Automotive

62 pages
6 views

2002 Polaris 700 XC SP SNOWMOBILE Service Repair Manual

of 62
All materials on our website are shared by users. If you have any questions about copyright issues, please report us to resolve them. We are always happy to assist you.
Share
Description
This is the Highly Detailed factory service repair manual for the2002 POLARIS 700 XC SP SNOWMOBILE, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.2002 POLARIS 700 XC SP SNOWMOBILE Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly. Service Repair Manual Covers: General Information Maintenance / Tune Up Engines Fuel System / Carburetion Drive / Drive Clutches Body and Steering Suspensions Brakes / Final Drive Electrical Wiring Diagrams File Format: PDF Compatible: All Versions of Windows & Mac Language: English Requirements: Adobe PDF Reader NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to have2002 POLARIS 700 XC SP SNOWMOBILE Service Repair Workshop Manual. Looking for some other Service Repair Manual,please check: https://www.aservicemanualpdf.com/ Thanks for visiting!
Transcript
  • 1. CHAPTER 1 GENERAL INFORMATION 2002 Publication Part Numbers / Service Manuals 1.1. . . . . . . . Model Number Identification 1.2. . . . . . . . . . . . . . . . . . . . . . . . . . . Vehicle Identification Number (VIN) 1.3. . . . . . . . . . . . . . . . . . . . . Standard Bolt Torque Specifications 1.4. . . . . . . . . . . . . . . . . . . . Decimal Equivalents 1.5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE Tap Drill Size Charts 1.6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Units of Measure Chart 1.7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Shop Supplies 1.8. . . . . . . . . . . . . . . . . . . . . . . . . Glossary of Terms 1.9 - 1.11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Precautions 1.12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Note Page 1.13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2002 Indy 500 XC EDGE Specifications 1.14 - 1.15. . . . . . . . . . . . . . . . . 2002 Indy 500 XC SP EDGE Specifications 1.16 - 1.17. . . . . . . . . . . . . . 2002 Indy 600 XC SP EDGE Specifications 1.18 - 1.19. . . . . . . . . . . . . . 2002 Indy 700 XC EDGE Specifications 1.20 -- 1.21. . . . . . . . . . . . . . . . . 2002 Indy 800 XC SP EDGE Specifications 1.22 -- 1.23. . . . . . . . . . . . . . 2002 Indy 800 XCR Specifications 1.24 -- 1.25. . . . . . . . . . . . . . . . . . . . . .
  • 2. GENERAL INFORMATION 1.1 2002 Publication Numbers Model Model No. Owner’s Manual Supplement Parts Manual Parts Microfiche 500 XC EDGE S02NP5AS 9917390 9917067 9917068 500 XC, SP EDGE S02NP5CSA S02NP5CSB 9916740 9917340 9917341 600 XC SP EDGE S02NP6ESA S02NP6ESB 9916753 9917342 9917343 700 XC SP EDGE S02NP7CSA S02NP7CSB 9916756 9916757 9916758 800 XC SP EDGE S02NP8CSA S02NP8CSB 9916759 9917346 9917347 800 XCR S02SB8AS 9916947 9916948 9916949 2000 Snowmobile Owner’s Manual (All) - PN 9916649 Snowmobile Assembly Manual - PN 9916508 2002 Service Manuals 120 XC SP 9917361 Trail Sport Super Sport, Indy 500, 340 Deluxe 9917362 Two-Up / Utility Wide Trak LX, 340 Touring, Sport Touring, Trail Touring, 500 Classic Touring, 600 Classic Touring 9917364 Trail Luxury 500 Classic, 550 Classic, 600 Classic, 700 Classic 9917363 Deep Snow Trail RMK, 500 RMK, 500 SKS Euro, 700 SKS, Trail RMK, 600/700/800 EDGE RMK 9917366 Performance 500 XC, 500/600/700/800 XC SP, 800 XCR 9917367 High Performance 440 XCF SP, 440 XC SP, 500/600/700/800 XC SP, 600/700/800 RMK, 800 XCR 9917365 Wallcharts 9917369
  • 3. GENERAL INFORMATION 1.2 MODEL NUMBER IDENTIFICATION YEAR DESIGNATION ENGINE DESIGNATION MODEL / CHASSIS DESIGNATION 2002 MODEL DESIGNATION S 0 2 S D 5 C SS=Snow U= European Model S= North American Model MODEL LINE (4TH DIGIT) MODEL TYPE (5TH DIGIT) S=Gen II A= Feature Option L= Lite B= Basic N= EDGE C= Feature Option W=Mini Indy D= Deluxe E= Feature Option M--10 F= Feature Option J= 136 RMK (Edge) K= 144 RMK (Edge) L= 151 RMK (Edge) M= 156 RMK (Edge) P= Performance R= RMK (Gen II) S= SKS T= Touring U= Utility X= Racer 2002 ENGINE DESIGNATION NUMBERS 1A - 121 F/C OHV 4 cycle Fuji 3A - 340 F/C Piston Port Fuji 4A - 440 F/C Cylinder Reed Fuji 4B - 488 L/C Piston Port Fuji 4C - 440VES L/C Case Reed (domestic) 4D -- 440 F/C Piston Port 4E - 488 F/C Piston Port Fuji 5A - 497 L/C Case Reed 2 Cyl (domestic) 5B - 544 F/C Cylinder Reed 5C - 500 VES L/C Case Reed 2 Cylinder (domestic) 6D - 600/700 L/C Case Reed 2 Cylinder (domestic) 6E - 600/440 VES L/C Case Reed 2 Cylinder (domestic) 7A - 700 L/C Case Reed 2 Cylinder (domestic) 7C -- 700 VES L/C Case Reed 2 Cyl (domestic) 8A - 800 VES L/C Case Reed 3 Cylinder Fuji 8B - 800 L/C Case Reed 2 Cylinder (domestic) 8C -- 800 VES L/C Case Reed 2 Cyl (domestic) MODEL NO. V.I.N. NO. MFD. DATE: THIS VEHICLE CONFORMS TO ALL APPLICABLE U.S. FEDERAL AND STATE REQUIREMENTS AND CANADA MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE. MADE IN U.S.A. 7072133 Mfd. by Polaris Industries Inc.. in Roseau, MN under one or more of the following patents: U.S. Patents 3,605,511 3,613,810 5,050,559 3,580,647 3,867,991 5,048,503 3,483,766 4,793,950 5,056,482 3,533,662 5,038,881 5,099,813 3,545,821 5,172,675 5,074,271 3,605,510 5,090,386 5,191,531 3,525,412 5,050,564 3,613,811 PATENT NOTICE Patented Canada 882,491/71 883,694/71 864,394/71 Canadian Rd. 34,573/71 34,572/71 1,227,823/87 TUNNEL DECAL These numbers should be referred to in any correspondence regarding warranty, service or replacement parts. The machine model and serial number identification decal is located on the right front side of the tunnel. The serial number is permanently stamped into the tunnel. The model number is embossed on the decal. Whenever corresponding about an engine it is important that the engine model and serial numbers be called out. Laser engraved model and serial numbers are located on the crankcase (intake side).
  • 4. GENERAL INFORMATION 1.3 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 4XA. 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. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4 X A S B 5 B S 0 2 2 0 0 0 0 0 0 Vehicle Descriptor Vehicle Identifier Type Engine Size Engine Modifier Model Year Manufacturing. Location Code Individual Serial No. Body Style Series World Mfg. ID Example of Current VIN Number Check Digit Vehicle Identification Number / Model Number Key Body Style Type Engine Size Engine Modifier Series L=Lite B=Base Model 1=100-199 cc A=Fan S=Domestic N=Edge D=Deluxe 2=200-299 cc B=Liquid Twin U=Europe S=Gen II P=Performance 3=300-399 cc C=Case Reed Twin W=Mini R=RMK 4=400-499 cc D=Liquid Triple S=SKS 5=500-599 cc E=Case Reed Triple T=Touring 6=600-699 cc U=Utility 7=700-799 cc X=Racer 8=800-899 cc Year / Letter Identification The tenth digit of a 17 digit VIN is the model year of the vehicle. Example: W = 1998; X = 1999 etc. Refer to the listing below. 1 = 2001 2 = 2002 3 = 2003
  • 5. GENERAL INFORMATION 1.4 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.
  • 6. GENERAL INFORMATION 1.5 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 . .1250. . . . . . . . 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 .25. . . . . . . . . . 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 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 .75. . . . . . . . . . 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. . . . . . . . . . . . . . . . . . . . . . . .
  • 7. GENERAL INFORMATION 1.6 SAE Tap Drill Sizes Thread Size Drill Size Thread Size Drill Size #0-80 3/64 #1-64 53 #1-72 53 #2-56 51 #2-64 50 #3-48 5/64 #3-56 45 #4-40 43 #4-48 42 #5-40 38 #5-44 37 #6-32 36 #6-40 33 #8-32 29 #8-36 29 #10-24 24 #10-32 21 #12-24 17 #12-28 4.6mm 1/4-20 7 1/4-28 3 5/16-18 F 5/16-24 I 3/8-16 O 3/8-24 Q 7/16-14 U 7/16-20 25/64 1/2-13 27/64 1/2-20 29/64 9/16-12 31/64 9/16-18 33/64 5/8-11 17/32 5/8-18 37/64 3/4-10 21/32 3/4-16 11/16 7/8-9 49/64 7/8-14 13/16 1-8 7/8 1-12 59/64 1 1/8-7 63/64 1 1/8-12 1 3/64 1 1/4-7 1 7/64 1 1/4-12 1 11/64 1 1/2-6 1 11/32 1 1/2-12 1 27/64 1 3/4-5 1 9/16 1 3/4-12 1 43/64 2-4 1/2 1 25/32 2-12 1 59/64 2 1/4-4 1/2 2 1/32 2 1/2-4 2 1/4 2 3/4-4 2 1/2 3-4 2 3/4 Metric Tap Drill Sizes Tap Size Drill Size Decimal Equivalent Nearest Fraction 3 x .50 3 x .60 4 x .70 4 x .75 5 x .80 5 x .90 6 x 1.00 7 x 1.00 8 x 1.00 8 x 1.25 9 x 1.00 9 x 1.25 10 x 1.25 10 x 1.50 11 x 1.50 12 x 1.50 12 x 1.75 #39 3/32 #30 1/8 #19 #20 #9 16/64 J 17/64 5/16 5/16 11/32 R 3/8 13/32 13/32 0.0995 0.0937 0.1285 0.125 0.166 0.161 0.196 0.234 0.277 0.265 0.3125 0.3125 0.3437 0.339 0.375 0.406 0.406 3/32 3/32 1/8 1/8 11/64 5/32 13/64 15/64 9/32 17/64 5/16 5/16 11/32 11/32 3/8 13/32 13/32
  • 8. GENERAL INFORMATION 1.7 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 x .03381 = Fluid Ounces (oz.) lb. x .454 = kg kg x 2.2046 = lb. Cubic inches (cu in) x 16.387 = Cubic centimeters (cc) Cubic centimeters (cc) 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
  • 9. GENERAL INFORMATION 1.8 Description Part Number Chaincase Lubricant - Quart 2871280. . . . . . . . . . . . . . . . . . . . . . . Chaincase Lubricant - Gallon 2870464. . . . . . . . . . . . . . . . . . . . . . Chaincase Lubricant - 2.5 Gallon 2872281. . . . . . . . . . . . . . . . . . . Fuel System Deicer (Isopropyl) 2870505. . . . . . . . . . . . . . . . . . . . . Loctite Primer T - 6 Oz. Aerosol 2870585. . . . . . . . . . . . . . . . . . . . Loctite RC 680 - 10cc Retaining Compound 2870584. . . . . . . . . . Loctite/Chisel -- Gasket Remover - 18 Oz. 2870601. . . . . . . . . . . Metal Polish - 8 Oz. 2870632. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DOT 3 Brake Fluid 2870990. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fogging Oil 2870791. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nyogelt Grease 2871329. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fox Shock Oil 2870995. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Premium All Season Grease (14 oz.) 2871423. . . . . . . . . . . . . . . . Premium All Season Grease (3 oz.) 2871322. . . . . . . . . . . . . . . . . Premium 60/40 Anti-Freeze/Coolant 2871323. . . . . . . . . . . . . . . . Premium Carbon Clean Fuel System Additive 2871326. . . . . . . . Polaris Battery Tender 2871076. . . . . . . . . . . . . . . . . . . . . . . . . . . . Carbon Clean Fuel System Additive 2871326. . . . . . . . . . . . . . . . . T-9 Metal Protectant 2871064. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankcase Sealant 3 Bond 1215 2871557. . . . . . . . . . . . . . . . . . .
  • 10. GENERAL INFORMATION 1.9 ACS: Alternator control switch. ACV: Alternating current voltage. Air Gap Spark Test: A good check for ignition voltage and general ignition system condition. Spark should arc 3/8” (1 cm..) minimum from end of high tension lead to ground. Several testers are available commercially. Alternator: Electrical generator producing alternating current voltage. Bore: Diameter of cylinder. BTDC: Before Top Dead Center. Bump Steer: When skis toe in and toe out through suspension travel. CDI: Capacitor Discharge Ignition. Ignition system which stores voltage generated by the stator plate exciter coil in a capacitor or condenser (in CDI box). At the proper moment a voltage generated by the stator plate pulser coil closes an electronic switch (thyristor) in the CDI box and allows the voltage in the capacitor to discharge into the primary windings of the ignition coil. Center Cylinder: On three cylinder engines, the cylinder between Mag and PTO ends. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8” or 1 cm..). Polaris measures chain length in number of pitches. Clutch Buttons: Plastic bushings which transmit rotation of the clutch to the movable sheave in the drive and driven clutch. Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearlystraight asit movesalong theclutch face as the engine torques back. Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to close. Coil: A winding of wire around an iron core which has the ability to generate an electrical current when a magnetic field passes through it. Combustion Chamber: Space between cylinder head and piston dome at TDC. Compression: Reduction in volume or squeezing of a gas. Condenser/Capacitor: A storage reservoir for electricity, used in both E.T. and CDI systems. Crankshaft Run-Out: Run-out or “bend” of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in lower half of crankcase. Measure at various points especially at PTO. Maximum allowable run-out is .006” (.02 cm..). DCV: Direct current voltage. Detonation: The spontaneous ignition of the unburned fuel/air mixture after normal spark ignition. Piston looks “hammered” through, rough appearance around hole. Possible causes: 1) lean fuel/air mixture; 2) low octane fuel; 3) over-advanced ignition timing; 4)compression ratio too high for the fuel octane. Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and out-of-round in the cylinder bore. Displacement: The volume of the cylinder displaced by the piston as it travels from BDC to TDC. The formula is: Effective Compression Ratio: Compression ratio measured from after the piston closes the exhaust port. Electrical Open: Open circuit. An electrical circuit which isn’t complete. (i.e.
  • We Need Your Support
    Thank you for visiting our website and your interest in our free products and services. We are nonprofit website to share and download documents. To the running of this website, we need your help to support us.

    Thanks to everyone for your continued support.

    No, Thanks