Specifications

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 2008 340 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 2008 340 TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 2008 SUPERSPORT / 550 LX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 2008 TRAIL TOURING DELUXE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 2008 TRAIL RMK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 2008 WIDETRAK LX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12

1.1

Model Specifications SPECIFICATIONS

Carburetor Jetting Ambient Temperature

< -25°F/<-35°C

-30°F to -10°F/-34°C to -23°C

-15°F to +5°F/-26°C to -15°C

0°F to +20°F/-18°C to -7°C

+15°F to +35°F/-9°C to +2°C

+30°F to +50°F/-1°C to +10°C

+45°F to +65°F/+7°C to +18°C

>+60°F/>+16°C

2008 340

0-600 (0-2000)

185 #4

180 #3

170 #3

165 #3

160 #3

155 #3

150 #3

Model Number: S08NB3AS Altitude Meters (feet)

Engine Fuji Fan-Cooled / Piston Port Induction

Engine Type Model Number

EC34-2PM074

Displacement / # Cylinders

339cc / 2

Bore (inches/mm)

2.45 / 62.23

Stroke (inches/mm)

2.19 / 55.6

600-1200 (2000-4000)

175 #3

170 #3

160 #3

155 #3

150 #3

140 #2

Piston to Cylinder Clearance (inches/mm)

.003 - .005 / .076 - .127

1200-1800 (4000-6000)

165 #3

160 #3

155 #3

150 #3

145 #3

140 #2

130 #2

Installed Ring Gap (inches / mm)

.008 - .014 / .203 - .356

1800-2400 (6000-8000)

155 #3

150 #3

140 #3

135 #3

135 #2

130 #2

120 #1

Operating RPM ±200

7000

2400-3000 (8000-10,000)

Idle RPM

1600

145 #3

140 #3

130 #2

125 #2

120 #1

110 #1

Engagement RPM ±200

4100

3000-3700 (10,000-12,000)

135 #3

130 #2

120 #2

115 #2

115 #1

110 #1

100 #1

Carburetor Settings Type

Clutch Settings Mikuni VM30SS

Main Jet

170

Pilot Jet

Jet Needle/Clip position

5DP13 / 3

Needle Jet

O-6 (169)

Throttle Gap (Under Cutaway) (in/mm) Drill Bit Size Cutaway

.240 / 6.1 B - 15/64 2.5 AL

Valve Seat

1.5 Viton

Starter Jet

1.5

Pilot Air Jet

2.5

Air Screw (Turns Out)

1.5

Recommended Fuel Octane (R+M/2)

1.2

87 (Non-Oxygenated)

ALTITUDE meters (feet)

DRIVE CLUTCH Shift Weight

0-900 (0-3000)

900-1800 (3000-6000)

10M-B

1800-2700 (6000-9000)

10M-W

2700-3700 (9000-12,000)

10M-R

DRIVEN CLUTCH

Clutch Spring

Driven Helix

Gearing

110 / 290 (2287)

RED/BLK

S36 LW ER

16:41-72

Drive Clutch Bolt Torque: 50 lb.ft. (68Nm)

Model Specifications General

Front Suspension

Width (in/cm)

48 / 121.9

Suspension Type

Length (in/cm)

113 / 287

Shocks

Height (in/cm)

48 / 121.9

100 (1.79)

Estimated Dry Weight (lb/kg)

IFS Spring Rate lbs/in (N/mm)

450 / 204.5

.625 (15.9)

Fuel (Gallons / Liters)

11.8 / 44.7

Spring Pre-load Inches (cm)

Oil (Quarts / Liters)

3.25 / 3.1

Brake Fluid

DOT 4

Drive Belt Part Number Width (inches / cm) Side Angle Circumference (inches / cm) Center Distance (inches / cm)

3211078 1.438 / 3.65 28_ 46.625 / 118.4 11.5 / 29.2

Chaincase Center Distance (inches) Top Gear (Stock) Bottom Gear (Stock) Chain (Stock) Gear Lube Capacity (oz / ml) Reverse System

7.92 16 41 72 Polaris Synthetic 9 / 266.2 Perc

Alternator Output Operating Voltage Watts @ 13.5 Vdc (Total)

13.5 - 14.5 Vdc 240

Ignition Timing

Arvin Nitrex Gas Bag

Front Vertical Travel Inches (cm)

40.44 +/- .25 (102.71 +/- .63) Inches (cm) Camber Inches (cm)

.59 +/- .31 (1.5 +/- .8)

Toe Out Inches (cm) (Measured over 20 inches)

.12 - .25 (.30 - .63)

Rear Suspension Suspension Type Front Track Shock (FTS) FTS Spring Rate lbs/in (N/mm)

Torsion Springs

26.5_ @3000 RPM

Spark Plug Gap in.(mm)

.028 (.70)

Spark Plug

NGK BR8ES

CDI Marking

CU7245

Flywheel Marking

FP9313

10 (25.4)

Suspension Width

Rear Track Shock (RTS)

Electrical

EDGE 42.5

Rear Travel Inches (cm)

EDGE 121 Arvin Nitrex Gas Bag 200 - 240 (3.6 - 4.3) Ryde FX MPV Compression Adjustable .359 / 77_ (Stock) - PN 7041629-067 - PN 7041630 - 067 .375 / 77_ (Firm) - PN 7041942 - 067 - PN 7041943 - 067 13.9 (35.3)

Track Width - Inches (cm)

15 (38)

Length - Inches (cm)

121 (307)

Lug Height - Inches (cm)

.82 (2.08)

Track tension sag in/cm with 10 lbs/4.54kg placed 16 in/ 40cm ahead of rear idler shaft

3/8” - 1/2” (1 - 1.3cm)

1.3

Model Specifications 2008 340 Transport

Carburetor Jetting Ambient Temperature

< -25°F/<-35°C

-30°F to -10°F/-34°C to -23°C

-15°F to +5°F/-26°C to -15°C

0°F to +20°F/-18°C to -7°C

+15°F to +35°F/-9°C to +2°C

+30°F to +50°F/-1°C to +10°C

+45°F to +65°F/+7°C to +18°C

>+60°F/>+16°C

Model Number: S08NT3AS / S08NT3AE

Bore (inches/mm)

2.45 / 62.23

Stroke (inches/mm)

2.19 / 55.6

0-600 (0-2000)

185 #4

180 #3

170 #3

165 #3

160 #3

155 #3

150 #3

Piston to Cylinder Clearance (inches/mm)

.003 - .005 / .076 - .127

600-1200 (2000-4000)

175 #3

170 #3

160 #3

155 #3

150 #3

140 #2

Installed Ring Gap (inches / mm)

.008 - .014 / .203 - .356

1200-1800 (4000-6000)

165 #3

160 #3

155 #3

150 #3

145 #3

140 #2

130 #2

Operating RPM ±200

7000

1800-2400 (6000-8000)

Idle RPM

1600

155 #3

150 #3

140 #3

135 #3

135 #2

130 #2

120 #1

Engagement RPM ±200

4100

2400-3000 (8000-10,000)

145 #3

140 #3

130 #2

125 #2

120 #1

110 #1

3000-3700 (10,000-12,000)

135 #3

130 #2

120 #2

115 #2

115 #1

110 #1

100 #1

Engine Fuji Fan-Cooled / Piston Port Induction

Engine Type Model Number

Altitude Meters (feet)

EC34-2PM074

Displacement / # Cylinders

339cc / 2

Carburetor Settings Type

Mikuni VM30SS

Main Jet

170

Pilot Jet

Clutch Settings ALTITUDE meters (feet)

DRIVE CLUTCH Shift Weight

Jet Needle/Clip position

5DP13 / 3

Needle Jet

O-6 (169)

0-900 (0-3000)

Throttle Gap (Under Cutaway) (in/mm) Drill Bit Size

.240 / 6.1 B - 15/64

900-1800 (3000-6000)

10M-B

2.5 AL

1800-2700 (6000-9000)

10M-W

Valve Seat

1.5 Viton

2700-3700 (9000-12,000)

10M-R

Starter Jet

1.5

Pilot Air Jet

2.5

Air Screw (Turns Out)

1.5

Cutaway

Recommended Fuel Octane (R+M/2)

1.4

87 (Non-Oxygenated)

DRIVEN CLUTCH

Clutch Spring

Driven Helix

Gearing

110 / 290 (2287)

BLU/BLK

54/38 .25 LW ER

17:41-72

Drive Clutch Bolt Torque: 50 lb.ft. (68Nm)

Model Specifications General

Front Suspension

Width (in/cm)

48 / 121.9

Suspension Type

Length (in/cm)

128 / 325.1

Shocks

Height (in/cm)

49.5 / 125.7

100 (1.79)

Estimated Dry Weight (lb/kg)

IFS Spring Rate lbs/in (N/mm)

497 / 225.6

.625 (15.9)

Fuel (Gallons / Liters)

12.25 / 46.4

Spring Pre-load Inches (cm)

Oil (Quarts / Liters)

3.4 / 3.2 6.3 / 6

Suspension Width

Brake Fluid

DOT 4

Inches (cm)

Drive Belt Part Number Width (inches / cm) Side Angle Circumference (inches / cm) Center Distance (inches / cm)

3211078 1.438 / 3.65 28_ 46.625 / 118.4 11.5 / 29.2

Chaincase Center Distance (inches) Top Gear (Stock) Bottom Gear (Stock) Chain (Stock) Gear Lube Capacity (oz / ml) Reverse System

7.92 17 41 72 Polaris Synthetic 9 / 266.2 Perc

Arvin Nitrex Gas Bag

Front Vertical Travel Inches (cm)

Cooling System Capacity (Quarts / Liters)

Camber Inches (cm)

.59 +/- .31 (1.5 +/- .8)

Toe Out Inches (cm) (Measured over 20 inches)

.12 - .25 (.30 - .63)

Rear Suspension Suspension Type Front Track Shock (FTS) FTS Spring Rate lbs/in (N/mm) Rear Track Shock (RTS)

Torsion Springs 13.5 - 14.5 Vdc 240

Ignition Timing

26.5_ @ 3000 RPM

Spark Plug Gap in.(mm)

.028 (.70)

Spark Plug

10 (25.4)

40.44 +/- .25 (102.71 +/- .63)

Electrical Alternator Output Operating Voltage Watts @ 13.5 Vdc (Total)

EDGE 42.5

Rear Travel Inches (cm)

EDGE 136 Arvin Nitrex Gas Bag 200 - 240 (3.6 - 4.3) Ryde FX MPV Compression Adjustable .405 / 77_ (Stock) - PN 7041940 - 067 - PN 7041941 - 067 .375 / 77_ (Softer) - PN 7041942 - 067 - PN 7041943 - 067 13.9 (35.3)

NGK BR8ES

CDI Marking

CU7245

Flywheel Marking

FP9313 Track

Width - Inches (cm)

15 (38)

Length - Inches (cm)

136 (345)

Lug Height - Inches (cm) Track tension sag in/cm with 10 lbs/4.54kg placed 16 in/ 40cm ahead of rear idler shaft

1.25 (3.175) 1 1/8” - 1 3/8” (2.9 - 3.5cm)

1.5

Model Specifications 2008 Supersport / 550 LX

Carburetor Jetting Ambient Temperature

< -25°F/<-35°C

-30°F to -10°F/-34°C to -23°C

-15°F to +5°F/-26°C to -15°C

0°F to +20°F/-18°C to -7°C

+15°F to +35°F/-9°C to +2°C

+30°F to +50°F/-1°C to +10°C

+45°F to +65°F/+7°C to +18°C

>+60°F/>+16°C

Model Number:

0-600 (0-2000)

270 #4

260 #4

250 #4

240 #4

230 #3

220 #3

210 #2

200 #1

600-1200 (2000-4000)

260 #4

250 #4

240 #3

230 #3

220 #3

220 #2

210 #2

200 #1

1200-1800 (4000-6000)

250 #4

240 #3

230 #3

220 #3

210 #2

200 #2

190 #1

1800-2400 (6000-8000)

230 #3

220 #3

210 #2

200 #2

190 #1

180 #1

2400-3000 (8000-10,000)

220 #3

210 #3

210 #2

200 #2

190 #2

180 #1

170 #1

3000-3700 (10,000-12,000)

210 #3

200 #3

190 #2

180 #2

170 #1

160 #1

Supersport = S08NP5BS / S08NP5ES 550 LX = S08ND5BS Altitude Meters (feet)

Engine Fuji Fan-Cooled / Piston Port w/Reed Assist Induction

Engine Type Model Number

EC55PM101

Displacement / # Cylinders

544cc / 2

Bore (inches/mm)

2.87 / 73

Stroke (inches/mm)

2.56 / 65

Piston to Cylinder Clearance (inches/mm) Installed Ring Gap (inches / mm)

.0039 - .0053 (.10 - .135) .016 - .022 (.40 - .55)

Operating RPM ±200

7000

Idle RPM

1600

Engagement RPM ±200

3800 Clutch Settings

Carburetor Settings Type

Mikuni VM34

Main Jet

240

Pilot Jet

Jet Needle/Clip position

6BGY41 / 4

ALTITUDE meters (feet) 0-600 (0-2000)

DRIVE CLUTCH Shift Weight

Clutch Spring

DRIVEN CLUTCH Clutch Spring

Driven Helix

Gearing

10-62

600-1200 (2000-4000)

19:39-72 10-60

Needle Jet

Q-0 (480)

1200-1800 (4000-6000)

Throttle Gap (Under Cutaway) (in/mm) Drill Bit Size

.256 / 6.5 F

1800-2400 (6000-8000)

10-58

3.0

2400-3000 (8000-10000)

10-56

Valve Seat

1.5 Viton 1.5

3000-3600 (10000-12000)

10-56

Starter Jet Pilot Air Jet

2.5

Air Screw (Turns Out)

1.0

Cutaway

Recommended Fuel Octane (R+M/2)

1.6

87 (Non-Oxygenated)

Dk. BLU/ WHT

RED/BLU

56/42 - .36 LW ER

Drive Clutch Bolt Torque: 50 lb.ft. (68Nm)

18:39 72

Model Specifications General

Front Suspension

Width (in/cm)

48 / 121.9

Suspension Type

Length (in/cm)

113 / 287

Shocks

Height (in/cm)

48 / 121.9

IFS Spring Rate lbs/in (N/mm)

100 (1.79)

Spring Pre-load Inches (cm)

.625 (15.9)

Estimated Dry Weight (lb/kg)

Supersport = 470 (213.6) 550 LX = 489 (222)

Fuel (Gallons / Liters)

11.8 / 44.7

Oil (Quarts / Liters)

3.25 / 3.1

Brake Fluid

DOT 4

Drive Belt Part Number Width (inches / cm) Side Angle Circumference (inches / cm) Center Distance (inches / cm)

3211078 1.438 / 3.65 28_ 46.625 / 118.4 11.5 / 29.2

Chaincase Center Distance (inches) Top Gear (Stock) Bottom Gear (Stock) Chain (Stock) Gear Lube Capacity (oz / ml) Reverse System

7.92 19 39 72 Polaris Synthetic 9 / 266.2 Perc

Electrical Alternator Output Operating Voltage Watts @ 13.5 Vdc (Total)

Suspension Setup Width Inches (cm)

.028 (.70)

Spark Plug

Toe Out Inches (cm) (Measured over 20 inches)

.12 - .25 (.30 - .63)

Rear Suspension Suspension Type Front Track Shock (FTS)

Width - Inches (cm)

15 (38)

Length - Inches (cm)

121 (307)

Lug Height - Inches (cm)

.82 (2.08)

Track tension sag in/cm with 10 lbs/4.54kg placed 16 in/ 40cm ahead of rear idler shaft

Arvin Nitrex Gas Bag 200 - 240 (3.6 - 4.3)

Rear Track Shock (RTS)

Ryde FX MPV Compression Adjustable

Torsion Springs

FP6318 Track

EDGE 121

FTS Spring Rate lbs/in (N/mm)

EC55PM100 / 110

Flywheel Marking

40.44 +/- .25 (102.71 +/- .63) .59 +/- .31 (1.5 +/- .8)

NGK BR9ES

CDI Marking

10 (25.4)

Camber Inches (cm)

27_ @ 3000 RPM 14_ @ 6500 RPM

Spark Plug Gap in.(mm)

Arvin Nitrex Gas Bag

Front Vertical Travel Inches (cm)

13.5 - 14.5 Vdc 280

Ignition Timing

EDGE 42.5

Rear Travel Inches (cm)

.359 / 77_ (Stock: 550LX / Soft: Supersport) - PN 7041629 - 067 - PN 7041630 - 067 .375 / 77_ ( Firm: 550LX / Stock: Supersport) - PN 7041942 - 067 - PN 7041943 - 067 .405 / 77_ (Firm: Supersport) - PN 7041940 - 067 - PN 7041941 - 067 13.9 (35.3)

3/8” - 1/2” (1 - 1.3cm)

1.7

Model Specifications 2008 Trail Touring Deluxe

Carburetor Jetting Ambient Temperature

< -25°F/<-35°C

-30°F to -10°F/-34°C to -23°C

-15°F to +5°F/-26°C to -15°C

0°F to +20°F/-18°C to -7°C

+15°F to +35°F/-9°C to +2°C

+30°F to +50°F/-1°C to +10°C

+45°F to +65°F/+7°C to +18°C

>+60°F/>+16°C

Model Number: S08NT5BS / S08NT5BE

0-600 (0-2000)

270 #4

260 #4

250 #4

240 #4

230 #3

220 #3

210 #2

200 #1

600-1200 (2000-4000)

260 #4

250 #4

240 #3

230 #3

220 #3

220 #2

210 #2

200 #1

1200-1800 (4000-6000)

250 #4

240 #3

230 #3

220 #3

210 #2

200 #2

190 #1

1800-2400 (6000-8000)

230 #3

220 #3

210 #2

200 #2

190 #1

180 #1

2400-3000 (8000-10,000)

220 #3

210 #3

210 #2

200 #2

190 #2

180 #1

170 #1

3000-3700 (10,000-12,000)

210 #3

200 #3

190 #2

180 #2

170 #1

160 #1

Engine Fuji Fan-Cooled / Piston Port w/Reed Assist Induction

Engine Type Model Number

Altitude Meters (feet)

EC55PM101

Displacement / # Cylinders

544cc / 2

Bore (inches/mm)

2.87 / 73

Stroke (inches/mm)

2.56 / 65

Piston to Cylinder Clearance (inches/mm) Installed Ring Gap (inches / mm)

.0039 - .0053 (.10 - .135) .016 - .022 (.40 - .55)

Operating RPM ±200

7000

Idle RPM

1600

Engagement RPM ±200

3800

Carburetor Settings Type Main Jet Pilot Jet Jet Needle/Clip position

240 35 6BGY41 / 4

Needle Jet

Q-0 (480)

Throttle Gap (Under Cutaway) (in/mm) Drill Bit Size

.256 / 6.5 F

Cutaway

3.0

Valve Seat

1.5 Viton

Starter Jet

1.5

Pilot Air Jet

2.5

Air Screw (Turns Out)

1.0

Recommended Fuel Octane (R+M/2)

1.8

Clutch Settings

Mikuni VM34

87 (Non-Oxygenated)

ALTITUDE meters (feet) 0-600 (0-2000)

DRIVE CLUTCH Shift Weight

Clutch Spring

DRIVEN CLUTCH Clutch Spring

Driven Helix

Gearing

10-62

600-1200 (2000-4000)

21:41-74 10-60

1200-1800 (4000-6000)

BLU / WHT RED/BLU

1800-2400 (6000-8000)

56/42 - .36 LW ER

10-58

2400-3000 (8000-10000)

20:41-74 10-56

3000-3600 (10000-12000)

Dark Blue

Drive Clutch Bolt Torque: 50 lb.ft. (68Nm)

Model Specifications General

Front Suspension

Width (in/cm)

48 / 121.9

Length (in/cm)

128 / 325.1

Height (in/cm)

49.5 / 125.7

Estimated Dry Weight (lb/kg)

570 / 258.8

IFS Spring Rate lbs/in (N/mm)

100 (1.79)

Fuel (Gallons / Liters)

12.25 / 146.4

Spring Pre-load Inches (cm)

.625 (15.9)

Oil (Quarts / Liters)

3.4 / 3.2

Brake Fluid

DOT 4

Drive Belt Part Number Width (inches / cm) Side Angle Circumference (inches / cm) Center Distance (inches / cm)

3211078 1.438 / 3.65 28_ 46.625 / 118.4 11.5 / 29.2

Chaincase Center Distance (inches) Top Gear (Stock) Bottom Gear (Stock) Chain (Stock) Gear Lube Capacity (oz / ml) Reverse System

7.96 21 41 74 Polaris Synthetic 9 / 266.2 Perc

Suspension Type

Arvin Nitrex Compression Adjustable

Shocks

Front Vertical Travel Inches (cm) Suspension Setup Width Inches (cm) Camber Inches (cm)

.59 +/- .31 (1.5 +/- .8)

Toe Out Inches (cm) (Measured over 20 inches)

.12 - .25 (.30 - .63)

Rear Suspension Suspension Type Front Track Shock (FTS) FTS Spring Rate lbs/in (N/mm) Rear Track Shock (RTS)

13.5 - 14.5 Vdc 280 27_ @ 3000 RPM 14_ @ 6500 RPM

Ignition Timing Spark Plug Gap in.(mm)

Torsion Springs

.028 (.70)

Spark Plug

NGK BR9ES

CDI Marking

10 (25.4)

40.44 +/- .25 (102.71 +/- .63)

Electrical Alternator Output Operating Voltage Watts @ 13.5 Vdc (Total)

EDGE 42.5

Rear Travel Inches (cm)

EDGE 136 Arvin Nitrex Gas Bag 200 - 240 (3.6 - 4.3) Ryde FX MPV Compression Adjustable .405 / 77_ (Stock) - PN 7041940 - 067 - PN 7041941 - 067 .375 / 77_ (Soft) - PN 7041942 - 067 - PN 7041943 - 067 13.9 (35.3)

EC55PM100 / 110

Flywheel Marking

FP6318 Track

Width - Inches (cm)

15 (38)

Length - Inches (cm)

136 (345.4)

Lug Height - Inches (cm) Track tension sag in/cm with 10 lbs/4.54kg placed 16 in/ 40cm ahead of rear idler shaft

1.0 / (2.5)

7/8” - 1 1/8” (2.2 - 2.9cm)

1.9

Model Specifications 2008 Trail RMK

Carburetor Jetting Ambient Temperature

< -25°F/<-35°C

-30°F to -10°F/-34°C to -23°C

-15°F to +5°F/-26°C to -15°C

0°F to +20°F/-18°C to -7°C

+15°F to +35°F/-9°C to +2°C

+30°F to +50°F/-1°C to +10°C

+45°F to +65°F/+7°C to +18°C

>+60°F/>+16°C

Model Number: S08NJ5BS / S08NJ5BE

0-600 (0-2000)

270 #4

260 #4

250 #4

240 #4

230 #3

220 #3

210 #2

200 #1

600-1200 (2000-4000)

260 #4

250 #4

240 #3

230 #3

220 #3

220 #2

210 #2

200 #1

1200-1800 (4000-6000)

250 #4

240 #3

230 #3

220 #3

210 #2

200 #2

190 #1

1800-2400 (6000-8000)

230 #3

220 #3

210 #2

200 #2

190 #1

180 #1

2400-3000 (8000-10,000)

220 #3

210 #3

210 #2

200 #2

190 #2

180 #1

170 #1

3000-3700 (10,000-12,000)

210 #3

200 #3

190 #2

180 #2

170 #1

160 #1

Engine Fuji Fan-Cooled / Piston Port w/Reed Assist Induction

Engine Type Model Number

Altitude Meters (feet)

EC55PM101

Displacement / # Cylinders

544cc / 2

Bore (inches/mm)

2.87 / 73

Stroke (inches/mm)

2.56 / 65

Piston to Cylinder Clearance (inches/mm) Installed Ring Gap (inches / mm)

.0039 - .0053 (.10 - .135) .016 - .022 (.40 - .55)

Operating RPM ±200

7000

Idle RPM

1600

Engagement RPM ±200

3800

Carburetor Settings Type Main Jet Pilot Jet Jet Needle/Clip position

210 35 6BGY41 / 2

Needle Jet

Q-0 (480)

Throttle Gap (Under Cutaway) (in/mm) Drill Bit Size

.264 / 6.71 G - 17/64

Cutaway

3.0

Valve Seat

1.5 Viton

Starter Jet

1.5

Pilot Air Jet

2.5

Air Screw (Turns Out)

.75

Recommended Fuel Octane (R+M/2)

1.10

Clutch Settings

Mikuni VM34

87 (Non-Oxygenated)

DRIVE CLUTCH

ALTITUDE meters (feet)

Shift Weight

0-600 (0-2000)

10-64

600-1200 (2000-4000)

10-62

DRIVEN CLUTCH

Clutch Spring

Driven Helix

Gearing

BLU/WHT

RED/BLU

56/42 .36 LW ER

19:43 - 74

1200-1800 (4000-6000) 10-60 1800-2400 (6000-8000) 2400-3000 (8000-10000)

10-58

3000-3600 (10000-12000)

10-56

Drive Clutch Bolt Torque: 50 lb.ft. (68Nm)

Model Specifications General

Front Suspension

Width (in/cm)

45.5 / 115.6

Length (in/cm)

124 / 315

Shocks

Height (in/cm)

48 / 121.9

100 (1.79)

Estimated Dry Weight (lb/kg)

IFS Spring Rate lbs/in (N/mm)

475 / 215.7

.625 (15.9)

Fuel (Gallons / Liters)

11.8 / 44.7

Spring Pre-load Inches (cm) Front Vertical Travel Inches (cm)

7.6 (19.3)

Oil (Quarts / Liters)

3.4 / 3.2

Brake Fluid

DOT 4

Drive Belt Part Number Width (inches / cm) Side Angle Circumference (inches / cm) Center Distance (inches / cm)

3211078 1.438 / 3.65 28_ 46.625 / 118.4 11.5 / 29.2

Chaincase Center Distance (inches) Top Gear (Stock) Bottom Gear (Stock) Chain (Stock) Gear Lube Capacity (oz / ml) Reverse System

7.92 19 43 74 Polaris Synthetic 9 / 266.2 Perc

Arvin Nitrex Gas Bag

Suspension Width 40.90 +/- .25 (103.88 +/- .63) Inches (cm) Camber Inches (cm)

.735 +/- .31 (1.5 +/- .8)

Toe Out Inches (cm) (Measured over 20 inches)

0 - .12 (0 - .30)

Rear Suspension Suspension Type Front Track Shock (FTS) FTS Spring Rate lbs/in (N/mm)

13.5 - 14.5 Vdc 280 27_ @ 3000 RPM 14_ @ 6500 RPM

Ignition Timing Spark Plug Gap in.(mm)

.028 (.70)

Spark Plug

Torsion Springs

NGK BR9ES

CDI Marking

EC55PM100 / 110

Flywheel Marking

FP6318 Track

Rear Travel Inches (cm)

Width - Inches (cm)

15 (38)

Length - Inches (cm)

136 (345)

Lug Height - Inches (cm) Track tension sag in/cm with 10 lbs/4.54kg placed 16 in/ 40cm ahead of rear idler shaft

EDGE RMK 41

Rear Track Shock (RTS)

Electrical Alternator Output Operating Voltage Watts @ 13.5 Vdc (Total)

Suspension Type

EDGE RMK 136 Arvin Nitrex Gas Bag 200 - 240 (3.6 - 4.3) Arvin Nitrex Compression Adjustable .347 / 77_ (Stock) - PN 7041627 - 067 - PN 7041628 - 067 .347 / 47 (Soft) - PN 7042081 - 067 - PN 7042082 - 067 .375 / 77 (Firm) - PN 7041631 - 067 - PN 7041632 - 067 .405 / 77_ (Most Firm) - PN 7041940 - 067 - PN 7041941 - 067 13.8 (35.1)

1.25 (3.175)

3/8” - 1/2” (1 - 1.3cm)

1.11

Model Specifications 2008 Widetrak LX

Carburetor Jetting Ambient Temperature

< -25°F/<-35°C

488cc / 2

-15°F to +5°F/-26°C to -15°C

0°F to +20°F/-18°C to -7°C

+15°F to +35°F/-9°C to +2°C

+30°F to +50°F/-1°C to +10°C

+45°F to +65°F/+7°C to +18°C

>+60°F/>+16°C

Displacement / # Cylinders

-30°F to -10°F/-34°C to -23°C

Model Number: S08SU4BS / S08SU4BE

Bore (inches/mm)

2.83 / 72

Stroke (inches/mm)

2.36 / 60

0-600 (0-2000)

210 #2

200 #2

195 #2

190 #2

185 #2

175 #2

170 #2

170 #1

.0035 - .0049 / .090 - .125

600-1200 (2000-4000)

195 #2

185 #2

180 #2

175 #2

170 #2

165 #2

155 #1

.0078 - .0157 / .20 - .40

1200-1800 (4000-6000)

185 #2

175 #2

170 #2

165 #2

160 #2

155 #1

145 #1

Operating RPM ±200

7000

1800-2400 (6000-8000)

Idle RPM

1600

170 #2

165 #2

155 #2

150 #1

140 #1

135 #1

Engagement RPM ±200

3800

2400-3000 (8000-10,000)

160 #2

155 #2

145 #1

140 #1

130 #1

120 #1

3000-3700 (10,000-12,000)

150 #2

140 #1

135 #1

130 #1

125 #1

120 #1

110 #1

Engine Fuji Liquid-Cooled / Piston Port Induction

Engine Type Model Number

Altitude Meters (feet)

EC50PL238

Piston to Cylinder Clearance (inches/mm) Installed Ring Gap (inches / mm)

Carburetor Settings Type

Mikuni VM34SS

Main Jet

195

Pilot Jet

Clutch Settings ALTITUDE meters (feet)

DRIVE CLUTCH Shift Weight

Clutch Spring Brown

Jet Needle/Clip position

6EJ26 / 2

Needle Jet

P-6 (166)

0-900 (0-3000)

Throttle Gap (Under Cutaway) (in/mm) Drill Bit Size

.240 / 6.1 B - 15/64

900-1800 (3000-6000)

3.0

1800-2700 (6000-9000)

10M-B

Valve Seat

1.5 Viton

2700-3700 (9000-12,000)

10M-W

Starter Jet

1.5

Pilot Air Jet

2.5

Air Screw (Turns Out)

Cutaway

Recommended Fuel Octane (R+M/2)

1.12

87 (Non-Oxygenated)

DRIVEN CLUTCH Clutch Spring

Driven Helix

Gearing

Silver

36D #2

19:41-66

RED/WHT

Drive Clutch Bolt Torque: 50 lb.ft. (68Nm)

Model Specifications General

Front Suspension

Width (in/cm)

43.5 / 110.5

Suspension Type

Length (in/cm)

128 / 325.1

Shocks

Height (in/cm)

51 / 129.5

105 (1.9)

Estimated Dry Weight (lb/kg)

IFS Spring Rate lbs/in (N/mm)

643 / 292

Spring Pre-Load

3 x .135” Shims

Fuel (Gallons / Liters)

13 / 55.4

Widetrak Arvin Nitrex Gas Bag

7.25 (18.4)

2 / 1.9

Front Vertical Travel Inches (cm)

Cooling System Capacity (Quarts / Liters)

3.4 / 3.2

Ski Center Distance Inches (cm)

38 (96.5)

Brake Fluid

DOT 4

Camber Inches (cm)

.82 ± 0.72 (20.8 ± 18.3)

Toe Out Inches (cm)

0 - 0.12 (0 - 0.31)

Oil (Quarts / Liters)

Drive Belt Part Number Width (inches / cm) Side Angle Circumference (inches / cm) Center Distance (inches / cm)

3211070 1.375 / 3.49 28_ 47.25 / 120 12 / 30.5

Chaincase Center Distance (inches) Top Gear (Stock) Bottom Gear (Stock) Chain (Stock) Gear Lube Capacity (oz / ml) Drive System

N/A 19 41 66 Polaris Synthetic 20 / 591.5 HI / LOW / REV

Rear Suspension Suspension Type Front Track Shock (FTS) FTS Spring Rate lbs/in (N/mm) Rear Track Shock (RTS) RTS Spring Rate lbs/in (N/mm)

Widetrak Coupled Rail 156 Arvin Nitrex Gas Bag 181 (3.2) Arvin Nitrex Gas Bag 105 (1.9) Cam Adjustable Pre-Load

Torsion Spring Diameter Tail Angle

.468 74_

Rear Travel Inches (cm)

9 (22.9)

Electrical Alternator Output Operating Voltage Watts @ 13.5 Vdc (Total)

13.5 - 14.5 Vdc 200

Ignition Timing

27_ @ 3000 RPM

Spark Plug Gap in.(mm)

.028 (.70)

Spark Plug

Champion RN3C

CDI Marking

IU2212

Flywheel Marking

FP5536 Track

Width - Inches (cm)

20 (51)

Length - Inches (cm)

156 (396)

Lug Height - Inches (cm)

1.0 / (2.5)

Track tension sag in/cm with 10 lbs/4.54kg placed 16 in/ 40cm ahead of rear idler shaft

3/4” - 1” (1.9 - 2.5cm)

1.13

Model Specifications

NOTES

1.14

General Information

CHAPTER 2 General Information SNOWMOBILE NUMBER DESIGNATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 MODEL NUMBER DESIGNATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2

VEHICLE IDENTIFICATION NUMBER (VIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2

TUNNEL DECAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 VIN NUMBER DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

PUBLICATION PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 2008 PUBLICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 MISC. PUBLICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

GENERAL REFERENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 STANDARD BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 FUEL / OIL PREMIX RATIOS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 GASOLINE VOLATILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 MEASUREMENT CONVERSION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 PISTON WASH / SPARK PLUG READING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7

2.1

General Information SNOWMOBILE NUMBER DESIGNATIONS Model Number Designation Example: S08ND5BS

GROUP

MODEL YEAR

MODEL LINE

MODEL TYPE

1st digit

2/3rd digit

4th digit

5th digit

6th digit*

S=Snow

M=Race IQ N=Edge P= IQ S=GenII W=Mini Indy

08 = 2008 09 = 2009

B = Basic D = LX G = 155 RMK H = 163 RMK J = 136 RMK K = 144 RMK M = 155 STD. N = 163 STD. P = Performance R = Switchback S = Switchback Prem. T = Touring U = Utility X = Race Y = Touring LTD.

VIN IDENTIFIER

OPTION IDENTIFIER

7th digit*

8th digit

9th digit**

ENGINE MODIFIER

1A=121 F/C OHV 4 Cycle Fuji 3A=340 F/C Piston Port 4B=488 L/C Piston Port 5B=544 F/C Cylinder Reed 6F=600 EV L/C Case Reed 6H=600 EV L/C Case Reed CFI 6J = 600 EV L/C Case Reed Race 7E=750 Four Stroke 7F=750 Four Stroke Turbo 7J=700 EV L/C Case Reed CFI 8E = 795 EV L/C Case Reed CFI

E=Europe M=Military R=Rolling Chassis S=Standard

Option

*=digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively **=9th digit will be used on color/featured versions of models (not including the base) First 3 digits and 9th digit are sued in model number only. They are not used with the 17 digit VIN.

VEHICLE IDENTIFICATION NUMBER (VIN) Tunnel Decal

referred to in any correspondence regarding warranty, service or replacement parts. The machine model and V.I.N. number identification decal is located on the right front side of the tunnel. The V.I.N. (2) number is permanently stamped into the tunnel. The model number is embossed on the decal.

The Tunnel Decal has the Model Number (1), V.I.N. Number (2), and the Manufactured Date (3). These numbers should be 1

2.2

General Information VIN Number Designation

Type

Engine Size

Engine Modifier

Series

Check Digit

Model Year

Mfg. Location

Vehicle Identifiers

Body Style

Vehicle Descriptors

World Mfg. ID

Individual Serial No.

PUBLICATION PART NUMBERS 2008 Publications MODEL

OWNER'S MANUAL

SUPPLEMENT

PARTS BOOK

340 340 Transport Supersport 550 LX Trail Touring Trail RMK Widetrak LX

9921041 9921056 9921041 9921041 9921056 9921054 9921429

9921045 9921061 9921052 9921050 9921059 N/A 9921063

9921046 9921058 9921053 9921051 9921060 9921055 9921064

Misc. Publications YEAR

PUBLICATION

PART NUMBER

ALL

Track Diagnosis Poster

9918459

ALL

Belt Failure Poster

9920936

ALL

Monotube Shock Rebuilding Video

9917736

ALL

Remote Reservoir Shock Rebuilding

9917737

2.3

General Information GENERAL REFERENCE

Gasoline Volatility

Standard Bolt Torque Specification

Grade 2

MAXIMUM REID VAPOR

Grade 8

8 (11)

12 (16)

1/4

6 (8)

10 (14)

14 (19)

5/16

11 (15)

17 (23)

25 (35)

5/16

12 (16)

19 (26)

29 (40)

3/8

20 (27)

30 (40)

45 (62)

3/8

23 (32)

35 (48)

50 (69)

7/16

30 (40)

50 (69)

70 (97)

7/16

35 (48)

55 (76)

80 (110)

1/2

50 (69)

75 (104)

110 (152)

1/2

55 (76)

90 (124)

120 (166)

GRADE 5

GRADE 8

5 (7)

FT-LB(N-M)

GRADE 2

FT-LB(N-M)

THREADS/IN

1/4

FT-LB(N-M)

BOLT SIZE

Grade 5

FT-LB

X 1.356 = N-M N-M X.7376 = FT-LB

Fuel / Oil Premix Ratios FUEL

(GALLONS)

20:1 RATIO

32:1 RATIO

CLASS

PRESSURE

LOW

HIGH

7.0 psi (0.5 bar)

60°F (16°C)

110°F+ (43°C+)

9.0 psi (0.6 bar)

50°F (10°C)

110°F (43°C)

10.5psi (0.7 bar)

40°F (4°C)

97°F (36°C)

12.0psi (0.8 bar)

30°F (-1°C)

85°F (29°C)

13.5psi (0.9 bar)

20°F (-7°C)

69°F (21°C)

Add 2.45°F for each 1000 ft (305m) above sea level When gasoline is blended, it is given a Reid Vapor Pressure (RVP) number which reflects its ability to vaporize or mix with air at a given temperature range. Gasoline vapor pressure is measured by putting a sample of fuel inside a closed container and applying a specified amount of heat to the container for a certain amount of time. RVP will vary from about 7.0 PSI during the summer to approximately 13.5 PSI during the colder months. Service stations selling a large volume of fuel will normally have the correct blend to work well at all times throughout the year in their local area. When the weather is very cold, gasoline must be able to vaporize very quickly in order for an engine to start and warm up properly. If summer blend fuel is being used in the winter, little or no vaporization will occur. Droplets will form causing flooding and very hard starting.

(OUNCES OF OIL) (OUNCES OF OIL)

6.4

Formula: • 1 Gallon = 128 Ounces • 128 ÷ (Desired Ratio) = Ounces of oil for every 1 gallon of fuel. • 128 ÷ 20 (20:1 Ratio) = 6.4 ounces of oil for every 1 gallon of fuel. Always mix ratio in 5 gallon increments.

2.4

AMBIENT AIR TEMP RANGE

If winter blend fuel is being used during the summer months, it may cause vapor lock (boiling fuel) inside the fuel lines, fuel pump, or carburetor. This will cause warm engine driveability problems and hard starting when warm.

General Information SAE Tap Drill Sizes Thread Size/ Drill Size #0-80 3/64 #1-64 53 #1-72 53 #2-56 51 #2-64 50 #3-48 5/64 #3-56 45 #4-40 43 #4-48 42 #5-40 38 #5-44 37 #6-32 36 #6-40 33 #8-32 29 #8-36 29 #10-24 24 #10-32 21 #12-24 17 #12-28 4.6mm 1/4-20 7 1/4-28 3 5/16-18 F 5/16-24 I 3/8-16 O 3/8-24 Q 7/16-14 U 7/16-20 25/64

Decimal Equivalents Thread Size / Drill Size 1/2-13 27/64 1/2-20 29/64 9/16-12 31/64 9/16-18 33/64 5/8-11 17/32 5/8-18 37/64 3/4-10 21/32 3/4-16 11/16 7/8-9 49/64 7/8-14 13/16 1-8 7/8 1-12 59/64 1 1/8-7 63/64 1 1/8-12 1 3/64 1 1/4-7 1 7/64 1 1/4-12 1 11/64 1 1/2-6 1 11/32 1 1/2-12 1 27/64 1 3/4-5 1 9/16 1 3/4-12 1 43/64 2-4 1/2 1 25/32 2-12 1 59/64 2 1/4-4 1/2 2 1/32 2 1/2-4 2 1/4 2 3/4-4 2 1/2 3-4 2 3/4

Metric Tap Drill Sizes Tap Size

Drill Size

3x.50 3x.60 4x.70 4x.75 5x.80 5x.90 6x1.00 7x1.00 8x1.00 8x1.25 9x1.00 9x1.25 10x1.25 10x1.50 11x1.50 12x1.50 12x1.75

#39 3/32 #30 1/8 #19 #20 #9 16/64 J 17/64 5/16 5/16 11/32 R 3/8 13/32 13/32

Decimal Equivalent 0.0995 0.0937 0.1285 0.125 0.166 0.161 0.196 0.234 0.277 0.265 0.3125 0.3125 0.3437 0.339 0.375 0.406 0.406

Nearest Fraction 3/32 3/32 1/8 1/8 11/64 5/32 13/64 15/64 9/32 17/64 5/16 5/16 11/32 11/32 3/8 13/32 13/32

1/64 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1/32- - - - - - - - - - - - - - - - - -.0312 - 3/64 - - - - - - - - - - - - - - - - - - - - - - - -.0469 - - - - - - 1/16- - - - - - - - - - - - - - - - - -.0625 5/64 - - - - - - - - - - - - - - - - - - - - - - - -.0781 - - - - - - - 3/32- - - - - - - - - - - - - - - - - -.0938 7/64 - - - - - - - - - - - - - - - - - - - - - - - -.1094 - - - - - - - 1/8 - - - - .1250 9/64 - - - - - - - - - - - - - - - - - - - - - - - -.1406 - - - - - - 5/32- - - - - - - - - - - - - - - - - -.1563 - 11/64 - - - - - - - - - - - - - - - - - - - - - - -.1719 - - - - - - 3/16- - - - - - - - - - - - - - - - - -.1875 - 13/64 - - - - - - - - - - - - - - - - - - - - - - -.2031 - - - - - - 7/32- - - - - - - - - - - - - - - - - -.2188 15/64 - - - - - - - - - - - - - - - - - - - - - - -.2344 - - - - - - - 1/4 - - - - .25 17/64 - - - - - - - - - - - - - - - - - - - - - - -.2656 - - - - - - - 9/32- - - - - - - - - - - - - - - - - -.2813 19/64 - - - - - - - - - - - - - - - - - - - - - - -.2969 - - - - - - 5/16- - - - - - - - - - - - - - - - - -.3125 - 21/64 - - - - - - - - - - - - - - - - - - - - - - -.3281 - - - - - - 11/32 - - - - - - - - - - - - - - - - -.3438 - 23/64 - - - - - - - - - - - - - - - - - - - - - - -.3594 - - - - - - 3/8 - - - - .375 25/64 - - - - - - - - - - - - - - - - - - - - - - -.3906 - - - - - - - 13/32- - - - - - - - - - - - - - - - -.4063 27/64 - - - - - - - - - - - - - - - - - - - - - - -.4219 - - - - - - - 7/16- - - - - - - - - - - - - - - - - -.4375 29/64 - - - - - - - - - - - - - - - - - - - - - - -.4531 - - - - - - 15/32- - - - - - - - - - - - - - - - -.4688 - 31/64 - - - - - - - - - - - - - - - - - - - - - - -.4844 - - - - - - 1/2 - - - - .5- - - - - - - - - - - - - - - - - 33/64 - - - - - - - - - - - - - - - - - - - - - - -.5156 - - - - - - 17/32- - - - - - - - - - - - - - - - -.5313 35/64 - - - - - - - - - - - - - - - - - - - - - - -.5469 - - - - - - - 9/16- - - - - - - - - - - - - - - - - -.5625 37/64 - - - - - - - - - - - - - - - - - - - - - - -.5781 - - - - - - - 19/32- - - - - - - - - - - - - - - - -.5938 39/64 - - - - - - - - - - - - - - - - - - - - - - -.6094 - - - - - - 5/8 - - - - .625 - - - - - - - - - - - - - - - 41/64 - - - - - - - - - - - - - - - - - - - - - - -.6406 - - - - - - 21/32- - - - - - - - - - - - - - - - -.6563 - 43/64 - - - - - - - - - - - - - - - - - - - - - - -.6719 - - - - - - 11/16 - - - - - - - - - - - - - - - - -.6875 45/64 - - - - - - - - - - - - - - - - - - - - - - -.7031 - - - - - - - 23/32 - - - - - - - - - - - - - - - - - -.7188 47/64 - - - - - - - - - - - - - - - - - - - - - - -.7344 - - - - - - - 3/4 - - - - .75 49/64 - - - - - - - - - - - - - - - - - - - - - - -.7656 - - - - - - 25/32- - - - - - - - - - - - - - - - -.7813 - 51/64 - - - - - - - - - - - - - - - - - - - - - - -.7969 - - - - - - 13/16- - - - - - - - - - - - - - - - -.8125 - 53/64 - - - - - - - - - - - - - - - - - - - - - - -.8281 - - - - - - 27/32- - - - - - - - - - - - - - - - -.8438 55/64 - - - - - - - - - - - - - - - - - - - - - - -.8594 - - - - - - - 7/8 - - - - .875 57/64 - - - - - - - - - - - - - - - - - - - - - - -.8906 - - - - - - - 29/32- - - - - - - - - - - - - - - - -.9063 59/64 - - - - - - - - - - - - - - - - - - - - - - -.9219 - - - - - - 15/16 - - - - - - - - - - - - - - - - - -.9375 - 61/64 - - - - - - - - - - - - - - - - - - - - - - -.9531 - - - - - - 31/32- - - - - - - - - - - - - - - - -.9688 - 63/64 - - - - - - - - - - - - - - - - - - - - - - -.9844 - - - - - - 1- - - - - - 1.0

- - - - - - .0156 1 mm= .0394" 2 mm = .0787" 3 mm =.1181" 4 mm = .1575" 5mm= .1969" 6 mm = .2362" 7 mm = .2756" 8mm= .3150" 9 mm = .3543" 10 mm = .3937" 11 mm =.4331" 12 mm = .4724" 13mm = .5118" 14 mm = .5512" 15 mm = .5906" 16mm=. 6299" 17 mm =.6693" 18 mm = .7087" 19 mm = .7480" 20 mm = .7874" 21 mm =.8268" 22 mm = .8661" 23 mm = .9055" 24 mm = .9449" 25 mm = .9843"

2.5

General Information Measurement Conversion Chart UNIT OF MEASURE

Piston Wash / Spark Plug Reading

MULTIPLIED BY

CONVERTS TO

ft-lb

x 12

= in-lb

in-lb

x.0833

= ft-lb

ft-lb

x 1.356

= N-m

in-lb

x.0115

= kg-m

N-m

x.7376

= ft-lb

kg-m

x 7.233

= ft-lb

kg-m

x 86.796

= in-lb

kg-m

x 10

= N-m

x 25.4

= mm

x.03937

= in

x 2.54

= cm

mile

x 1.6

= km

x.6214

= mile

Ounces (oz)

x 28.35

= grams (g)

grams (g)

x.035

= Ounces (oz)

ccâ&#x20AC;&#x2122;s

x.03381

= Fluid Ounces (oz)

lbs

x.454

= kg

x 2.2046

= lbs

Cubic Inches

x 16.387

= Cubic Centermeters

Cubic Centimeters

x.061

= Cubic Inches

Imperial pints

x.568

= liters (l)

liters (l)

x 1.76

= Imperial pints

Imperial quarts

x 1.137

= liters (l)

liters (l)

x.88

= Imperial quarts

Imperial quarts

x 1.201

= US quarts

US quarts

x.833

= Imperial quarts

US quarts

x.946

= liters

liters

x 1.057

= US quarts

US gallon

x 3.785

= liter

liter

x.264

= US gallon

Pounds force per square inch (psi)

x 6.895

= Kilo pascals (kPa)

Kilo pascals (kPa)

x.145

= Pounds force per square inch (psi)

2.6

Changing temperature, barometer, altitude, and fuel supply are just a few of the factors that can affect the day to day performance of your engine. That is why using Exhaust Gas Temperatures (EGT) are important for maintaining optimum performance. There are two methods for helping you determine what the EGTs are for your machine. Piston wash and the coloring of your spark plug. The piston wash is by far the most valuable tool in concluding EGTs, with the spark plug color running a distant second. Use the illustrations below to help establish the EGTs for your machine. Once the proper jetting is established, you can reference the EGT gauge for your baseline numbers. Then, if there is a rise or fall of 25 degrees, you must jet accordingly to return your EGTs to the baseline numbers.

Glossary Of Terms ABDC: After bottom dead center. ACV: Alternating current voltage. Alternator: Electrical generator producing voltage alternating current. ATDC: After top dead center. BBDC: Before bottom dead center. BDC: Bottom dead center. BTDC: Before top dead center. CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8" or 1 cm). Polaris measures chain length in number of pitches. CI: Cubic inches.

General Information Clutch Buttons: Plastic bushings which aid rotation of 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. Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to close and grip the drive belt. Crankshaft Run-Out: Run-out or â&#x20AC;&#x153;bendâ&#x20AC;? of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in crankcase. Measure at various points especially at PTO. CVT: Continuously Variable Transmission (Drive Clutch System) DCV: Direct current voltage. Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and out-ofround in the cylinder bore. Electrical Open: Open circuit. An electrical circuit which isn't complete. Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load. (i.e. a bare wire touching the chassis). 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. ft.: Foot or feet. ft-lb: (foot pounds) 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. gal.: Gallon. ID: Inside diameter. in.: Inch/inches. in-lb: (inch pounds) A force of one pound at the end of a lever one foot in length, applied in a rotational direction. 12 in. lbs. = 1 ft. lb. kg/cm2: Kilograms per square centimeter. kg-m: Kilogram meters. Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction. l or ltr: Liter. lbs/in2: Pounds per square inch. Left or Right Side: Always referred to based on normal operating position of the driver. m: Meter/meters. Mag: Magneto. Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the windings. Mechanical energy is converted to electrical energy in the stator. mi.: Mile/miles. mm: Millimeter. Unit of length in the metric system. 1 mm = approximately .040". N-m: Newton meters. OD: Outside diameter. Ohm: The unit of electrical resistance opposing current flow. oz.: Ounce/ounces. Piston Clearance: Total distance between piston and cylinder wall.

psi.: Pounds per square inch. PTO: Power take off. qt.: Quart/quarts. Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases. Reservoir Tank: The fill tank in the liquid cooling system. Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat. RPM: Revolutions per minute. Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall. Stator Plate: The plate mounted under the flywheel supporting the battery charging coils. TDC: Top dead center. Piston's most outward travel from crankshaft. 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. WOT: Wide open throttle.

2.7

General Information

NOTES

2.8

Maintenance

CHAPTER 3 Maintenance PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 PERIODIC MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2

MAINTENANCE PRODUCTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 ENGINE OILS / LUBRICANTS / MISC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4

DRIVE / DRIVEN CLUTCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 BELT DEFLECTION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 DEFLECTION ADJUSTMENT - POLARIS DRIVEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 DEFLECTION ADJUSTMENT - TEAM DRIVEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 TORQUE STOP ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 WIDETRAK TORQUE STOP ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6

ENGINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 WIDETRAK COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 SURGE TANK HOSE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 SURGE TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 FILL TUBE / PRESSURE CAP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8 RECOMMENDED COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8 COOLING SYSTEM BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8 WATER PUMP DRIVE BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8 OIL PUMP ADJUSTMENT - 340 / 550 ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8 OIL PUMP ADJUSTMENT - 488 LC ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9 OIL PUMP BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9 OIL PUMP BLEEDING - 550 ENGINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9 OIL / FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9

CHASSIS LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10 FRONT SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10 REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11 JACKSHAFT BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12 DRIVESHAFT BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12 WIDETRAK DRIVE COUPLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12 THROTTLE CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12 CHOKE AND CHOKE CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12 CHAINCASE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12 WIDETRAK GEARCASE OIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13 CHAINCASE / GEARCASE OIL REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13

BRAKE SYSTEM MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13 BRAKE LEVER TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13 BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13

THROTTLE AND CHOKE CABLE ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14 IDLE SPEED GAP / THROTTLE FREE PLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14 CHOKE LEVER ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15

STEERING / SUSPENSION MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15 HANDLEBARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15 SKI / SKI SKAG FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16 TRACK TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16 TRACK ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17

ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18 HEADLIGHT BULB REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18

OFF-SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18 CHASSIS AND HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18 CLUTCH AND DRIVE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18 CONTROLS AND LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18 ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18 CARBURETOR/THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18 FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18 CORROSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18 SHOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18

3.1

Maintenance PERIODIC MAINTENANCE Periodic Maintenance Schedule Periodic Maintenance Table - EDGE / Gen II / Widetrak Frequency Item

150 mi. (240 km)

500 mi. (800 km)

1000 mi. (1600 km)

2000 mi. (3200 km)

Pre-Season

Clutch Alignment / Offset

Drive Belt Condition

Drive / Driven Clutch Condition

Drive Belt Tension

Engine Mounts

Recoil Handle / Rope / Function

Engine Torque Stop

Drive / Driven Clutch

Engine

Cylinder Head Bolts

Cylinder Base Nuts Ignition Timing Spark Plug Condition

Water Pump Drive Belt

Liquid Cooling System

Fan Cooling System

Oil Filter

Exhaust System / Retaining Springs

Brake System Hose Condition / Routing

Fluid Level / Leaks / Fluid Condition

Brake Pads / Brake Disc

Parking Brake

Brake Fluid

Fuel System Idle RPM

Carburetor Adjustments

Throttle Lever / Chock Lever

Oil Pump Arm Throttle / Choke Cables

3.2

Maintenance Periodic Maintenance Table - EDGE / Gen II / Widetrak Frequency Item

150 mi. (240 km)

500 mi. (800 km)

1000 mi. (1600 km)

2000 mi. (3200 km)

Pre-Season

Fuel / Vent Hoses

Oil Hoses

Air Box

Carburetor Drains / Water Traps

Electrical System Auxiliary Shut-Off

Throttle Safety Switch

Ignition Switch

Headlights / Brake light / Taillights

Hand / Thumbwarmers

Perc Reverse System

Chassis Ski Toe Alignment Suspension Mounting Bolts

Steering Fasteners / Linkage / Handlebars

Driveshaft / Jackshaft Bearings

Ski Fasteners

Drive Chain Tension

Chaincase / Gearcase Oil

Track Alignment / Track Tension

Rail Slide Condition

Bogie / Wheel Condition / Fastener Bolts

Hood / Seat / Chassis / Engine Compartment

L = Lubricate / I = Inspect or Adjust / R = Replace / C = Clean

3.3

Maintenance MAINTENANCE PRODUCTS Engine Oils / Lubricants / Misc. DESCRIPTION

PART NUMBER

Premium 2-Cycle Oil Quart Gallon 2.5 Gallon 16 Gallon 55 Gallon 330 Gallon

2875035 2875036 2874037 2875038 2875039 2875040

VES Gold 2-Cycle Oil Quart Gallon 2.5 Gallon 16 Gallon 55 Gallon 330 Gallon

2874438 2874439 2874443 2874440 2874441 2874442

Racing 2-Cycle Oil Quart Gallon 16 Gallon

2873025 2873023 2873919

PS-4 4-Cycle 0W-50 Oil Quart 55 Gallon

2874865 2874867

PS-4 4-Cycle 2W-50 Oil Quart Gallon 16 Gallon 55 Gallon

2876244 2876245 2876247 2876246

Synthetic Chaincase Lubricant Quart Gallon 2.5 Gallon

2873105 2873106 2872952

Antifreeze 60/40 Premix Quart Gallon 55 Gallon

2871534 2871323 2872278

Shock Oil - 5W - Walker Evans

2874522

Shock Oil - Fox Quart Gallon

2870995 2872279

Shock Oil - Ryde FX / Arvin

2873716

Brake Fluid - DOT 4

2872189

Fogging Oil Aerosol Quart

2870791 2871517

3.4

DESCRIPTION

PART NUMBER

Premium All Season Grease 3oz. Grease Gun Kit 14oz.

2871312 2871423

Starter Grease

2871460

Carbon Clean Plus

2871326

Isopropyl

2870505

Fuel Stabilizer Quart 2.5 Gallon

2870652 2872280

Cross Shaft Assembly Lubricant 8oz. 2.5 Gallon

2872435 2872436

Three Bond Sealant 5oz.

2871557

Loctite 242

2871950

Maintenance DRIVE / DRIVEN CLUTCHES

Belt Deflection Inspection Too much belt deflection is when the belt is too long or the center distance is too short. The initial starting ratio will be too high, resulting in performance loss. This is due to the belt rising too high in the drive clutch sheaves upon engagement (A). Not enough belt deflection (B) is when the belt is too short or the center distance is too long. The initial starting ratio will be too low. In addition, the machine may creep when the engine idles, causing damage to the internal face of the drive belt.

The measurement should be 1 1/4" (3.2cm).

= In. / mm. Belt Deflection: 1.25" (3.2cm) 5.

If the measurement is not correct adjust driven clutch.

Deflection Adjustment - Polaris Driven 1. 2.

Loosen the 3 bolts on the adjustment cam. To reduce distance between clutch sheaves (reduce deflection) rotate the cam towards position 1. 3. To increase distance between clutch sheaves (increase deflection) rotate the cam towards position 5. 4. Torque cam fasteners to 10 ft.lbs. (12 Nm). 5. Raise rear of snowmobile up off of the ground using a track stand to allow the track to spin. 6. Start the engine and apply enough throttle to spin the track. 7. Turn off the engine, then re-check the belt deflection. NOTE: Do not rotate the cam past positions 1 or 5. If the adjustment cam no longer affects the belt deflection, replace the belt and re-adjust the deflection. If the desired deflection still cannot be achieved with a new belt, the driven clutch should be reconditioned.

Deflection Adjustment - Team Driven 1.

1. 2. 3.

Measure the belt deflection with both clutches at rest and in their full neutral position. Place a straight edge across the two clutches, on top of the belt. Apply downward pressure to the belt and measure the distance at point (D).

Verify the drive system is in FWD drive by rotating the driven clutch forward. 2. While holding the set screw with an Allen wrench, loosen the jam nut. 3. Turn the set screw clockwise while holding the jam nut stationary to increase the distance between the clutch sheaves (increase belt deflection). 4. Turn the set screw counter-clockwise while holding the jam nut stationary to decrease the distance between the clutch sheaves (decrease belt deflection). 5. Secure the jam nut while holding the set screw stationary. 6. Raise the rear of the snowmobile using a track stand to allow the track to spin. 7. Start the engine and apply enough throttle to spin the track. 8. Turn off then engine, then re-check the belt deflection. NOTE: Do not adjust the belt deflection to the point where the drive belt cord line is visible when the belt is seated in the driven clutch.

3.5

Maintenance Torque Stop Adjustment

Widetrak Torque Stop Adjustment

GAP

NOTE: Engine removed in photo for clarity. Set torque stop bumper gap to specification after aligning drive and driven clutches.

= In. / mm. Torque Stop Bumper-to-Engine Gap .010 - .030 (.25 - .75mm) After setting gap, torque jam nut to specification.

=T Torque Stop Jam Nut: 15-17 ft-lb. (21-24 Nm) NOTE: Where applicable, when installing a new torque stop, position bumper so the tip is just touching crankcase.

3.6

Set the torque stop so it just touches the engine mount. After setting torque stop, torque jam nut to specification.

=T Torque Stop Jam Nut: 15-17 ft-lb. (21-24 Nm)

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