Bearings, Clutch and Drive System | Polaris 2002 specification

MAINTENANCE

Extended Storage

Bearings

Grease jackshaft and drive shaft clutch side bearings with a high quality bearing grease to prevent corrosion.

Clutch and Drive System

Remove drive belt and store in cool dry location. Lubricate sheave faces of drive and driven clutches with a light coat of oil or Polaris Cable Lubricant (PN 2870510). Do not lubricate clutch components except driven clutch shaft bushing as outlined in Master Repair Manual. See your dealer.

Engine and Carburetor Protection

Proper preparation of the engine and fuel system is vital to the prevention of rust and corrosion on precision engine parts during storage. Whenever the machine is stored for a period of more than 60 days,the engine must be fogged (Polaris PN 2870791). Follow the engine fogging instructions provided on the can.

Always add a fuel conditioner/stabilizer or Premium Carbon Clean (PN 2871326) to the fuel tank. Follow the instructions on the can, running the engine for five minutes to get additives through the entire fuel system. Top off with fresh fuel.

HINT: For easier starting after extended storage, add lubricant to the fuel in the tank at a 40:1 ratio and run the engine for three to five minutes before storage. This will lubricate the fuel pump diaphragm to keep it flexible and help prevent loss of prime.

If stabilizer is not used, drain the carburetors by removing the water trap drain plugs (see page 116). Catch fuel in a container or shop cloth. Reinstall plugs securely. Observe all fire safety rules when draining carburetors. See gasoline warnings on page 80.

Jet restriction caused by improper storage can cause lean conditions and very poor slow speed driving quality.

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Polaris 2002 manual Bearings, Clutch and Drive System, Engine and Carburetor Protection

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