2002 POLARIS INDY 600 XC SP EDGE Factory Service & Work Shop Manual

II ~ ') I I I' / ( :J ~ - 0 :J ~ I 'j :;), ')' I-- ,;z::. ;r:. .:d ?ecq? ,(, I """:) C '-I YD ......,6 PDLRRIS® The Way O ut. UfIIDERSTA THE IUlliN -: hI VE THE RllilJ!G "n. E. QR~ Til ~tAia : IT BETTER . , FJ t. ~I~ 11',;'''''"1':""' PERFORMANCE SERVICE MANUAL Foreword L/-'- -. --. This manual is designed primarily for use by Polaris snowmobile service technicians in a properly equipped r . 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 2002 Polaris Indy 500 XC , 500 XC SP, 600 XC SP, 700 XC SP, 800 XC SP and 800 XCR snowmobiles. A table of contents is placed at the beginning of each chapter, and an alphabetic index is provided at the end ofthe 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. 2002 Performance Snowmobile Service Manual (PN 9917367) . Copyright 2001 Pol aris 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: AThe Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! ~ DANGER Failure to follow DANGER instructions will result in severe injury or death tothe 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: I 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 ( \ , , /

\ / , ) ~ GENERAL 91 MAINTENANCE o I ENGINE 11"'-111 CARBURETION ~ I DRIVE/DRIVEN CLUTCHES ~ I BODY AND STEERING I ~ I SUSPENSIONS 101 BRAKES AND FINAL DRIVE [Q] ELECTRICAL [Q] WIRING DIAGRAMS '1 II o

) ) .... CHAPTER1 ~GENERAL INFORMATION 2002 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 SAE Tap Drill Size Charts . ................. .. .. ..... .. 1.6 Units of Measure Chart ......................... . ..... 1.7 Recommended Shop Supplies . . . . . . . . . . . . . . . . . • . . . . . .. 1.B Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.9 - 1 .11 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 Note Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.13 2002 Indy 500 XC EDGE Specifications . . . . . . . . . . . . . . . . . 1.14 - 1. 15 2002 Indy 500 XC SP EDGE Specifications . . . . . . . . . . . . . . 1.16 - 1.17 2002 Indy 600 XC SP EDGE Specifications . . . . . . . . . . . . .. 1.1B - 1.19 2002 Indy 700 XC EDGE Specifications. . . . . . . . . . . . . . . .. 1.20 - 1.21 2002 Indy BOO XC SP EDGE Specifications. . . . . . . . . . . . .. 1.22 - 1.23 2002 Indy BOO XCR Specifications. . . . . . . . . . . . . . . . . . . . .. 1.24 - 1.25 II

GENERAL INFORMATION ~ ( 2002 Publication Numbers Model Model No. Owner's Manual Supplement 500 XC EDGE S02NP5AS 9917390 500 XC, SP EDGE S02NP5CSA 9916740 S02NP5CSB 600 XC SP EDGE S02NP6ESA 9916753 S02NP6ESB 700 XC SP EDGE S02NP7CSA 9916756 S02NP7CSB 800 XC SP EDGE S02NP8CSA 9916759 S02NP8CSB 800XCR S02SB8AS 9916947 2000 Snowmobile Owner's Manual (All) - PN 9916649 Snowmobile Assembly Manual - PN 9916508 2002 Service Manuals 120XC SP Trail Sport Super Sport, Indy 500, 340 Deluxe Two-Up / Utility Parts Manual 9917067 9917340 9917342 9916757 9917346 9916948 Wide Trak LX, 340 Touring , Sport Touring , Trail Tour ing, 500 Classic Touring, 600 Classic Touring Trail Luxury 500 Classic, 550 Classic, 600 Classic, 700 Classic Deep Snow Trail RMK, 500 RMK, 500 SKS Euro, 700 SKS, Trail RMK, 600/700/800 EOGE RMK Performance 500 xc , 500/600/700/800 xc SP, 800 XCR High Performance 440 XCF SP, 440 xc SP, 500/600/700/800 xc SP, 600/700/800 RMK, 800 XCR Wallcharts ) @ PDLRRIS' Parts Microfiche 9917068 9917341 9917343 9916758 9917347 9916949 9917361 9917362 9917364 9917363 9917366 9917367 9917365 9917369 1.1

~ GENERAL INFORMATION MODEL NUMBER IDENTIFICATION 2002 MODEL DESIGNATION YEAR DESIGNATION - -- ----- ---; S!02L;Pi I S ENGINE DESIGNATION S=Snow ------- MODEL I CHASSIS DESIGNATION __ - MODEL LINE (4TH DIGIT) S=Gen II L= Lite N= EDGE W=Mini Indy 2002 ENGINE DESIGNATION NUMBERS MODEL TYPE (5TH DIGIT) A= Feature Option B= Basic C= Feature Option 0 = Deluxe E= Feature Option M-1 0 F= Feature Option J= 136 RMK (Edge) K= 144 RMK (Edge) L= 151 RMK (Edge) M= 156 RMK (Edge) P= Performance R= RMK (Gen II) S= SKS T= Touring U= Utility X= Racer 1A - 121 FIC OHV 4 cycle Fuji 3A - 340 FIC Piston Port Fuji 4A - 440 FIC Cylinder Reed Fuji 4B - 488 LJC Piston Port Fuji 4C - 440VES LJC Case Reed (domestic) 40 - 440 FIC Piston Port 4E - 488 FIC Piston Port Fuji 5A - 497 LJC Case Reed 2 Cyl (domestic ) 5B - 544 FIC Cylinder Reed 5C - 500 VES LIC Case Reed 2 Cylinder (domestic) 60 - 600/700 LJC Case Reed 2 Cylinder (domestic) 6E - 600/440 VES LJC Case Reed 2 Cylinder (domestic) 7 A - 700 LJC Case Reed 2 Cylinder (domestic) 7C - 700 VES LJC Case Reed 2 Cyl (domestic) 8A - 800 VES LJC Case Reed 3 Cylinder Fuji 8B - 800 LJC Case Reed 2 Cylinder (domestic) 8C - 800 VES LJC Case Reed 2 Cyl (domestic) TUNNEL DECAL MODEL NO MADE IN U.S.A. V.!.N.NO. TH IS VE HICLE CONFORMS TO ALL APPLI CABLE U.S. FEDE RAL AND STATE REQUI REMENTS AND CANADA MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE DA TE OF MANUFACTURE. MFO. DATE· S= North American Model U= European Model PClLRRIS PATENT NOTICE Mfd. by Polaris Industries Inc. in Roseau, MN under one or more of the following patent s; U.S. Patents 3,605,511 3,580,647 3,483,766 3,533,662 3,545,821 3, 605,510 3,525,412 3,613 ,810 3,867,991 4,793,950 5,038 ,881 5,172,675 5,090,386 5,050 ,564 5,050,559 5,048,503 5,056,482 5,099,813 5,074,271 5,191,531 3,613,811 Patellted Canada 882,491/71 883.694(71 864,394/71 Canadian Rd. 34,573/71 34 ,572/71 1,227,823{87 7072 133 These numbers should be referred to in any correspondence regarding warranty, se rvi ce or replacement parts. The machine model and serial number identification decal is located on the right fro nt side of th e 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). 1.2 GB PClLRRIS'

( GENERAL INFORMATION ~ Vehicle Identification Number Current snowmobiles have a 17 digit Vehicle Identification Number (VI N) . The VI N 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. Example of Current VIN Number World Mfg. ID 2 4 X A Vehicle Descriptor 6 7 B 5 B S 0 Vehicle Identifier 10 2 2 o Body Style I Eng l ;ne I. se~;es I ~eOald rel I i I' Individual Serial No. Size Engine Check Manufacturing. Type Modifier Digit Location Code Vehicle Identification Number / Model Number Key Bodll Stl£Ie IllJm Engine Size Engine Modifier Series L=Lite B=Base Model 1=100-199 cc A=Fan S=Domestic N-Edge D-Deluxe 2- 200-299 cc B-Liquid Twin U=Europe S= Gen II P=Performance 3=300-399 cc C=Case Reed Twin W=Mini R=RMK 4=400-499 cc D=Liquid Triple S- SKS 5=500-599 cc E=Case Reed Triple 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 (B PDLRRIS' 1.3

2002 POLARIS INDY 600 XC SP EDGE Factory Service & Work Shop Manual

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