2001-2002 Polaris Snowmobile Indy 500/600/700/800 Service & Repair Manual

1 CHAPTER 1 GENERAL INFORMATION 2001 Publication Part Numbers / Service Manuals 1.1 ........ Model Number Identification 1.2 ........................... Vehicle Identification Number (VIN) 1.3 ..................... Standard Bolt Torque Specifications 1.4 .................... Decimal Equivalents 1.5 .................................. Tap Drill Size Charts 1.6 .................................. Units of Measure Chart 1.7 ............................... Recommended Shop Supplies 1.8 ......................... Glossary of Terms 1.9 - 1.11 .................................... General Precautions 1.12 .................................. Notes 1.13 ............................................... 2001 Indy 340 Touring Specifications 1.14 - 1.15 ................... 2001 Indy Wide Trak LX Specifications 1.16 - 1.17 .................. 2001 Indy Sport Touring Specifications 1.18 - 1.19 .................. 2001 Indy 500 Classic Touring Specifications 1.20 -- 1.21 ............ 2001 Indy 600 Classic Touring Specifications 1.22 -- 1.23 ............

GENERAL INFORMATION 1.1 2001 Publication Numbers Model Model No. Owner’s Manual Supplement Parts Manual Parts Microfiche Indy Wide Trak LX S01SU4BS 9916156 9916157 9916158 Indy 340 Touring S01LT3AS 9916114 9916115 9916116 Indy Sport Touring S01SD5BS 9916047 9916048 9916049 Indy Sport Touring ES S01ST5BS 9916047 9916048 9916049 Indy 500 Classic Touring S01ST4BS 9916077 9916078 9916079 Indy 600 Classic Touring S01ST6ES 9916082 9916083 9916084 Indy Sport Touring (European) E01SS5AU 9916130 9916131 9916132 2001 Snowmobile Owner’s Manual (All) - PN 9915622 2001 Snowmobile Assembly Manual - PN 9916508 Service Manuals Snowmobile MRM Volume II Through 1995 9912121 Snowmobile MRM Volume III 1996-1998 9913263 Snowmobile MRM Volume IV 1999 9915081 2000 Snow Complete Set w/wallcharts (all models except race) 2000 9915986 Fan Cooled Models 2000 9915980 Mid Range Liquid Cooled (500s, 600 triple) 2000 9915981 Performance Liquids (600 twins,700s, 800s) 2000 9915982 120 XCR 2000 9915983 High Performance (Race) 2000 9915985 Wall Chart Packet only 2000 9915984 120 XC SP 2001 9916684 Trail Sport 340 DLX, Indy 500 EDGE, SuperSport EDGE 2001 9916685 Two-Up / Touring Wide Trak LX, 340 Touring, Sport Touring, Sport Touring ES, 500 Classic Touring, 600 Classic Touring 2001 9916686 Trail Luxury 500 Classic, 600 Classic, 700 Classic, 800 LE 2001 9916687 Deep Snow 700 SKS, Trail RMK, 500/600/700/800 RMK, 800 RMK Snowcheck Special 2001 9916688 Performance 500 XC, 500/600/700/800 XC SP, 600 EDGE X, 800 XCR 2001 9916689 High Performance 440 XCF SP, 440 XC SP, 500/600/700/800 XC SP, 600/700/800 RMK, 800 XCR 2001 9916690 Suspension Systems 2001 9916691 Wallcharts 2001 9916692

GENERAL INFORMATION 1.2 MODEL NUMBER IDENTIFICATION YEAR DESIGNATION ENGINE DESIGNATION MODEL / CHASSIS DESIGNATION 2001 MODEL DESIGNATION S01 SD 5 BS (A) E=European Model U= European Model Color Option S= North American Model MODEL LINE (4TH DIGIT) MODEL TYPE (5TH DIGIT) S= Standard Indy B= Basic L= Lite U= Utility N=EDGE D= Deluxe P= Performance R= RMK X= Racer T= Touring S= SKS 2001 2001 MODEL DESIGNATION ENGINE DESIGNATION NUMBERS (Chassis) NUMBERS SU - WideTrak LX 1A - 121 F/C OHV 4 cycle Fuji SD - 500 Classic/700 Classic 2A - 250 F/C Piston Port Fuji SB - 800 XCR 3A - 340 F/C Piston Port Fuji ST - Sport Touring/Sport Touring ES/500-600 Classic Touring 4A - 440 F/C Cylinder Reed Fuji SS - 700 SKS 4B - 488 L/C Piston Port Fuji SR - Trail RMK/500,600,700 RMK (136) 4C - 440 L/C Case Reed (domestic) SM - 700, 800 RMK (144)/800 RMK S.C. Special 4E - 488 F/C Piston Port Fuji LD - 340 Deluxe 4F - 440 F/C Cylinder Reed/Nicasil Fuji LT - 340 Touring 5A - 500/440 L/C Fuji WB - 120 XC SP 5B - 544 F/C Cylinder Reed Fuji ND - 600 Classic/800 LE 5C - 500/440 VES L/C Case Reed 2 Cylinder (domestic) NB - Supersport/Indy 500 6A - 597 L/C 3 Cylinder Fuji NX - XCF SP 6D - 600/700 L/C Case Reed 2 Cylinder (domestic) NP - 500 XC/500 XC SP/600 XC SP/600 EDGE X 6E - 600/440 VES L/C Case Reed 2 Cylinder (domestic) 700 XC SP/800 XC SP 7A - 700 L/C Case Reed 2 Cylinder (domestic) 8A - 800 VES L/C Case Reed 3 Cylinder Fuji 8B - 800 L/C Case Reed 2 Cylinder (domestic) MODEL NO. V.I.N. NO. MFD. DATE: THIS VEHICLE CONFORMS TO ALL APPLICABLE U.S. FEDERAL AND STATE REQUIREMENTS AND CANADA MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE. MADE IN U.S.A. 7072133 Mfd. by Polaris Industries Inc.. in Roseau, MN under one or more of the following patents: U.S. Patents 3,605,511 3,613,810 5,050,559 3,580,647 3,867,991 5,048,503 3,483,766 4,793,950 5,056,482 3,533,662 5,038,881 5,099,813 3,545,821 5,172,675 5,074,271 3,605,510 5,090,386 5,191,531 3,525,412 5,050,564 3,613,811 PATENT NOTICE Patented Canada 882,491/71 883,694/71 864,394/71 Canadian Rd. 34,573/71 34,572/71 1,227,823/87 TUNNEL DECAL These numbers should be referred to in any correspondence regarding warranty, service or replacement parts. The machine model and serial number identification decal is located on the right front side of the tunnel. The serial number is permanently stamped into the tunnel. The model number is embossed on the decal. Whenever corresponding about an engine it is important that the engine model and serial numbers be called out. Laser engraved model and serial numbers are located on the crankcase (intake side).

GENERAL INFORMATION 1.3 Vehicle Identification Number Current snowmobiles have a 17 digit Vehicle Identification Number (VIN). The VIN is organized as follows: Digits 1-3: World Manufacturer Identifier. For Polaris, this is 4XA. Digits 4-9: Vehicle Descriptor Section. Digits 10-17: Vehicle Indicator Section. Digits 4-8 of the VIN identify the body style, type, engine type, and series. The VIN and the model number must be used with any correspondence regarding service or repair. 1 2 3 4 5 6 7 8 9 10 1 1 12 13 14 15 16 17 4 X A S B 5 B S 0 W 2 0 0 0 0 0 0 Vehicle Descriptor Vehicle Identifier Type Engine Size Engine Modifier Model Year Asm. Line Number Individual Serial No. Body Style Series World Mfg. ID Example of Current VIN Number Check Digit Vehicle Identification Number / Model Number Key Body Style T ype Engine Size Engine Modifier Series A=Aggressive B=Base Model 1=100-199 cc A=Fan S=Domestic S=Std Indy D=Deluxe 2=200-299 cc B=Liquid Twin U=Europe E=Evolved P=Performance 3=300-399 cc C=Case Reed Twin L=Lite R=RMK 4=400-499 cc D=Liquid Triple N=Edge S=SKS 5=500-599 cc E=Case Reed Triple W=Mini T=Touring 6=600-699 cc U=Utility 7=700-799 cc X=Racer 8=800-899 cc Year / Letter Identification The tenth digit of a 17 digit VIN is the model year of the vehicle. Example: W = 1998; X = 1999 etc. Refer to the listing below. 1=2001 2=2002 3=2003

GENERAL INFORMATION 1.4 Standard Torque Specifications The following torque specifications are to be used as a general guideline when torque value is not specified. There are exceptions in the steering, suspension, and engine areas. Always consult the torque chart and the specific manual section for torque values of fasteners. Bolt Size Threads/In Grade 2 Grade 5 Grade 8 (MM/Thread) Torque in. lbs. (Nm) #10 - 24 27 (3.1) 43 (5) 60 (6.9) .............. ................ ............... #10 - 32 31 (3.6) 49 (5.6) 68 (7.8) .............. ................ .............. Torque ft. lbs. (Nm) * 1/4 - 20 5 (7) 8 (11) 12 (16) .............. .................. ................ 1/4 - 28 6 (8) 10 (14) 14 (19) .............. .................. .............. 5/16 - 18 11 (15) 17 (23) 25 (35) .............. ................ .............. 5/16 - 24 12 (16) 19 (26) 29 (40) .............. ................ .............. 3/8 - 16 20 (27) 30 (40) 45 (62) .............. ................ .............. 3/8 - 24 23 (32) 35 (48) 50 (69) .............. ................ .............. 7/16 - 14 30 (40) 50 (69) 70 (97) .............. ................ .............. 7/16 - 20 35 (48) 55 (76) 80 (110) .............. ................ .............. 1/2 - 13 50 (69) 75 (104) 110 (152) .............. ................ ............. 1/2 - 20 55 (76) 90 (124) 120 (166) .............. ................ ............. *To convert ft. lbs. to Nm multiply foot pounds by 1.356. *To convert Nm to ft. lbs. multiply Nm by .7376.

GENERAL INFORMATION 1.5 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 ............

GENERAL INFORMATION 1.6 SAE Tap Drill Sizes Thread Size Drill Size Thread Size Drill Size #0-80 3/64 #1-64 53 #1-72 53 #2-56 51 #2-64 50 #3-48 5/64 #3-56 45 #4-40 43 #4-48 42 #5-40 38 #5-44 37 #6-32 36 #6-40 33 #8-32 29 #8-36 29 #10-24 24 #10-32 21 #12-24 17 #12-28 4.6mm 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 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 Decimal Equivalent Nearest Fraction 3 x .50 3 x .60 4 x .70 4 x .75 5 x .80 5 x .90 6 x 1.00 7 x 1.00 8 x 1.00 8 x 1.25 9 x 1.00 9 x 1.25 10 x 1.25 10 x 1.50 11 x 1.50 12 x 1.50 12 x 1.75 #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 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 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

GENERAL INFORMATION 1.7 Unit of Measure Multiplied by Converts to ft. lbs. x 12 = in. lbs. in. lbs. x .0833 = ft. lbs. ft. lbs. x 1.356 = Nm in. lbs. x .0115 = kg-m Nm x .7376 = ft. lbs. kg-m x 7.233 = ft. lbs. kg-m x 86.796 = in. lbs. kg-m x 10 = Nm in. x 25.4 = mm mm x .03937 = in. in. x 2.54 = cm mile (mi.) x 1.6 = km km x .6214 = mile (mi.) Ounces (oz) x 28.35 = Grams (g) Grams (g) x 0.035 = Ounces (oz) cc x .03381 = Fluid 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

GENERAL INFORMATION 1.8 Recommended Shop Supplies Description Part Number Chaincase Lubricant - Quart 2871280 ....................... Chaincase Lubricant - Gallon 2870464 ...................... Chaincase Lubricant - 2.5 Gallon 2872281 ................... Fuel System Deicer (Isopropyl) 2870505 ..................... Loctite Primer T - 6 Oz. Aerosol 2870585 .................... Loctite RC 680 - 10cc Retaining Compound 2870584 .......... Loctite/Chisel -- Gasket Remover - 18 Oz. 2870601 ........... Metal Polish - 8 Oz. 2870632 ............................... DOT 3 Brake Fluid 2870990 ............................... Fogging Oil 2870791 ...................................... Nyogelt Grease 2871329 ................................. Fox Shock Oil 2870995 .................................... Premium All Season Grease (14 oz) 2871423 ................ Premium All Season Grease (3 oz) 2871322 ................. Premium 60/40 Anti-Freeze/Coolant 2871323 ................ Premium Carbon Clean Fuel System Additive 2871326 ........ Polaris Battery Tender 2871076 ............................ Carbon Clean Fuel System Additive 2871326 ................. T-9 Metal Protectant 2871064 .............................. Crankcase Sealant 3 Bond 1215 2871557 ...................

GENERAL INFORMATION 1.9 Service Glossary ACS: Alternator control switch. 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 (No. 35 = 3/8” or 1 cm). 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) lean fuel/air mixture; 2) low octane fuel; 3) over-advanced ignition timing; 4)compression ratio too high for the fuel octane. 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: 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. 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. 4 Bore x Stroke x 3.1416 2 = Displacement in CCs

2001-2002 Polaris Snowmobile Indy 500/600/700/800 Service & Repair Manual

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