2005 Polaris Trail RMK 136 SNOWMOBILE Service Repair Manual

9919302
PART #
PN 99193029919302
2005 DEEP SNOW
SERVICE MANUAL
TRAIL RMK
600 RMK
700 RMK
800 RMK
900 RMK
600 SWITCHBACK™
800 SWITCHBACK™
2005DEEPSNOWSERVICEMANUAL
CVR_9919302 9/23/04 9:17 AM Page 1

UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS
Throughout these instructions, important information is brought to your attention by the following symbols:
NOTE: S A NOTE provides key information to clarify instructions.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid personal injury,
or snowmobile or property damage.
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 property 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

i
2005 DEEP SNOW
MANUAL
SPECIFICATIONS 1
GENERAL 2
MAINTENANCE 3
FUEL DELIVERY 4
ENGINE 5
CLUTCHING 6
FINAL DRIVE 7
BRAKE SYSTEM 8
STEERING 9
FRONT SUSPENSION 10
REAR SUSPENSION 11
CHASSIS / HOOD 12
ELECTRICAL SYSTEM 13
WIRING DIAGRAMS 14
Foreword
This manual is designed primarily for use by certified
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 fa-
miliar 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 seatedin a normal
riding position.
This manual includes 2005 Model Year information,
along with service specifications. 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.
Snow Engineering Publications Department
2100 Hwy 55 Medina, Minnesota 55340.
2005 DEEP SNOW MANUAL
(PN9919302)
Copyright 2004 Polaris Sales Inc. Printed in U.S.A.

TRAIL RMK 1.2 -- 1.3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
600 RMK 1.4 -- 1.5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
700 RMK 1.6 -- 1.7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
800 RMK 1.8 -- 1.9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
900 RMK 1.10 -- 1.11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
600 SWITCHBACK 1.12 -- 1.13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
800 SWITCHBACK 1.14 -- 1.15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIFICATIONS
1.2
MODEL: TRAIL RMK. . . . . . . . . . . . . .
MODEL NUMBER: S05NJ5BS(A). . . .
ENGINE MODEL: EC55PM071. . . . .
ENGINE CARBURETION
Engine Type Libertyt Type
Mikuni
VM34SS w/ACCS
Engine Displacement cc’s 544 Main Jet 260 PTO / 250 MAG
Bore in / mm 2.87” / 73mm Pilot Jet 35
Stroke in / mm 2.56” / 65mm Jet Needle 6DEH11 / 3
Cylinders 2 Needle Jet Q--0 (480)
Piston / Cylinder Clearance
in / mm
.0045 -- .0053”
.114 -- .135mm
Throttle Gap UnderCutaway
in / mm
.250”
6.35mm
Piston Ring End Gap in / mm
.015 -- .022”
.4 -- .55mm
Cutaway 3.0
Piston Marking 5MD Valve Seat 1.5 Viton
Piston Ring Marking N Starter Jet 1.5
Operating RPM ±200 7000 Fuel Screw N/A
Idle RPM ±200 1600 Pilot Air Jet N/A
Air Screw 1.0 Turns
Engagement RPM ±300 3800
Fuel Octane (R+M/2)
87 Oct. NonOxy /
89 Oct. Oxy
AMBIENT TEMPERATURE
Altitude Below -30°F -30_ to --10_F --10_to +10_F +10_to +30_F +30_to +50_F Above +50_FAltitude Below -30 F
Below -34°C
-30_ to --10_F
-34_to -23_C
--10_to +10_F
-23_ to --12_C
+10_to +30_F
-12_to --1_C
+30_to +50_F
-1_to +10_C
Above +50_F
Above +10_C
0--600
(0--2000)
290/280
#3
280/270
#3
270/260
#3
260/250
#3
250/240
#3
240/230
#3
600--1200
(2000--4000)
290/280
#3
280/270
#3
270/260
#3
260/250
#3
250/240
#3
240/230
#3
1200--1800 290/280 280/270 270/260 260/250 250/240 240/2301200--1800
(4000--6000)
290/280
#3
280/270
#3
270/260
#3
260/250
#3
250/240
#3
240/230
#3
Meters
(Feet)
1800--2400
(6000 8000)
290/280 280/270 270/260 260/250 250/240 240/230(Feet)
(6000--8000)
290/280
#3
280/270
#3
270/260
#3
260/250
#3
250/240
#3
240/230
#3
2400--3000
(8000 10000)
290/280 280/270 270/260 260/250 250/240 240/230
(8000--10000)
290/280
#3
280/270
#3
270/260
#3
260/250
#3
250/240
#3
240/230
#3
3000--3700
(10000 12000)
290/280 280/270 270/260 260/250 250/240 240/230
(10000--12000)
290/280
#3
280/270
#3
270/260
#3
260/250
#3
250/240
#3
240/230
#3
DRIVE CLUTCH DRIVEN CLUTCH
Altitude Shift Clutch Clutch Driven ChaincaseAltitude Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Chaincase
Gearing
0-900
10 64 Bushed
Dark Blue /
Red / Blue
40°
19 43 74P
0-900
(0-3000)
10--64 Bushed
Dark Blue /
White
Red / Blue
40
Team Reverse
19--43 74P
M t
900-1800
10 62 Bushed
Dark Blue /
Red / Blue
40°
19 43 74PMeters
(Feet)
900-1800
(3000-6000)
10--62 Bushed
Dark Blue /
White
Red / Blue
40
Team Reverse
19--43 74P
(Feet)
1800-2700
10 60 Bushed
Dark Blue /
Red / Blue
40°
19 43 74P
1800-2700
(6000-9000)
10--60 Bushed
Dark Blue /
White
Red / Blue
40
Team Reverse
19--43 74P
2700-3700
10 58 Bushed
Dark Blue /
Red / Blue
40°
19 43 74P
2700-3700
(9000-12000)
10--58 Bushed
Dark Blue /
White
Red / Blue
40
Team Reverse
19--43 74P

SPECIFICATIONS
1.3
DRIVE CLUTCH CHAINCASE
Type P--85 Center DIstance 7.92” / 20.12cm.
Shift Weights 10--60 Bushed Gearing : Chain 19--43 :74P
Drive Spring Red/Blue Reverse Electronic Reverse
DRIVEN CLUTCH Brake Pads Type 81
Type Team Roller Reverse
Brake Type Air Cooled
Spring Dark Blue/White
Brake Type Air Cooled
Helix Angle
40_
Team Reverse
CAPACITIES
BELT Fuel Tank 11.8 Gal. / 45 Liters
Belt Part Number 3211078 Oil Tank 3.25 Qts / 3 Liters
Belt Width (Projected) 1.438” / 3.65cm. Coolant N/A
Side Angle (Overall) 28_ Chain Case Oil 9 fl. oz. / 266 ml
Outside Diameter 46.625” / 118.4cm. SLED DIMENSION
Center Distance 11.5” / 29.2cm.
Unit Length / Height /
Width in / cm.
121” / 48” / 48”
308 / 122 / 122 cm.
FRONT SUSPENSION REAR SUSPENSION
Type EDGE RMK (V/ESC) Type EDGE RMK
Standard IFS Shocks 7042197 Nitrex Standard FTS 7042085 Nitrex
Standard IFS Spring Rate 80#/in. Standard FTS Spring Rate 170#
Standard Spring Pre--Load .75”/1.9cm Standard Spring Pre--Load N/A
Premium IFS Shocks 7042059 Arvin IFP Premium FTS 7042084 Arvin IFP
Premium Spring Rate 75#/In. Premium Spring Rate 170#
Premium Spring Pre--Load
9.75”/24.8cm Installed
length
Premium Spring Pre--Load
2.98” (7.57cm) from bottom
of shock body to bottom of
spring retainer
Front Vertical Travel 7 6” / 19 3cm
Standard RTS Select / PN 7042058
Front Vertical Travel 7.6” / 19.3cm.
Premium RTS Arvin IFP C/A 7042176
TRACK Torsion Spring .347” (Sq) x 77_
Width / Length / Lug Height
15”/136”/1.25” (38 cm./345
cm./3.18 cm.) See page 11.7 for optional springs
Track Tension See page 3.10
See page 11.7 for optional springs
ELECTRICAL
Flywheel I.D. FP9312 Spark Plug / Gap
NGK BR9ES
.028” / .70mm
CDI Marking CU7236 Voltage Regulator
LR7
Alternator Output 240 watts Magneto Pulses 6
Ignition Timing (see conver- 27_@3000 RPM±1.5_ Electric Start
Standard AccessoryIgnition Timing (see conver
sion chart page 13.4)
27 @3000 RPM±1.5
14_@6500 RPM±1.5_
Electric Start
y
Premuim Optional

SPECIFICATIONS
1.4
MODEL: 600 RMK 144”. . . . . . . . . . . . . .
MODEL NUMBER: S05NK6ES(A). . . .
ENGINE MODEL: S2712--6044--PI6E. . . . .
ENGINE CARBURETION
Mikuni
TM 38
Engine Displacement cc’s 599 Main Jet 310
Bore in / mm 3.04” / 77.25mm Pilot Jet 45
Stroke in / mm 2.52” / 64mm Jet Needle 9DGI01--60 / 2
Cylinders 2 Needle Jet P--8
in / mm
.0045 -- .0059”
.115 -- .149mm
in / mm
.11”
2.7mm
.014 -- .020”
.14 -- .20mm
Cutaway 1.5 (N)
Piston PN 3021308 Valve Seat 1.5
Piston Ring Marking N/A Starter Jet 140
Operating RPM ±200 8000 Fuel Screw 1.0 Turns
Engagement RPM ±300 3900 Air Screw .75
Exhaust Valve Spring Green/White Fuel Octane (R+M/2)
87 Oct. NonOxy /
89 Oct. Oxy
AMBIENT TEMPERATURE
Below -34°C
-30_ to --10_F
-34_to -23_C
--10_to +10_F
-23_ to --12_C
+10_to +30_F
-12_to --1_C
+30_to +50_F
-1_to +10_C
Above +50_F
Above +10_C
0--600
(0--2000)
450
#4
430
#4
420
#3
400
#3
380
#3
370
#3
600--1200
(2000--4000)
410
#4
390
#3
380
#3
360
#3
340
#3
330
#2
1200--1800 380 360 350 330 320 3001200--1800
(4000--6000)
380
#3
360
#3
350
#3
330
#3
320
#2
300
#2
Meters
(Feet)
1800--2400
(6000 8000)
360 340 320 310 290 280(Feet)
(6000--8000)
360
#3
340
#3
320
#3
310
#2
290
#2
280
#2
2400--3000
(8000 10000)
340 320 300 290 270 260
(8000--10000)
340
#3
320
#3
300
#2
290
#2
270
#2
260
#2
3000--3700
(10000 12000)
330 310 290 280 260 240
(10000--12000)
330
#3
310
#2
290
#2
280
#2
260
#2
240
#2
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Chaincase
Gearing
0--900
10 60 Bushed
0--900
(0-3000)
10-60 Bushed
900-1500
10 58 Bushed
900-1500
(3000-5000)
10-58 Bushed
1500-2100
10 56 Bushed
Meters
1500-2100
(5000-7000)
10-56 Bushed
56 / 42 -- 36Meters
(Feet) 2100-2700
10 54 Bushed
Black/Green 7043063
56 / 42 -- .36
ER
19--39 : 72P(Feet) 2100-2700
(7000-9000)
10-54 Bushed ER
2700-3350
(9000-11000)
10AL Bushed
3350-4000
(11000-13000)
10 Bushed

SPECIFICATIONS
1.5
Type P--85 Center Distance 7.92” / 20.12cm.
Shift Weights 10--54 Bushed Gearing : Chain 19--39 : 72 P
Drive Spring Black/Green Reverse Electronic Reverse
Brake Type Liquid Cooled
Spring 7043063
Helix Angle 54 / 42 -- .36 Reverse CAPACITIES
Belt Width (Projected) 1.438” / 3.65cm. Coolant 5 Qts / 4.7 Liters
Side Angle (Overall) 28_ Chain Case Oil 9 fl. oz. / 299ml
Width in / cm.
124” / 48” / 45.5”
315 / 122 / 116cm.
Standard IFS Spring Rate 100# Standard FTS Spring Rate 170#
Standard Spring Pre--Load 9.75”/24.7cm Installed Standard Spring Pre--Load 7.375”/18.7 Installed
Premium Spring Rate 100# Premium Spring Rate 170#
Premium Spring Pre--Load 4.25”/10.8cm Premium Spring Pre--Load 2.98”/7.6cm
Front Vertical Travel 7 6”/19 3cm
Standard RTS 7042085 Select
Front Vertical Travel 7.6”/19.3cm
Premium RTS 7042176 Arvin IFP C/A
TRACK Torsion Spring .359/47_
15”/144”/2” (38 cm./366
cm./5 cm.) See page 11.7 for optional springs
ELECTRICAL
Flywheel I.D. 4010677 Spark Plug / Gap
Champion RN57YCC /
.028” / .70mm
CDI Marking 4010834 Voltage Regulator T1
Ignition Timing (see conver- 24_@3500 RPM±1.5_ Electric Start
Standard AccessoryIgnition Timing (see conver
sion chart on page 13.4)
24 @3500 RPM±1.5
w/TPS Disconnected
Electric Start
y
Premium Optional

SPECIFICATIONS
1.6
MODEL: 700 RMK. . . . . . . . . . . . . .
MODEL NUMBER: S05N(K,L)7CS(A). . . .
ENGINE MODEL: S2775--7070--PI7C. . . . .
ENGINE CARBURETION
Mikuni
TM 40
Stroke in / mm 2.68” / 68mm Jet Needle 9DGN5--57 / 2
in / mm
.0044” -- .0058”
.111 -- .147mm
in / mm
0.098”
2.5mm
Piston Ring End Gap
in / mm
.012” -- .018”
.304 -- .457 mm
Cutaway 2.0
Engagement RPM ±300 3800 Air Screw 1.0 Turns
Exhaust Valve Spring Orange Fuel Octane (R+M/2)
87 Oct. NonOxy /
89 Oct. Oxy
AMBIENT TEMPERATURE
Below -34°C
-30_ to --10_F
-34_to -23_C
--10_to +10_F
-23_ to --12_C
+10_to +30_F
-12_to --1_C
+30_to +50_F
-1_to +10_C
Above +50_F
Above +10_C
0--600
(0--2000)
500
#4
490
#4
470
#3
450
#3
430
#3
410
#3
600--1200
(2000--4000)
470
#4
450
#3
430
#3
410
#3
390
#3
380
#2
1200--1800 440 420 400 380 370 350
M t
1200--1800
(4000--6000)
440
#3
420
#3
400
#3
380
#3
370
#2
350
#2
Meters
(Feet)
1800--2400
(6000 8000)
400 380 360 340 330 310(Feet) (6000--8000)
400
#3
380
#3
360
#3
340
#2
330
#2
310
#2
2400--3000
(8000 10000)
360 340 320 300 290 270
(8000--10000)
360
#3
340
#3
320
#2
300
#2
290
#2
270
#2
3000--3700
(10000 12000)
320 300 290 270 250 230
(10000--12000)
320
#3
300
#2
290
#2
270
#2
250
#2
230
#2
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Chaincase
Gearing
0--600
10 64 Bushed Black/Green
0--600
(0-2000)
10--64 Bushed Black/Green
600-1200
600-1200
(2000-4000)
10-62 Bushed Black/Green
1200-1800
Meters
1200-1800
(4000-6000)
10-60 Bushed Black/Green
56 / 42 -- 36Meters
(Feet) 1800-2400
7043063
56 / 42 -- .36
ER
19--39 : 72P(Feet) 1800-2400
(6000-8000)
10-58 Bushed Black/Green ER
2400-3000
(8000-10000)
3000-3600
(11000-12000)
EV Spring
Recommendation
Altitude EV Spring
0--1200
(0--4000)
Green/Yellow
1200--3600
(4000--12000)
Orange
meters(feet)

SPECIFICATIONS
1.7
Type Team Roller Reverse Brake Type Liquid Cooled
Driven Spring 7043063 CAPACITIES
Helix Angle 58 / 42 -- .36 Reverse Fuel Tank 11.8 Gal. / 45 Liters
BELT Oil Tank 3.25 Qts / 3 Liters
Belt Part Number 3211080 Coolant 5 Qts. / 4.7 Liters
Belt Width (Projected) 1.438” / 3.65cm. Chain Case Oil 9 fl. oz. / 266ml
Side Angle (Overall) 28_ SLED DIMENSION
Outside Diameter 46.625” / 118.4cm.
Width in / cm. (144”)
124” / 48” / 45.5”
315 / 122 / 116 cm.
Width in / cm. (151”)
130” / 48” / 45.5”
330 / 122 / 116 cm.
TRACK Torsion Spring .359/47_
15”/144”/2” (38 cm./366
cm./5 cm.)
15”/151”/2” (38 cm./384
cm./5 cm.)
Track Tension See Page 3.10
ELECTRICAL
Champion RN57YCC .025”
/ .70mm
Ignition Timing(see conver-
20 @ 2000 RPM
w/ TPS Disconnected
Electric Start
Standard Accessory
Premium Optional

SPECIFICATIONS
1.8
MODEL: 800 RMK. . . . . . . . . . . . . .
MODEL NUMBER: S05N(M,K,L)8CS(A,B). . . .
ENGINE CARBURETION
Mikuni
TM40
Stroke in / mm 2.76” / 70mm Jet Needle 9DGN6--57 / 2
in / mm
.006 -- .0074”
.152 --.188mm
in / mm
0.102”
2.6mm
Piston Ring End Gap
in / mm
.016 -- .022”
.40 -- .559mm
Cutaway 2.0
Engagement RPM ±300 3800 Air Screw .75 Turns
Exhaust Valve Spring Pink Fuel Octane (R+M/2)
87 Oct. NonOxy /
89 Oct. Oxy
AMBIENT TEMPERATURE
Below -34°C
-30_ to --10_F
-34_to -23_C
--10_to +10_F
-23_ to --12_C
+10_to +30_F
-12_to --1_C
+30_to +50_F
-1_to +10_C
Above +50_F
Above +10_C
0--600
(0--2000)
510N
#5
490
#3
470
#4
450
#4
430
#3
410
#3
600--1200
(2000--4000)
480
#4
470
#4
450
#4
430
#3
410
#3
390
#2
1200--1800 450 430 410 390 370 350
M t
1200--1800
(4000--6000)
450
#4
430
#4
410
#3
390
#3
370
#2
350
#2
Meters
(Feet)
1800--2400
(6000 8000)
410 390 370 350 330 310(Feet) (6000--8000)
410
#4
390
#3
370
#3
350
#2
330
#2
310
#2
2400--3000
(8000 10000)
370 350 330 310 290 270
(8000--10000)
370
#3
350
#3
330
#2
310
#2
290
#2
270
#2
3000--3700
(10000 12000)
340 320 300 280 260 240
(10000--12000)
340
#3
320
#2
300
#2
280
#2
260
#2
240
#1
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Chaincase
Gearing
0--900
10 66 Bushed
0--900
(0-3000)
10-66 Bushed
900-1500
10 64 Bushed
900-1500
(3000-5000)
10-64 Bushed
1500-2100
10 62 Bushed
Meters
1500-2100
(5000-7000)
10-62 Bushed
58 / 42 -- 36Meters
(Feet) 2100-2700
10 60 Bushed
Black/Green 7043063
58 / 42 -- .36
Rev.
19--39 : 72P(Feet) 2100-2700
(7000-9000)
10-60 Bushed Rev.
2700-3350
(9000-11000)
10--58 Bushed
3350-4000
(11000-13000)
10--56 Bushed
EV Spring
Recommendation
Altitude EV Spring
0--1200
(0--4000)
Pink/Yellow
1200--3600
(4000--12000)
Pink
meters(feet)

SPECIFICATIONS
1.9
Type P--85 Center DIstance 7.92” / 20.12cm.
Type Team Roller Reverse Brake Type Liquid Cooled
Driven Spring 7043063 CAPACITIES
Helix Angle 58 / 42 -- .36 Reverse Fuel Tank 11.8 Gal. / 45 Liters
BELT Oil Tank 3.25 Qts / 3 Liters
Belt Part Number 3211080 Coolant 5 Qts / 4.7 Liters
Belt Width (Projected) 1.438” / 3.65cm. Chain Case Oil 9 fl. oz. / 266 ml
Side Angle (Overall) 28_ SLED DIMENSION
Outside Diameter 46.625” / 118.4cm.
124” / 48” / 45.5”
315 / 122 / 116 cm.
Width in / cm. 130” / 48” / 45.5”
330 / 122 / 116 cm.
TRACK TORSION SPRINGS
15”/144”/2” (38 cm./366
cm./5 cm.)
Torsion Spring .359/47_
15”/151”/2” (38 cm./384
cm./5 cm.) See page 11.7 for optional springs
Track Tension See Page 3 10
Track Tension See Page 3.10
ELECTRICAL
Flywheel PN 4010677 Spark Plug / Gap
Champion RN57YCC/ .025”
/ .64mm
CDI PN 4010842 Voltage Regulator T1
Ignition Timing(see conver- 29_@3250 RPM±1.5_ Electric Start
Standard AccessoryIgnition Timing(see conver
29 @3250 RPM±1.5
w/ TPS disconnected
Electric Start
y
Premium Optional

SPECIFICATIONS
1.10
MODEL: 900 RMK. . . . . . . . . . . . . .
MODEL NUMBER: S05P(L,M)8DS(A,B,C,D). . . .
ENGINE MODEL: S2884--8686--PI8D. . . . .
ENGINE FUEL SYSTEM
Engine Type Liberty Type Clean Fire Injection
Engine Displacement cc 866 Regulator Pressure 4 Bar (58psi)
Bore in / mm 3.46”/ 83mm THROTTLE BODY
Stroke in / mm 3.15” / 80mm Throttle Body Bore Size in/cm 2” / 51mm
Cylinders 2 TPS voltage @ idle .92 -- .94
in / mm
.0045” -- .0098”
.114 -- .249
Throttle Body Manufacture Mikuni
.016” -- .022”
.406--.56
DRIVE CLUTCH
Piston Marking 3021327 Type P--85
Piston Ring Marking N/A Center Distance in/cm 11.5” / 29.2
Operating RPM ±200 7400 Spring Black / Green
*Idle RPM ±200 1400 Shift Weight 10--70
Engagement RPM ±300 3700 DRIVEN CLUTCH
Exhaust Valve Spring Purple Type TEAM
CHAINCASE Spring 7043058
Center Distance in/cm 11.35” / 28.83cm Helix 62/46--36 ER
Gearing 19 : 39 -- 90P BELT
Reverse Electronic Width in/cm 1.438” / 3.652cm
Brake Pads 2202727 Length in/cm 46.625” / 118.4275cm
Brake Type Type 94 (DOT 4) Part Number 3211080
CAPACITIES DIMENSIONS
Fuel Tank gal./l 10.8 / 40.9 Length in/cm
128 / 325
134 / 340
Oil Tank qts./l 3 / 2.8 Height in/cm 46.5 / 118
Coolant qts. / l 6.7 -- 6.9 / 6.3 -- 6.4
Width in/cm 46 33 / 118
Chain Case Oil oz. / ml 11 / 325.3
Width in/cm 46.33 / 118
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Chaincase
Gearing
0-900
10 74
0-900
(0-3000)
10--74
900-1500
10 74
900-1500
(3000-5000)
10--74
1500-2100
10 72
Meters
1500-2100
(5000-7000)
10--72
Bl k/G 7043058 62/46 36 ER 19 39 90P
Meters
(Feet) 2210-2700
10 70
Black/Green 7043058 62/46--36 ER 19 : 39 -- 90P
(Feet) 2210-2700
(7000-9000)
10--70
2700--3350
(9000--11000)
10--68
3350--4000
(11000--13000)
10--66
Idle RPM is factory set and is adjusted automatically through the barometric sensor inside the ECU. DO NOT attempt to adjust
idle on the throttle body or engine performance may be affected.

SPECIFICATIONS
1.11
Type IQ Type IQ
Standard IFS Shocks 7043049 AFX Standard FTS 7043048 FX
Stock IFS Spring Rate 110# Standard FTS Spring Rate 170#
Stock Spring Pre--Load 11.38” / 29cm Installed Standard Spring Pre--Load Fixed
Premium Spring Rate 100# Premium FTS Spring Rate 170#
Premium Spring Pre--Load 10” / 25.4cm Installed
Premium FTS Spring Pre--
Load
7.25” / 18.4 cm Installed
Front Vertical Travel 8.84 in / 22.4cm Standard RTS 7043047 AFX
TRACK Premium RTS 7043046 Arvin IFP/Res CA
Width in/cm 15/38.1 TORSION SPRINGS
Length in/cm
151/384
159/404
166/422
Stock Torsion Spring .359/77_
Lug Height in/cm
(151) 2 or 2.4/5 or 6.1
(159) 2 or 2.4/5 or 6.1
(166) 2.4/6.1
Light Torsion Spring .347/77_
Track Tension See page 3.10 Heavy Torsion Spring .375/77_
ELECTRICAL
Champion RN57YCC /
.025mm(.003”)
Base ECU 4011081 Voltage Regulator 4010866
Alternator Output 400watts Stator 4010727
Ignition Timing(see conver- 14_ @ 3000RPM Electric Start TBDIgnition Timing(see conver
14_ @ 3000RPM Electric Start TBD

SPECIFICATIONS
1.12
MODEL: 600 SWITCHBACKt. . . . . . . . . . . . . .
MODEL NUMBER: S05NS6ES(A). . . .
ENGINE MODEL: S2709--6044--PI6E. . . . .
ENGINE CARBURETION
Mikuni
TM 38
Bore in / mm 3.04” / 77.25mm Pilot Jet 50
Stroke in / mm 2.52” / 64mm Jet Needle 9DGI01--60 / 4
in / mm
.0045”--.0059”
.115 -- .149mm.
in / mm
0.079”
2.0mm
Piston Ring End Gap
in / mm
.014--.020”
.356 -- .508mm
Cutaway 1.5
Exhaust Valve Spring Green/White Fuel Octane (R+M/2)
87 Oct. NonOxy /
89 Oct. Oxy
AMBIENT TEMPERATURE
Below -34°C
-30_ to --10_F
-34_to -23_C
--10_to +10_F
-23_ to --12_C
+10_to +30_F
-12_to --1_C
+30_to +50_F
-1_to +10_C
Above +50_F
Above +10_C
0--600
(0--2000)
450
#5
430
#5
420
#4
400
#4
380
#4
370
#4
600--1200
(2000--4000)
410
#5
390
#4
380
#4
360
#4
340
#4
330
#3
1200--1800 380 360 350 330 320 300
M t
1200--1800
(4000--6000)
380
#4
360
#4
350
#4
330
#4
320
#3
300
#3
Meters
(Feet)
1800--2400
(6000 8000)
360 340 320 310 290 280(Feet) (6000--8000)
360
#4
340
#4
320
#4
310
#3
290
#3
280
#3
2400--3000
(8000 10000)
340 320 300 290 270 260
(8000--10000)
340
#4
320
#4
300
#3
290
#3
270
#3
260
#3
3000--3700
(10000 12000)
330 310 290 280 260 240
(10000--12000)
330
#4
310
#3
290
#3
280
#3
260
#3
240
#3
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Chaincase
Gearing
0--900
10 60 Bushed 22 40:74P
0--900
(0-3000)
10-60 Bushed 22--40:74P
900-1500
10 58 Bushed 22 40:74P
900-1500
(3000-5000)
10-58 Bushed 22--40:74P
1500-2100
10 56 Bushed 22 40:74P
Meters
1500-2100
(5000-7000)
10-56 Bushed
56 / 42 -- 36
22--40:74P
Meters
(Feet) 2100-2700
10 54 Bushed
Black/Green 7043063
56 / 42 -- .36
ER 19 39:72P
(Feet) 2100-2700
(7000-9000)
10-54 Bushed ER 19--39:72P
2700-3350
(9000-11000)
10AL Bushed 19--39:72P
3350-4000
(11000-13000)
10 Bushed 19--39:72P

SPECIFICATIONS
1.13
Drive Spring Black / Green Reverse Electronic Reverse
Driven Spring 7043063
Helix Angle 56 / 42 -- .36 Reverse CAPACITIES
Belt Width (Projected) 1.438” / 3.65cm. Coolant 5 Qts / 4.7 Liters
Width in / cm.
124” / 48” / 47”
315 / 122 / 119 cm.
Type EDGE RMK Type EDGE RMK
IFS Shocks 7043083 Alum IFP FTS 7042084 Arvin IFP
IFS Spring Rate 100#/in FTS Spring Rate 170#/inIFS Spring Rate 100#/in. FTS Spring Rate 170#/in.
IFS Spring Pre--Load 10.5” / 26.7cm Installed
FTS Pre Load 2 98” / 7 6 cm
Front Vertical Travel 7.1--7.4 / 18 -- 18.8cm.
FTS Pre--Load 2.98” / 7.6 cm.
TRACK
RTS 7042176 Arvin IFP C/A
Width 15” / 38 cm.
Length 144” / 366 cm. Torsion Spring .359” (Sq) x 47_
Lug Height 1.25” / 3.175 cm.
Track Tension See page 3 10
Optional springs see page 11.7
p p g p g
ELECTRICAL
Champion RN57YCC .028”
/ .70mm
Ignition Timing(see conver- 24_@3000 RPM±1.5_ Electric Start AccessoryIgnition Timing(see conver
24 @3000 RPM±1.5
w/TPS Disconnected
Electric Start Accessory

SPECIFICATIONS
1.14
MODEL: 800 SWITCHBACKt. . . . . . . . . . . . . .
MODEL NUMBER: S05NSCS(A). . . .
ENGINE CARBURETION
Mikuni
TM 40
Stroke in / mm 2.76” / 70mm Jet Needle 9DGN6--57/4
in / mm
.006 -- .0074”
.152 -- .188mm
in / mm
0.079”
2.0mm
Piston Ring End Gap
in / mm
.016 -- .022”
.406 -- .559mm
Cutaway 2.0
Exhaust Valve Spring Pink / Yellow Fuel Octane (R+M/2)
87 Oct. NonOxy /
89 Oct. Oxy
AMBIENT TEMPERATURE
Below -34°C
-30_ to --10_F
-34_to -23_C
--10_to +10_F
-23_ to --12_C
+10_to +30_F
-12_to --1_C
+30_to +50_F
-1_to +10_C
Above +50_F
Above +10_C
0--600
(0--2000)
510N
#5
490
#4
470
#4
450
#4
430
#3
410
#3
600--1200
(2000--4000)
480
#4
470
#4
450
#4
430
#3
410
#3
390
#2
1200--1800 450 430 410 390 370 350
M t
1200--1800
(4000--6000)
450
#4
430
#4
410
#3
390
#3
370
#2
350
#2
Meters
(Feet)
1800--2400
(6000 8000)
410 390 370 350 330 310(Feet) (6000--8000)
410
#4
390
#3
370
#3
350
#2
330
#2
310
#2
2400--3000
(8000 10000)
370 350 330 310 290 270
(8000--10000)
370
#3
350
#3
330
#2
310
#2
290
#2
270
#2
3000--3700
(10000 12000)
340 320 300 280 260 240
(10000--12000)
340
#3
320
#2
300
#2
280
#2
260
#2
240
#1
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Chaincase
Gearing
0--600
10 66 Bushed 23 39:74P
0--600
(0-2000)
10-66 Bushed 23--39:74P
600-1200
10 64 Bushed 23 39:74P
600-1200
(2000-4000)
10-64 Bushed 23--39:74P
1200-1800
10 62 Bushed 23 39:74P
Meters
1200-1800
(4000-7000)
10-62 Bushed
58 / 42 -- 36
23--39:74P
Meters
(Feet) 1800-2400
10 60 Bushed
Black/Green 7043063
58 / 42 -- .36
ER 21 41:74P
(Feet) 1800-2400
(6000-8000)
10-60 Bushed ER 21--41:74P
2400-3000
(8000-10000)
10--58 Bushed 21--41:74P
3000-3600
(10000-12000)
10--56 Bushed 21--41:74P

SPECIFICATIONS
1.15
Drive Spring Black / Green Reverse Electronic Reverse
Driven Spring 7043063
Driven Helix Angle 58/42--.36 ER CAPACITIES
Belt Width (Projected) 1.438” / 3.65cm. Coolant 5 Qts/ 4.7 Liters
Width in / cm.
124” / 48” / 47”
315 / 122 / 119 cm.
Type EDGE RMK Type EDGE RMK
IFS Shocks 7043083 Alum IFP FTS 7042084 Arvin IFP
IFS Spring Rate 100#/in FTS Spring Rate 170#/inIFS Spring Rate 100#/in. FTS Spring Rate 170#/in.
IFS Spring Pre--Load 10.5” / 26.7cm Installed
FTS Pre Load 2 98” / 7 6 cm
Front Vertical Travel 7.1--7.4 / 18 -- 18.8cm.
FTS Pre--Load 2.98” / 7.6 cm.
TRACK
Width 15” / 38 cm.
Length 144” / 366 cm. Torsion Spring .359” (Sq) x 47_
Lug Height 1.25” / 3.175 cm.
Track Tension See page 3 10
Optional springs see page 11.7
p p g p g
ELECTRICAL
Flywheel PN 4010677 Spark Plug / Gap
Champion RN57YCC /
.025” / .70mm
CDI PN 4010841 Voltage Regulator T1
Ignition Timing(see conver- 29_@3250 RPM±1.5_ Electric Start AccessoryIgnition Timing(see conver
29 @3250 RPM±1.5
w/TPS Disconnected
Electric Start Accessory

2005 Model Number Designation 2.1. . . . . . . . . . . . . . . . . . . . . . . . .
Tunnel Decal 2.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vehicle Identification Number 2.2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
2005 Publication Part Numbers 2.3. . . . . . . . . . . . . . . . . . . . . . . . . . .
General Service Precautions 2.4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Torque Specifications 2.5. . . . . . . . . . . . . . . . . . . . . . . . . . .
Decimal Equivalents 2.6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tap Drill Sizes 2.7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conversion Chart 2.8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston Wash and Spark Plug Color 2.9. . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Inspections 2.10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston Measurements 2.11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Honing 2.12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Port Chamfering 2.13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Rod Bearing Inspection 2.14. . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Indexing 2.15 -- 2.17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump Operation and Troubleshooting 2.18. . . . . . . . . . . . . . . . . . .
Oil Pump Bleeding 2.19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump Adjustment 2.20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling System Overview 2.21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
900 Fusion Cooling System 2.22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL INFORMATION
2.1
2005 MODEL NUMBER DESIGNATION
EXAMPLE: S05NB4BS
S 05 N B 4 B S #
Identifier
(1st Digit)
ModelYear
(2nd/3rd Dig-
it)
Model Line
(4th Digit)
Model Type
(5th Digit)
Engine Size
(cc)
(6th Digit)
Engine modifier
(6th/7th Digit)
VIN
Identifier
(8th Digit)
Option
Identifier
(9th
Digit)
S=Snow 05=2005 M=Fusion A=50th Anniv Spe-
cial
0=0--99cc 1A=121 F/C OHV 4 cycle Fuji E=Europe unit
N=Edge B=Basic or Stan-
dard
1=100--199 3A=340 F/C Piston Port S=Standard
Production
Unit
P=IQ RMK D=Classic 2=200--299cc 4B=488 L/C Piston Port
S=Gen II E=M--10 Perfor-
mance
3=300--399cc 4C=440 EV L/C Case Reed (Dom)
W=Mini Indy J=136 RMK 4=400--499cc 5B=544 F/C Cylinder Reed
K=144 RMK 5=500--599cc 5C=500 EFV L/C Case Reed 2 Cyl
(Dom)
L=151 RMK 6=600--600cc 6E=600 EV L/C Case Reed 2 Cyl
(Dom)
M=159 RMK 7=700--799cc 7C=700 EV L/C Case Reed 2 Cyl
(Dom)
N=166 RMK 8=800--899cc 7D=780 4--stroke EFI 2 Cyl (Dom)
P=Performance 9=900+cc 8C=800 EV L/C Case Reed 2 Cyl
(Dom)
S=Switchback 8D=866 EV SDI Case Reed
T=Touring
U=Utility
X=Racer/Pro X
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
2.2
VEHICLE IDENTIFICATION NUMBER
Current snowmobiles have a 17 digit Vehicle Identification Number (VIN). The VIN is organized as follows: Digits 1-3: World
ManufacturerIdentifier. For Polaris, this isSN1. Digits 4-9: Vehicle Descriptor Section. Digits10-17: Vehicle IndicatorSection.
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 11 12 13 14 15 16 17
S N 1 S B 5 B S 0 2 2 0 0 0 0 0 0
Vehicle Descriptor Vehicle Identifier
Type
Engine
Size Engine
Modifier
Model
Year
Manufacturing.
Location Code
Individual Serial No.
Body Style Series
World Mfg. ID
Example of
Current
VIN Number
Check
Digit
Vehicle Identification Number / Model Number Key
Body Style Type Engine Size Engine Modifier Series
L=Lite B=Base Model 1=100-199 cc’s A=Fan S=Domestic
N=Edge D=Deluxe 2=200-299 cc’s B=Liquid Twin U=Europe
S=Gen II P=Performance 3=300-399 cc’s C=Case Reed Twin
W=Mini R=RMK 4=400-499 cc’s D=Liquid Triple
S=SKS 5=500-599 cc’s E=Case Reed Triple
T=Touring 6=600-699 cc’s
U=Utility 7=700-799 cc’s
X=Racer 8=800-899 cc’s

GENERAL INFORMATION
2.3
PUBLICATION PART NUMBERS
Model Model No. Owner’s Manual
Owners Manual
Supplement
Parts
Manual
Microfiche
Trail RMK S05NJ5BS(A) 9919706 9919097 9919276 9919277
600 RMK S05NK6ES(A) 9919706 9919098 9919278 9919279
700 RMK S05N(K,L)7CS(A) 9919706 9919381 9919278 9919279
800 RMK S05N(M,K,L)8CS(A,B) 9919706
9919383 (144)
9919384 (151)
9919385 (159)
9919278 9919279
900 RMK S05P(L,M)8DS(A,B,C,D) 9919077
9919104 (151)
9919105 (159)
9919106 (166)
9919292 9919293
600 Switchback S05NS6ES(A) 9919076 9919095 9919280 9919281
800 Switchback S05NSCS(A) 9919076 9919095 9919280 9919281
SERVICE MANUALS
Service Manuals 2004
2000--2005
120 XC SP / PRO X
9919307
Trail Sport
500 Indy, Supersport
9919300
Touring
340 Edge Touring, Trail Touring (Deluxe), Widetrak LX, 600 Edge Touring (50th), 800 Edge Touring
9919304
Frontier
Frontier Touring
9919305
Classic
340 Classic, 500 Classic, 550 Classic, 600 Classic, 800 Classic
9919301
Deep Snow
Trail RMK, 600/700/800 RMK, 600/800 Switchbackt, 900 RMK
9919302
Performance
500/600/700/800 XC SP, 900 Fusion
9919303
2005 Specification Handbook 9919311
2005 Snowmobile Wallcharts 9919309
Track Poster 9918459
Flat Rate Manual 9919308
Snowmobile Care and Adjusting for the Perfect Ride (DVD) (2004) 9918923
Snowmobile Care and Adjusting for the Perfect Ride (VHS) (2004) 9918908
2005 Snowmobile Quick Start Guide (DVD) (2005) 9919129

GENERAL INFORMATION
2.4
GENERAL SERVICE PRECAUTIONS
In order to perform service work efficiently and to prevent costly errors, the technician should read the text in this manual,
thoroughlyfamiliarizinghim/herselfwithproceduresbefore beginning. Photographsand illustrationshave beenincluded withthe
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 fastenersin the snowmobile were installed withlocking agents. Use ofimpact driversor wrencheswill helpavoid
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 ofany gasket or O-Ringis inquestion, replace it witha newone. Be sure the mating surfacesaround 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 voidif otherbrands
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.

GENERAL INFORMATION
2.5
DECIMAL EQUIVALENTS
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. .125. . . .
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 .250. . . .
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 00 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 .750. . . .
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 1.000. . . . . .

GENERAL INFORMATION
2.6
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
2.7
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
2.8
CONVERSION CHART
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’s x .03381 = Fluid Ounces (oz)
lb. x .454 = kg
kg x 2.2046 = lb.
Cubic inches (cu in) x 16.387 = Cubic centimeters (cc’s)
Cubic centimeters (cc’s) 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
2.9
PISTON WASH AND SPARK PLUG COLOR
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 (EGTs) 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 you establish the EGTs for your machine.
n If the wash is 1/4” - 3/8” and cocoa
brown, the machine’s EGTs are just right.
n Wet and Black wash indicates too rich a fuel
mixture
n A dry, ash colored piston indicates too lean a
mixture for the operating conditions.
n If the plug is light to cocoa brown, the ma-
chine’s EGTs are just right.
n If the plug is wet or very dark, the fuel is
running too rich.
n A ash white plug with speckles indicates too
lean a mixture for the operating conditions.
Piston Wash Spark Plug Color
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.
Correct
Correct
Wash
Dry

GENERAL INFORMATION
2.10
CYLINDER INSPECTIONS
CYLINDER HEAD INSPECTION
Inspect eachpistondome area ofthe cylinderhead forwarping byplac-
ing a straight edge across the dome area.
With a feeler gauge measure any gap under the straight edge.
Replace cylinder head if measurement exceeds the service limit of
.003” (.08mm).
NOTE:
Cylinder Head Warp
Service Limit .003” (.08mm)
CYLINDER MEASUREMENT
Inspect each cylinder for wear, scratches, or damage. If no damage is evident, measure the cylinder for taper and out of round
with a telescoping gauge or a dial bore gauge. Measure the bore 1/2, from the top of the cylinder; in line with the piston pin and
90_ to the pin to determine if the bore is out of round. Repeat the measurements at the middle of the cylinder and the bottom
of the cylinder to determine taper or out of round at the bottom. Use the chart below and record all measurements.
TOP
Tx Ty
MIDDLE
Mx My
BOTTOM
Bx By
Out of round =
Tx--Ty and By--Bx
Taper Limit=
Ty--By and Tx--Bx
Limit .003” (.08mm)
Top
Middle
Bottom
Tx
Mx
Bx
Ty
My
By
S Cylinder Taper Limit: .002” MAX
S Cylinder Out of Round Limit: .002”

GENERAL INFORMATION
2.11
PISTON INSPECTION / MEASUREMENT
90° to pin
DOMESTIC ENGINES - Measure 3/8″ (10.0mm)
up from bottom of skirt
Piston Ring
Feeler Gauge
1/2″ (1.3cm.)
Straight Edge
Keystone Piston Ring Cutaway
Up
FUJI ENGINES - Measure 1/2″ (12.7mm) up
from bottom of skirt
1/2″ (1.3cm.)
Cylinder
Piston RingA B C
D
Check piston for scoring or cracks in piston crown or pin area. Excessive carbon buildup below the ring lands is an indication
of piston, ring or cylinder wear.
For Libertyt engines, measure piston outside diameter at a point 3/8” (10mm) up from the bottom of the skirt at a 90_ angle
to the direction of the piston pin (diagram A).
For Fuji engines, measure piston outside diameter at a point that is 1/2” (12.7mm) up form the bottom of the skirt at a 90_ angle
to the direction of the piston pin (diagram A).
NOTE: The piston must be measured at this point to provide accurate piston to cylinder measurements.
Subtract this measurement from the minimum cylinder measurement recorded previously when you recorded the cylinder mea-
surements. If clearance exceeds the service limit, the cylinder should be re-bored and new pistons and rings installed. Refer to
piston to cylinder clearance limits in the General Information section listed per model.
PISTON RING INSTALLED GAP
Position the ring 1/2“ (1.3 cm) from the top of the cylinder using the piston to push it squarely into place. Measure installed gap
with a feeler gauge at both the top and bottom of the cylinder (diagram B).
NOTE:
A difference in end gap indicates cylinder taper. The cylinder should be measured for excessive
taper and out of round. Replace rings if the installed end gap exceeds the service limit.
NOTE: Always check piston ring installed gap after re-boring a cylinder or when installing new rings.
NOTE: Piston rings are installed with marking or beveled side up see diagram D.

GENERAL INFORMATION
2.12
CYLINDER HONING
The cylinder bore must be de-glazed whenever new piston rings are installed. A light honing with fine stones removes only a
very small amount of material. A proper crosshatch pattern is important to provide a surface that will hold oil, and allow the rings
to seat properly. If the crosshatch is too steep, oil retention will be reduced. A crosshatch angle which is too shallow will cause
ring vibration, poor sealing, and overheating of the rings due to blow-by and reduced contact with the cylinder wall. Service life
of the pistons and rings will be greatly reduced.
CYLINDER HONE SELECTION
A Nikasil cylinder can be lightly honed with
a soft stone hone but can not be oversized.NOTE:
DE--GLAZING
If cylinder wear or damage is minimal, honing the cylinder lightlywith
finish stones. Follow the procedure outlined above
HONING TO OVERSIZE (340 AND 500 FUJI ENGINES ONLY)
If cylinder wear or damage is excessive, it will be necessary to oversize the cylinder using a new oversize piston and rings. This
may be accomplished by either boring the cylinder and then finish honing to the final bore size, or by rough honing followed by
finish honing.
Portable rigid hones are not recommended for oversizing cylinders, cylinder boring, and finish honing.
The use of an arbor type honing machine is recommended.NOTE:
For oversize honing always wet hone using honing oil and a coarse roughing stone. Measure the new piston at room temperature
(see piston measurement) and rough hone to the size of the piston or slightly larger. Always leave .002” - .003“ (.05 - .07 mm)
for finish honing. Complete the sizing with fine grit stones to provide the proper cross-hatch finish and required piston clearance.
Inspect cylinder for taper and out-of-round. Taper or out-of-round on the finished bore should not exceed .0004“ (.002mm).
NOTE: Always check piston to cylinder clearance and piston ring installed gap after boring/honing is complete.
HONING PROCEDURE
Wash the cylinder with solvent.
Clamp the cylinder in a soft jawed vise by the exhaust port studs.
Place hone in cylinder and tighten stone adjusting knob until stone contacts the cylinder walls (DO NOT OVERTIGHTEN).
Cylinders may be wet or dry honed depending on the hone manufacturer’s recommendations. Wet honing removes more material
faster and leaves a more distinct pattern in the bore. Using a 1/2“ (13 mm) drill motor rotating at a speed of 300-500 RPM, run
the hone in and out of the cylinder rapidly until cutting tension decreases. Remember to keep the hone drive shaft centered to
prevent edge loading and always bring the stone approximately 1/2“ (1.3 cm) beyond the bore at the end of each stroke.
Release the hone at regular intervals to inspect bore size and finish.
EXAMPLE OF A CROSS HATCH PATTERN

GENERAL INFORMATION
2.13
PORT CHAMFERING
Remove the sharp edges at the bottom and top of each port whenever boring or honing is performed. Make sure there are no sharp
edges.
IMPORTANT:
It is very important that the cylinder be thoroughly cleaned after honing to remove all grit material.
Wash the cylinder in a solvent, then in hot soapy water. Pay close attention to areas where the cylinder
sleeve meets the aluminum casting (transfer port area). Use electrical contact cleaner if necessary to
clean these areas. Rinse thoroughly, dry with compressed air, and oil the bore immediately with Polaris
Premium 2 Cycle Lubricant.
CLEANING THE CYLINDER AFTER HONING
It is very important that the cylinder be thoroughly cleaned after honing to remove all grit material. Washthe cylinderin a solvent,
then in hot soapy water. Pay close attention to areas where the cylinder sleeve meets the aluminum casting (transfer port area).
Use electrical contact cleaner if necessary to clean these areas. Rinse thoroughly, dry with compressed air, and oil the bore im-
mediately with Polaris Premium 2 Cycle Lubricant.
Always check piston to cylinder clearance and piston ring installed gap after boring/honing is
complete!
NOTE:
CRANKCASE INSPECTION / BEARING FIT
Any time crankshaft bearing failure occurs and the case isto be reused,
Polaris recommends checking the bearing fit into the case halvesusing
the following procedure.
With case halves cleaned, press a replacement bearing into each of the
main bearing journals to determine a basic amount of press fit.
NOTE: Crankcase Bearing Interference Fit:.001” -- .002” (.026 -- .051mm)
Do a comparison check of all journals by manually forcing the bearing into the bearing seats noting if
any are noticeably loose or tight. Normal hand installation will be an indication of the recommended
interference fit. If the bearing falls out of the case when the case is inverted, or if the crankcase bear-
ing surface is severely galled or damaged, the case should be replaced
NOTE:
CRANKSHAFT MAIN BEARING INSPECTION
Clean crankshaft thoroughly and oil main and connecting rod bearings with Polaris engine oil. Carefully check each main bearing
on the shaft.
Due to extremely close tolerances, the bearings must be inspected visually, and by feel. Look for signs
of discoloration, scoring or galling. Turn the outer race of each bearing. The bearings should turn
smoothly and quietly. The inner race of each bearing should fit tightly on the crankshaft. The outer
race should be firm with minimal side to side movement and no detectable up and down movement.
Replace any loose or rough bearings.
NOTE:

GENERAL INFORMATION
2.14
CONNECTING ROD (BIG END) BEARING INSPECTION
Measure connecting rod big end side clearance with a feeler gauge. 500/600 Libertyt Engines should have a clearance of
(.28 --.75mm) and 700/800/900 Libertyt Engines should have (.28 -- .70mm) and be equal on all rods (within .002″) Rotate rod
on crankshaft and check for rough spots. Check radial end play in rod by supporting rod against one thrust washer and alternately
applying up and down pressure. Replace bearing, pin, and thrust washers if side clearance is excessive or if there is any up and
down movement detectable in the big end bearing.
Specialized equipment and a sound knowledge
of crankshaft repair and straightening is required
to perform crankshaft work safely and correctly.
Crankshaft repair should be performed by
trained Polaris service technicians in a properly
equipped shop.
NOTE:
PISTON PIN / NEEDLE BEARING INSPECTION
Clean needle bearing in solvent and dry with compressed air.
Inspect needle cage carefully for cracks or shiny spots which indicate
wear. Replace needle bearings if worn or cracked, and always replace
them if piston damage has occurred.
Visually inspect piston pin for damage, discoloration, or wear. Runyour
fingernail along the length of the pin and replace it if any rough spots,
galling or wear is detected.
CONNECTING ROD SMALL END INSPECTION
Clean small end of connecting rod and inspect inner bore with a magni-
fying glass. Look for any surface irregularities including pitting, wear,
or dents.
Run your fingernail around the inside of the rod and check for rough
spots, galling, or wear.
Oil and install needle bearing and pin in connecting rod. Rotate pin
slowly and check for rough spots or any resistance to movement. Slide
pin back and forth through bearing while rotating and check for rough
spots.
With pin and bearing centered in rod, twist ends back and forth in all
directions to check for excessive axial play. Pull up and down evenly
on both ends of pin to check for radial play. Replace pin and bearing
if there is any resistance to rotation or excessive axial or radial move-
ment. If playor roughnessis evident with a new pinand bearing, replace
the connecting rod.
Within .002” (.05mm)

GENERAL INFORMATION
2.15
CRANKSHAFT INDEXING
Dial Indicator
Degree
Wheel
.100 ATDC
Crankshaft center line
Dial Indicator
Degree
Wheel
.100 ATDC
MAG PTO
CAUTION:
Disconnect battery ground cable and ALL spark plug high tension leads: ground high tension
leads to engine. Disconnect lanyard (if equipped) and or press engine stop switch before proceed-
ing with this following procedure.
Polaris crankshafts are pressed together or ‘‘indexed” so the connecting rod journal center lines are 180_ (twins).
It is sometimes necessary to check multi-cylinder crankshafts to verify that one cylinder has not been forced out of position rela-
tive to the other cylinder or cylinders. Some causes for out-of-index crankshafts include but are not not limited to:
S Hydraulock from water or fuel
S Impact to drive clutch from foreign object or accident
S Abrupt piston or other mechanical failure
S Engine lock--up due to drive belt failure
REQUIRED SERVICE: Belt Removal, Drive Clutch Removal
Securely fasten a degree wheel on the flywheel or PTO end of crankshaft. Use a large degree wheel for more accuracy, and make
sure it is mounted concentrically with the crankshaft center line.
Sharpen a coat hanger or section of welding rod and anchor it to a convenient spot. Point the sharpened end at the outer perimeter
of the degree wheel.
Install a dial indicator into the magneto end cylinder spark plug hole. (The ignition timing is referenced by the magneto end.)
With the indicator installed on the MAG cylinder rotate the engine to bring the piston to top dead center (TDC).
Locate TDC as accurately as possible by finding the center of the point where there is no piston movement then ‘‘Zero” the dial
indicator at this point. Continue to rotate the crankshaft in the normal direction of rotation until the dial indicator reads .100”
(2.54mm) after top dead center (ATDC).
Bend the pointer or move the degree wheel until the pointer aligns with a 180_ mark on the degree wheel.
With the pointer aligned, make sure the degree wheel and pointer are secured and will not move out of position. Re-check accura-
cy of this location a few times. The pointer should align with the 180_ mark when the dial indicator reads .100“ (2.54mm) ATDC.
IMPORTANT: Do not move the crankshaft, degree wheel or pointer after the initial setting on the MAG end cylinder --
simply read the wheel and dial indicator.
Remove the dial indicatorandinstall in PTOcylinder. Repeat finding TDC. Note the degree wheel indication whenthe dial indica-
tor reads .100” ATDC. It should be 180_ (± 2_) from the MAG cylinder mark.

GENERAL INFORMATION
2.16
Symptoms of an out of index crankshaft can include:
S Difficulty calibrating carburetor (repetitive plug fouling on one cylinder with no other cause)
S Unexplained piston failure on one cylinder (i.e. severe detonation, broken ring lands, piston holing)
S Excessive vibration of engine, backfiring, etc.
S Rough idle, poor top speed.
CRANKSHAFT TRUING
Lubricate the bearings and clamp the crankshaft securely in the holding fixture. If truing the crankshaft requires striking with a
hammer, always be sure to re-check previously straightened areas to verify truing. Refer to the illustrations below. Use Crank-
shaft alignment kit PN 2870569.
NOTE:
The Rod Pin position in relation to the dial indicator tells you what action is required to straighten
the shaft.
To correct a situation like the one shown in illustration 1, strike the
shaft at point A with a brass hammer.
To correct a situation like the one shown in illustration 2, squeeze the
crankshaft at point A. you will use the tool from the alignment kit PN
2870569.
If the crank rod pin location is 180_ from the dial indicator (opposite
that shown in illustrating 2), it will be necessary to spread the crank-
shaft at the A position as shown in illustration 3. When rebuilding and
straightening a crankshaft, straightness is of utmost importance. Run-
out must be as close to zero as possible.
A
B
HIGH .004 (.1mm)
HIGH .004 (.1mm)
SUPPORT CRANKSHAFT
AT THESE TWO BEARINGS
1
A A
HIGH .002 (.05mm)
HIGH .005 (.13mm)
2
A
HIGH .002 (.05mm)
HIGH .005(.13mm)A
3

GENERAL INFORMATION
2.17
CRANKSHAFT RUNOUT INSPECTION
1/2” (12.7mm)
Flywheel (MAG) side
Measure where taper starts
PTO Side
When checking the crankshaft runout on the MAG side measure the runout 1/2” (12.7mm) from the bearing flat.
When checking the crankshaft runout from the PTO side, measure runout where the taper starts after the bearing flat.
Acceptable crankshaft runout
(in crank fixture) is
Libertyt Engines .000” -- .00015” (0--.04mm)
FUJI Engines .000” -- .0024” (0--.07mm)
NOTE:

GENERAL INFORMATION
2.18
OIL PUMP OPERATION AND TROUBLESHOOTING
BANJO TYPE
PRESS IN TYPE
Any time the engine is disassembled or repaired, it is important that the oil supply from the pump to
the engine be checked.
Banjo type or pressed in valves should open with 2 to 7 lbs. of pressure. Perform this test with 40:1
premix in the fuel tank.
Install new sealing washers upon installation on either side of the banjo check valve.
NOTE:
With engine in chassis, oil reservoir full, and pump bled, remove two oil feed line banjo bolts (A) from their location on the
manifold or carburetors.
Loosely thread the banjo bolts back into the manifold or carburetors.
Place oil feed lines with their check valves away from the clutch area.
Start the engine and let it idle at normal idle RPM.
Drops of oil should be visible from the banjo check valves after the engine is idled one to two minutes, with a drop occurring
approximately every few seconds
If oil does not flow from one of the check valves, remove oil line from check valve and again idle engine. If oil then flows, the
check valve is defective and must be replaced.
If oil does not flow with check valves removed from their feed lines, the malfunction is one of the following:
S Inline filter blocked.
S Air not bled from oil pump.
S Feed lines leaking.
S Oil tank vent restricted or kinked.
S Defective pump.

GENERAL INFORMATION
2.19
OIL PUMP BLEEDING
(A)
(A)
FUSION OIL PUMP
NOTE:
Any time the engine is disassembled or repaired, it is important that the oil supply from the pump
to the engine be checked.
IMPORTANT: The oil pump must always be bled following any service to the injector system or engine.
Fill oil reservoir with the appropriate Polaris injector oil. This will add pressure to the oil lines to aid in bleeding the air out.
Loosen bleed screw (A). After :30 seconds or so, oil should flow from beneath the screw head to indicate the pump is free of air.
Tighten bleed bleed screw securely.

GENERAL INFORMATION
2.20
OIL PUMP ADJUSTMENT PROCEDURE
.010-.030, (.25-.8 mm)
Throttle Freeplay
Figure 2 Figure 3
Figure 4
REQUIRED SERVICE: Carburetor synchronization.
VM TYPE: Verify that carburetor slides leave their respective resting positions upon opening within .01, to .03, of throttle cable
movement, not throttle lever movement. See figure 2.
TM TYPE: Verify that carburetor slides are within .0625” of each other when passing the top of the carburetor throat. You may
have to move slides with the starter lever.
Adjust throttle cable freeplay to .010, - .030, (.25 - .8mm).
Set idle to specified idle speed listed in the specifications chapter.
Verify that the oil pump alignment lines are aligned at the point where the carburetor slides begin to raise from their resting posi-
tions. Note: Marks may not line up without throttle engagement. See figure 3.
Make adjustments so that the lines are at the position shown in figure 4.
Torque cable locknuts to 10 - 20 in.lbs.
NOTE: Use a mirror when aligning the oil pump marks whenever the oil pump is difficult to view.
THROTTLE BODY TYPE (900)
All you need to do for the 900 oil pump isto verifythat the oil pumpmarks line up (figure 4) whenthe throttle is inthe idle position.
You may need a mirror to see the marks straight on. If the line does not line up (figure 3) you will need to adjust the oil cable
at the throttle bell housing.
To adjust this loosen the lock nut and thread the barrel nut in or out depending on the direction you need the line to move.
Moving the barrel nut in will adjust the line more to the top.
DO NOT adjust the idle. This is all set at the factory and should not be tapered with.

GENERAL INFORMATION
2.21
COOLING SYSTEM OVERVIEW
DANGER
Never remove the pressure cap when the engine is warm or hot. If the pressure cap is to be removed,
the engine must be cool. Severe personal injury could result from steam or hot liquid.
Use of a non-standard pressure cap will not allow the recovery system to function properly.
If the cap should need replacement, install the correct Polaris cap with the same pressure rating.
Refer to the appropriate parts manual.
COOLANT LEVEL
Coolant level in the coolant bottle must be maintained between the MINIMUM and MAXIMUM levels to prevent overheating
and serious engine damage.
RECOMMENDED COOLANT
Use a 60/40 mixture of antifreeze and distilled water depending on the freeze protection required for your area.
Do not use tap water in the system or reduced cooling or filter contamination may result.
Replace coolant every 2 years or if contaminated.
BLEEDING THE COOLING SYSTEM
Allow the system to cool completely.
Loosen the bleed screw and full the reservoir to the indicated Full Cold mark.
Once Full, tighten the bleed screw.
Apply parking brake and run the engine at specified idle RPM until the thermostat opens (approximately 5 to 8 minutes).
NOTE:
It is important that the thermostat stays open! When the thermostat opens it will draw in cold coolant
from the heat exchangers and the cold coolant may close the thermostat again. Make sure the thermo-
stat opens and stays open! Once the thermostat is open tip the snowmobile slightly on its right side.
Cycle the RPM from idle to enough RPM (4000) to get coolant to flow but not enough RPM to engage
the clutch. This allows air to bleed from the rear crossover tube. Then tilt the machine slightly on its
left side so that the coolant bottle is the highest point in the cooling system. Cycle the RPM from idle to
enough RPM (4000) to get coolant to flow but not enough RPM to engage the clutch. It is important to
get enough coolant flow to purge the air from the front close-off cooler and observe this air reaching the
bottle.
Place the snowmobile in its normal riding position and loosen the bleed screw at the top of the water outlet manifold until trapped air
has been purged.
Tighten the bleed screw. Turn off the machine and release parking brake. Allow the system to cool completely. Re-check the cool-
ant level after the cap has been removed and add coolant to fill line if necessary. After the machine has cooled down, 3 ounces
or more of coolant may have to be added.
This procedure should take approximately 15 minutes.
NOTE: It is important to get enough coolant flow to purge the air from the crossover hose or rear
cooler and observe this air reaching the bottle.
DANGER
When performing the following checks and adjustments, stay clear of all moving parts to avoid
serious personal injury.
Never remove the pressure cap when the engine is warm or hot. If the pressure cap is to be
removed, the engine must be cool. Severe personal injury could result from stream or hot liquid.

GENERAL INFORMATION
2.22
900 FUSION* COOLING SYSTEM
E 2004 Polaris Sales Inc.
1.
3.
5.
7.
11.
13.
17.
18.
19.
21.
26.
2.
4.
6.
12.
14.
16.
9.
9.
9.
15.
15.
15.
8.
8.
8.
4.
2.
22.
22.
10.
9.
9.
9.
9.20.
23.
24.
9.
9.
25.
27.
1. Mount, Radiator, Rubber 2. Exchanger, Gripper/Cooler, LH
Exchanger, Gripper/Cooler, RH
3. Asm., Radiator 4. Hose, Gripper/Rear Cooler, LH
Hose, Gripper/Rear Cooler, RH
5. Mount, Radiator, Foam 6. Asm., Rear Cooler, Long
7. Hose, Tee/Radiator Inlet 8. Clamp, Springband, Brown
9. Clamp, Springband, Black 10. Rivet
11. Hose, Radiator/Bottle 12. Hose, Tube/Gripper, LH
13. Fitting, Tee 14. Cooler, Center
15. Clamp, Springband, Black 16. Hose, Tee/Center Cooler
17. Hose, Coolant Bottle/Engine
18. Hose, Engine Out/Tee
19. Cap, Pressure
20. Line, Fuel
21. Bottle, Coolant
22. Clamp, Hose
Clamp, Narrow
23. Nut
24. Clamp, Rubber Coated, .75
25. Tube, Coolant, Front, RH
26. Hose, Bottle/Tube
27. Hose, Gripper, Front, RH
*For other cooling diagrams please refer to the models parts book.

Maintenance Program Chart 3.1 -- 3.3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Filter 3.4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Sediment Trap 3.4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Filter 3.5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter 3.5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication Points 3.6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Suspension Lubrication 3.7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chaincase 3.8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Track 3.9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Track Tension 3.10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spark Plug Reading 3.11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Clutch Removal 3.12 -- 3.13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlight 3.14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bulb Replacement 3.15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handlebar Adjustment 3.16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake System 3.17 -- 3.18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Lever Free Play 3.19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Care 3.20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust System 3.21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IQ Air Intake System 3.22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Edge Exhaust Valve Maintenance 3.23. . . . . . . . . . . . . . . . . . . . . . . . . .
IQ Exhaust Valve Maintenance 3.24. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat / Temperature Sensor 3.25. . . . . . . . . . . . . . . . . . . . . . . . . .
900 Liberty Coolant 3.26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
900 Liberty Oil Pump/Line Bleeding 3.27. . . . . . . . . . . . . . . . . . . . . . .
Typical Recoil Service 3.28 -- 3.29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
700/800 Liberty Water Pump Service 3.30. . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE
3.1
POLARIS RECOMMENDED MAINTENANCE PROGRAM
To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and service checks
outlined in this manual.The recommended maintenance schedule on your snowmobile calls for service and maintenance inspec-
tions at 150 miles (240 km), 1000 miles (1600 km), and 2000 miles (3200 km). These inspections should be performed by a
qualified service technician. For continuedoptimum performance and component life, continue maintenance checksat 1000mile
(1600 km) intervals. All necessary replacement parts and labor incurred, with the exception of authorized warranty repairs, be-
come the responsibility of the registered owner. If, during the course of the warranty period, part failures occur as a result of owner
neglect in performing recommended regular maintenance, the cost of repairs are the responsibility of the owner.
Personal safety is critical when attempting to service or adjust your snowmobile. If you’re not familiar with safe service or adjust-
ment procedures and the use of tools, or if youdon’t feel comfortable performingthese tasksyourself, contact an authorizedPolar-
is dealer for service.
The followingchart is a guide basedon average riding conditions. Youmay needto increase frequency basedon ridingconditions.
When inspection reveals the need for replacement parts, always use genuine Polaris parts, available from your Polaris dealer.
MAINTENANCE PROGRAM
MILEAGE
ITEM
PRE--RIDE
150 MILES
(240 KM)
1000 MILES
(1600 KM)
2000 MILES
(3200 KM)
PRE--SEASON
C
CLUTCH OFFSET ALIGNMENT (WITH OUT
BELT) I I
C
L
U
DRIVE BELT CONDITION I I I I
U
T DISASSEMBLE AND CLEAN CLUTCHES C CT
C
H
BELT TENSION I I I
H
CLUTCH SHEAVES I I I
ENGINE MOUNTS I I I
RECOIL ROPE I I I I
ENGINE MOUNTING PLATE I I
ENGINE TORQUE STOP I I I
CYLINDER HEAD BOLTS I I
CYLINDER BASE NUTS I I I
E
IGNITION TIMING BTDC I I
E
N
G
VES SYSTEM C C I
G
I
COOLANT LEVEL I I R I
I
N
E
WATER PUMP DRIVE BELT I I
E
COOLANT HOSE I I I
HEAT EXCHANGERS I I I I I
COOLANT CIRCULATION I I
COOLANT LEAKS I I I
SPARK PLUG CONDITION I I I I
EXHAUST PIPE I I
EXHAUST RETAINING SPRINGS I I I
I: Inspect and Clean, Adjust, Tighten or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate. T: Test

MAINTENANCE
3.2
MILEAGE
ITEM
PRE--RIDE
150 MILES
(240 KM)
1000 MILES
(1600 KM)
2000 MILES
(3200 KM)
PRE--SEASON
HOSE ROUTING I I I
HOSE CONDITION I I I
FLUID LEAKS I I I
BRAKE PADS I I I
B
R
BRAKE DISC I I I
R
A IGNITION SWITCH I I I IA
K
E
TAIL LIGHT T I
E
S BRAKE LIGHT I I
HEAD LIGHT OPERATION I I
PARKING BRAKES T I I I
BRAKE SYSTEM I I
BRAKE FLUID R
F
U
PILOT AIR SCREWS I I
U
E
L CARBURETOR SYNCHRONIZATION I I
M
IDLE RPM I I
M
A
N
A
THROTTLE LEVER FREE PLAY I I
A
G
E
SYNCHRONIZE OIL PUMP LEVER I I
E
M
E
THROTTLE CABLE LUBRICATION L L L
E
N
T
OIL CABLE LUBRICATION L L L
F
CHOKE CABLE LUBRICATION L L
F
U
E
VENT LINES I I I
E
L
THROTTLE POSITION SENSOR I IL
CHOKE I I
M
A
FUEL FILTER I I
A
N
FUEL LINES I I
N
A
G
OIL FILTER I I
G
E OIL LINES I IE
M
E
CHANGE OIL R R I
E
N
T
AIR BOX I I I I
T
CHECK DRAIN AND WATER TRAPS I I

MAINTENANCE
3.3
ITEM
MILEAGE
PRE SEASONITEM
PRE--RIDE 150 1000 2000
PRE--SEASON
SKI TOE ALIGNMENT I I
SUSPENSION MOUNTING BOLTS I I I I
STEERING FASTENERS I I C
REAR SUSPENSION FASTENERS I I I
SUSPENSION SHOCK OIL I I I
COOLING FINS AND SHROUD I I I
DRIVE SHAFT BEARINGS L L I
JACKSHAFT BEARINGS L L I
SKI WEAR BARS I I
SKI SADDLE AND SPINDLE BOLTS I
SKI PIVOTS L L L I
SKI SPINDLE L L L I
STEERING ARM(S) L L L I
UPPER / LOWER STEERING POST SUPPORT
BRACKET L L L I
DRIVE CHAIN TENSION I
C
H
AUXILIARY SHUT--OFF SWITCH T
H
A
THROTTLE SAFETY SWITCH TA
S
S
AUXILIARY SHUT--OFF SWITCH
S
I
S
HOOD STRAPS I
S
THROTTLE LEVER T
BATTERY FLUID LEVEL I
REAR WHEEL IDLER BOLTS I
IDLER ADJUSTING BOLT JAM NUT I
REAR SUSPENSION PIVOT SHAFTS L L
CAMBER ALIGNMENT I I
RADIUS ROD BUSHINGS I
HANDLE BAR CENTERING I
TORQUE TIE ROD END NUTS I
TETHER SWITCH AND STRAP T
TRACK ALIGNMENT I
TRACK TENSION I
FRONT LIMITER STRAP I
HYFAX CONDITION I I
CHAINCASE OIL I R I
GEARCASE OIL I R I
Items in this chart require some mechanical knowledge. Items marked * and ** may require more technical information
and tools and should be performed by your authorized Polaris dealer.
RECOMMENDED MAINTENANCE PRODUCTS
Remember to use Pure Polaris parts and Lubricants to keep your sled running and looking like new. Pure Polaris products are
specifically engineered to rigid specifications that apply to the parts that wear and tear.

Thank you very much
for your reading.
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2005 Polaris Trail RMK 136 SNOWMOBILE Service Repair Manual