2005 Polaris 800 XC SP Edge SNOWMOBILE Service Repair Manual PDF

CVR_9919304 9/2/04 8:37 AM Page 1
2005 PERFORMANCE SERVICE MANUAL

2005 PERFORMANCE
SERVICE MANUAL
500 XC SP
600 XC SP
700 XC SP
800 XC SP
900 FUSION
9919303 PN9919303
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.
A CAUTION indicates special precautions that must be taken to avoid personal injury,
CAUTION:
or snowmobile or property damage.
Failure to follow DANGER instructions will result in severe injury or death to the operator,
DANGER
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
2005 PERFORMANCE
MANUAL
Foreword SPECIFICATIONS 1
This manual is designed primarily for use by certified
Polaris snowmobile service technicians in a properly
equipped shop. Persons using this manual should have GENERAL 2
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- MAINTENANCE 3
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 FUEL DELIVERY 4
and tools as well as the work area is of primary impor-
tance. ENGINE 5
All references to left and right side of the vehicle are
from the operator’s perspective when seated in a normal
riding position. CLUTCHING 6
This manual includes 2005 Model Year information,
along with service specifications. A table of contents is FINAL DRIVE 7
placed at the beginning of each chapter, and an
alphabetic index is provided at the end of the manual for
location of specific page numbers and service BRAKE SYSTEM 8
information. Keep this manual available for reference
in the shop area.
STEERING 9
At the time of publication all information contained in
this manual was technically correct. However, all
materials and specifications are subject to change FRONT SUSPENSION 10
without notice.
Comments or suggestions about this manual may be
directed to: REAR SUSPENSION 11
Polaris Sales Inc.
Snow Engineering Publications Department
CHASSIS / HOOD 12
2100 Hwy 55 Medina, Minnesota 55340.
2005 PERFORMANCE MANUAL ELECTRICAL SYSTEM 13

(PN9919303)
WIRING DIAGRAMS 14
Copyright 2004 Polaris Sales Inc. Printed in U.S.A.
i
INTRODUCTION
NOTES
ii
500 XC SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 -- 1.3
600 XC SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 -- 1.5
700 XC SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 -- 1.7
800 XC SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 -- 1.9
900 FUSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 -- 1.11
SPECIFICATIONS
NOTES
1.1
SPECIFICATIONS
MODEL: . . . . . . . . . . . . . . 500 XC SP
MODEL NUMBER: . . . . S05NE(P)5CS(A,B)
ENGINE MODEL: . . . . . S2715--5044--PI5C
ENGINE CARBURETION
Engine Type Libertyt Type TM38
Engine Displacement cc 500 Main Jet 410
Bore in / mm 2.78/70.5 Pilot Jet 45
Stroke in / mm 2.52/64 Jet Needle 9DFH6-- 57/2
Cylinders 2 Needle Jet P-- 8
Piston / Cylinder Clearance .0045” - .0059” Throttle Gap UnderCutaway
0.079”/2.0mm
in / mm 0.115 - 0.149mm in / mm
.014” - .020”
Piston Ring End Gap in / mm Cutaway 1.5
0.356 - 0.508
Piston Marking N/A Valve Seat 1.5
Piston Ring Marking N/A Starter Jet 145
Operating RPM ±200 8250-- 8500 Fuel Screw 3.0
Idle RPM ±200 1500 Pilot Air Jet N/A
Engagement RPM ±300 4200 Air Screw 1.25
Exhaust Valve Spring Pink/Yellow Fuel Octane 87 min non-- oxygentaed
AMBIENT TEMPERATURE
Altitude Below -30
-30°F
F -30_ to --10_F --10_to +10_F +10_to +30_F +30_to +50_F Above +50_F
Below -34°C -34_to -23_C -23_ to --12_C -12_to --1_C -1_to +10_C Above +10_C
440 430 410 390 380 360

0--600 (0--2000) #3 #3 #2 #2 #2 #2
600--1200 420 400 390 370 350 340
(2000--4000) #3 #2 #2 #2 #2 #1
1200--1800 390 380 360 340 330 310
(4000--6000) #2 #2 #2 #2 #1 #1
Meters 1800--2400
370 350 340 320 300 290
(Feet) (6000--8000)
(6000 8000)
#2 #2 #2 #1 #1 #1
2400--3000
340 330 310 300 280 260
(8000--10000)
(8000 10000)
#2 #2 #1 #1 #1 #1
3000--3700
320 300 290 270 250 240
(10000--12000)
(10000 12000)
#2 #1 #1 #1 #1 #1
DRIVE CLUTCH DRIVEN CLUTCH

Altitude Shift Clutch Clutch Driven Chaincase
Weight Spring Spring Helix Gearing
0-900
10 -56
10- 56 Bushed
B h d 56/42 -36
56/42- 36 ER 22 40 -74
22:40- 74
(0-3000)
900-1800
Meters
M t 10 -54
10- 54 Bushed
B h d 56/42 -36
56/42- 36 ER 22 40 -74
22:40- 74
(3000-6000)
(Feet) Bl k/G
Black/Green 7043058
1800-2700
10 Bushed
B h d 56/42 -36
56/42- 36 ER 21 40 -74
21:40- 74
(6000-9000)
2700-3700
10MB Bushed
B h d 56/42 -36
56/42- 36 ER 21 40 -74
21:40- 74
(9000-12000)
1.2
SPECIFICATIONS
DRIVE CLUTCH CHAINCASE
Type P-- 85 Center Distance 7.92”
Shift Weights 10-- 56 Bushed Gearing : Chain 22:40-- 74
Drive Spring Black/Green Reverse Electronic Reverse
DRIVEN CLUTCH Brake Pads 2202202
Type Team Roller Reverse
Brake Type Type 81
Spring Red/Black
Helix Angle 56/42-- 36 ER CAPACITIES
BELT Fuel Tank 11.8 gal / 44.7 l
Belt Part Number 3211080 Oil Tank 3.25 qts. / 3.1 l
Belt Width (Projected) 1.438” Coolant 5.6 qts. / 5.3 l
Side Angle (Overall) 28_ Chain Case Oil 9 oz. / 266 ml
Outside Diameter 46.625” SLED DIMENSION
Unit Length / Height / 113 / 46 / 48
Center Distance 11.50”
Width in / cm. 287 / 117 / 122
FRONT SUSPENSION REAR SUSPENSION

Type Edge Type Edge / M-- 10
M10/STD 7043082
IFS Shocks STD / F/O 7041975
F/O 7042211 Stock FTS
M - 10 7042224
M-
Stock IFS Spring Rate M10/STD 68/160
F/O 90/180
M-- 10/STD (Inst. length) STD / F/O 160/VAR
FTS Spring Rate
IFS Spring Pre-- Load 10.56” M-- 10 160
F/O .625”
Front Vertical Travel 10.28”/26cm. STD / F/O N/A (eyelet to re-
FTS Pre-
Pre - Load tainer) 3.50”
3 50”
TRACK M-- 10 .90”
Width 15” STD 7042129
Stock RTS F/O 7042212
Length 121” M-- 10 7042216
STD/F/O .91” / 1.25”
Lug Height Torsion Spring .375(sq.)
M-- 10 1.0”
M-- 10 RTS Springs 7041935/7041936
Track Tension See page 3.10
3 10
Optional Torsion Springs found on page 11.7-- 11.8
ELECTRICAL
Flywheel I.D. 4010677 Spark Plug / Gap RN57YCC / .70mm/.025”
CDI Marking 4010829 Voltage Regulator N/A
Alternator Output 280w Magneto Pulses 6
Ignition Timing(see conver-

conver 25_ @ 2500 RPM Electric Start STD / M
M-- 10 Accessory
sion chart on page 13.4) F/O / M-- 10 F/O Standard
1.3
SPECIFICATIONS
MODEL: . . . . . . . . . . . . . . 600 XC SP
MODEL NUMBER: . . . . S05N(A,E,P)6E(E,S)(A,B)
ENGINE MODEL: . . . . . S2761--6044--PI6E
ENGINE CARBURETION
Engine Type Libertyt Mikuni

Type
TM 38
Engine Displacement cc’s 599 Main Jet 440
Bore in / mm 3.04” / 72.25mm Pilot Jet 45
Stroke in / mm 2.52” / 64mm Jet Needle 9DFH7-- 60 / 3
Piston / Cylinder Clearence .0045 - .0059” Throttle Gap UnderCutaway 0.079”
in / mm .115 - .149mm in / mm 2.0 mm
Piston Ring End Gap .014”-- .020”
Cutaway 2.5
in / mm .356 - .508mm
Piston Marking 3021308 Valve Seat 1.5
Operating RPM ±200 8100 Fuel Screw 2.5 Turns
Engagement RPM ±300 4000 Air Screw 1.0 Turns
87 Oct. NonOxy /
Exhaust Valve Spring Green/Yellow Fuel Octane (R+M/2)
89 Oct. Oxy
AMBIENT TEMPERATURE
Altitude Below -30°F
-30 F -30_ to --10_F --10_to +10_F +10_to +30_F +30_to +50_F Above +50_F
480 460 440 420 400 390

0--600
#4 #4 #3 #3 #3 #2
(0--2000)
600--1200 450 430 410 400 380 360
(2000--4000) #4 #4 #4 #3 #2 #2
1200--1800 420 400 390 370 350 330
(4000--6000) #4 #4 #3 #2 #2 #2
Meters
M t
1800--2400
(Feet) 400 380 360 340 330 310
(6000--8000)
(6000 8000)
#4 #3 #2 #2 #2 #2
2400--3000
370 350 330 320 300 280
(8000--10000)
(8000 10000)
#3 #2 #2 #2 #2 #2
3000--3700
340 330 310 290 270 260
(10000--12000)
(10000 12000)
#2 #2 #2 #2 #1 #1

0-900
10 58
10-58 58 42 36 ER
58--42--.36 23 39: 74P
23--39:
(0-3000)
900-1800
Meters
M t 10 56
10-56 58 42 36 ER
58--42--.36 23 39 : 74P
23--39
(3000-6000)
(Feet) Dark Blue/White Red / Blue
1800-2700
10 54
10--54 58 42 36 ER
58--42--.36 22 39 : 74P
22--39
(6000-9000)
2700-3700
10 58 42 36 ER
58--42--.36 22 39 : 74P
22--39
(9000-12000)
1.4
SPECIFICATIONS
Type P-- 85 Center Distance 7.92” / 20.12cm
Shift Weights 10-- 58 Gearing : Chain 23-- 39 : 74 P
Drive Spring Dark Blue / White Reverse Electronic Reverse
DRIVEN CLUTCH Brake Pads Type 81
Brake Type Liquid Cooled
Driven Spring Red / Blue
Driven Helix Angle 58-- 42-- .36 ER CAPACITIES
BELT Fuel Tank 11.8 Gal. / 45 Liters
Belt Part Number 3211080 Oil Tank 3.25 Qts / 3 Liters
Belt Width (Projected) 1.438” / 3.65cm Coolant 5.6 Qts / 5.3 Liters
Side Angle (Overall) 28_ Chain Case Oil 9 fl. oz. / 266 ml
Outside Diameter 46.625” / 118.4cm SLED DIMENTIONS
Unit Length / Height / 113” / 48” / 48”
Center Distance 11.5” / 29.2cm
Width in / cm 287 / 122 / 122 cm

Type EDGE Type EDGE
7043082
IFS Shocks STD (F/O) Stock FTS IFP / PN 7041975
(7042211)
Stock IFS Spring Rate 68/160#/in. FTS Spring Rate 160#/in Var
F/O IFS Spring Rate 90/180#/in. M-- 10 FTS (ACE) Fox IFP / PN 7042224
Stock IFS Spring Pre-- Load 3.25” / 8.26cm
M-- 10 FTS Spring Rate 160#/in
(F/O) (.625” / 16 mm)
Front Vertical Travel 10.28” / 26cm FTS Pre-- Load .25” / .635 cm
TRACK M-- 10 FTS Pre-- Load .90” / 23mm
Width 15” / 38 cm Stock RTS Fox PS / PN 7042129
Length 121” / 307 cm F/O RTS Fox PS / CA PN 7042212
.91” / 2.3 cm
Lug Height
(1” / 2.54 cm / M-- 10 RTS Fox IFP Res PN 7042216
(M-- 10/F/O)
1.25”/3.175cm)
M-- 10 RTS Spring Rate 210/278 #/in.
(M-- 10 ACE Spring Rate) (220/1140)
T kT
Track Tension
i S Page
See P 33.10
10 Torsion Springs .375(Sq.) 77_
Optional M-- 10 Springs see page 11.7-- 11.8
ELECTRICAL
Flywheel I.D. 4010677 Spark Plug / Gap RN57YCC / .028” / .70mm
CDI Marking 4010830 Voltage Regulator T1
Alternator Output 280 watts Magneto Pulses 6
Ignition Timing (see conver
conver-
24_@3500 RPM±1.5_
RPM±1 5_ Electric Start Accessory
sion chart on page 13.4 )
1.5
SPECIFICATIONS
MODEL: . . . . . . . . . . . . . . 700 XC SP
MODEL NUMBER: . . . . S05N(E,P)7CS(A,B)
ENGINE MODEL: . . . . . S2469--7070--PR7C
ENGINE CARBURETION

Type
TM 40
Bore in / mm 3.19” / 81mm Pilot Jet 45
Stroke in / mm 2.68” / 68mm Jet Needle 9DGN-- 57 / 3
Piston / Cylinder Clearence .0044-- .0058” Throttle Gap UnderCutaway 0.079”
in / mm .111-- .147mm in / mm 2.0 mm
Piston Ring End Gap .012-- .018”
Cutaway 1.5
in / mm .304 - .457mm
87 Oct. NonOxy /
Exhaust Valve Spring Green/Yellow Fuel Octane (R+M/2)
89 Oct. Oxy
AMBIENT TEMPERATURE
480 460 440 420 400 390

0--600
#4 #3 #3 #3 #3 #2
(0--2000)
600--1200 450 430 410 400 380 360
(2000--4000) #3 #3 #3 #3 #2 #2
1200--1800 420 400 390 370 350 330
(4000--6000) #3 #3 #3 #2 #2 #2
Meters
M t
1800--2400
(Feet) 400 380 360 340 330 310
(6000--8000)
(6000 8000)
#3 #3 #2 #2 #2 #2
2400--3000
370 350 330 320 300 280
(8000--10000)
(8000 10000)
#3 #2 #2 #2 #2 #2
3000--3700
340 330 310 290 270 260
(10000--12000)
(10000 12000)
#2 #2 #2 #2 #2 #2

0-900
10 62
10-62 62 42 46 ER
62--42--.46 25 41: 76P
25--41:
(0-3000)
900-1800
Meters
M t 10 60
10-60 62 42 46 ER
62--42--.46 25 41: 76P
25--41:
(3000-6000)
(Feet) Black/Green 7043063
1800-2700
10 58
10--58 62 40 46 ER
62--40--.46 23 39 : 74P
23--39
(6000-9000)
2700-3700
10 56
10--56 62 40 46 ER
62--40--.46 23 39 : 74P
23--39
(9000-12000)
1.6
SPECIFICATIONS
Type P-- 85 Center DIstance 7.92” / 20.12cm
Drive Spring Black / Green Reverse Electronic Reverse
Driven Spring 7043063
Helix Angle 62-- 42-- .46 ER CAPACITIES
Width in / cm 287 / 122 / 122 cm

Type EDGE Type EDGE
7043082
(7042211)
(F/O) (.625” / 16 mm)
.91” / 2.3 cm
Lug Height
(M-- 10/F/O)
1.25”/3.175cm)
T kT
Track Tension
i S Page
See P 33.10
ELECTRICAL

conver-
20_@2000 RPM±1.5_
RPM±1 5_ Electric Start Accessory
sion chart on page 13.4 ) STD M-- 10
1.7
SPECIFICATIONS
MODEL: . . . . . . . . . . . . . . 800 XC SP
MODEL NUMBER: . . . . S05N(E,P)8CS(A,B)
ENGINE MODEL: . . . . . S2774--8070--PI8C
ENGINE CARBURETION

Type
TM 40
Bore in / mm 3.35” / 85mm Pilot Jet 40
Stroke in / mm 2.76” / 70mm Jet Needle 9DGN5-- 57 / 3
Piston / Cylinder Clearence .006 - .0074” Throttle Gap UnderCutaway 0.079”
in / mm .152-- .188mm in / mm 2.0 mm
Piston Ring End Gap .016-- .022”
Cutaway 1.5
in / mm .406 - .559mm
87 Oct. NonOxy /
Exhaust Valve Spring Pink/Yellow Fuel Octane (R+M/2)
89 Oct. Oxy
AMBIENT TEMPERATURE
500 480 460 440 420 400

0--600
#4 #4 #3 #3 #2 #2
(0--2000)
600--1200 470 450 430 410 400 380
(2000--4000) #4 #3 #3 #2 #2 #2
1200--1800 440 420 400 390 370 350
(4000--6000) #3 #3 #2 #2 #2 #2
Meters
M t
1800--2400
(Feet) 410 400 380 360 340 320
(6000--8000)
(6000 8000)
#3 #2 #2 #2 #2 #2
2400--3000
390 370 350 330 310 290
(8000--10000)
(8000 10000)
#2 #2 #2 #2 #2 #2
3000--3700
360 340 320 300 290 270
(10000--12000)
(10000 12000)
#2 #2 #2 #2 #2 #2

0-900
10 64
10-64 62 46 46 ER
62--46--.46 25 41: 76P
25--41:
(0-3000)
900-1800
Meters
M t 10 62
10-62 62 42 46 ER
62--42--.46 25 41: 76P
25--41:
(3000-6000) Dark Blue /
(Feet) 7043063
1800-2700 White
10 60
10--60 62 40 46 ER
62--40--.46 23 39 : 74P
23--39
(6000-9000)
2700-3700
10 58
10--58 62 40 46 ER
62--40--.46 23 39 : 74P
23--39
(9000-12000)
1.8
SPECIFICATIONS
Type P-- 85 Center Distance 7.92” / 20.12cm
Drive Spring Dark Blue / White Reverse Electronic Reverse
Driven Spring 7043063
Helix Angle 62-- 46-- .46 CAPACITIES
Width in / cm 287 / 122 / 122 cm

Type EDGE Type EDGE
7043082
(7042211)
(F/O) (.625” / 16 mm)
.91” / 2.3 cm
Lug Height
(M-- 10/F/O)
1.25”/3.175cm)
T kT
Track Tension
i S Page
See P 33.10
ELECTRICAL
conver- 29 @3250 RPM±1.5_
29_@3250 RPM±1.5 Electric Start Accessory
sion chart on page 13.4 ) w/TPS disconnected
1.9
SPECIFICATIONS
MODEL: . . . . . . . . . . . . . . 900 FUSION
MODEL NUMBER: . . . . S05MP8D(E,S)(A,B,C)
ENGINE MODEL: . . . . . S2883--8686--PI8D
ENGINE FUEL SYSTEM
Engine Type Libertyt 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
Piston / Cylinder Clearance .0045” - .0098”
Throttle Body Manufacture Mikuni
in / mm .114 - .249
.016” - .022”
Piston Ring End Gap in / mm DRIVE CLUTCH
.406-- .56
Piston Marking 3021327 Type P-- 85
Piston Ring Marking N/A Center Distance in/cm 11.5” / 29.2
Operating RPM ±200 7500 Spring Dark Blue / White
Idle RPM ±200 1700 Shift Weight 10-- 74
Engagement RPM ±300 3700 DRIVEN CLUTCH
Exhaust Valve Spring Purple Type TEAM
CHAINCASE Spring 7043063
Center Distance in/cm 11.35” / 28.83cm Helix 62/46-- 36 ER
Gearing 25 : 37 - 92P 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 112.5 / 286
Oil Tank qts./l 3 / 2.8 Height in/cm 47 / 119
Coolant qts. / l 6.7 / 6.3
Width in/cm 47 25 / 120
47.25
Chain Case Oil oz. / ml 11 / 325.3
0-900
10 -74
10- 74 25 37 -92
25:37- 92
(0-3000)
900-1500
10 -70
10- 70 25 37 -92
25:37- 92
(3000-5000)
1500-2100
10 -68
10- 68 22 39 -92
22:39- 92
Meters (5000-7000) Dark Blue /
7043063 62/46 -36
62/46- 36 ER
(Feet) 2210-2700 White
10 -66
10- 66 22 39 -92
22:39- 92
(7000-9000)
2700--3350
10--64 22:39--92
(9000--11000)
3350--4000
10--62 22:39--92
(11000--13000)
1.10
SPECIFICATIONS
Type IQ Type IQ
Stock IFS Shocks 7042258 Stock FTS 7042327
F/O IFS Shocks 7043095 F/O FTS 7043096
Stock IFS Spring Rate 100# Stock FTS Spring Rate 170#
F/O Spring Rate 120# F/O FTS Spring Rate 190#
Stock Spring Pre-- Load 10.25”/26cm installed length Stock Spring Pre-- Load 7.25 installed length
F/O Spring Rate 11.17”/28cm installed length F/O FTS Spring Pre-- Load 7.25 installed length
Front Vertical Travel 10in / 25.4cm Stock RTS 7042218
TRACK F/O RTS 7043097
Width in/cm 15/38.1 TORSION SPRINGS
Length in/cm 121/307.34 Stock Torsion Spring .359/80_ 12.5#
Lug Height in/cm 1.25/3.175 Light Torsion Spring .359/80_ 11.25#
Track Tension See page 3.10 Heavy Torsion Spring .405/80_ 16.25#
ELECTRICAL
Champion RN57YCC /
Flywheel I.D. 4011119 Spark Plug / Gap
.025mm(.003”)
Base ECU 4011081 Voltage Regulator 4010866
Alternator Output 400watts Stator 4010727
Ignition Timing(see conver-
conver 14_ @ 3000RPM Electric Start TBD
sion chart on page 13.4)
1.11
SPECIFICATIONS
NOTES
1.12
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
2005 MODEL NUMBER DESIGNATION
EXAMPLE: S05NB4BS
S 05 N B 4 B S #
Option
ModelYear Engine Size VIN
Identifier Model Line Model Type Engine modifier Identifier
(2nd/3rd Dig- (cc) Identifier
(1st Digit) (4th Digit) (5th Digit) (6th/7th Digit) (9th
it) (6th Digit) (8th Digit)
Digit)
S=Snow 05=2005 M=Fusion A=50th Anniv Spe- 0=0-- 99cc 1A=121 F/C OHV 4 cycle Fuji E=Europe unit
cial
N=Edge B=Basic or Stan- 1=100-- 199 3A=340 F/C Piston Port S=Standard
dard Production
Unit
P=IQ RMK D=Classic 2=200-- 299cc 4B=488 L/C Piston Port
S=Gen II E=M-- 10 Perfor- 3=300-- 399cc 4C=440 EV L/C Case Reed (Dom)
mance
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
TUNNEL DECAL
MODEL NO. MADE IN U.S.A. PATENT NOTICE
Mfd. by Polaris Industries Inc.. in Roseau, MN under one or
V.I.N. NO. more of the following patents:
U.S. Patents Patented Canada
THIS VEHICLE CONFORMS TO ALL APPLICABLE 882,491/71
3,605,511 3,613,810 5,050,559
U.S. FEDERAL AND STATE REQUIREMENTS AND 3,580,647 3,867,991 5,048,503 883,694/71
CANADA MOTOR VEHICLE SAFETY STANDARDS 3,483,766 4,793,950 5,056,482 864,394/71
IN EFFECT ON THE DATE OF MANUFACTURE. 3,533,662 5,038,881 5,099,813 Canadian Rd.
3,545,821 5,172,675 5,074,271 34,573/71
3,605,510 5,090,386 5,191,531 34,572/71
MFD. DATE: 3,525,412 5,050,564 3,613,811 1,227,823/87
7072133
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).
2.1
GENERAL INFORMATION
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 SN1. 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.
World Mfg. ID Vehicle Descriptor Vehicle Identifier

Example of 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Current S N 1 S B 5 B S 0 2 2 0 0 0 0 0 0
VIN Number Body Style Engine Series Model

Year Individual Serial No.
Size Engine Check Manufacturing.
Type Modifier Digit Location Code
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
2.2
GENERAL INFORMATION
PUBLICATION PART NUMBERS
Owners Manual Parts
Model Model No. Owner’s Manual Microfiche
Supplement Manual
500 XC SP S05NE(P)5CS(A,B) 9919073 9919084 9919274 9919275
600 XC SP S05N(A,E,P)6E(S,E)(A,B) 9919073 9919086 9919274 9919275
700 XC SP S05N(E,P)7CS(A,B) 9919073 9919377 9919379 9919380
800 XC SP S05N(E,P)8CS(A,B) 9919073 9919378 9919379 9919380
900 FUSION S05MP8D(E,S)(A,B,C) 9919074 9919093 9919256 9919257
SERVICE MANUALS
Service Manuals 2004
2000-- 2005
9919307
120 XC SP / PRO X
Trail Sport
9919300
500 Indy, Supersport
Touring
9919304
340 Edge Touring, Trail Touring (Deluxe), Widetrak LX, 600 Edge Touring (50th), 800 Edge Touring
Frontier
9919305
Frontier Touring
Classic
9919301
340 Classic, 500 Classic, 550 Classic, 600 Classic, 800 Classic
Deep Snow
9919302
Trail RMK, 600/700/800 RMK, 600/800 Switchbackt, 900 RMK
Performance
9919303
500/600/700/800 XC SP, 900 Fusion
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
2.3
GENERAL INFORMATION
GENERAL SERVICE PRECAUTIONS
In order to perform service work efficiently and to prevent costly errors, the technician should read the text in this manual,
thoroughly familiarizing him/herself with procedures before beginning. Photographs and illustrations have been included with the
text as an aid. Notes, cautions and warnings have also been included for clarification of text and safety concerns. However, a
knowledge of mechanical theory, tool use and shop procedures is necessary to perform the service work safely and satisfactorily.
Use only genuine Polaris service parts.
Cleanliness of parts and tools as well as the work area is of primary importance. Dirt and foreign matter will act as an abrasive
and cause damage to precision parts. Clean the snowmobile before beginning service. Clean new parts before installing.
Watch for sharp edges which can cause personal injury, particularly in the area of the tunnel. Protect hands with gloves when
working with sharp components.
If difficulty is encountered in removing or installing a component, look to see if a cause for the difficulty can be found. If it is
necessary to tap the part into place, use a soft face hammer and tap lightly.
Some of the fasteners in the snowmobile were installed with locking agents. Use of impact drivers or wrenches will help avoid
damage to fasteners.
Always follow torque specifications as outlined throughout this manual. Incorrect torquing may lead to serious machine
damage or, as in the case of steering components, can result in injury or death for the rider(s).
If a torquing sequence is indicated for nuts, bolts or screws, start all fasteners in their holes and hand tighten. Then, following
the method and sequence indicated in this manual, tighten evenly to the specified torque value. When removing nuts, bolts or
screws from a part with several fasteners, loosen them all about 1/4 turn before removing them.
If the condition of any gasket or O-Ring is in question, replace it with a new one. Be sure the mating surfaces around the gasket
are clean and smooth in order to avoid leaks.
Some procedures will require removal of retaining rings or clips. Because removal weakens and deforms these parts, they
should always be replaced with new parts. When installing new retaining rings and clips use care not to expand or compress them
beyond what is required for installation.
Because removal damages seals, replace any oil or grease seals removed with new parts.
Polaris recommends the use of Polaris lubricants and greases, which have been specially formulated for the top performance
and best protection of our machines. In some applications, such as the engine, warranty coverage may become void if other brands
are substituted.
Grease should be cleaned from parts and fresh grease applied before reassembly of components. Deteriorating grease loses
lubricity and may contain abrasive foreign matter.
Whenever removing or reinstalling batteries, care should be taken to avoid the possibility of explosion resulting in serious
burns. Always disconnect the negative (black) cable first and reconnect it last. Battery electrolyte contains sulphuric acid and is
poisonous! Serious burns can result from contact with the skin, eyes or clothing. ANTIDOTE: External - Flush with water.
Internal - Drink large quantities or water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician
immediately. Eyes - Flush with water for 15 minutes and get prompt medical attention.
2.4
GENERAL INFORMATION
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.
2.5
GENERAL INFORMATION
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
2.6
GENERAL INFORMATION
SAE TAP DRILL SIZES
Thread Size Drill Size Thread Size Drill Size
#0-80 3/64 1/2-13 27/64
#1-64 53 1/2-20 29/64
#1-72 53 9/16-12 31/64
#2-56 51 9/16-18 33/64
#2-64 50 5/8-11 17/32
#3-48 5/64
5/8-18 37/64
#3-56 45
#4-40 43 3/4-10 21/32
#4-48 42 3/4-16 11/16
#5-40 38 7/8-9 49/64
#5-44 37 7/8-14 13/16
#6-32 36 1-8 7/8
#6-40 33 1-12 59/64
#8-32 29 1 1/8-7 63/64
#8-36 29 1 1/8-12 1 3/64
#10-24 24
1 1/4-7 1 7/64
#10-32 21
1 1/4-12 1 11/64
#12-24 17
#12-28 4.6mm 1 1/2-6 1 11/32
1/4-20 7 1 1/2-12 1 27/64
1/4-28 3 1 3/4-5 1 9/16
5/16-18 F 1 3/4-12 1 43/64
5/16-24 I 2-4 1/2 1 25/32
3/8-16 O 2-12 1 59/64
3/8-24 Q 2 1/4-4 1/2 2 1/32
7/16-14 U 2 1/2-4 2 1/4
7/16-20 25/64
2 3/4-4 2 1/2
3-4 2 3/4
METRIC TAP DRILL SIZES

Tap Size Drill Size Decimal Equivalent Nearest Fraction
3 x .50 #39 0.0995 3/32
3 x .60 3/32 0.0937 3/32
4 x .70 #30 0.1285 1/8
4 x .75 1/8 0.125 1/8
5 x .80 #19 0.166 11/64
5 x .90 #20 0.161 5/32
6 x 1.00 #9 0.196 13/64
7 x 1.00 16/64 0.234 15/64
8 x 1.00 J 0.277 9/32
8 x 1.25 17/64 0.265 17/64
9 x 1.00 5/16 0.3125 5/16
9 x 1.25 5/16 0.3125 5/16
10 x 1.25 11/32 0.3437 11/32
10 x 1.50 R 0.339 11/32
11 x 1.50 3/8 0.375 3/8
12 x 1.50 13/32 0.406 13/32
12 x 1.75 13/32 0.406 13/32
2.7
GENERAL INFORMATION
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
2.8
GENERAL INFORMATION
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.
Piston Wash Spark Plug Color
n Wet and Black wash indicates too rich a fuel

mixture
n If the plug is wet or very dark, the fuel is
Wash running too rich.
Correct
Correct
n If the wash is 1/4” - 3/8” and cocoa
brown, the machine’s EGTs are just right.
Dry n If the plug is light to cocoa brown, the ma-
chine’s EGTs are just right.
n A dry, ash colored piston indicates too lean a

mixture for the operating conditions.
n A ash white plug with speckles indicates too
lean a mixture for the operating conditions.
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.
2.9
GENERAL INFORMATION
CYLINDER INSPECTIONS
CYLINDER HEAD INSPECTION

Limit .003” (.08mm)
Inspect each piston dome area of the cylinder head for warping by plac-
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).
Cylinder Head Warp

NOTE: 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.
S Cylinder Taper Limit: .002” MAX

S Cylinder Out of Round Limit: .002”
TOP
Ty
Tx Ty
Top Tx
MIDDLE
Mx My
My
Middle Mx
BOTTOM
Bx By
By
Out of round =
Tx--Ty and By--Bx Bottom Bx
Taper Limit=
Ty--By and Tx--Bx
2.10
GENERAL INFORMATION
PISTON INSPECTION / MEASUREMENT
B Piston Ring C Piston Ring

A
1/2″ (1.3cm.)
1/2″ (1.3cm.)
Cylinder
Feeler Gauge
90° to pin
Up
D
DOMESTIC ENGINES - Measure 3/8″ (10.0mm)
up from bottom of skirt
Straight Edge
FUJI ENGINES - Measure 1/2″ (12.7mm) up

from bottom of skirt Keystone Piston Ring Cutaway
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).
A difference in end gap indicates cylinder taper. The cylinder should be measured for excessive
NOTE:
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.
2.11
GENERAL INFORMATION
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

NOTE: a soft stone hone but can not be oversized.
DE--GLAZING
If cylinder wear or damage is minimal, honing the cylinder lightly with EXAMPLE OF A CROSS HATCH PATTERN
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.
NOTE: The use of an arbor type honing machine is recommended.
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.
2.12
GENERAL INFORMATION
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.
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
IMPORTANT: 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. 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 im-
mediately with Polaris Premium 2 Cycle Lubricant.
Always check piston to cylinder clearance and piston ring installed gap after boring/honing is
NOTE:
complete!
CRANKCASE INSPECTION / BEARING FIT

Any time crankshaft bearing failure occurs and the case is to be reused,
Polaris recommends checking the bearing fit into the case halves using
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
NOTE: 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
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
NOTE: 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.
2.13
GENERAL INFORMATION
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.
Within .002” (.05mm)
Specialized equipment and a sound knowledge

of crankshaft repair and straightening is required
to perform crankshaft work safely and correctly.
NOTE:
Crankshaft repair should be performed by
trained Polaris service technicians in a properly
equipped shop.
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. Run your
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 play or roughness is evident with a new pin and bearing, replace
the connecting rod.
2.14
GENERAL INFORMATION
CRANKSHAFT INDEXING
.100 ATDC .100 ATDC

Dial Indicator Dial Indicator
MAG PTO
Degree Degree
Wheel Wheel
Crankshaft center line
Disconnect battery ground cable and ALL spark plug high tension leads: ground high tension
CAUTION: 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 indicator and install in PTO cylinder. Repeat finding TDC. Note the degree wheel indication when the dial indica-
tor reads .100” ATDC. It should be 180_ (± 2_) from the MAG cylinder mark.
2.15
GENERAL INFORMATION
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.
The Rod Pin position in relation to the dial indicator tells you what action is required to straighten
NOTE:
the shaft.
HIGH .004 (.1mm)

To correct a situation like the one shown in illustration 1, strike the A HIGH .004 (.1mm)
shaft at point A with a brass hammer.
B
SUPPORT CRANKSHAFT
AT THESE TWO BEARINGS
1
HIGH .002 (.05mm)

HIGH .005 (.13mm)
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.
A A
HIGH .002 (.05mm)

A A HIGH .005(.13mm)
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-
3
out must be as close to zero as possible.
2.16
GENERAL INFORMATION
CRANKSHAFT RUNOUT INSPECTION
1/2” (12.7mm) Measure where taper starts
Flywheel (MAG) side 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
NOTE:
Libertyt Engines .000” - .00015” (0-- .04mm)
FUJI Engines .000” - .0024” (0-- .07mm)
2.17
GENERAL INFORMATION
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.
NOTE: 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.
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.
2.18
GENERAL INFORMATION
OIL PUMP BLEEDING
(A)
(A)
FUSION OIL PUMP
Any time the engine is disassembled or repaired, it is important that the oil supply from the pump
NOTE:
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.
2.19
GENERAL INFORMATION
OIL PUMP ADJUSTMENT PROCEDURE
Figure 2 Figure 3
.010-.030, (.25-.8 mm)

Throttle Freeplay 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 is to verify that the oil pump marks line up (figure 4) when the throttle is in the 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.
2.20
GENERAL INFORMATION
COOLING SYSTEM OVERVIEW
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.
DANGER 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).
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
NOTE:
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.
When performing the following checks and adjustments, stay clear of all moving parts to avoid
serious personal injury.
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 stream or hot liquid.
2.21
GENERAL INFORMATION
900 FUSION* COOLING SYSTEM
E 2004 Polaris Sales Inc.
4.
9.
6.
25. 2.
20. 9.
24. 9.
4.
19. 26.
21.
15.
23. 9.
27.
18.
17.
22.15.
9. 8.
11. 15.
9.
13.
9.
2.
7. 9.
5.
9. 14. 10.
22. 12. 8.
16. 8.
3.
1.
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.
2.22
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 - 3.16
Handlebar Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18 - 3.19
Throttle Lever Free Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
General Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
IQ Air Intake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
Edge Exhaust Valve Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
IQ Exhaust Valve Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
Thermostat / Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
900 Liberty Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27
900 Liberty Oil Pump/Line Bleeding . . . . . . . . . . . . . . . . . . . . . . . 3.28
Typical Recoil Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29 -- 3.30
700/800 Liberty Water Pump Service . . . . . . . . . . . . . . . . . . . . . . . 3.31
MAINTENANCE
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 continued optimum performance and component life, continue maintenance checks at 1000 mile
(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 you don’t feel comfortable performing these tasks yourself, contact an authorized Polar-
is dealer for service.
The following chart is a guide based on average riding conditions. You may need to increase frequency based on riding conditions.
When inspection reveals the need for replacement parts, always use genuine Polaris parts, available from your Polaris dealer.
MAINTENANCE PROGRAM
MILEAGE
ITEM 150 MILES 1000 MILES 2000 MILES PRE-- SEASON
PRE-- RIDE
(240 KM) (1600 KM) (3200 KM)
CLUTCH OFFSET ALIGNMENT (WITH OUT
BELT) I I
C
L DRIVE BELT CONDITION I I I I
U
T DISASSEMBLE AND CLEAN CLUTCHES C C
C 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
IGNITION TIMING BTDC I I
E
N VES SYSTEM C C I
G COOLANT LEVEL I I R I
I
N 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
3.1
MAINTENANCE
MILEAGE
ITEM 150 MILES 1000 MILES 2000 MILES PRE-- SEASON
PRE-- RIDE
(240 KM) (1600 KM) (3200 KM)
HOSE ROUTING I I I
HOSE CONDITION I I I
FLUID LEAKS I I I
BRAKE PADS I I I
B BRAKE DISC I I I
R
A IGNITION SWITCH I I I I
K 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 PILOT AIR SCREWS I I
U
E
L CARBURETOR SYNCHRONIZATION I I
IDLE RPM I I
M
A THROTTLE LEVER FREE PLAY I I
N
A
G SYNCHRONIZE OIL PUMP LEVER I I
E
M THROTTLE CABLE LUBRICATION L L L
E
N
OIL CABLE LUBRICATION L L L
T
CHOKE CABLE LUBRICATION L L
F
U VENT LINES I I I
E
L
THROTTLE POSITION SENSOR I I
CHOKE I I
M FUEL FILTER I I
A FUEL LINES I I
N
A OIL FILTER I I
G
E OIL LINES I I
M CHANGE OIL R R I
E
N AIR BOX I I I I
T
CHECK DRAIN AND WATER TRAPS I I
3.2
MAINTENANCE
MILEAGE
ITEM PRE - SEASON
PRE-
PRE-- RIDE 150 1000 2000
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 AUXILIARY SHUT--OFF SWITCH T
H
A
THROTTLE SAFETY SWITCH T
S AUXILIARY SHUT--OFF SWITCH
S
I 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.
3.3
MAINTENANCE
AIR FILTER
A
A
B
A
Do not operate a machine with the intake filters removed. This may cause carburetor icing
NOTE: resulting poor fuel economy of carburetor malfunction.
The intake foam filter (A) limits snow ingestion into the intake system. When operating in loose powder, check the top of the
foam filter periodically to remove any accumulation of snow.
WATER / SEDIMENT TRAP
When draining the traps, fuel spillage will occur. be sure to work in a well ventilated area away
DANGER from anything which may cause the fuel to ignite such as an open flame, heaters, trouble lights or
cigarettes, certifying
Most Polaris snowmobiles incorporate a patented carburetor bowl water / sediment traps which are located at the bottom of each
carburetor. The trap consists of a hose with a plug which should be inspected for contamination every 1000 miles (1600 km).
CLEANING PROCEDURE
Turn the fuel tank supply valve to the “OFF” position.
Position a container or shop towels under the work area to help catch
some of the contaminated gasoline.
Slide the clamp (A) away from the drain plug (B) and remove the drain A
plug from the sediment tube and let the water/gasoline drain from the
bowl. Repeat for other carburetor(s).
Wipe off residue from plug and reinstall with clamps.
3.4
MAINTENANCE
OIL FILTER / FUEL FILTER
OIL FILTERS IN-- TANK FUEL FILTERS
IN LINE OIL FILTER
Filter
IN-- LINE FUEL FILTER

IN TANK SENDER/FILTER
The in tank fuel filter and fuel lines should be inspected regularly. Special attention should be given
CAUTION: to the systems fuel line condition after periods of storage. Normal deterioration from weather and
fuel can occur. Do not damage fuel lines when removing them. If a fuel line has been damaged or
kinked, replace it.
The direction of the arrow indicates the direction of the flow through the filter.
NOTE: After changing the oil filter, the oil injection system must be bled of all trapped air. See page
3.28 for instructions on bleeding procedure.
Most models use an oil and fuel filters which are of a special design and must not be substituted. These filters should be changed
and the oil and fuel lines should be inspected annually or every 100 miles (1600 km).
EDGE models utilize a special oil filter that is built into the oil sending unit located in the bottom of the oil tank. It should be
replaced every two years or 2400 miles (3862 km).
FUSION/RMK in-- line fuel filters should be replaced every 2 years.
3.5
MAINTENANCE
LUBRICATION POINTS
Jackshaft Bearing
Steering post
support
brackets
Spindles
Driveshaft Bearing
Ski pivots
NOTE: A grease gun kit comes with grease and adaptors to lubricate all the fittings on Polaris snowmobiles.
Lubricate the following fittings with Polaris Premium All Season grease annually or approximately every 1000 miles (1600 km)
and before summer storage each year. .
When applying grease to these points free the weight from the component being greased to permit better penetration.
♦ Both ski spindles and ski pivots. ♦ ⎜Use Polaris Multi-- Purpose Lubricant to the steering pos bracket
♦ Steering post (lower pivot). ♦ ⎜Jackshaft and Driveshaft bearings
♦ Rear suspension pivot shafts. See page 3.7 for rear suspension grease points.
JACKSHAFT BEARING
Loosen driven clutch retaining bolt and pull clutch outward to expose bearing grease point. Apply grease until grease purges out
inside or outside the bearing seal.
Push driven clutch back onto the shaft and replace clutch retaining bolt. Refer to clutch installation page 6.15.
EDGE DRIVESHAFT BEARING

Inject grease into the fitting on the speedometer drive adaptor until grease purges out inside or outside the bearing seal.
3.6
MAINTENANCE
SUSPENSION LUBRICATION
EDGE SUSPENSION
NOTE: A grease gun kit comes with grease and adaptors to lubricate all the fittings on Polaris snowmobiles.
To maintain rider comfort and to retard wear of the pivot shafts, the suspension pivot shafts should be lubricated with Polaris
Premium All Season Grease at 150 miles (240 km) initially; 1000 miles (1600 km) and before summer storage each year. The
riding characteristics of the snowmobile will be affected by lack of lubrication of these shafts.
3.7
Thank you very much
for your reading.
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CVR_9919304 9/2/04 8:37 AM Page 1

2005 PERFORMANCE SERVICE MANUAL

NOTE: S A NOTE provides key information to clarify instructions.

Polaris acknowledges the following products mentioned in this manual:

FLEXLOC, Registered Trademark of SPS Technologies

2005 PERFORMANCE MANUAL ELECTRICAL SYSTEM 13

440 430 410 390 380 360

DRIVE CLUTCH DRIVEN CLUTCH

FRONT SUSPENSION REAR SUSPENSION

Ignition Timing(see conver-

Engine Type Libertyt Mikuni

480 460 440 420 400 390

DRIVE CLUTCH DRIVEN CLUTCH

FRONT SUSPENSION REAR SUSPENSION

Engine Type Libertyt Mikuni

480 460 440 420 400 390

DRIVE CLUTCH DRIVEN CLUTCH

FRONT SUSPENSION REAR SUSPENSION

Ignition Timing (see conver

Engine Type Libertyt Mikuni

500 480 460 440 420 400

DRIVE CLUTCH DRIVEN CLUTCH

FRONT SUSPENSION REAR SUSPENSION

World Mfg. ID Vehicle Descriptor Vehicle Identifier

VIN Number Body Style Engine Series Model

Vehicle Identification Number / Model Number Key

2005 Specification Handbook 9919311

Bolt Size Threads/In Grade 2 Grade 5 Grade 8

*To convert ft. lbs. to Nm multiply foot pounds by 1.356.

METRIC TAP DRILL SIZES

Unit of Measure Multiplied by Converts to

°C to °F: 9 (°C + 40) ÷ 5 -- 40 = °F

Piston Wash Spark Plug Color

n Wet and Black wash indicates too rich a fuel

n A dry, ash colored piston indicates too lean a

CYLINDER HEAD INSPECTION

Cylinder Head Warp

S Cylinder Taper Limit: .002” MAX

B Piston Ring C Piston Ring

FUJI ENGINES - Measure 1/2″ (12.7mm) up

PISTON RING INSTALLED GAP

CYLINDER HONE SELECTION

A Nikasil cylinder can be lightly honed with

HONING TO OVERSIZE (340 AND 500 FUJI ENGINES ONLY)

CLEANING THE CYLINDER AFTER HONING

CRANKCASE INSPECTION / BEARING FIT

NOTE: Crankcase Bearing Interference Fit:.001” - .002” (.026 - .051mm)

CRANKSHAFT MAIN BEARING INSPECTION

Specialized equipment and a sound knowledge

PISTON PIN / NEEDLE BEARING INSPECTION

CONNECTING ROD SMALL END INSPECTION

.100 ATDC .100 ATDC

HIGH .004 (.1mm)

HIGH .002 (.05mm)

To correct a situation like the one shown in illustration 2, squeeze the

HIGH .002 (.05mm)

1/2” (12.7mm) Measure where taper starts