Suspension Troubleshooting | Polaris 2002 manual

TROUBLESHOOTING

Suspension Troubleshooting

X-12

Problem	Solution (perform only one change at a time)

Rear suspension	-Check to be sure FRSS block is in highest position
bottoms too easily	-Adjust torsion spring blocks to highest position
	-Adjust coil over spring on front track shock to increase preload
	-Change torsion springs to .421 diameter (on 121″ models only)
	-Change to next heavier coil spring
	-Increase front track shock compression damping by turning
	screw clockwise

Rides too stiff in	-Check for binding suspension shafts and grease all pivot points
rear	-Decrease torsion spring preload adjustments
	-Remove rear track shock spring
	-Decrease front track shock compression damping by turning
	screw counter-clockwise
	-Adjust front track shock spring to less preload.

Machine darts from	-Make sure skis are aligned properly
side to side	-Make sure spindles and all steering components are free turning
	-Make sure skags are straight on skis
	-Ensure use of E-Z Steert skags
	-Shift FRSS to highest position

Front end pushes	-Check for worn skags
	-Check for binding suspension shafts and grease all pivot points
	-Increase front IFS preload
	-Change FRSS to low setting or move to forwardmost hole

Steering is heavy	-Check ski alignment
	-Check skags and skis for damage
	-Change FRSS to high setting
	-Decrease IFS spring preload
	-Make sure spindles and all suspension components are free
	turning

Setting up for deep	-Rotate FRSS to lowest setting, depending upon rider preference
snow operation	-Decrease preload on front track spring
	-Tighten limiter strap one hole
	-Move FRSS to forwardmost hole
	-Tighten limiter strap one hole

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Polaris 2002 manual Suspension Troubleshooting, Problem Solution perform only one change at a time

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 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 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 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 IFS Adjustment Options Front Suspension AdjustmentsIndependent Front Suspension IFS 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-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 Check Before Starting Engine Start the Engine and Check Throttle Safety Switch Check Throttle and Brake for Proper Operation 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 Your Engine Starting a Cold Engine Manual Start Starting a Cold Engine Electric Start Starting a Warm Engine Engine Break-In Variable Exhaust System Oil Injection SystemLubrication 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 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 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 Overheating NormalWet Fouled 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 Mixture Coolant High Temperature Indicator LightCoolant Level Flushing the Cooling System Recovery System ModelsBleeding 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/Low Beam Installing the BulbRemoving Halogen Bulbs High Beam Wrap Around Taillight Bulb Replacement Installing the Side BulbsRemoving the Side Bulbs Standard Belt Removal Electronic Reverse Belt Removal Standard Belt Installation Electronic Reverse Belt Installation Clutch System Clutch Alignment and Offset Drive Belt Deflection Clutch Center Distance Reverse Kit MaintenanceTorque Stop Accessory Reverse Kit Chain TensionOil Level Oil Change Tool Pouch Clip Tool KitAlways keep the tool kit with the snowmobile For Your Protection Maintenance ItemsFall Tune-Up Suspension Weight Measurement Track Tension Data If the track needs adjustment Track Tension Track Alignment Track Lubrication Steering Inspection and Adjustment Ski Alignment 146 Ski Skags Skag ReplacementSkag Identification Hi-Fax Wear Cleaning and Preservation of Hood, Chassis, and Trim Controls and Linkage Clutch and Drive System BearingsEngine and Carburetor Protection 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