Exhaust System, Engine Cooling Liquid Cooled Models | Polaris 2002

MAINTENANCE

General Maintenance

Exhaust System

Check the exhaust system for wear or damage at approximately 2000 miles (3200 km). To inspect, allow the engine and exhaust system to cool completely. Open the hood and inspect the muffler and pipes for cracks or damage. Check for weak or missing retaining springs or damper/support grommets.

WARNING

Hot exhaust system parts can cause serious burns. Allow adequate time for the exhaust system to cool. Never perform this procedure with the engine running.

Engine Cooling - Liquid Cooled Models

The cooling system on liquid cooled models consists of the following major components:

DRecovery tank DWater pump DCylinders DHeads

DInlet and outlet manifolds DPressure cap

DHeat exchangers

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Polaris 2002 manual Exhaust System, Engine Cooling Liquid Cooled Models

Contents

Page Proposition What’s the hottest thing on snow? Page Welcome Table of Contents HOW to USE this Manual Important Notes For Owners And Drivers Noise Level Preservation Of The EnvironmentAir Pollution HOW to USE this Manual Vehicle Identification Numbers Page Safety Operator Safety Safety Stay Away From Moving Parts Be Prepared for the Unexpected Be Seated and in Position to Control the Vehicle Always Wear Clothing Designed for Snowmobiling Do Not Overload Cargo Carrier Know the Limitations of the Machine Your Skills as a Driver Disabled Operators Safety Operation on Hard-Packed Snow or Slippery Surfaces Ice and Snow Build-up Driving in Hilly Terrain Do Not Operate Engine With Clutch Guard Removed Riding DownhillDo Not Operate Engine With Drive Belt Removed Cold Weather Drive-Away Do Not Service Clutches YourselfMachine Maneuverability Powder Snow Operation Safety Responsible Driving Wind Chill Chart F Windchill/Temperature Charts Wind Chill Chart C Clutch Cover Warning Decal Safety Decals And LocationsAirbox Warning Decal Pressure Cap Warning Decal Cargo Carrier Warning Decal Track Warning Decal Passenger Warning Vehicle Capable of Excessive Reverse Speed Standard Reverse Warning Decal Operation Warning Decal Electronic Reverse Warning Decal Operation Warning Decal Text Before Starting Engine Features and Controls Location of Controls Features and Controls Features and Controls Features Features and Controls Features and Controls Page Perfect FIT IFS Adjustment Options Front Suspension AdjustmentsIndependent Front Suspension IFS Shock Absorber Components Adjusting Front ShockSpring Preload Changing Shock Valving Indy Select IFS Shock Suspension Performance Tips Rear Suspensions Perfect FIT Rear Spring Tension Perfect FIT Rear Torque Arm Adjustment SKS Models Rear Torsion Spring Adjustment Xtra-12 Indy Select Front Track Shock Adjustment Indy Select Rear Shock Position Sensitive Shock PPS Optional Coil SpringsSuspension Coupling Front To Rear Coupling and the Front Rear Scissor Stop Frss Rear Rear Scissor Stop Rrss Attributes Rear To Front Coupling and the Rear Rear Scissor Stop Rrss Xtra-10 and Edge Rear Rear Scissor Stop Rrss Weight Transfer During AccelerationXtra-12 Rear Rear Scissor Stop Rrss Handlebar Adjustment Accessories Traction Products Perfect FIT Wear Strips Page Start the Engine and Check Check Before Starting Engine Check Throttle and Brake for Proper Operation Throttle Safety Switch Brake Lever Travel Hydraulic BrakesLever Feel Mechanical Brakes Park Brake Lever Lock Track Inspection Check for Proper Operation of Steering SystemCheck for Securely Latched Hood Check Surroundings to Verify Clear Operating Area Page Operation Starting a Cold Engine Manual Start Starting Your Engine Starting a Warm Engine Starting a Cold Engine Electric Start Engine Break-In Variable Exhaust System Oil Injection SystemLubrication Track Warm-Up Operation Fuel Premium Fuel Switch Fuel System Deicers Fuel Reserve Capacity Low Oil Indicator Light Low Oil Level Carburetion Engine Stop Switch Throttle Lever System What IT does Throttle Condition Stopping Starting Reverse Operation Mechanical Reverse Operation Electronic Forward Altitude Setting Towing Page Maintenance Polaris Recommended Maintenance Program Maintenance Chart Tighten idler adjusting bolt jam Mile 1600 km Maintenance Inspection Mile 240 km Initial Maintenance InspectionMile 3200 km Maintenance Inspection Additional Services Performed + + 102 LL L 104 105 Suspension Lubrication X-10, Edge Driveshaft Bearing Greasing Jackshaft Bearing GreasingCoupler Greasing WideTrak Choke and Cable Lubrication Throttle Cable Lubrication Chaincase Oil Level Gearcase Oil Level WideTrak Models Intake Filter Spark Plug Selection Under Hood Air Intake System Overheating NormalWet Fouled Spark Plug Removal and Replacement Water Pump Belt Inspection Variable Exhaust System V.E.S Plug Cleaning Procedure Water/Sediment Trap Service Oil Filter Fuel Filter/Fuel Lines General Carburetor Information Carburetor Adjustments Engine Cooling Liquid Cooled Models Exhaust System Coolant Mixture Coolant High Temperature Indicator LightCoolant Level Flushing the Cooling System Recovery System ModelsBleeding the Cooling System Surge Tank Models Edge RMKs Drive Chain Tension Hydraulic Brake Inspection Excessive Lever Travel Brake Components Replenishing Brake Fluid Bleeding the Hydraulic Brake System Mechanical Brake Lever Travel Headlight Adjustment Removing Halogen Bulbs High/Low Beam Installing the BulbRemoving Halogen Bulbs High Beam Wrap Around Taillight Bulb Replacement Installing the Side BulbsRemoving the Side Bulbs Electronic Reverse Belt Removal Standard Belt Removal Electronic Reverse Belt Installation Standard Belt Installation Clutch System Drive Belt Deflection Clutch Alignment and Offset Clutch Center Distance Reverse Kit MaintenanceTorque Stop Chain Tension Accessory Reverse KitOil Level Oil Change Tool Pouch Clip Tool KitAlways keep the tool kit with the snowmobile For Your Protection Maintenance ItemsFall Tune-Up Track Tension Data Suspension Weight Measurement Track Tension If the track needs adjustment Track Alignment Track Lubrication Steering Inspection and Adjustment Ski Alignment 146 Ski Skags Skag ReplacementSkag Identification Hi-Fax Wear Controls and Linkage Cleaning and Preservation of Hood, Chassis, and Trim Clutch and Drive System BearingsEngine and Carburetor Protection Electrical Connections Battery Transporting the Snowmobile Track and Suspension Battery Fluid Battery Removal Battery Connections Battery Installation 156 Troubleshooting Problem Solution perform only one change at a time Suspension Troubleshooting 12, 133″ Edge Edge RMK Xtra Lite Belt Wear/Burn Causes Solutions 164 165 166 167 168 Warranty Administration Service And Warranty InformationObtaining Service and Warranty Assistance Polaris Anti-Theft System Limited Warranty 172 Engine Oil Coverage Conditions Coverage Exclusions Index 177 178